photos added
 

http://s50.photobucket.com/albums/f340/sid15/kit/

Took some more photos of tacking the engine mounts in place, adjustable steering column and fabricating a stainless exhaust manifold from some off cuts and bends.
Still a bit more to to on the chassis, adding cross braces, making handbrake brackets, seat runners and seatbelt anchors.

Should be ready for some paint by the end of the week then can start running pipes, cables and start to panel.

If you can notice the drivers tunnel is wider than the passengers for extra room which makes the engine slightly off center. Extra room for pedals etc

Very nice exhaust mainfold :cool:

Chassis is very different , have you used the Roadster plans for the extreme outer chassis dimension ? ( noticed the Saturn scuttle ).

I like the rear lower wishbones , lots of adjustment there :cool:

Nice work Rich .

cheers
andy

Thanks!!

yes i have purchased complete Saturn bodywork kit and took the measurements off that

more photos from the weekend
 

http://s50.photobucket.com/albums/f340/sid15/kit/

Hi all i have uploaded some more photos from the weekend, finally got some primer on the chassis, we have started fabricating a inlet plenum manifold using some hand rolled some sheet metal.

Have now got an endless shopping list of bits to get for the engine, sump gasket, waterpump, clutch etc :( oh and need to get the propshaft shortened.

Im really determined to get it running before the summer is over.
I have also managed to find a small gear reduction starter motor that is ford OE that fits the bell housing. Im using the original 2.0 zetec sump, shortened the steel bit and cut out the aliminium section for the new located starter.

Cool
 

Looks like you are making some rapid progress there Rich :) :o

Certainly done a better job of your exhaust manifold than I did mine .... Done it on a day that I had fabricators block & really wish I had just left it untill my brain got into gear :o

Keep the Pictures coming :cool:

another update
 

Some more photos from a busy week. Made the most of the lovely weather and finished painting the chassis (by hand!!) Had some help making the templates for the sheet aluminium, overlapped each panel to try and get them watertight.
Cut out all the sheets from the templates and trial fitted. I have acquired some windscreen bond to seal the sheets after riveting

Ordered my seats from inter trim at telford and ordered some bits for the engine.
I have been given a 1.8 flywheel for the 2.0 zetec, much lighter :), purchased a clutch, thrust bearing, waterpump, gaskets, and my gaz shocks and springs arrived today
so an expensive month!

Great progress there Rich :cool:

Looks like you,ll have no problems hitting your target of a rolling chassis before the summer :cool:

May I suggest one thing....maybe a worthwhile mod, to use 3mm steel plate for the drivers footwell / pedal box bulkhead.....hope you don,t mind my suggestion :o

keep the progress pics coming:)

cheers
andy

Thanks!
Why steel? im using 2.5mm sheet ali for the floor and footwell. the pedal box will be fixed to the chassis

Sorry, I thought you might be fixing the pedal box as in the Roadster plans, where its sort of half n half where the pedal box actually fits to the bulkhead/footwell plate.
Tho even in the book it suggests 1.6mm plate I personally don,t think its "man enough" , it also tends to to distort when welding it to the chassis .

If you are fitting the pedal box direct to the chassis tubes then I,ll shut up :o

Chassis is looking great Rich :cool:

cheers
andy

Thanks!
No probs I welcome any info and help from you guys, no doubt i will come across some more problems soon

Nice job Rich !
Very nice photo's !
Where did you get your exhaust ?

greetz,

Wim

Thanks!
The exhaust manifold we fabricated from some stainless bends.
The silencer and cat was given to me for mock up. I wont be using it, was off a robin hood with the same engine and failed the IVA noise test!

more progress!!
 

Made a bit more progress this weekend, started fitting the suspension, managed to get the pedals mounted, the master cylinders, paneled the tunnel, sides and foot well and got a bit of pipework in. Also got the plenum/inlet manifold painted, injectors in and fuel rail fitted.
Im having a break tomorrow so back on it Monday to get the rear hubs and brakes fitted and might get it on its wheels

:cool: That's great progress for a weekends work :cool:

It certainly looks like its all coming together nicely Rich :cool:

There also looks something interesting being built in the photo behind your chassis/next to the green car , may I ask what it is please ?

Best wishes for getting your chassis to the rolling stage, a great milestone of the build:)

cheers
andy

Lol Its not my garage i have been kind enough to be lent garage space not far from me, get me to the stage of a rolling chassis and the engine in. then i will have it back home inside my garage to wire it and get it running and fit the bodywork.
The garage belongs to wildmoor mtc. They did all the chassis and suspension design for me. Next to mine is a blitz world buggy with a cinquicento engine being built to pass IVA. The red mini has a 2L zetec in the back

Another busy 2 days! got the engine and gearbox in, rear suspension fitted apart from one driveshaft that decided to fall to bits in my hand! not happy if i need a new one. Also cut the hole in side panel for the exhaust.
With the modified sump i can keep the perfectly flat floor so just need to make a flap for the sump plug and hammer a slight bulge to clear the starter motor as its just touching.
I have test fitted some fiberglass panels. The bonnet needs some modification as i knew anyway as the engine is offset and sits further back, the bulge is in wrong place and cant get the clearance.
Other than the driveshaft getting me down, not a bad bank holiday weekend!!

Hi guys, passed the milestone of getting the chassis on its wheels, brakes are fitted after finding out the correct disc sizes, prop shaft is in and engine is in for the final time! (5 times its been in and out!) Radiator is mounted and had some stainless pipes made up to plumb it in.
Took my alternator to work and made use of the shot blast cabinet and painted the brackets orange. Managed to mount the alternator to the sump using existing threaded holes to bolt a bracket.
Not really done much more, im waiting for some other bits to arrive, fuel line, pump and wiring loom and then thats my budget spent for the next couple of months!!

hi all
Got some more photos uploaded from the past couple of weeks.
The photos show the fuel tank, pump and filter in and plumbed, engine management loom, battery cables, alternator and master switch all wired.
Managed to stick a gallon of fuel in, spin her over and she eventually fired up for the first time!
Ok it wasn't that straight forward, had a minor fuel leak, had to set up the ecu on the computer. Had to search high and low to find the right lead! and then when it did fire up found out i had a slight air leak. i think the reason might be there was only 2 nuts holding the inlet manifold!

Hi guys, been away couple of weeks but last weekend managed to do a bit more.
Nearly finished the installing and connecting the wiring, being in the auto leccy game its the first task that i could do without too much head scratching!. I purchased a complete loom from SVC thinking it would save me some time, wasn't too bad working out the sierra column switches. fuel pump and cooling fan i have wired via relays controlled by the omex management. i also treated myself to a digi dash with a sensor that clipped straight into the original type 9 cable housing, well was suppose to! had to do a slight mod but fitted eventually!

Also started fabricating the front cycle wing brackets, had the roll bar made.
Ordered my exhaust silencer box from custom chrome.
Next step is to try and get the bodywork fitted and connect the lights!

Hi rich,
been trying to get your pics up but not having much luck, just says no pics. it seems others have no probs, any idea why.
cheers
tony

The pictures where there early, but they have gone now????

Terry

ok cheers terry
tony

sorry guys, been having trouble with my photo bucket account since i downloaded the mobile app, its messed up my albums, will try to get it sorted:confused:

Rich - did you ever get your pictures back up? I'm trying to get as many pics of builds in progress as I can now that i've started a build - but guess you've stuck them somewhere else now?