photos added

[rich]

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

[HandyAndy]

Very nice exhaust mainfold

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

Nice work Rich .

cheers
andy

[rich]

Thanks!!

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

[rich]

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.

[Bonzo]

Looks like you are making some rapid progress there Rich

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

Keep the Pictures coming

[rich]

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!

[HandyAndy]

Great progress there Rich

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

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

keep the progress pics coming

cheers
andy

[rich]

Originally Posted by HandyAndy

Great progress there Rich

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

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

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

[HandyAndy]

Originally Posted by rich

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

Chassis is looking great Rich

cheers
andy

[rich]

Originally Posted by HandyAndy

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

Chassis is looking great Rich

cheers
andy

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