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Herald estate Mazda project Print
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Mike Evans
April 28, 2016, 9:13pm Report to Moderator

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Finally got round to building this long time in the planning project so I thought I'd share the progress with everyone

The car is a 1970 1360 estate, the rear tub, bulkhead and chassis were beyond saving but the doors bonnet and tailgate are good to go again

As this car was going to be a mishmash of bits I didn't mind having a bit of fun with it

A couple of years ago the car was stripped down and all usable parts put into storage

Last year a Mazda mx5 became available for a good price and a plan was hatched

Another chassis was required but I didn't want to cut up a decent one as they are in short supply

A post on here led me to buy a chassis off a member, the rear diff area had been welded but not well, ideal for my needs

From here I have some pics of the work that has gone into her so far


Mazda rear subframe was 4" too wide so out came the cutter, I had a plan


No going back for this chassis now


Needed to attach a new bit but didn't fancy just a but join so this was made up ready to slip inside


Frame mocked up, spent a lot of time with the tape here to get it square



Rear end all sorted apart from shock mounts but not sure on unloaded ride height yet need to measure an mx5


Starting the front suspension this week so more pics to follow, am thinking I may convert the estate to a van now not sure if there will be room for rear seats
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sx2visuvesi
April 28, 2016, 9:31pm Report to Moderator


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Interesting.... got me thinking now

I'm in the process of fitting an RX8 Engine into a Spitfire, plan was to use the 8 rear subframe but the plan stalled when it came to narrowing of the rear subframe.
It looks like the MX5 subframe has a much closer rear track than the 8

I'll be watching this one How would you feel about making up a 2nd chassis if this one works out for you?


Gary S

----------------------------------------------------------------------------

Financier & Technical Director to sons '78 Spitfire resto-mod project

Project Rotisserie coming soon

Proud member of the Essex Wankelist Massive
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JohnD
April 29, 2016, 6:35am Report to Moderator


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You must have been inspired by Project Binkie!
Or was it the other way around?

Well done!  Keep reporting g please. (When you have finished your biscuit)

John


Serial Vitesse racer.

Old Blue.  1995-2001
Silverback. 2001-2007
SofS. 2007 - to date.

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Jonny-Jimbo
April 29, 2016, 8:17am Report to Moderator

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Some nice work there.

One thing though - if you narrow the subframe, how does the differential still fit?

Keep up the good work, and keep the updates going.


62 Vitesse 1600 - Slammed & modified
67 2000 - Fitted with 2.5 o/d - 2012 RBRR, 2015 Essex Rally, 2016 HCR, 2016 RBRR
67 2000 Estate - Dormant
70 Herald 13/60 - First car, many bits
77 CZ 125 Sport - 70 miles on the clock
77 Kawasaki KM90 - Shop hack
81 Yamaha DT125 - Many bits
88 Ginetta G4/4 - Dead
88 BMW E30 320i - For Sale
89 Citroen AX GT - Rally car!
90 BMW E30 318iS - Building to FIA spec
90 Mazda Eunos 1.6 - 'Popeye'
93 BMW 530i - Donor
95 BMW E34 540i - 4L V8
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Mike Evans
April 29, 2016, 8:05pm Report to Moderator

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The rear diff on the mx5 has 2 cast alloy arms that support it. There is enough room to shorten these and make it all fit in, both shafts look like they will need to be remade shorter but there is a local firm that can do this

Thanks for the comments I'll keep you updated
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Jonny-Jimbo
May 3, 2016, 7:42am Report to Moderator

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Yup, We got an MX5 diff to trip over in the garage... Not sure what else it's doing there other than being a trip hazard... anyway.

I wasn't sure how close to the subframe the diff body sat, so I wondered if the new narrowed subframe would clash.


62 Vitesse 1600 - Slammed & modified
67 2000 - Fitted with 2.5 o/d - 2012 RBRR, 2015 Essex Rally, 2016 HCR, 2016 RBRR
67 2000 Estate - Dormant
70 Herald 13/60 - First car, many bits
77 CZ 125 Sport - 70 miles on the clock
77 Kawasaki KM90 - Shop hack
81 Yamaha DT125 - Many bits
88 Ginetta G4/4 - Dead
88 BMW E30 320i - For Sale
89 Citroen AX GT - Rally car!
90 BMW E30 318iS - Building to FIA spec
90 Mazda Eunos 1.6 - 'Popeye'
93 BMW 530i - Donor
95 BMW E34 540i - 4L V8
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Mike Evans
May 3, 2016, 9:18pm Report to Moderator

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Didn't have any other time on her over the weekend, permission wasn't given, managed to get an hour tonight so I started to clean up the main rail where I'm looking to mount the front wishbone

Found a bit of rot behind the front out rigger so this was patched




Old strut tower mount was removed and all the weld dressed ready for tomorrow's fabrication



Excuse the mess you wouldn't think I'd swept the table before I started tonight
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Mike Evans
May 9, 2016, 8:27pm Report to Moderator

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It's taken a bit of thinking time to get to where I'm at now,
I wanted to use the Mazda front suspension and mount it to the main chassis rails

Only problem is that the wishbones are 15mm longer than I was hoping making the track too wide

So after a good think I've decided to put a c notch in the main rail to carry the wishbones mounts

The side of the chassis rail was cut away to reveal this



So a bit if strengthening was required at the same time as a notch

After a while this was created




This is a L shape so the base of the main rail will be strengthened also

Mounting lugs will be welded onto tomorrow is all goes to plan
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ferny
May 9, 2016, 8:33pm Report to Moderator

Mr Hoppy!
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Club member
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Acclaim - fully working and on the road
13/60 Herald - mx5 powered and other such fun things, legal enough...
Mk1 2000 - it's still alive, just sleeping
Expert 815d - the slug

If in doubt, do up until you hear the crack and then go another 1/4 turn to ensure tightness.
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JohnD
May 10, 2016, 8:34am Report to Moderator


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Md,
What are your plans to restore the strength of the rail?  Taking out one side of the box section will have reduced its torsional stiffness by a factor of 10 to 100!
John


Serial Vitesse racer.

Old Blue.  1995-2001
Silverback. 2001-2007
SofS. 2007 - to date.

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Jonny-Jimbo
May 10, 2016, 10:21am Report to Moderator

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I assume you're intending to put the bolts in from the inside of the wishbones? Just thinking it would be hard to get the arms off otherwise!!

Nice fabrication work etc though, looks tidy.

This is a chassis I made a few years back for a Ginetta G15, I'm sure people will recognise what the front suspension mounts are based on!

I'll be very interested to see how your chassis turns out and the resulting car of course! Good work!



62 Vitesse 1600 - Slammed & modified
67 2000 - Fitted with 2.5 o/d - 2012 RBRR, 2015 Essex Rally, 2016 HCR, 2016 RBRR
67 2000 Estate - Dormant
70 Herald 13/60 - First car, many bits
77 CZ 125 Sport - 70 miles on the clock
77 Kawasaki KM90 - Shop hack
81 Yamaha DT125 - Many bits
88 Ginetta G4/4 - Dead
88 BMW E30 320i - For Sale
89 Citroen AX GT - Rally car!
90 BMW E30 318iS - Building to FIA spec
90 Mazda Eunos 1.6 - 'Popeye'
93 BMW 530i - Donor
95 BMW E34 540i - 4L V8
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Mike Evans
May 10, 2016, 8:28pm Report to Moderator

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I'm not leaving the side out of the chassis I've made this up to notch the rail in



The ends will be caped and the whole thing will be seam welded in with adoptions plug welds to secure the lower side of the rail to the new panel,

Once the wishbone mounts are welded in I would say that this area will be stronger than factory especially at the age this chassis is,

Only managed to mock the mount up tonight, I'm fitting the adjustable camber bolts that's why the mounting hole is an oval



Yeah the bolts are going to be installed from the centre of the wishbone out over, the first concept was 2 small notches for the wishbone but there was no way to bolt it in
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Mike Evans
May 15, 2016, 5:51pm Report to Moderator

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Have hit a bit of a stumbling block at the min, I need these brackets cutting from 2mm plate but can't find anyone who is willing to take on a small order, does anyone know where I could get these laser/water cut??

Thanks in advance

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sx2visuvesi
May 15, 2016, 6:19pm Report to Moderator


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How many do you need? just the one or 2?

2mm Mild steel yes?


Gary S

----------------------------------------------------------------------------

Financier & Technical Director to sons '78 Spitfire resto-mod project

Project Rotisserie coming soon

Proud member of the Essex Wankelist Massive
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JohnD
May 15, 2016, 6:22pm Report to Moderator


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Some Colleges  that have engineering Departments have water cutters.
And half - no, 90% of the work will be punching the data into CADCAM.  Can you transfer your nice (but not to any BS/ISO standard) drawing into a CADCAM file, TurboCAD maybe?  Again a local College might use it as an class exercise.
Your suppliers might accept it then.

But me, I'd cut those out by hand!  Two only?    Take half a day, max!
John


Serial Vitesse racer.

Old Blue.  1995-2001
Silverback. 2001-2007
SofS. 2007 - to date.

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Mike Evans
May 15, 2016, 6:31pm Report to Moderator

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I need 10 in 2mm plate, I've cut a couple by hand and although they where close they weren't exactly the same and it annoyed me

Thought drawing was better than the scrap of card I started with lol
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Jonny-Jimbo
May 16, 2016, 8:56am Report to Moderator

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MD, I'm PMing you as we speak.


62 Vitesse 1600 - Slammed & modified
67 2000 - Fitted with 2.5 o/d - 2012 RBRR, 2015 Essex Rally, 2016 HCR, 2016 RBRR
67 2000 Estate - Dormant
70 Herald 13/60 - First car, many bits
77 CZ 125 Sport - 70 miles on the clock
77 Kawasaki KM90 - Shop hack
81 Yamaha DT125 - Many bits
88 Ginetta G4/4 - Dead
88 BMW E30 320i - For Sale
89 Citroen AX GT - Rally car!
90 BMW E30 318iS - Building to FIA spec
90 Mazda Eunos 1.6 - 'Popeye'
93 BMW 530i - Donor
95 BMW E34 540i - 4L V8
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Jonny-Jimbo
May 18, 2016, 7:35am Report to Moderator

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Cad done, on it's way to the laser choppers now.



This post contains attachments; to download them you must login.



62 Vitesse 1600 - Slammed & modified
67 2000 - Fitted with 2.5 o/d - 2012 RBRR, 2015 Essex Rally, 2016 HCR, 2016 RBRR
67 2000 Estate - Dormant
70 Herald 13/60 - First car, many bits
77 CZ 125 Sport - 70 miles on the clock
77 Kawasaki KM90 - Shop hack
81 Yamaha DT125 - Many bits
88 Ginetta G4/4 - Dead
88 BMW E30 320i - For Sale
89 Citroen AX GT - Rally car!
90 BMW E30 318iS - Building to FIA spec
90 Mazda Eunos 1.6 - 'Popeye'
93 BMW 530i - Donor
95 BMW E34 540i - 4L V8
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Mike Evans
May 18, 2016, 11:40am Report to Moderator

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Looking well can't wait for them to come back so I can get the front suspension finished

Cheers again
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rustbuckit2011
May 18, 2016, 12:57pm Report to Moderator


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J-J that is awesome of you!


1960 Herald Coupe Replica - mazda, datsun, and all over the garage floor
1964 Herald 1200 coupe - standard.

https://www.facebook.com/rust.buckit.94
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Jonny-Jimbo
May 18, 2016, 2:12pm Report to Moderator

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I just hope I've understood the drawing correctly! Looks about right though.


62 Vitesse 1600 - Slammed & modified
67 2000 - Fitted with 2.5 o/d - 2012 RBRR, 2015 Essex Rally, 2016 HCR, 2016 RBRR
67 2000 Estate - Dormant
70 Herald 13/60 - First car, many bits
77 CZ 125 Sport - 70 miles on the clock
77 Kawasaki KM90 - Shop hack
81 Yamaha DT125 - Many bits
88 Ginetta G4/4 - Dead
88 BMW E30 320i - For Sale
89 Citroen AX GT - Rally car!
90 BMW E30 318iS - Building to FIA spec
90 Mazda Eunos 1.6 - 'Popeye'
93 BMW 530i - Donor
95 BMW E34 540i - 4L V8
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Jonny-Jimbo
May 27, 2016, 10:58pm Report to Moderator

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Well, job done off to the OP after the bank holiday.



This post contains attachments; to download them you must login.



62 Vitesse 1600 - Slammed & modified
67 2000 - Fitted with 2.5 o/d - 2012 RBRR, 2015 Essex Rally, 2016 HCR, 2016 RBRR
67 2000 Estate - Dormant
70 Herald 13/60 - First car, many bits
77 CZ 125 Sport - 70 miles on the clock
77 Kawasaki KM90 - Shop hack
81 Yamaha DT125 - Many bits
88 Ginetta G4/4 - Dead
88 BMW E30 320i - For Sale
89 Citroen AX GT - Rally car!
90 BMW E30 318iS - Building to FIA spec
90 Mazda Eunos 1.6 - 'Popeye'
93 BMW 530i - Donor
95 BMW E34 540i - 4L V8
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Mike Evans
May 28, 2016, 7:37am Report to Moderator

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Look spot on them, might be able to call in and pick these up on my way back from London, should be able to get some good progress this week on her again

Thanks again
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RAGTOP
July 22, 2016, 10:05am Report to Moderator

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Hi,  Whats happened to this project, I enjoy reading & following this project.  Alan
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Jonny-Jimbo
July 22, 2016, 1:45pm Report to Moderator

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I was wondering the same!


62 Vitesse 1600 - Slammed & modified
67 2000 - Fitted with 2.5 o/d - 2012 RBRR, 2015 Essex Rally, 2016 HCR, 2016 RBRR
67 2000 Estate - Dormant
70 Herald 13/60 - First car, many bits
77 CZ 125 Sport - 70 miles on the clock
77 Kawasaki KM90 - Shop hack
81 Yamaha DT125 - Many bits
88 Ginetta G4/4 - Dead
88 BMW E30 320i - For Sale
89 Citroen AX GT - Rally car!
90 BMW E30 318iS - Building to FIA spec
90 Mazda Eunos 1.6 - 'Popeye'
93 BMW 530i - Donor
95 BMW E34 540i - 4L V8
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Mike Evans
August 12, 2016, 8:59pm Report to Moderator

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Sorry for the lack of updates, it's something I'm trying to get on with but work has been getting in the way,
I run a garage and body shop and over the last month or 3 I've had staff come and go and gained a couple of large trade contracts that has ment I've had to do some long days of work rather than having fun on this

Since my last update I've done a bit more mocking up at the front then realised I'd cut up the front subframe without making a jug to create the upper arm mount locations, new front subframe came yesterday so I can now create a jig and get moving again I hope
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Mike Evans
August 14, 2016, 9:42pm Report to Moderator

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Got given a free pass today so made a bit of progress on this

First job was to sort the disaster area

Once tidy the notch was final welded in and the end closed up


The camber adjuster was pinched from the old subframe and welded to the brackets


One side welded up and finished, tried a spare floor pan to see how the arm would interfere with it, as luck would have it looks like the floors won't need modifying



Started the other side, should go a lot faster this side now I know where I'm going with it



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Jonny-Jimbo
August 15, 2016, 7:56am Report to Moderator

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Nice to see a bit of progress, and the laser cut plates being put to good use!


62 Vitesse 1600 - Slammed & modified
67 2000 - Fitted with 2.5 o/d - 2012 RBRR, 2015 Essex Rally, 2016 HCR, 2016 RBRR
67 2000 Estate - Dormant
70 Herald 13/60 - First car, many bits
77 CZ 125 Sport - 70 miles on the clock
77 Kawasaki KM90 - Shop hack
81 Yamaha DT125 - Many bits
88 Ginetta G4/4 - Dead
88 BMW E30 320i - For Sale
89 Citroen AX GT - Rally car!
90 BMW E30 318iS - Building to FIA spec
90 Mazda Eunos 1.6 - 'Popeye'
93 BMW 530i - Donor
95 BMW E34 540i - 4L V8
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Mike Evans
August 20, 2016, 4:23pm Report to Moderator

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Yes the plates have saved me a whole load of time and they are perfect quality

Had another day on it today and made a milestone

It's all been much of the same

Notch welded


All flapped and dressed


Lower arm all welded in place


We have lower front suspension finally
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Mike Evans
August 22, 2016, 6:56pm Report to Moderator

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Had another productive day today and got a few hours in, I was having issues measuring up the upper a arm mounts so I decided to make a jig off another front subframe so I could get them
In the right place


This jig was then removed and narrowed by 6 inches to mount to the herald chassis


Got the cardboard out and started boxing in from the tube down to the chassis
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Jonny-Jimbo
August 23, 2016, 10:35am Report to Moderator

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Some nice fabrication work there again, should be good when it's done!

It amazes me how rusty MX5s get, mine is about the same... When you think that a lot of 1920's Sunbeam motorcycles still wear their original paint (Sunbeam did patent their paint technology), you'd have thought that by now the Japanese would know how to stop a car going rusty!


62 Vitesse 1600 - Slammed & modified
67 2000 - Fitted with 2.5 o/d - 2012 RBRR, 2015 Essex Rally, 2016 HCR, 2016 RBRR
67 2000 Estate - Dormant
70 Herald 13/60 - First car, many bits
77 CZ 125 Sport - 70 miles on the clock
77 Kawasaki KM90 - Shop hack
81 Yamaha DT125 - Many bits
88 Ginetta G4/4 - Dead
88 BMW E30 320i - For Sale
89 Citroen AX GT - Rally car!
90 BMW E30 318iS - Building to FIA spec
90 Mazda Eunos 1.6 - 'Popeye'
93 BMW 530i - Donor
95 BMW E34 540i - 4L V8
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ferny
August 23, 2016, 12:37pm Report to Moderator

Mr Hoppy!
Club Officer
Club member
Posts: 10,685
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Why? They give no value to old or secondhand cars. That's why Australia gets things like half cuts for next to nothing.


Acclaim - fully working and on the road
13/60 Herald - mx5 powered and other such fun things, legal enough...
Mk1 2000 - it's still alive, just sleeping
Expert 815d - the slug

If in doubt, do up until you hear the crack and then go another 1/4 turn to ensure tightness.
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Mike Evans
August 23, 2016, 9:16pm Report to Moderator

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Although rust on the surface both subframe a I've had are solid which surprised me

But more done today, turned card into steel and got it welded in



Thinking about boxing this in but feel it may be over kill?? All contact points are welded on both sides

Then did it all again in a miror image


Suspension tried on, wheel sits nice and square


Also new wheels came today, 15" steels from a mini, gonna be widened in rear and have fixings for centre caps from the herald to be fitted to keep a sort of stock look
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Jonny-Jimbo
August 24, 2016, 8:30am Report to Moderator

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Looks good, glad this is getting somehere!

In terms of boxing in, that may not be needed - it would be overkill unless you're intending to put big power or high cornering loads through it, but at that point the rest of the chassis flexing is going to be the issue! You could maybe make some nice rounded gussets though to tie it all together nicely?


62 Vitesse 1600 - Slammed & modified
67 2000 - Fitted with 2.5 o/d - 2012 RBRR, 2015 Essex Rally, 2016 HCR, 2016 RBRR
67 2000 Estate - Dormant
70 Herald 13/60 - First car, many bits
77 CZ 125 Sport - 70 miles on the clock
77 Kawasaki KM90 - Shop hack
81 Yamaha DT125 - Many bits
88 Ginetta G4/4 - Dead
88 BMW E30 320i - For Sale
89 Citroen AX GT - Rally car!
90 BMW E30 318iS - Building to FIA spec
90 Mazda Eunos 1.6 - 'Popeye'
93 BMW 530i - Donor
95 BMW E34 540i - 4L V8
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Bitumen Boy
August 24, 2016, 9:34am Report to Moderator
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Boxing in may well be overkill, but when boxed it wouldn't be inclined to trap mud and salt which can only help longevity.
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Mike Evans
August 29, 2016, 5:37pm Report to Moderator

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Still thinking about boxing the mounts in as I can see the mud traps but am I just adding weight,

Any ways got a good 5 hours in today, decided I could do with getting some bodywork on so I can see what's gonna get in my way, with this in mind new front out riggers where made from 4x2 box. Realised that I wouldn't be able to get at the nut for the wishbone so added a tube to give me access. I'm trying to think ahead as much as possible because I hate redoing jobs

Final outrigger, not the same shape as original as my wishbone is now in the way


Luckily remembered about these camber adjusters before I welded it on, wouldn't of got in afterwards


Welded on and a copy made for the other side


Then another major job started but ran out of time, engine mocked up in the hole


Engine mounts should be nice and easy but card may not be strong enough


I think I'm gonna loose the passengers foot well recess as this is getting in the way of the exhaust pipe and I want to keep the underside of the car flat, I'm thinking to notch the pipe in the passengers side out riggers and bring it out the sill just in front of the rear wheel. Loosing the footwell will give me room for a box or 2 also to keep noise down

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Mike Evans
August 30, 2016, 9:05pm Report to Moderator

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Finally a triumph part back on it today, felt so good to be looking at a car rather than a skateboard, still a lot to do but it feels like progress today


Started making rear strut towers also tonight but ran out of time
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rustbuckit2011
August 31, 2016, 9:26am Report to Moderator


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Gday,, looking great! Gotta love those mini steels!

I am fitting a 1.6 to my coupe and have modified the bulkhead a little and machined off the front a/c pulley-  just to sit it back 'n low. Is yours a 1.8? I believe they are longer in the block from the mounts forward- does this interfere with the rack at all?

Also- and you probably know this already- but it is a piece of cake to shorten the shifter remote to a near stock location. I can post more info if you need it.

Keep up the inspiring work!


1960 Herald Coupe Replica - mazda, datsun, and all over the garage floor
1964 Herald 1200 coupe - standard.

https://www.facebook.com/rust.buckit.94
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Mike Evans
August 31, 2016, 9:19pm Report to Moderator

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Hi yeah I'm using a 1.8 which is a bit longer, I've got mine set up so the crank pulley is 15mm above the rack, this position puts the box in a good place and makes the engine sit nice and level. I'm using the ac drive pulley to run the supercharger so I've had to keep it
The info on shortening the remote would be nice as this is a job I need to do

Bit more done today, both rear strut towers made and welded into place with bracing




New well part worn tyres fitted to rears also, ready for front strut towers now to get her on her legs, might have a look at rear body tomorrow as I'm not sure front frame will be ready yet

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Jonny-Jimbo
September 1, 2016, 7:54am Report to Moderator

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Looking good! Is it a saloon or convertible body? Or even a bit of a sleeper and using an estate?

Also, if you're using the AC pulley on the supercharger, is it possible to make it 'switchable' using the AC switch from the MX5, or is the clutch on the AC pump end normally rather than the engine?


62 Vitesse 1600 - Slammed & modified
67 2000 - Fitted with 2.5 o/d - 2012 RBRR, 2015 Essex Rally, 2016 HCR, 2016 RBRR
67 2000 Estate - Dormant
70 Herald 13/60 - First car, many bits
77 CZ 125 Sport - 70 miles on the clock
77 Kawasaki KM90 - Shop hack
81 Yamaha DT125 - Many bits
88 Ginetta G4/4 - Dead
88 BMW E30 320i - For Sale
89 Citroen AX GT - Rally car!
90 BMW E30 318iS - Building to FIA spec
90 Mazda Eunos 1.6 - 'Popeye'
93 BMW 530i - Donor
95 BMW E34 540i - 4L V8
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Mark Hammond
September 1, 2016, 5:24pm Report to Moderator

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Quoted from Jonny-Jimbo
Looking good! Is it a saloon or convertible body? Or even a bit of a sleeper and using an estate?

Also, if you're using the AC pulley on the supercharger, is it possible to make it 'switchable' using the AC switch from the MX5, or is the clutch on the AC pump end normally rather than the engine?


JJ the clue's in the OP's title of the thread!!!  

Mark


Herald 1200 Saloon, owned (in the family) from new, Royal Blue/Black trim
[color=purple]MX-5 Z-Sport (Tweaked to 200bhp)2007,
Suzuki Vitara S Auto, Cosmic Black, 2017.
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Mike Evans
September 1, 2016, 7:50pm Report to Moderator

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Yeah building a 1360 estate but I've a good 1200 bonnet so I may see how everything fits under there,

The AC clutch is on the compressor so no option for switchable power

Didn't get any time today but did collect the tubing for the front space frame so should have all suspension made this weekend
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Jonny-Jimbo
September 2, 2016, 8:33am Report to Moderator

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Quoted from Mark Hammond


JJ the clue's in the OP's title of the thread!!!  

Mark






62 Vitesse 1600 - Slammed & modified
67 2000 - Fitted with 2.5 o/d - 2012 RBRR, 2015 Essex Rally, 2016 HCR, 2016 RBRR
67 2000 Estate - Dormant
70 Herald 13/60 - First car, many bits
77 CZ 125 Sport - 70 miles on the clock
77 Kawasaki KM90 - Shop hack
81 Yamaha DT125 - Many bits
88 Ginetta G4/4 - Dead
88 BMW E30 320i - For Sale
89 Citroen AX GT - Rally car!
90 BMW E30 318iS - Building to FIA spec
90 Mazda Eunos 1.6 - 'Popeye'
93 BMW 530i - Donor
95 BMW E34 540i - 4L V8
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Mark Hammond
September 2, 2016, 5:49pm Report to Moderator

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Another irrelevant question, is that a NOS bulkhead I see or have you renovated the old one and used red primer?

Mark


Herald 1200 Saloon, owned (in the family) from new, Royal Blue/Black trim
[color=purple]MX-5 Z-Sport (Tweaked to 200bhp)2007,
Suzuki Vitara S Auto, Cosmic Black, 2017.
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Mike Evans
September 2, 2016, 6:52pm Report to Moderator

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I don't mind the questions and welcome the input

This bulkhead was advertised on eBay as NOS and I spoke to the seller and that's what he told me, when I arrived the 3 hour drive it was a bit of a let down, it's a very good condition one that's had some work to a good standard but not NOS.

Got a little bit done today, got main hoop tacked onto place and started mocking up front bars to see how it will all fit and line up, even sat super charger roughly where it will live
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JohnD
September 3, 2016, 1:55pm Report to Moderator


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That frame!  That spirit level! ("Make the noise!")
Are you going all Binkie on us??

John


Serial Vitesse racer.

Old Blue.  1995-2001
Silverback. 2001-2007
SofS. 2007 - to date.

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Mike Evans
September 3, 2016, 6:46pm Report to Moderator

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I wish I understood any of the reference's there might be amusing
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Mike Evans
September 3, 2016, 8:49pm Report to Moderator

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After a long day looking at the front suspension I've come to the decision the shock mounts need a new plan, I was trying to keep the bulkhead pretty untouched and so was trying to work round it. The limited space lead to some poor decisions so it's gonna have to be modified

Im now thinking I'm gonna run a hoop under the battery shelf with 2 rails coming forward to the steering rack area, this should give me an easier time getting the upper shock mounts where I need them and keep the structure strong enough

Once the suspension is done I'll then sort the bulkhead location and do the modifications to the front area

Makes more sense in my head but hopefully should work, I'll post pics as I get it started, please give me any help or assistance as this is my first major surgery
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JohnD
September 3, 2016, 10:21pm Report to Moderator


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Dear me, MD!  As fabricator you are missing a treat!
allow for several hours of viewing!
http://www.badobsessionmotorsport.co.uk

John


Serial Vitesse racer.

Old Blue.  1995-2001
Silverback. 2001-2007
SofS. 2007 - to date.

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Mike Evans
September 4, 2016, 6:11pm Report to Moderator

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Have just got back from a very inspiring afternoons viewing, thank you john, just need to gets me a posh level that will indeed " make the noise "

Cheers mike
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Mike Evans
September 5, 2016, 8:15pm Report to Moderator

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And here is plan G, both shocks held in place where they need to be for angle heights etc. Frame started to be bent up and tacked in.

This new frame will require modification of the bulkhead but should give a near her appearance under the bonnet, the less chassis modifications on show the better really as I want to keep the original reg

Couple of pics



Both sides where set up with a good strut, the broken Spring one allowed me to check clearances through the suspension travel without putting strain on the tacked up areas
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Jonny-Jimbo
September 6, 2016, 8:01am Report to Moderator

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Are you going to brace the upper wishbone mount up to the tubes too to add more strength in? This set up looks similar-ish to how a lot of the drag cars have the front suspension mounted... Certainly will be strong.


62 Vitesse 1600 - Slammed & modified
67 2000 - Fitted with 2.5 o/d - 2012 RBRR, 2015 Essex Rally, 2016 HCR, 2016 RBRR
67 2000 Estate - Dormant
70 Herald 13/60 - First car, many bits
77 CZ 125 Sport - 70 miles on the clock
77 Kawasaki KM90 - Shop hack
81 Yamaha DT125 - Many bits
88 Ginetta G4/4 - Dead
88 BMW E30 320i - For Sale
89 Citroen AX GT - Rally car!
90 BMW E30 318iS - Building to FIA spec
90 Mazda Eunos 1.6 - 'Popeye'
93 BMW 530i - Donor
95 BMW E34 540i - 4L V8
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Mike Evans
September 6, 2016, 7:08pm Report to Moderator

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Yeah upper wishbone mounts will be braced into it, gonna bring it down the gearbox tunnel also to tie the main rails into the front frame

Might not be the lightest looking thing but I was surprised at how light the tube was for steel

Not had any time on it today, I'm a bit reluctant to do a lot till my inclometer arrives so I can get all the tube notches at the correct angles. Did get the box for the side rails but was too tired to do any work
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Mike Evans
September 10, 2016, 6:47pm Report to Moderator

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Well inclometer arrived earlier in the week but had too much work on to have any time till today

Got a solid 5 hours in today although it don't look like it, been plenty measuring and double checking



Got one strut tower nearly finished then had to leave


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Jonny-Jimbo
September 12, 2016, 9:16am Report to Moderator

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Looking good - hope you can hide it all under the body work!!


62 Vitesse 1600 - Slammed & modified
67 2000 - Fitted with 2.5 o/d - 2012 RBRR, 2015 Essex Rally, 2016 HCR, 2016 RBRR
67 2000 Estate - Dormant
70 Herald 13/60 - First car, many bits
77 CZ 125 Sport - 70 miles on the clock
77 Kawasaki KM90 - Shop hack
81 Yamaha DT125 - Many bits
88 Ginetta G4/4 - Dead
88 BMW E30 320i - For Sale
89 Citroen AX GT - Rally car!
90 BMW E30 318iS - Building to FIA spec
90 Mazda Eunos 1.6 - 'Popeye'
93 BMW 530i - Donor
95 BMW E34 540i - 4L V8
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Mike Evans
September 12, 2016, 6:47pm Report to Moderator

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Funny you should say that, today's plan was to get only on its legs and try and get the body to fit and still sort of look stock, by the end of today I've got to here


I've just cut the minimum out today so I could visualise a plan to get it to fit nice




Think I'm gonna move the firewall back this far but still keep the original shelf and sides where the bonnet catches go
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ferny
September 13, 2016, 6:23am Report to Moderator

Mr Hoppy!
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Couple of quick questions.

What pedal system are you planning on using?
And, have you raised the diff from its standard height? The way it comes across in those photos is that the gearbox is very high.


Acclaim - fully working and on the road
13/60 Herald - mx5 powered and other such fun things, legal enough...
Mk1 2000 - it's still alive, just sleeping
Expert 815d - the slug

If in doubt, do up until you hear the crack and then go another 1/4 turn to ensure tightness.
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Mike Evans
September 13, 2016, 8:02pm Report to Moderator

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Please ask away you may see something I've over looked

I'm looking at using a bespoke pedal box like this one

I've got all the Mazda pedals but they mounted on the bulkhead and extended into the engine bay if I remember rightly

The rear diff area is all Mazda also, the diff does sit higher than the original, the engine and box are as low as they will go without the sump hanging out, I'm looking to keep the underside flat, to this end in notching the passengers floor so I can run exhaust up heigh and out of the passenger side sill
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Mike Evans
September 14, 2016, 7:19pm Report to Moderator

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Bit more done, looked at boxing in the firewall today

Made these end pieces


Welded in, bulkheads upside down here


And one side infill panel stuck in


I'm going to add a plate to the underside of the shelf to strengthen it, I'm thinking I can bolt through the shelf into the strut tops to add an additional body mount up here
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Mike Evans
September 21, 2016, 6:56pm Report to Moderator

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Had a busy week customer wise so not had much chance on this,

However we have a body


Was a a bit of luck but the rear suspension I've built fit between the rear arch tubs, considering I didn't measure this I was presently surprised


Had to try the skirt on to see what it looked like for position in the arch, now I've had this on I think the rear wheels will get widened by 40mm
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Mike Evans
April 3, 2017, 9:41pm Report to Moderator

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Here's a bit of an update for those who are interested

There has been a hold on the project due to a garage move, didn't quite realise it had been 6 months though.

Here she is in her new home



Need to make a new build table that is adjustable as the floors aren't good enough for the drum system

Bought some banded wheels off a friend though, had to try them on, only want banded rears I
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rustbuckit2011
April 4, 2017, 9:39am Report to Moderator


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Looking great! I love dished mini wheels


1960 Herald Coupe Replica - mazda, datsun, and all over the garage floor
1964 Herald 1200 coupe - standard.

https://www.facebook.com/rust.buckit.94
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Jonny-Jimbo
April 4, 2017, 9:40am Report to Moderator

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I was just thinking the other day that this build had gone a bit quiet. Good to know it's still ticking over in the background.


62 Vitesse 1600 - Slammed & modified
67 2000 - Fitted with 2.5 o/d - 2012 RBRR, 2015 Essex Rally, 2016 HCR, 2016 RBRR
67 2000 Estate - Dormant
70 Herald 13/60 - First car, many bits
77 CZ 125 Sport - 70 miles on the clock
77 Kawasaki KM90 - Shop hack
81 Yamaha DT125 - Many bits
88 Ginetta G4/4 - Dead
88 BMW E30 320i - For Sale
89 Citroen AX GT - Rally car!
90 BMW E30 318iS - Building to FIA spec
90 Mazda Eunos 1.6 - 'Popeye'
93 BMW 530i - Donor
95 BMW E34 540i - 4L V8
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RAGTOP
April 6, 2017, 9:39pm Report to Moderator

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Hi, Ive missed it,  i realy like reading about this a very interesting project.  alan
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Mike Evans
April 14, 2017, 9:18pm Report to Moderator

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Bit done over last few days, first job was to build level table


Car positioned and levelled

That took care of a few late nights this week

Got a bit done today but don't feel like it, made a rear put rigger from some box and plate but no pics, then started side rail again from box section. I'm going to have exhaust exit the passenger side sill so notch was required

Hole cut

Plate rolled and tried in


All welded and dressed


Got a stainless exhaust from an omega for £20 so started to see how parts were going to work


Then home time, tidy up tomorrow too late in the day


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ferny
April 14, 2017, 10:13pm Report to Moderator

Mr Hoppy!
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Club member
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Nice. I'd like you get mine out just behind the front wheel but it's not going to be possible.

Are you raising the floorpan for the rear tub?


Acclaim - fully working and on the road
13/60 Herald - mx5 powered and other such fun things, legal enough...
Mk1 2000 - it's still alive, just sleeping
Expert 815d - the slug

If in doubt, do up until you hear the crack and then go another 1/4 turn to ensure tightness.
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Mike Evans
April 15, 2017, 6:14am Report to Moderator

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That was where I was looking at to start with but no room, yeah I'm going to build all the mechanical items and then modify the body to fit, the passengers floor pan will have a small tunnel in it next to the main chassis rails to allow the exhaust to run down there and the rear tub floors will all be reworked,

I'm also thinking about putting the fixing points for the seats on the chassis for strength
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JohnD
April 15, 2017, 9:35am Report to Moderator


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Mike,
I hope you find this as a compliment, but your project IS very Binkie!

Have you seen the motorised level table in the BO workshop?
John


Serial Vitesse racer.

Old Blue.  1995-2001
Silverback. 2001-2007
SofS. 2007 - to date.

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Mike Evans
April 15, 2017, 9:23pm Report to Moderator

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Yes I can defiantly see where you are coming from, I've seen the table and it's impressive but that would be most of my build budget right there.  I'm from a crash repair background so I'm used to using bench jigs and that's what mine was modelled round,

Another few hours today, made centre outrigger from some 60x40 box with the off cut from the rear outrigger welded to the base, mainly because I was running out of 100x50 box and this one didn't need to be as heavy duty


After this's also got a c notch for the exhaust it was engine back in time again


Then rather than start the other sides out riggers I fancied a change so cut up the omega exhaust and played with some bends to make up the exhaust


I'm trying to build as much as possible before the body goes on so I can do all modifications before the shell goes away to be dipped, hoping to build the full car apart from the wiring
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JohnD
April 17, 2017, 8:53am Report to Moderator


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BO doesn't stand for Bad Obsession for nothing!

Please keep on reporting - 'm looking forward to the result.
John


Serial Vitesse racer.

Old Blue.  1995-2001
Silverback. 2001-2007
SofS. 2007 - to date.

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Mike Evans
May 13, 2017, 9:32pm Report to Moderator

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As if it's going on for a month and this is all I've got done

Finally finished the other side outriggers, this has been a slog as it doesn't look like I've made progress. However all the centre rails and outriggers have now been remade in 3mm box section, feels so much sturdier now


Started to refit body again today ready to make rear chassis extensions and body mounts, passengers foot well has had to loose a bit more room but it's ok will keep the feet warm

All body mounts had a 5mm timber block added (couldn't find any factory spacers and was keen to crack on), all mounts have the same size packers and everything lined up nicely so must of done something right


Minor bit of tub spread to sort on the n/a bit pretty happy with the panel gaps so far

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Jonny-Jimbo
May 15, 2017, 2:27pm Report to Moderator

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Looking awesome!


62 Vitesse 1600 - Slammed & modified
67 2000 - Fitted with 2.5 o/d - 2012 RBRR, 2015 Essex Rally, 2016 HCR, 2016 RBRR
67 2000 Estate - Dormant
70 Herald 13/60 - First car, many bits
77 CZ 125 Sport - 70 miles on the clock
77 Kawasaki KM90 - Shop hack
81 Yamaha DT125 - Many bits
88 Ginetta G4/4 - Dead
88 BMW E30 320i - For Sale
89 Citroen AX GT - Rally car!
90 BMW E30 318iS - Building to FIA spec
90 Mazda Eunos 1.6 - 'Popeye'
93 BMW 530i - Donor
95 BMW E34 540i - 4L V8
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Mike Evans
June 12, 2017, 8:42pm Report to Moderator

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Havnt had much time on the old girl recently but got an afternoon in yesterday

Job plan was to sort out the rear outriggers so the body was solid, these took some figuring out as they needed compound mitres on the ends




I've had to weld temp art braces to the table as it has a bit of flex in the rear diff area at the min, will have a bolt in brace to stiffen all this up and some gussets applied once the body is off again

Another 2 hours of messing got me door gaps like these


Just goes to show that just because it's an old car stuff can still be made to fit nice, I hate bad gaps on a nice car just ruins them
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Mike Evans
September 2, 2017, 10:09pm Report to Moderator

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After a 3 month break its back

Bit of cad today to box in exhaust in passenger foot well
Then made in steel

Next was the minor issue that the chassis was in the way of the steering rack

So out came a new jig to relocate the bonnet tube once I'm done then out with the grinder

And there you go rack now has a space to live

Going to look at the missing support for the suspension next time, needs a bit of looking at and tea drinking for now



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Mike Evans
September 2, 2017, 10:10pm Report to Moderator

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Rack image too big but here she is



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Mike Evans
September 2, 2017, 10:12pm Report to Moderator

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Next issue anyone know where I can get steering rack sizes

I need one that is about 550mm knuckle to knuckle to eliminate bump steer

Don't need power steering just a basic rack
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Nick Jones
September 2, 2017, 10:27pm Report to Moderator

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Is that longer or shorter than a Triumph one?  A Triumph one would be pretty easy to shorten.....

Nick


Nick Jones
Somerset UK

Vitesse Mk 1.5 Convertible EFI, Survivor of RBRR 2008, HCR & 10CR 2009, HCR 2010, 10CR2011, HCR 2012, 10CR2013, 10CR2015, HCR 2016 & HCR 2017.
GT6 Mk3 Roto - project in progress
Spitfire MKIV son's project now on the road as a daily driver
2.5 PI Saloon now EFI (PIe?), Engine rebuilt and running sweet.  Diff howling...... Survivor of HCR 2013 & 2014 Gone to live in Swansea

http://www.tengaston.plus.com
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Mike Evans
September 3, 2017, 9:50am Report to Moderator

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It's shorter than a triumph one, how would you go about shortening a rack??
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Nick Jones
September 3, 2017, 1:09pm Report to Moderator

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The non-drive end of the rack itself is just a simple bar with a screw thread cut on it.  Could be shortened by the required amount and the thread recut, probably best with a lathe.  Simple, quick job for a competent machinist.  The rack housing is also a plain tube at the non-drive end with a simple bush pressed into it.  This could be easily cut down and the bush pressed in further up.

Biggest pain is probably the mount stops which might need to be cut off and re-done, or perhaps just cut off if you are using alloy rack clamps (though I'd put some simple stops on to prevent any sideways slippage if the clamps loose grip).

Nick


Nick Jones
Somerset UK

Vitesse Mk 1.5 Convertible EFI, Survivor of RBRR 2008, HCR & 10CR 2009, HCR 2010, 10CR2011, HCR 2012, 10CR2013, 10CR2015, HCR 2016 & HCR 2017.
GT6 Mk3 Roto - project in progress
Spitfire MKIV son's project now on the road as a daily driver
2.5 PI Saloon now EFI (PIe?), Engine rebuilt and running sweet.  Diff howling...... Survivor of HCR 2013 & 2014 Gone to live in Swansea

http://www.tengaston.plus.com
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John Bonnett
September 3, 2017, 1:25pm Report to Moderator


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Is there any truth in the track rod threads being rolled and using a die to extend the threads causes a weakness?


La Coupe Florio 2015
https://www.youtube.com/watch?v=4-rtCbygnIM
GT6 to Spain
http://www.youtube.com/watch?v=RtFH-Q3n2Gg

Located Whiddon Down Devon
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Nick Jones
September 3, 2017, 8:14pm Report to Moderator

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Yes, I think that is true, plus you wouldn't get a full thread as the diameter is a bit too small.  However, I understood that we were talking about the centre section of the rack, between the inner ball-joints, and needing to shorten that to bring the inner ball joint to a position to minimise bump steer.

I think, but have never actually had the opportunity to measure, that the centre sections of TR2 - 6, all small chassis and the non-PAS saloons are all basically the same (6 tooth/7 tooth pinion aside) but there are track-rod length differences with saloon ones presumably being the longest.  I could be wrong about this as I've long forgotten where I saw/heard this.

Nick


Nick Jones
Somerset UK

Vitesse Mk 1.5 Convertible EFI, Survivor of RBRR 2008, HCR & 10CR 2009, HCR 2010, 10CR2011, HCR 2012, 10CR2013, 10CR2015, HCR 2016 & HCR 2017.
GT6 Mk3 Roto - project in progress
Spitfire MKIV son's project now on the road as a daily driver
2.5 PI Saloon now EFI (PIe?), Engine rebuilt and running sweet.  Diff howling...... Survivor of HCR 2013 & 2014 Gone to live in Swansea

http://www.tengaston.plus.com
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Mike Evans
September 4, 2017, 6:26pm Report to Moderator

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We'll update on the rack, after an hour of looking and tea drinking I've come up with this

The size I need was struggling to find, if I narrow the Mazda rack I will be able to use original track rods and keep original steering set up.

The Mazda rack was pas but won't be once I'm done, it's got an alloy pinion area with a steel tube pressed onto the end

The main sliding part is hollow where I want to remove material from, so plan is to cut and remove material from centre, tap a thread into both ends and screw a dowel inside before welding

Sleeve and weld up outer then make bungs to blank off pas pipe holes

Looks like I'll have enough room in middle to remove the 140mm required
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Mike Evans
September 4, 2017, 6:30pm Report to Moderator

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Nick, from research I've also read that all triumph small chassis racks are the same size, I looked at the triumph rack in detail, can't remember why I discounted it yesterday but there was a good reason, may of been location of steering shaft not sure
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Mike Evans
October 7, 2017, 7:18pm Report to Moderator

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Little update, I now have a narrowed Mazda steering rack, it's a manual rack now but will work nicely, the rack has been threaded and welded back together with a stud screwed inside it so should be strong enough. The outer steel tube has been sleeved and welded. All work carried out by coded welders and engineers so I'm happy with its strength and functionality




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