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Discussion Starter #61
Shafts are now redrilled to suit the new stud pattern, so will soon be able to build the axle up (finally!), once the rear caliper mounts are made.

Also had a small bit of luck concerning the gearbox, managed to find a 'Ridgeback' Ford C6 with small-block bellhousing, which came with a high-stall convertor for the princely sum of $360 (around 180 GBP):





I like the C6, and having had them in both of my previous race cars I know a) how to build them for power and b) that they will last!
 

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Discussion Starter #62
At last the tube frame is coming together. It still needs finish-welding, the 'funny car' style drivers cage needs to be fitted, and suspension & steering mounts also need to be manufactured & fitted but largely the big work is done!









So far I'm really pleased with the way it's turning out. I trial fitted the front axle after these pics were taken, so it's really close to being a rolling chassis!!!! :)
 

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Discussion Starter #64
I bought a nice Momo steering wheel from a local boot sale, which just happened to have the right boss for my column, but the boss was rough-as, so after removing all of the unnecessary plastic crap it looked like this:



After a quick clean up (ignore the American flag!):



I don't like the exposed shaft look on columns so turned up this tube which is an interference fit on the boss, but spins freely arount the column outer:



Tidies it all up very nicely:





:)
 

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Discussion Starter #66
Scraped a few 'evening hours' in the fab-room:

Bought these springs and adjustable sleeves for all 4 corners ($77 !) so made up the spring mounts:



The front and rear platforms are the same, but the gussets will need to be different on the rear:



Also made up the fuel tank subframe. This is probably a bit overkill, but I figure there will be around 40kg of fuel sloshing around if the tank's full so don't want to take any chances.
this will be welded between the boot front and rear chassis tubes:





There are threaded bosses welded into the box section (top & bottom). Also modified the tank straps (that came with the fuel cell) from being all floor mounted to being accessible in the small confines of an Escort boot:



Really great thing is that all of the materials have been 'recycled' from stuff that people had lying around, and in the case of most of it literally lying in the road :)

More soon!
 

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Discussion Starter #67 (Edited)
Started to make the dash up today. Keeping with the 'black and alloy' look of the shifter I made this from another offcut of the black perspex, and the tubes from an old VHF TV aerial.


Only cost involved were the M5 button-head SS screws.

This will have a centrally mounted tach, with Boost Gauge, Oil Press, Water Temp and a BOFO Oil Light, along with a few smaller warning lights. The frame will be welded to an aluminium subframe which will have sheet alloy formed over the top of it.
 

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Discussion Starter #69
Heads now painted in psuedo-aluminium:



And rear axle casing now finished.
This has been narrowed 300mm, and has the 4-link, panhard rod mount, shock mounts and spring perches mounted along with a box-section reinforcement:





Close-up of the spring mounts. These are made from 5mm steel plate with the spring locator made from 1" wide steel bar, welded into the platform bore:



And then welded and gussetted to the casing:



Built-up with springs and panhard rod:





Mounted this in the car this afternoon, but due to some technical cock-up I appear to have made the 4-link bars too long:shake:

This turned up last week. Delivered to my door for $140 (£70) !:



The Last major component of the engine.

The engine bulkhead/rear motor plate is now roughed out, so hopefully will be able to mock-up the engine in place within the next week or so which will allow me to make/position the front motor plate and finalise the position of the steering components.
 

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Discussion Starter #70
Not a hugely productive weekend, but did manage to make up the rear top spring perches.
Made from a bit of flat bar, a couple of old strut top cups and a bit of a Dexion shelf support. You'd never know :)
These will be welded under the chassis tubes, with the adjusters attached to them by M5 grubscrews:





I did also manage to finish the engine bulkhead framework, and have the rear motor-plate cut ready to be drilled to fit.
I'm resisting taking pics of the chassis until it's finished as there are a couple of surprises in store!!!!!
It's coming along!
 

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Discussion Starter #71
Mid plate/Motor plate

I've been working on a lot of cars recently that have really sexy ball-milled engine mount plates.
Unfortunately my budget won't stretch to that, so I came up with a plan to make a relief cut laminate plate.

The plates are cut from a plate that was at one time a trailer floor. It's good quality tempered plate which is just under 5mm thick.
First the plates were rough-cut to shape:



Then marked out, and the engine mount holes and relief holes cut:



Then the plates were cleaned up, and extra holes drilled in the large plate so that the two plates can be plug-welded together:



All welded up and sparkly:



Bolt flanges welded to the bulkhead structure. Aside from giving mount points these also strengthen the bulkhead (not that it needs it!)



Plate in position and mount holes drilled:



On the laminate plate the bolts will be countersunk, but the rest of the plate will have either hex or cap-head bolts.

 

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Discussion Starter #73
Front struts are heavily modified Skyline R33. The adjustable platforms were bought from TradeMe and shortened by around 70mm. Springs also from TradeMe.
Top mounts are fabricated as per one of my previous posts. As you can guess the suspension is not even loosely based on Escort stuff.
 
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