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Discussion Starter · #1 · (Edited)
Hi there, well as requested I am going to put up some pic of my 27 T build up. Ive been on it for about a year with most of that being a learning curve and sourcing parts. Ive not done anything like this before so lots to learn!!..

Initially I bought a Chevy Caprice off ebay which was agreed would have an MOT on by the time I collected it so I could Drive it Home.. The car was 300+ miles from home so getting it any other way was not an option.. I arrives after a day on public transport only to find the muppet has not bothered to get the Ticket sorted!!.. I managed to keep my cool and duely strapped the bloke to the car until he fixed it.
Finally got a ticket at 6.15pm but now it was too late to get Tax.. He was decent enough to offer me a sofa for the night but i did think this was the least he could do!!..
taxed it the next morning, chucked some fuel in it and headed home to somerset. Made an ace discovery on the way home, the mileometer was actually in KM so my motor with 80K on it now only had 50K on it.. result!..

Below is said beasty!!..


Ater getting it home and ripping the bits out of it the Chevy was duly scrapped as the body shell was rusting from the inside out. My only real regret is not running it for a while but I didnt have the space.
Next I found a bodyshell (cheers Matt if you come across this) and did a mock up to do measurements etc



Im trying to use as much as poss from the Chevy and have saved enging, gearbox, rear axle, steering column, wheels, seat belts, various cables and attachments. With all these bits in mind I did a full size drawing of the chassis on paper on my kitchen floor so I could make sure it was all going to work out.

I got busy with my plastic next and shipped in a lowered tube axle from MAS in the states.. BIG MISTAKE!!.. I trusted in them and bought there "KIT".. In my nievety I didnt know about the Hairpins with Bat wings issue and promptly paid over £500 notes for something that dosent actually go together or work or is even right!!. The Axle turned up with the end bosses in the wrong places. One was 4mm ahead of C/L the other 4mm behind. Good by henry Ford standards but shite for now!. The hairpins are good but dont match the batwings as the Clevices will have hole centres of 4 and a half inches and the batwings 5 and a half!.. all in all a pile of shite that they had no intention of taking back when bending there ear on the phone. Anyway, remember that name.. "MAS" and dont go there!!..

More to follow..
 

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Discussion Starter · #2 · (Edited)
Having done my home work and designed the chassis I started to build. Chassis will be 7 inches from the ground at the front with a slight kick at the bulk head and a major one at the back end.




Above is chassis and front axle at ride height. Spring should compress with weight of engine on it.



Having added the front spring mount I tried a few things out again.. All looks well with the body on and at the right height. Got hold of a few more bits at the Southern swap meet and liked how things are..



 

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Discussion Starter · #3 · (Edited)
Next stop front brakes.. I managed to get some early ford spindles from the US via ebay, the challenge being to get some UK hubs and disks/calipers to work. Lots of heat needed to reshape the steering arms!..

With the lug spacing on the wheels being 5x5 it has made the whole thing quite challenging. I settled on Rover SD1 hubs an disks as the outer bearing appeared to work already with out any work to do.

Next stop was the local bearing shop who measured up the spindle and have provided a pair of inner bearings that work with both parts. I have not put the whole thing together yet so dont hold your breath as to it all being perfect but will let you know. Have also got some ford escort calipers which with a bit of bracketry should work ok with the Rover disks. Hoping to get this together this week so will post when I can..
 

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Discussion Starter · #7 · (Edited)
Its been a long time since I have posted as ive been a tad busy. I had the steering arms bent to suit the front axle, I know they are a weird shape, it had to be done to get them to work with the tube axle. Unfortunately this distorted the bottom insert in the spindle so I have recently had to get this sorted also.

Ok, I split the front hubs and disks and then decided to put the front end together. First issue was the inner bearing had been measured up a little wrong. Bearing could still be used but hub needed a little machining. Got that sorted and chucked in the bearings having cleaned up the hubs and disks a little. Bearings worked fine so attached disks again to see how things looked. Did some mearuring and decided there was enough space to get a caliper mounting bracket bolted to the inside with just enough room to spare.

I made a template for the caliper plates and made myself a couple in a few hours.
 

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Discussion Starter · #8 · (Edited)


The finished item in place and checked for size.



Bolted in place ready for the Hub.



Ta Da!!!.. well, I think I would do it slightly differently next time but all in all quite successful. Next stop 4bars........

Ive been busy again so not had too much time to spend on the car recently but still things are coming on.. Ive had a few parts come through the post and put some wheels on the front axle. The 4 bars are on order as is the steering cross bar. The rear axel has gone off to be shortened an Ive finally got the engine out of storage and not a mo too soon. Its bee stored since last year and has gone down hill a bit since I took it out of the car.





Next job is to get engine at right height and make up engine mount seats to take biscuit mounts. After that its on with K member etc and setting up the brake pedal assembly. More pics as soon as Ihave them.
 

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Discussion Starter · #9 · (Edited)
After much trouble and strife I have found time to get back to the garage again. The pic below was taken about a month ago after making up a set of engine mounts from scratch. Didn't take too long and Im quite chuffed with the end result..
 

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Discussion Starter · #11 · (Edited)
Ive been out there again over the last few days and have managed to get together the K members. Next step is the gearbox mount which is proving to be a bit of a head scratcher at present.
I have had the rear axle back from the shop and it has been shortened. Beyond the Gearbox mount the next step will be fitting the back axle.. Wayhay!!... Its been a long time coming..


 

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Discussion Starter · #12 · (Edited)
:pWell its been a long time and another small person has entered my life :D so time in the garage has dwindled dramatically..:sniff:
Anyway.. I have managed a few hours over the last couple of months and done some good stuff when there. I had been scratching my head about the gear box mount and locating the enging/box and rear axle properly. Due to how I have designed it (and my lack of knowledge when starting this) the propshaft runs uphill at 4 degrees, this has meant I have had to level out the rest of the drive line so the UJ angles are not too steep. Seems to have worked out overall. Below is the GB support which Ive had to add acouple of pack plates to to get it right.

After that I made up some brackets to attach to the rear axle to the ladder bars. I used some of the bits supplied with the (shite:wanker:) front axle.

The ladder bar steel is cut and ready to be made up and the front bushes are on order.
I got hold of the front 4 bars ive been waiting for for a while but when offering them up the angles just didnt look right. sSo I lopped off the ends and made up a jig so I could get them sorted at the right angle.

Given a few brackets, some welding and a bit of time I should have a rolling chassis at last8) it feels like its been a long time coming but it will hopefully spur me on a bit when I get there. :tup::D:tup::D
 

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Discussion Starter · #13 ·
Cracking toast Gromit!!..

These pics are from a while back now, I dragged it out of the garage and started planning the rear ladder bars.





Having made the mock up, as always I drew out what I wanted and then made a jig. The curved bar was just heated and bent around a fixed point.







A while later I started putting things together and was happy with what I had done.





Panhard rod gone in.



Unfortunately I had my phone nicked which had the pics of the front end going together on it so there is a bit of a jump now. I may have them somewhere and will add later if I find them.

Finally I had a rolling chassis and got a real boost from getting to this point. There were some issues to sort but all in all I was really chuffed.





There has been more since the last pic but time has been tight. i have done some work on the seats, the Brake/Clutch set up an the fuel tank. More pics at a later date.. J
 

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Discussion Starter · #14 ·
As promised the pics of recent progress. Seat shells are from a Scimitar and have been narrowed to fit. Will need to be covered before being finished.





Gat given a dash by a friend so measured it up and narrowed to suite. Not sure if I will use as yet , the radius does not match the bodyshell so will have to adapt to suit.





Started on the pedals, used two moggie minor brake pedals and bent one to be the opposite from origional. Used pop brown spindle and boss, land rover clutch master and Camero brake.





Fuel tank is from a jensen healey and will sit behind the rear axle.





Battery to go behind the drivers seat.



Next installment next year probably..:shake::shake: Plan is to finish it this year but dont hold ur breath.. J
 

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Discussion Starter · #15 ·
Next bit!!

Finished the tank hanging setup, I had to make it so I could get it out with the body still in place. Hopefully I have achieved this.





I decided that taking my kids out in this thing when its done would be a really bad idea unless I made it strong enough to take an impact from the side. I'd been having nightmares as the body is not very thick and anything hitting it side on is just going to keep going!!.. below is so far, got some side bars to go in as well to complete the cage.



 
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