Haynes roadster build

Zebrano

Ok so ive decided to build a haynes roadster its something ive wanted to do since i was a teenager so i finally got a welder and a chop saw and some steel and so started my decent into madness

Welder by stephen harborne, on Flickr
Welder by stephen harborne, on Flickr

I opted for a redline 210 mig welder package it came with wire gas and a regulator first impressions were that it looked a bit cheap and chinese
but i have to say i was impressed with its performance so far.

More toys by stephen harborne, on Flickr
More toys by stephen harborne, on Flickr

I also went a bit ott with the saw but its been worth it so far after about an hour of setting up it has cut perfect

Untitled by stephen harborne, on Flickr
Untitled by stephen harborne, on Flickr

And the build table

Into The Blue

Sierra as donor?

Zebrano

Ok so for those who don't know the Haynes roadster its basically a tubular space frame chassis that uses running gear from a donor vehicle.
In my case im using Mx5 running gear you can also use a sierra.

The space frame is made from 25mm x 25mm x 2mm box section tubes and some other size tubes but mainly this size.
There is a Haynes manual available with all the plans and plenty of online support as its quite a common project.

First cut by stephen harborne, on FlickrFirst cut by stephen harborne, on Flickr
This was the first cut on my chassis

Chassis first pics by stephen harborne, on Flickrchassis first pics by stephen harborne, on Flickr
These are the upright tubes

Chassis first pics by stephen harborne, on FlickrChassis first pics by stephen harborne, on Flickr
The bottom chassis rails all tacked up

Zebrano

Next up was the front frame this requires its own jig this is a bit complicated but the haynes forum have some helpful guides

Untitled by stephen harborne, on FlickrUntitled by stephen harborne, on Flickr
Front frame in jig ready to be tacked in place

Untitled by stephen harborne, on FlickrUntitled by stephen harborne, on Flickr
Tacked up and put in place

Zebrano

Ok so next up you tack in the uprights and start putting the top rails in place this went quiet smoothly

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

kev1.3s

Following with interest, I'm more than a little surprised that you have to weld up the chassis yourself. Always taught that would be factory built.

Zebrano

kev1.3s wrote: »

Following with interest, I'm more than a little surprised that you have to weld up the chassis yourself. Always taught that would be factory built.

You can buy fabricated chassis alright but thats a bit too easy for my liking.

Alkers

What's the rough cost for the whole build? How is it to get insured etc?

Zebrano

Simona1986 wrote: »

What's the rough cost for the whole build? How is it to get insured etc?

Hard to know really. If i have it on the road for under 10k ill be happy.
As far as i know the irish kit car club have an insurance scheme set up with axa.

Zebrano

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

Seat back

Zebrano

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

side rails

Zebrano

Untitled by stephen harborne, on Flickr
Transmission tunnel

Untitled by stephen harborne, on Flickr

View from the drivers seat

Untitled by stephen harborne, on Flickr

Zebrano

Untitled by stephen harborne, on Flickr
Diff cage

Untitled by stephen harborne, on Flickr
Strut towers

Untitled by stephen harborne, on Flickr
Rear frame work

Zebrano

by stephen harborne, on Flickr

by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

Some of the doner parts

Zebrano

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

Diff mocked up

kev1.3s

Excellent work, you aren't wasting any time, any idea how long it'll take?

Zebrano

kev1.3s wrote: »

Excellent work, you aren't wasting any time, any idea how long it'll take?

Im jus copying from another thread i started in august maybe. If done in 4 years ill be happy

Ded_Zebra

Fantastic project!!! Really really cool. Was it last August you started the project?

I know absolutely nothing about Haynes roadsters, I'll have a quick google now but it would be great of you could post some more information about it and maybe a picture of what your end vision of the project will be :D

Zebrano

https://upload.wikimedia.org/wikipedia/commons/thumb/c/c5/Haynes_Roadster.jpg/1280px-Haynes_Roadster.jpg
This is a pic of what a finished one look like

https://en.wikipedia.org/wiki/Haynes_Roadster
Some more info

https://haynes.co.uk/forums/index.php
Dedicated forum

I actually started building in october but i started getting tools and steel in september

Zebrano

Untitled by stephen harborne, on Flickr
Suspension wishbone brackets
Had to make 16 of these little bit tedious but got there in the end

Untitled by stephen harborne, on Flickr
Lower rear brackets clamped ready to be tacked in place

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr
Left rear brackets tacked in place

Untitled by stephen harborne, on Flickr
Right rear brackets in place

Notch000

class, i'm starting a welding course next week & i've an MX5 already, 10 yrs of surfing the internet and being a machinist / builder in my head must amount to some fab skill.......

What final weigh are you aiming planning for ?? is it 1.6 or 1.8 ??? would love to tackle something like this, I think il start with a go kart first tho

Notch000

class, i'm starting a welding course next week & i've an MX5 already, 10 yrs of surfing the internet and being a machinist / builder in my head must amount to some fab skill.......

What final weigh are you aiming planning for ?? is it 1.6 or 1.8 ??? would love to tackle something like this, I think il start with a go kart first tho

Zebrano

Its a 1.8
Hoping for around 700kg we shall see.
Just go for it. Welding is probably the most difficult part.
All the rest just takes time and patience.
Plus you already have the doner

Zebrano

Ok so i got the front suspension brackets mounted this required a jig to be made
it was a bit fiddly but got done in the end

Top jig
Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on FlickrUntitled by stephen harborne, on Flickr

Zebrano

Bottom Jig

by stephen harborne, on Flickr

by stephen harborne, on Flickr

Zebrano

Brackets tacked in place

by stephen harborne, on Flickr

by stephen harborne, on Flickr

Also added a support brace

Untitled by stephen harborne, on Flickr

Got these cut for the lower adjusters for the wishbones

Untitled by stephen harborne, on Flickr

Zebrano

Got my hand brake mounted

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr
ade these to bolt it to

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

Zebrano

Ok so i haven't updated this in a while.
But i have been busy as i said i had to upgrade the power supply to the shed to run the welder properly so i have since done this and also installed new lights to brighten the place up a bit.
So since i have most of the the chassis tacked together i decided to fully weld up as much as i can and my bandsaw had broken so i couldn't cut anymore steel anyway
Im currently about 95%or more welded after about 6 to 7 hours of welding


Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

Zebrano

Ive also got a radiator to make up the rad mounts its from a mk3 golf
So i wasn't really sure about the mounting so there was a nose cone second on eBay
and after a bit of a bidding war it was on its way across the sea i also won a dash blank


by stephen harborne, on Flickr

by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

Zebrano

by stephen harborne, on Flickr

by stephen harborne, on Flickr

by stephen harborne, on Flickr

So as you can see the rad was touching the nose cone so that needs to be adjusted glad i found out now

Zebrano

So i got another little bit done
got the bulkhead tacked in place i still need to cut a hole and mount a bearing for the steering column and the pedal box is the lower half of the bulkhead.

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

I also started on the suspension
I have made the camber adjusters for the wishbones which need to be made first to complete the wishbones

Untitled by stephen harborne, on Flickr
The jig for aligning them

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

Zebrano

Started on my wishbones
I was dreading these a bit but the first one worked out fine

Untitled by stephen harborne, on Flickr
The two bush tubes and the m16 x 1.5 threaded tube for the ball joint clamped in place

Untitled by stephen harborne, on Flickr
The first arm tacked in place

Untitled by stephen harborne, on Flickr
one side welded

Untitled by stephen harborne, on Flickr
Other side welded

Untitled by stephen harborne, on Flickr
Cleaned up a bit

Only seven more to do

Zebrano

Ok so its been a while but i have been tipping away

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr
Rear upper wishbone

Zebrano

Untitled by stephen harborne, on Flickr
Rear lower

Untitled by stephen harborne, on Flickr
Front lower

Untitled by stephen harborne, on Flickr

These were quiet time consuming but very satisfying to make

Untitled by stephen harborne, on Flickr

Zebrano

Untitled by stephen harborne, on Flickr
Getting the engine and gearbox in place

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

engine mounts tacked up gearbox mount also done

Zebrano

Untitled by stephen harborne, on Flickr
Front suspension in place

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

Zebrano

Untitled by stephen harborne, on Flickr
Wheels on

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr
View from the door

sgalvin

Congratulations on the progress.
Great to see the builds moving on from the idea to start!

Whereabouts in the country are you?
Is this planed as a road car or a track you as am curious about nsai and insurance for road use.

Thanks steve g

Zebrano wrote: »

Untitled by stephen harborne, on Flickr
Wheels on

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr
View from the door

Ded_Zebra

This is such a cool project! really love the work you're doing, keep it up:)

OldMrBrennan83

This post has been deleted.

Zebrano

sgalvin wrote: »

Congratulations on the progress.
Great to see the builds moving on from the idea to start!

Whereabouts in the country are you?
Is this planed as a road car or a track you as am curious about nsai and insurance for road use.

Thanks steve g

Hi
Im in north dublin
I hoping for it to be road legal But we shall see when the time comes.
Ive been on to the nsai and they haven't tested a kit car since the took over the responsibility so maybe that will have changed by the time I'm finished.
But I'm also prepared for it to be a track car if it gets too complicated or expensive.
As for insurance there are people in the country with kit cars insured and i think the icky have a group thing with axa.

Zebrano

Ded_Zebra wrote: »

This is such a cool project! really love the work you're doing, keep it up:)

Thanks

Zebrano

Patww79 wrote: »

This post has been deleted.

Thanks

Thargor

Great read and great pics thanks.

MAJJ

Thargor wrote: »

Great read and great pics thanks.

Completely agree, enjoying the thread. Thanks and best of luck with it.

RustyNut

Awesome

Zebrano

RustyNut wrote: »

Awesome

Thanks

Zebrano

Ok so here is where im at

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

This is what i have removed from the original loom

Havnt had a lot of time since ive been back from holidays but been tipping awayat the wiring

galwaytt

Zebrano wrote: »

Hi
Im in north dublin
I hoping for it to be road legal But we shall see when the time comes.
Ive been on to the nsai and they haven't tested a kit car since the took over the responsibility so maybe that will have changed by the time I'm finished.
But I'm also prepared for it to be a track car if it gets too complicated or expensive.
As for insurance there are people in the country with kit cars insured and i think the icky have a group thing with axa.

Excellent project, and excellent progress - well done.

If you're happy to have it as a track car only, that's great, but it would annoy me to not have it road-legal.

I work in a place that is involved with NSAI on a daily basis on EWVTA, and to put it mildly, it's a nightmare. Quite how any kit car will end up on the road here at all since 2013 escapes me.

Even prior to that, to register it, you have to pay VRT and VAT on it's finished value and they calculated the approx number of hours you spend building it........

The nuclear option of course is to get it registered in the UK/NI, and the import it here........ https://www.gov.uk/vehicle-approval/individual-vehicle-approval

The NSAI here would have no idea where to start, whereas at least in the UK they have a path you can follow: https://www.gov.uk/government/uploads/system/uploads/attachment_data/file/277534/guide-to-the-iva-scheme.pdf

Zebrano

Yes that will most likley be the best option but will still have to pay vrt and vat

Zebrano

https://youtu.be/yeAGCuPd5FQ
so the engine still runs since i removed all the wires