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Haynes roadster build

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124

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    #92
    listermint
    Registered Users Posts: 33,613 ✭✭✭✭listermint


    I was starting to get concerned from your pics in the old shed as to how you would get a completed car out with 1 small door until seen the new shed. Surprised no one picked up on that. Clean build btw


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    #93
    Zebrano
    Registered Users Posts: 699 ✭✭✭Zebrano


    Wibbs wrote: »
    Great result with the rust. It's so effective it looks like it's puling rust outa the wall. :)

    I've used that Bilt Hamber DeOx stuff before. Works well for small parts you can submerge. I found the gel pretty crap though. Both take much longer than the instructions say, but the results look like yours.

    Yea it works well also didnt cost a lot as i had everything


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    #94
    Zebrano
    Registered Users Posts: 699 ✭✭✭Zebrano


    listermint wrote: »
    I was starting to get concerned from your pics in the old shed as to how you would get a completed car out with 1 small door until seen the new shed. Surprised no one picked up on that. Clean build btw

    Well i knew that was a problem but when i moved the chassis was as big as it was going to get so if i had a fully finished car i would of just had to strip it down completely


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    #95
    Zebrano
    Registered Users Posts: 699 ✭✭✭Zebrano


    So ive a serious pain in my face at the moment cleaning and painting and reassembling the engine
    Before
    42090164242_b90b4d3fea_c.jpgUntitled by stephen harborne, on Flickr
    Current
    43514085161_860605fe85_c.jpgUntitled by stephen harborne, on Flickr
    Im also doing a coil on plug upgrade as i had all the parts i needed so it didnt cost me anything
    29875205138_683aabf5c0_c.jpgUntitled by stephen harborne, on Flickr
    43746373151_a5513d6ba1_c.jpgUntitled by stephen harborne, on Flickr


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    #96
    Zebrano
    Registered Users Posts: 699 ✭✭✭Zebrano


    Some more progress

    41961263790_1d1ec3b24a_c.jpgUntitled by stephen harborne, on Flickr

    Im also going to do some kind of diy coolant reroute
    Havnt got it fully figured out yet

    43055001974_90559da1d2_c.jpgUntitled by stephen harborne, on Flickr

    This part fits nicely of the back of the engine like so
    41961262470_1dd24163a7_c.jpgUntitled by stephen harborne, on Flickr


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    #97
    funkey_monkey
    Registered Users Posts: 8,053 ✭✭✭funkey_monkey


    Have you done or planning any engine mods? What spec is that engine?


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    #98
    Zebrano
    Registered Users Posts: 699 ✭✭✭Zebrano


    funkey_monkey wrote: »
    Have you done or planning any engine mods? What spec is that engine?

    Its a mx5 1.8.engine. I think around 130bhp.
    Nothing planned at the moment mods wise just want to get the car on the road


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    #99
    Zebrano
    Registered Users Posts: 699 ✭✭✭Zebrano


    Finally got the engine back together mostly

    43172969454_4846251668_c.jpgUntitled by stephen harborne, on Flickr

    43172968934_a41df060d5_c.jpgUntitled by stephen harborne, on Flickr


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    #100
    Zebrano
    Registered Users Posts: 699 ✭✭✭Zebrano


    So ive got a bit done recently
    First i built an spacer for the new rear coolant pipe for the reroute to move it out from the block

    42582039290_dbb3e8292a_c.jpgUntitled by stephen harborne, on Flickr

    Then i filled in the the hole in the side coolant connector

    43482733325_ee511bd63e_c.jpgUntitled by stephen harborne, on Flickr

    Used a 20 cent to stop the epoxy running into it

    30523215778_255f262c9b_c.jpgUntitled by stephen harborne, on Flickr

    Filled with epoxy

    30523216778_43f731ee84_c.jpgUntitled by stephen harborne, on Flickr

    The hole was a feed for the interior heater so is not needed


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    #101
    Zebrano
    Registered Users Posts: 699 ✭✭✭Zebrano


    This is the coolant reservoir That i got
    It only has this mounting point so i made a bracket to hold the whole thing

    44579539301_5bb94b1194_c.jpgUntitled by stephen harborne, on Flickr

    44579545341_e30caa4b12_c.jpgUntitled by stephen harborne, on Flickr

    43861103614_b57c6fb011_c.jpgUntitled by stephen harborne, on Flickr

    I also removed the old mounting points for the heat shield from the manifold and cleaned and painted it

    43861100704_0ba58ea292_c.jpgUntitled by stephen harborne, on Flickr


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    #102
    Zebrano
    Registered Users Posts: 699 ✭✭✭Zebrano


    I also started on the pedal box

    43861102074_9d6323071b_c.jpgUntitled by stephen harborne, on Flickr

    I also mounted the ecu under the dash

    42790994440_9f6741394d_c.jpgUntitled by stephen harborne, on Flickr

    And made a bracket for the accelerator cable

    29663289327_9ca8fae0d4_c.jpgUntitled by stephen harborne, on Flickr

    And the engine is back in

    43861104224_5f4025784d_c.jpgUntitled by stephen harborne, on Flickr


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    #103
    Zebrano
    Registered Users Posts: 699 ✭✭✭Zebrano


    Next up was to mount the radiator to the chassis
    I was originally going to use a spurious golf rad which was not great looking to be fair then coolex had nice ali rads for a polo for quiet cheap at the national kit car show so i picked one up

    I Got two brackets bent up for it to mount it to the chassis

    43713607345_e19604a1cc_c.jpgUntitled by stephen harborne, on Flickr

    Clamped in place to check everything lines up

    43713612265_0e214b5336_c.jpgUntitled by stephen harborne, on Flickr

    Checking the fit of the nose cone

    43713604895_d59b18502a_c.jpgUntitled by stephen harborne, on Flickr

    I decided to add two new pieces to the chassis rather than drill through the existing chassis

    43734472845_b5bff8982d_c.jpgUntitled by stephen harborne, on Flickr


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    #104
    Zebrano
    Registered Users Posts: 699 ✭✭✭Zebrano


    Then i started on the piping for the cooling system which i picked some of it up at the kit car show
    And some of the rest of the parts came from aliexpress
    I picked up the wrong size pipe so i need to get some more 32mm id piping

    30773850458_b70a5bbf8b_c.jpgUntitled by stephen harborne, on Flickr

    Then i started on the wiring which is a whole other can of worms

    42851445150_a8c5573b4f_c.jpgUntitled by stephen harborne, on Flickr

    29724056147_107f5be42c_c.jpgUntitled by stephen harborne, on Flickr


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    #105
    funkey_monkey
    Registered Users Posts: 8,053 ✭✭✭funkey_monkey


    Good luck with the wiring!


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    #106
    Zebrano
    Registered Users Posts: 699 ✭✭✭Zebrano


    funkey_monkey wrote: »
    Good luck with the wiring!

    Shouldnt be too bad 😂


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    #107
    ozmo
    Registered Users Posts: 3,842 ✭✭✭ozmo


    Looks a great build! Well done so far.
    Then i filled in the the hole in the side coolant connector with epoxy

    But does that bit get hot? I've had epoxy repairs melt and fail on me before over time at under the rated temperatures of epoxy...?

    “Roll it back”



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    #108
    Zebrano
    Registered Users Posts: 699 ✭✭✭Zebrano


    ozmo wrote: »
    Looks a great build! Well done so far.



    But does that bit get hot? I've had epoxy repairs melt and fail on me before over time at under the rated temperatures of epoxy...?

    Yes it gets hot. but ive no other option at the moment ill see how it goes


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    #109
    Zebrano
    Registered Users Posts: 699 ✭✭✭Zebrano


    30225897287_789e83fd93_c.jpgUntitled by stephen harborne, on Flickr
    Finished the fabricating on the expansion tank bracket

    44442676734_7ddeb25820_c.jpgUntitled by stephen harborne, on Flickr

    31291100728_ddde108d8d_c.jpgUntitled by stephen harborne, on Flickr

    43350690470_53d3c665ec_c.jpgUntitled by stephen harborne, on Flickr

    Bracket for top hose
    Cooling system nearly finished i just need a new thermostat and a few jubilee clips


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    #110
    Zebrano
    Registered Users Posts: 699 ✭✭✭Zebrano


    30226455457_55d625a5ce_c.jpgUntitled by stephen harborne, on Flickr
    I had to move the steering wheel a bit closer to the seat
    43349989190_3b116b9f35_c.jpgUntitled by stephen harborne, on Flickr
    And i made a supporting bracket for the steering shaft
    31291112238_feb48d7152_c.jpgUntitled by stephen harborne, on Flickr
    And i tacked the steering shaft extension in place


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    #111
    Zebrano
    Registered Users Posts: 699 ✭✭✭Zebrano


    30226456087_3381a88663_c.jpgUntitled by stephen harborne, on Flickr
    More wiring
    44442683204_1cc6966655_c.jpgUntitled by stephen harborne, on Flickr
    I got my rear lights they are for a defender
    I got all clear ones
    31291112718_6440d93f92_c.jpgUntitled by stephen harborne, on Flickr
    Mounted my maf using some turbo intercooler piping
    31291108758_ac38fbac78_c.jpgUntitled by stephen harborne, on Flickr
    Mounted my fan aswell


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    #112
    Wibbs
    Moderators, Science, Health & Environment Moderators, Society & Culture Moderators Posts: 60,071 Mod ✭✭✭✭Wibbs


    This is real quality work Zed and addictive to watch.

    Rejoice in the awareness of feeling stupid, for that’s how you end up learning new things. If you’re not aware you’re stupid, you probably are.



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    #113
    Zebrano
    Registered Users Posts: 699 ✭✭✭Zebrano


    Been away from the build for a while
    Next on the list was too hinge the bonnet at the front
    So i made a steel frame for the front of the nose cone which i riveted in place the fibreglassed over to give strength

    32619467268_781243c552_c.jpgUntitled by stephen harborne, on Flickr

    46440756462_0f398e1451_c.jpgUntitled by stephen harborne, on Flickr

    45768706634_23d13da01d_c.jpgUntitled by stephen harborne, on Flickr

    32619468418_1d2ff3a125_c.jpgUntitled by stephen harborne, on Flickr


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    #114
    Zebrano
    Registered Users Posts: 699 ✭✭✭Zebrano


    Bonnet now in place

    46440752642_6fea80ff8a_c.jpgUntitled by stephen harborne, on Flickr

    45768710214_8a0a755ed3_c.jpgUntitled by stephen harborne, on Flickr

    Bonnet in place passenger side gap to scuttle panel

    45775422964_839077153c_c.jpgUntitled by stephen harborne, on Flickr

    Drivers side gap
    This will not do
    31558891167_2f64a78992_c.jpgUntitled by stephen harborne, on Flickr


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    #115
    Zebrano
    Registered Users Posts: 699 ✭✭✭Zebrano


    Along came a grinder
    45775423004_5f9ed34ff9_c.jpgUntitled by stephen harborne, on Flickr

    And the i cleaned up a bit
    45780742744_f9365e90ed_c.jpgUntitled by stephen harborne, on Flickr


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    #116
    JamBur
    Registered Users Posts: 834 ✭✭✭JamBur


    Just found this now. Excellent work. How long until you have her on the road? What part of the country are you in?


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    #117
    Zebrano
    Registered Users Posts: 699 ✭✭✭Zebrano


    JamBur wrote: »
    Just found this now. Excellent work. How long until you have her on the road? What part of the country are you in?


    Thanks.
    No idea when it will be finished.
    Depends on time money and motivation.

    Im in north co dublin


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    #118
    SuperTortoise
    Registered Users Posts: 2,947 ✭✭✭SuperTortoise


    Randomly browsing the front page and found this thread! Read from start to finish, great build, great thread, well done.
    Looking forward to seeing the finished article.


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    #119
    Zebrano
    Registered Users Posts: 699 ✭✭✭Zebrano


    It lives again
    https://youtu.be/6oTIjozuTWQ


    Im happy out considering since the last time it ran ive changed the timing belt and done a coil on plug conversion plus lots of other wire chopping

    There is one coolant leak on the plates i made for the coolant reroute which i just sealed up and maybe i need to get some gaskets to do it properly


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    #120
    Zebrano
    Registered Users Posts: 699 ✭✭✭Zebrano


    I also did some wiring and due to the fact i like my fingers i made this to split the conduit

    32659495938_c71eca8904_c.jpgUntitled by stephen harborne, on Flickr

    45809045804_29abbb524e_c.jpgUntitled by stephen harborne, on Flickr

    Got the side and head lights working aswell

    44715457050_4e4f1a6846_c.jpgUntitled by stephen harborne, on Flickr

    44715456730_7c99219762_c.jpgUntitled by stephen harborne, on Flickr


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    #121
    Zebrano
    Registered Users Posts: 699 ✭✭✭Zebrano


    For some stupid stupid reason i decided i wasnt happy with the wiring as the loom was too long in places and the fuse boxes were too messy for me so ive spent a good while at it now and am happy enough where it is now.

    32779555918_c9ef9f865a_c.jpgUntitled by stephen harborne, on Flickr

    45815874975_bb29b77e78_c.jpgUntitled by stephen harborne, on Flickr

    39852601543_6d10bde6c9_c.jpgUntitled by stephen harborne, on Flickr


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