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Haynes roadster build

15-01-2016 8:39pm

#1

Zebrano

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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

4

Comments

#2 15-01-2016 8:44pm

Into The Blue

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Sierra as donor?

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#3 15-01-2016 8:45pm

Zebrano

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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

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#4 15-01-2016 8:47pm

Zebrano

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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

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#5 15-01-2016 8:51pm

Zebrano

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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

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#6 16-01-2016 12:40am

kev1.3s

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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.

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#7 16-01-2016 10:36am

Zebrano

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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.

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#8 16-01-2016 6:49pm

Alkers

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

0
#9 17-01-2016 12:40am

Zebrano

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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.

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#10 17-01-2016 10:30pm

Zebrano

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Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

Seat back

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#11 17-01-2016 10:32pm

Zebrano

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Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

side rails

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#12 17-01-2016 10:35pm

Zebrano

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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

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#13 17-01-2016 10:39pm

Zebrano

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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

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#14 17-01-2016 10:43pm

Zebrano

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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

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#15 17-01-2016 10:47pm

Zebrano

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Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

Untitled by stephen harborne, on Flickr

Diff mocked up

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#16 17-01-2016 11:05pm

kev1.3s

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

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#17 17-01-2016 11:24pm

Zebrano

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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

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#18 24-01-2016 1:27am

Ded_Zebra

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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

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#19 24-01-2016 10:32pm

Zebrano

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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

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#20 28-01-2016 9:28pm

Zebrano

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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

0
#21 29-01-2016 1:23pm

Notch000

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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

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#22 29-01-2016 1:23pm

Notch000

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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

0
#23 29-01-2016 2:41pm

Zebrano

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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

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#24 05-02-2016 8:49pm

Zebrano

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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 Flickr Untitled by stephen harborne, on Flickr

0
#25 05-02-2016 8:53pm

Zebrano

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Bottom Jig

by stephen harborne, on Flickr

by stephen harborne, on Flickr

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#26 05-02-2016 8:58pm

Zebrano

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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

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#27 02-03-2016 9:47pm

Zebrano

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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

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#28 02-04-2016 2:50pm

Zebrano

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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

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#29 02-04-2016 9:07pm

Zebrano

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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

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#30 02-04-2016 9:10pm

Zebrano

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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

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#31 22-04-2016 6:17am

Zebrano

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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

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