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My Haynes Roadster Build


st3v3nw

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looks awesome so far. Are you going completely by the book? i've come across a few bits in the past about adding a few extra tubes here and there to increase the stiffness. Pretty sure i've seen it put through a computer modelling program to evaluate the stiffness. Sorry don't have any links but could be worth a google search if you haven't already.

 

Good job, looking forward to seeing the progress.

 

 

here is some stuff about chassis stiffness - http://locost7.info/.../aussiemods.php

 

Interesting stuff there but my chassis is based on the newer roadster one and not the original Ron Champion chassis that had the torsion issues in Australia.

 

I'm following the book for the most part, still undecided on the engine.

 

I have narrowed down to three.

 

New 2L blacktop zetec

Used 1.7 VVT Zetec SE (puma)

Used Saab B207 2L turbo

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cool, although i did notice a modification you might consider (depending on your engine choice). In the picture you posted you have the single brace in the engine bay. The modification is to replace this bar with a Y shaped arrangement on both sides. It increases torsional stiffness and provides increased room around the engine, which could be useful if you engine is a tight fit.

It's your car so please don't think i am trying to tell you how to do it (seeing as i haven't build one myself) but you may not have seen the mod and it will be easier to do at this stage if you did decide it is worth doing. There are quite a few extra bits on my 2b i wish i had done which is too late now it's together.

 

this is a pic i found online showing what the mod is (although they have used round tube). Can't find the evidence at the mo about it increasing stiffness but definitely read it this morning.

 

Hope thats helps either way. As said above keep posting your progress.

 

Sept11011.jpg

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That looks neat. would be good to see the science to back it up. I will be fitting a cross brace behind the steering rack like they have on the new zero chassis. that should get rid of torsion across the front suspension area. Got to do that once the rack is fitted though to make sure it fits.

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  • 3 weeks later...

Sorry about the delay in updating...

 

As I plan on making every panel from carbon fibre I started with the steering column shroud.

 

Started by blanking off the holes then body filler, sanding, high build primer, more sanding, gloss top coat and more flatting.

 

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Gearbox was checked over and found to be near perfect inside with no wear so cleaned and painted

 

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Diff was stripped and casing bead blasted. I'll be fitting an LSD in here so stripped it right back and had to make some special tools to get it apart.

 

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Rear hubs were treated in the Deox C bath which stripped them of rust, then washed and primed then painted

 

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Final parts were welded to the chassis minus the engine mounts while I wait for an alloy bellhousing to be made to connect the puma engine to the type 9 box

 

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Meanwhile, I made the jigs for making the suspension wishbones

 

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And also started on the plates to make the engine mounts using a broken 1.7 zetec se engine as a guide

 

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Finally, whole chassis was cleaned, primed and has had it's first top coat

 

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  • 2 weeks later...

Been on holiday this weekend just gone so less progress this week.

 

Fabricated and painted my roll bar. 50mm x 2mm wall seamless tube hoop with a 40mm x 2mm seamless harness bar across it. Into this I welded four threaded inserts for the harnesses.

 

 

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Primed then painted with Plasti-kote gloss black. This stuff leaves a finish like powder coating.

 

 

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Diff brackets welded up and painted as above but in satin black

 

 

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Made the inserts for the suspension bushes. These are seamless stainless steel. 22 of them made then polished up.

 

 

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Poly bushes inserted into the lower wishbones, then they were packed away till final assembly.

 

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Guest alfaGTA

Hi, good progress so far! From the pics it looks like (but isn't clear to me) your upper seat belt mounts pass the whole way through the roll bar cross member and are welded at both sides? That will keep Mr IVA happy.

 

Good engine choice too

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