MarkBzero

Next job was to remove the diff, drive shafts and rear brakes. My little trolley jack did not have the clearance to lift the car so in the end I had to use some railway sleepers in the center of the car, removed the front wheels and asked my neighbour to sit on the bonnet to pivot the car like a see-saw. Then I managed to roll the the complete unit into the garage, and rested the car on blocks of wood. Next job was to remove the front brakes and hubs, and most other ancillaries.

This picture shows the sphere they use for sharp edges.

I started to strip the donor parts from the Sierra during the winter in 2009. It was good fun, and I had my little helper 'Craig' my over eager son to break everything or smash it with a hammer (you'll see more of his help later). First I removed the engine then the gearbox the health and safety brigade would not approved of some of the techniques I used but they both came out relatively easy. It was very cold. I cannot argue about his dedication, I just wished he completed his home work with the same passion. You might have noticed, it is a 4 speed box at this stage I could not decide what gearbox to fit.

First of many surprises and a reminder not to buy a car from Ebay without inspecting it. The car was taxed and MOT'd and the seller agreed to drive it my brothers, so I thought why not buy it! My brother is not a mechanic but has some experience with older cars, he called me and asked what engine was I expecting it's a Sierra a pinto of course. Well I was wrong, it was a good old fashion Ford crossflow. I hear some shout Ford did not do a Sierra with a Crossflow and you would be right in this country, however after a bit of delving I discovered the car is a South African Ford import, they used the crossflow in Sierra's until 1986 would you believe it. Unlucky for me because the only other engine fitted to Sierra's in SA was the V6 Cologne engine, now that would be a nice engine to fit in a kit car.

First problem, I did not have a suitable location to build a kit car. I looked at local lock-ups but price and trying to find one with electric and heating was proving very difficult. So I made some queries on building a garage next to the house. I had to convince the other half this was a good idea and would add value to our property. I used a a pre-fab Hanson garage (Timberland Products completed the build, great bunch guys, highly recommended), building application was easy and I had no problems with the build except the building inspector want 1.7m footings. This annoyed the hell out of the contractor who had built over 3000 units on 4inch hardcore and 4inch cement foundations. Garage sorted I had to fit electrics and workbench, this was back in Oct 2009.

Well I have dreamed of building a kit car for over 20 years. I decided on building a Robinhood 2B but I was in the Army and posted around the world. Finally I was medically discharged after 11 1/2 years due to injury and had more time and fixed location. However since leaving Robinhood engineering went through a few changes and I decided on a GBS Zero, why because it was cheap and used a single donor. I have not had time to create a blog whilst building the kit, it has taken me about 4 years and just waiting for IVA re-test date so whilst am waiting I thought I would share some photos and issues that may help others. I am a mechanic by trade although I have not worked in a garage for 8 years, except on the kit car. Finally I would like to thank many on this forum for their help and guidance. How do I turn this; and this; Into this;

Winter project to resolve IVA failures 3 completed 1 to go, no old school carb tuners in this area to reduce emissions. Finally found someone with good reputation need to organise a day off work.

Going to be very difficult with those curves, I doubt any off the shelf version will fit. You could buy a plastic version and cut down to size, or my preferred option would be to make a fibre-glass version specific to your needs.

Congratulations looks like a decent build, must be great with all that power under the bonnet. Welcome to the club.

Hi Kevin, I only sent photo's when applying for the IVA test, lots of my mug and bits of car at various stages. IVA tester did not want to see any.

KIA 7 years warranty. I am biased currently have Kia Sportage picked up in June 2013, 35,000 miles including towing 5 berth caravan, one service and no other issues.

Sounds like an interesting project.

Hi Craig, Down to personal choice, the next debate will be on the fuel system, bike carbs, standard, injection, twin 40s it never stops. I have a xflow and with twin 40 dellortos and yes occasionally I would like more power, but very rarely it was not built to race. But the sound is great. Why do you want to upgrade?

Steve, Very rare, ebay has the steering column wiring loom might be your only choice. http://www.ebay.co.uk/itm/FORD-SIERRA-MK2-STEERING-COLUMN-STALK-WIRING-KIT-CAR-/281235616695

I have a stand currently on loan to somebody in work, when do you need it? Mark

Hi Dan, I have used Advanced automotive a few years ago for chokes for my twin 40 dellorto's great service and quick delivery. Not sure how compare on price but they were recommended by a friend. They also have an Ebay shop. http://www.advancedautomotives.com/weber-45-dcoe-38mm-chokes-venturi-set-of-4-fse-sytec-quality-1744-p.asp

I can not make Thursday, working away in Basingstoke. Please let me know future dates hopefully the kit will pass the re-test soon. Regards Mark

Hi Alan, welcome to Rhocar hope to see you at next event or meet.

I found it was the little jobs that took much longer than any big task, not to mention all the times I had to take something off to fix another part of the car. Looking good so far.

Just looking at the Malvern site and it does not list Rhocar in the club stand. Is anyone talking to the organisers?

Smart, more picture please, how long did it take to build?

I don't like the over the top exhaust systems so I used Ashley's Exhausts in Birmingham excellent job made the manifold and silencer. Even gave me two invoices one for the wife and one for me!

The guys who made my exhuast in stainless steel said 'never use wrap' and they have been making exhuasts for race cars for years. Ashley's exhausts they done a really good job, highly reccommended.

Excellent Christmas present, well done not long now.

Looks good, I'll add this to the jobs to do after IVA.