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Hi Ross There is a shed load of info on this forum, you need to look at the last 4 Freestyle buggy builds, been through IVA. All the questions you are asking are well documented. I did the whole braided hose thing on the buggy and on my recent build I went with solid pipe as the clutch and...

Good point Alan, I welded a piece of 3mm plate to the side to stop flex as you recommended then they are all over the handbrake and seatbelt strength testing at IVA. Also if you have the front cycle wing brackets off make sure you beef them up, mine have failed twice. The design picks up on 4...

Welcome 😃

Good to see another Freestyle buggy project in build 😃

Couple of pics for you, hope it helps 😃

You can see the material to take off from the pic, enough for the lock and adjust collars to clear the channel. Remember to get thick gauge channel, the forces here are substantial!

Alan is right, I tried a few flaring tools and then got that one and produced perfect results every time. Get the kunifer, don't be tempted to get the cheapest stuff as it is not copper, you can hold a magnet up to it and see it is ferrous. It looks tatty and corrodes pretty quickly if not. Get...

You don't really need a template, just find a piece of heavy gauge channel that is wide enough to take both the shock ends, bolt through the eyes and take any slop up with washers, bolt the channel to the bulkhead and then remove enough material so the shock body clears the channel when fixed at...

How did lose the template, it was bright blue!

When I built the Freestyle I could just about man handle the A series out of the subframe to refurb and back in again with a beam and rachet strap. I managed to get the Zetec in the 7 without using an engine crane the hard way but said if it had to come out again I would buy one, it did as I...

I am building a GBS Zero, 40% of builders put the Mazda MX5 engine in and 40% put the Ford Zetec and now Duratec engines in, the other 20% of people have the skills to fabricate and the knowledge to choose a different option which is quite interesting. Seen some S2000 engines, the Calibra...

Decision made then 😃

Have you got a Rover V8 in stock?

My ST 225 duratec has bags of torque, might be a good choice? and a bit lighter. RX8 gearbox? Got to be plenty of those lying around.

Seen a couple of Dax rush with the YB cosworth engine in, that will be a great project. What engine are you thinking of using Andy? I got some Dax rush mirrors and windscreen uprights for my 7 as I liked the design, came from Belgium.

Hi Alan, I looked at rebuilding an old robin hood but the most un roadworthy version I could find with a v5c were starting at £3K. My Freestyle costs were IVA plus 15 minute retest. Plus 2 days off work plus 2 delivery trips plus registration fees. It soon adds up to an awful lot 😕...

Still only a few degrees but found some motivation to get some jobs done 😃 Got the manifold back on, dip stick bolted back on. The gap didn't need enlarging which is one less thing to do so result with that. Think it should be fine. Found some 3mm mild steel, an old bracket now made...

Hi Rich that looks really smart. Can you get a boost gauge on there for the turbo too? The CAN Comms works really well in mine, really impressed. All sensors wired into ECU then two wires to the dash and you have all the access to what ever data that you are interested in, much more than room...

Hi Rich, happy new year too mate! 😃 Thanks very much for getting back to me, your info is very helpful and just what I was after. It's really good to be able to share info as to what works and what doesn't. I started printing with PLA and had some rolls that came with the printer and bought...

Only a few degrees here today, wanted to get a few jobs done. Had another look at exhaust heat wrap, wasn't 100% happy so took it all off and did it again, knew I could get it a bit neater. Got rid of those fluffy edges. Fitted the new printed bracket, made out of PETG. Coolant bottle is...