Wills Build

[Will]

Morning All,

you may remember a while ago I posted about "upgrading" to a K series, well the time has come to fit one!  Due to time, money and storage issues I never finished the buggy with the A series and lost interest.  I've made the decision to buy a car trailer and say bugger the road and use the buggy for off road and track days for now and maybe get it road legal eventually when time and cash permits.

The Plan

Refurbish the mini front end components (rack, callipers, hubs, tiebars etc)

MGTF rear subframe, Kseries mated to a Rover PG1 gearbox (TF subframe has mounting holes for PG1 Box, and integral coil overs)

I was planning on using a 1.6 k series from an old 416 or something along those lines, but I found something too tempting on fleebay; a complete MGF rear end with an 1800 solid cam engine with all ancillaries for a price that was amazing.  I've experienced the 1.4 16v in a ZR and a Metro and always found the engine a bitter disappointment up until about 4krpm, the 1.6 is a lot smoother lower down and the 1800 is much nicer to drive and has plenty of kick low down (perfect for off roading  ;D).

I've attached some picies of the subframe and a mock up of the mounts I intend to fabricate.

Mount:
<img src="http://lh5.ggpht.com/_iJH0cqQjfRQ/SaXJAX1mGUI/AAAAAAAAAE4/oToOaLhao5I/s144/untitled.JPG" />

Subframe 1:
<img src="http://lh3.ggpht.com/_iJH0cqQjfRQ/SaXI_4OuKeI/AAAAAAAAAEo/98ce_IWf1-k/s144/18022009064.jpg" />

Subframe 2:
<img src="http://lh5.ggpht.com/_iJH0cqQjfRQ/SaXJACXTZ8I/AAAAAAAAAEw/vsbzIWDF0VA/s144/18022009065.jpg" />

Keep checking the gallery as I may not always link to the updated pictures.

 

[Phaeton]

Will,

Looks like you need to make your album public, I get an error message when trying to view.

Alan...

 

[Phaeton]

I have a Buggy in the garage with a K series subframe, Metro not MGTF bolted to it, if you want I can take a picture of how it mounts to the frame for you at the weekend.

Alan...

 

[Will]

I have a Buggy in the garage with a K series subframe, Metro not MGTF bolted to it, if you want I can take a picture of how it mounts to the frame for you at the weekend.

Alan...

That would be brilliant Alan any advice or help is appreciated.  Is that the one with the 8v 1.4 I saw some pictures of a while ago? If it is I think I'm going to need a bit more space for the 16v head and manifold hence the triangular brackets.

I've done a lot of work with Metros and I think the TF and Metro subframes are basically the same, the TF frame has revised turrets with coils as standard, track rods on the back of the frame, tie bars to mount the hubs instead of solid arms, and revised engine and gearbox mounting "arms".

 

[Will]

Morning all,

A lot done today, picked up my engine on Saturday and took a day off work today to sort it out.  Pics attached, apologies for the quality, a garage with the door open doesn't give the best light!

Engine on MGF subframe removed from car.
<img src="http://lh5.ggpht.com/_iJH0cqQjfRQ/Sawspk5udQI/AAAAAAAAAFE/XVGiNF6JwNk/s144/02032009071.jpg" />

One of the reasons for using Rover PG1 gearbox, you can just make out the hydraulic clutch slave cylinder (under the red cap). The next picture in the album is of the same thing.
<img src="http://lh3.ggpht.com/_iJH0cqQjfRQ/SawsqbXF6AI/AAAAAAAAAFM/3FHAR-W1UHY/s144/02032009072.jpg" />

This ones a bit poor as its taken from below, my second reason for using PG1 box out of an MGF, cable gear selection!  These are the brackets on the bottom of the box.
<img src="http://lh4.ggpht.com/_iJH0cqQjfRQ/SawsrHznIQI/AAAAAAAAAFc/p882BUCgBBQ/s144/02032009074.jpg" />

Engine removed from MGF subframe
<img src="http://lh3.ggpht.com/_iJH0cqQjfRQ/Saws_W-11uI/AAAAAAAAAFw/R77tmDzvTyU/s144/02032009076.jpg" />

Engine back on MGTF frame (using TF due to prefabricated coil over turrets on the frame.)
<img src="http://lh3.ggpht.com/_iJH0cqQjfRQ/Saws_7S7uAI/AAAAAAAAAF4/Nwwj9L5HMaQ/s144/02032009077.jpg" />

A close up of the subframe bracket I intend to use to mount the frame to the freestyle chassis, my semi CAD mock up in my first post might make more sense now.
<img src="http://lh3.ggpht.com/_iJH0cqQjfRQ/SawtA7xLHPI/AAAAAAAAAGI/XcsKnxd5e1E/s144/02032009079.jpg" />




Note to moderators:  I'd like to leave this topic unlocked for now as I'm welcoming comments, if they get irrelevant or too many I'll remove them. TA

 

[Phaeton]

Will,

Did you get the gear change cables with the engine, if not I have a set here you can have in exchange for a contribution to the spotlight fund.

Alan...
p.s. Make a lot more sense now I see the difference in the subframe

 

[Will]

All boring tonight...

Fitted the MGF hubs to the rear subframe so I can get some wheels on it and see exactly how much suspension travel there is running on the standard MGTF coils.  (They will be coming off and replaced with TF hubs as there is a subtle difference in the steadying trailing arm design between the MGF and TF that doesn't allow the hubs to be interchangeable.)  Having both the chassis and rear subframe rolling will also give me a better idea of where to mount to subframe so that its not higher or lower at the back when its sitting in its natural position.

Finished refurbishing the front mini hubs, basically new ball joints and new bearing grease.  All the front arms have been polly bushed where it matters and fitted, just the hubs left to fit and then she'll be rolling at the front.

I've butted the subframe upto the chassis so I can get all the dimensions and clearances straight in my head before I make the first mock up of my brackets on Sunday:

LH Rear side on

<img src="http://lh6.ggpht.com/_iJH0cqQjfRQ/SbGlGSRnuFI/AAAAAAAAAHY/lXTcn8-HZkE/s144/06032009082.jpg" />

RH side on, plenty of clearance!  I was worried the 16v head with manifold would foul on the chassis but it doesn't even protrude past the subframe!

<img src="http://lh4.ggpht.com/_iJH0cqQjfRQ/SbGlGo2sQaI/AAAAAAAAAHg/AZAu9sEw73E/s144/06032009083.jpg" />

Top down

<img src="http://lh6.ggpht.com/_iJH0cqQjfRQ/SbGlHEJodqI/AAAAAAAAAHo/jJvIgKy49N8/s144/06032009084.jpg" />

I'm a tad worried about the fuelling system as the tank will have to go somewhere on the back and the IVA draft states that fuelling components must not be positioned where they'll cause a fire hazard if there was a leek, the K series has a nice hot exhaust manifold at the front and a nice hot exhaust back box at the rear.  Ill have to figure something out!

 

[Phaeton]

Will,

Have you seen the other post where I mentioned this to the VOSA inspector, he currently couldn't give me a straight answer as the rules may change in our favour. The only issue might be that there may have to be certification on the tank, i.e. construction & use. But logically with a firewall in front of the tank, a firewall behind the tank you should hopefully be okay. The thing is logically, if you have an accident in a Freestyle so severe it damages a behind the seat tank, you're not going to be in a position to care 

Alan...

 

[Will]

Will,

Have you seen the other post where I mentioned this to the VOSA inspector, he currently couldn't give me a straight answer as the rules may change in our favour. The only issue might be that there may have to be certification on the tank, i.e. construction & use. But logically with a firewall in front of the tank, a firewall behind the tank you should hopefully be okay. The thing is logically, if you have an accident in a Freestyle so severe it damages a behind the seat tank, you're not going to be in a position to care 

Alan...

I did see it, I was hoping to avoid a behind the seat tank as I'm 6'4" but I think to comply with IVA I'll have to go down that route.  I know I said in the first post that I wasn't bothering with SVA/IVA for now but I figure its worth bearing in mind as I don't want to have to go through a major redesign if I decide to put in on the road (which I probably will because it'll be too much fun to leave in the garage!!)

 

[Danny]

I am 6ft 4 and the tank is fine behind the seats!!

Danny

 

[esdebe]

For mr IVA put a small a small tank behind the passenger chair, that way you don't loose your leg room, you can then use the old style fireextinguishers for offroading (long distance), and take it off to get it IVAed.

Simon

 

[Will]

I am 6ft 4 and the tank is fine behind the seats!!

Danny

Good!  Behind the seats has just become an option again!

Didn't get as much done today as I'd have liked but some pictures and more info for you guys.

Front end nearly done, just need to put springs, dampers and rack on.

<img src="http://lh6.ggpht.com/_iJH0cqQjfRQ/SbRH9UHk-TI/AAAAAAAAAII/MDUDpDl6_YE/s144/08032009085.jpg" />

<img src="http://lh6.ggpht.com/_iJH0cqQjfRQ/SbRH9vRfCfI/AAAAAAAAAIQ/6BM8araUpMk/s144/08032009086.jpg" />

Started on the subframe mounting brackets changed the design slightly and am now encapsulating (good word!) the box section with 3mm plate just to add a bit of extra strength.  Will also be adding an upright to somewhere higher up on the chassis, not really necessary as I think they will be strong enough without but the upright will make triple sure!

These aren't finished yet, need to add another piece of plate on the underside.  I left it off so I can use it to get the dimensions of the other 3 similar brackets.

<img src="http://lh3.ggpht.com/_iJH0cqQjfRQ/SbRH-m6kuKI/AAAAAAAAAIg/G2XSBGzrtPM/s144/08032009088.jpg" />

<img src="http://lh3.ggpht.com/_iJH0cqQjfRQ/SbRH_Ao27YI/AAAAAAAAAIo/lR5jY5rpqSk/s144/08032009089.jpg" />

Intention is to mount it like this:

<img src="http://lh6.ggpht.com/_iJH0cqQjfRQ/SbRH-PKJjXI/AAAAAAAAAIY/zgo4UDSU4Xk/s144/08032009087.jpg" />

It looks a bit of a mess at the moment but watch this space as they will take shape over the next few days.

Also discovered that metro 13" alloys wont fit over the TF trailing arms or track rod ends, bit gutted as I think the Metro SPI alloys (http://images.google.co.uk/images?rlz=1 ... =en&tab=wi) come in the different PCDs I need as they were fitted to the K and A series Metros.  Would have been nice to use 13" wheels with my gear ratios as the buggy would have been like a bullet off the line!  I'll have to use some after market 14" wheels and skinny tyres to get the same effect.

EDIT: Forgot to mention I set fire to myself (No harm done though)!  Don't play with welders or angle grinders when your oily !

 

[Will]

Finished making my V brackets out of box tonight, the time got a bit antisocial for cutting plate up with an angle grinder so I had to leave it there.  Tomorrow I'll be putting the plate top and bottom and grinding bits of the chassis that get in the way of where they will mount to.  Watch this space......

 

[Will]

Because of having to use 14" wheels I'm going to be changing my box to one with a 4.2 final drive instead of a 3.9, should give the ratios I want:

<img src="http://lh4.ggpht.com/_iJH0cqQjfRQ/SbeWOlvKiLI/AAAAAAAAAI0/9A92Xtz4Hd8/s144/New%20Bitmap%20Image.jpg" />

 

[Will]

Morning all,

Thanks to Alan and Alan who popped out today to drop some bits off for me, I hope bumble got back in one piece!

A lot done today, fitted new gearbox to the engine and finished off making one of the new chassis to subframe brackets.  Looks a bit rough in these pictures hammerite hides all!

<img src="http://lh5.ggpht.com/_iJH0cqQjfRQ/Sb1ycWLSRjI/AAAAAAAAAI8/Dt27IV18u30/s144/15032009095.jpg" />

<img src="http://lh5.ggpht.com/_iJH0cqQjfRQ/Sb1ydB7zP-I/AAAAAAAAAJE/AxpRYDdQSRk/s144/15032009096.jpg" />

Made up a 5th mount to stress test it and nearly broke my workmate.  All progressing nicely!  Last mount will be finished tomorrow night then I need some wheels to get the rear subframe rolling and get the position of the bolts right.

 

[Will]

Had a break last night as welding all day Saturday and Sunday battered my eyes.

Just placed an order with an MGF breakers yard for all the bits I need (ECU, Fob, 5AS, loom, pipework, steelies, TF hubs, switches, clocks, etc) which I will be picking up on Thursday, fingers crossed the engine should be mounted on the front brackets and running by next weekend. 

Next job come payday is buy a pipe bender and attach the rear of the subframe to the chassis.  As always I'll keep you posted.

 

[Phaeton]

If you want a pipe bender I have a brand new one here you're welcome to borrow. I've never actually used it, it was one of those, they look nice I'll buy one type of thing.

Alan...

 

[Will]

If you want a pipe bender I have a brand new one here you're welcome to borrow. I've never actually used it, it was one of those, they look nice I'll buy one type of thing.

Alan...

Machine Mart does that to me, that's the first place I'm going to go when I win the lottery!  If you don't mind mate, saves me £100!

 

[Will]

Picked up all the bits I need last night. I'm going to use a MK2 MGF body loom because its got an electronic speedo but because my engines from a MK1 MGF I've got to make an intermediate loom to go between the body loom and the engine loom which was something I was hoping to avoid, suppose it gives me a chance to waterproof the connectors.

For anyone hoping to use a front mounted RAD, the MGF and TF are rear engined with front radiator and have nice long steel pipes that go from front to back.  I got some for free because one of the ends is rotten!

 

[jason_l]

Picked up all the bits I need last night. I'm going to use a MK2 MGF body loom because its got an electronic speedo but because my engines from a MK1 MGF I've got to make an intermediate loom to go between the body loom and the engine loom which was something I was hoping to avoid, suppose it gives me a chance to waterproof the connectors.

For anyone hoping to use a front mounted RAD, the MGF and TF are rear engined with front radiator and have nice long steel pipes that go from front to back.  I got some for free because one of the ends is rotten!

Thats great news Will, sounds like it really coming along fast now! interesting to know about the MGF pipes. Im planning the mounting the radiator up front and have been wondering about the pipes, might be worth a look at me thinks. If you are doing a front mounted radiator then have a look at the fiat seicento/cinquecento radiator, its the radiator i will be using on mine and i reckon it will fit at the front nicely because of its size!

Jason