RWD 2 litre 16v Mini [Archive] - 16v Mini Club Forums

MattG

23-10-2005, 05:44 PM

Started striping it ... will take the front end off before i remove the engine.
http://www.teamorchard.co.uk/wp-content/DSCF0002.JPG
Dodgy repair work ... not even welded ! :eek:
http://www.teamorchard.co.uk/wp-content/DSCF0003.JPG

windows are out , boot / petrol tank is out
I have a fibre glass front lined up for it ...

thats it for today ... had to get my other mini back on the road ... and knock down a wall ! lol

MattG

23-10-2005, 05:46 PM

a bad artist impresion ! : will be lower .. and more level
http://www.teamorchard.co.uk/DSCF0022.JPG

BassAddict

24-10-2005, 07:45 AM

I wonder what the "project" will be ......
http://cgi.ebay.co.uk/Chance-to-Drive-of-a-16v-RWD-Vauxhall-powered-Mini_W0QQitemZ4584559089QQcategoryZ100916QQrdZ1QQc mdZViewItem

:)

MattG

24-10-2005, 07:55 AM

lol .. got to try anything to earn some money ! lol

MattG

24-10-2005, 12:10 PM

Ok front end cut off ..
http://www.teamorchard.co.uk/wp-content/DSCF0004.JPG
and interior gutted , doors off ...
http://www.teamorchard.co.uk/wp-content/DSCF0005.JPG

so once i get rid of both subframes it will be time to get on with putting the vauxhall subframes on (once i find some cav ones ;) )

QuadCam

24-10-2005, 04:14 PM

heh heh ... class ... I'll be keeping my eye on this :wink:

MattG

27-10-2005, 04:24 PM

went to Griffin Spares today , and picked up some struts , subframes , steering rack , gearbox , old block ... should keep me busy over the next week :

http://www.teamorchard.co.uk/wp-content/DSCF0007.JPG

strudel

27-10-2005, 05:23 PM

Matt, Need a place to go on a holiday? Free lodging and all the beer you can drink. And the catch. Help to complete my build. Can also supply a car to drive to the mountains,etc. Seems you have too much time on your hands to have fun with cars. I think you should share your expertise. JS

QuadCam

27-10-2005, 06:51 PM

went to Griffin Spares today , and picked up some struts , subframes , steering rack , gearbox , old block ... should keep me busy over the next week :

.. from what motors Matt?

MattG

27-10-2005, 07:00 PM

all from a vauxall cav ... not sure if i will be using a subframe up front or not ... dont know yet .. need to get rid of the old auto lump...

bought 4 lower arms for 70 quid... :cry:

PaulC

27-10-2005, 08:39 PM

went to Griffin Spares today , and picked up some struts , subframes , steering rack , gearbox , old block ... should keep me busy over the next week :

Matt is that a corsa B power steering column i can see there?

Paul

MattG

27-10-2005, 08:51 PM

no std ..wont need it ..weight will be at the back :wink:

MattG

01-11-2005, 07:54 AM

First suspension mock ups :

http://www.teamorchard.co.uk/wp-content/DSCF0039.JPG

http://www.teamorchard.co.uk/wp-content/DSCF0040.JPG

http://www.teamorchard.co.uk/wp-content/DSCF0041.JPG

http://www.teamorchard.co.uk/wp-content/DSCF0042.JPG

http://www.teamorchard.co.uk/wp-content/DSCF0043.JPG

http://www.teamorchard.co.uk/wp-content/DSCF0044.JPG

http://www.teamorchard.co.uk/wp-content/DSCF0045.JPG

In this position the steering rack will need to be mounted inside the car .. not sure if thats ok or not ? and then the track rods will come out of the inner wing.
I think the whole suspesnion needs to come in a few inches to match the vauxhall track .. so it might not be that wide in the end.
The main problem i have is the strut height at the front ... i can put some lowering springs on which will bring it down (think this one is lower than std anyway) but if i want this car built ASAP i dont think i will be going for my LOW look.

Also the back mounting point looks like it lines up with the bottom of the mini floor quite well ..so i now need to see if its worth using the vauxhall subframe .. or just build my own..... comments welcome

QuadCam

01-11-2005, 09:31 AM

excellent approach - brand new wishy's lol ...

Are you doing all that work on the front, solely to match the track of the rears?

MattG

01-11-2005, 09:33 AM

Are you doing all that work on the front, solely to match the track of the rears?

sort of yes .. i wanted to run bigger wheels/ bigger brakes ..so made sense to use vauxhall suspension ... then to save cutting steering racks etc i am just keeping it the std width.

Matt .. not sure if it will work how i think yet though :)

Vtec Steve

01-11-2005, 01:11 PM

Matt

If it helps a few of my mates have had springs custom made for them. I think all they had to let the company know is what the car is (or what it was in your case) and how much lower you wanted it. If you want the number let me know.

Steve

MattG

02-11-2005, 10:11 PM

Started cutting up the vauxhall subframe ... have decided to reverse it (rotate 180deg) , this now allows room for the suspension arms and i can raise the hight of the subframe compared to the body.
http://www.teamorchard.co.uk/wp-content/DSCF0002_01.jpg

http://www.teamorchard.co.uk/wp-content/DSCF0003_01.jpg

http://www.teamorchard.co.uk/wp-content/DSCF0004_01.jpg

http://www.teamorchard.co.uk/wp-content/DSCF0007_01.jpg
I am planning on running the car very low , but the vauxhall strut is nearly bottoming out ..so i might have to raise the car .. or think of a work around.
Will go get some plate metal tommorow to make up some plates that will bolt to the orginal floor mounts ..and then i will weld the subframe to them. Then its a matter of making some subframe braces...

i did read somwhere about short struts you can buy ? any gen ?

Minimivic

03-11-2005, 06:24 AM

By turning the subframe around does that not alter the camber and caster angles. How are you going to position the top shock mounts accurately so that the steering is right. Just asking because it was a lot harder than it looks which is why I used the donor clip to get it right.
I spent ages with bump steer calculations and caster angles then gave up for the tried and tested route.

MattG

03-11-2005, 08:25 AM

it may well do paul :lol: lets talk about somthing else :wink:

MattG

06-11-2005, 07:32 PM

Ok well .. it was going well .. made some subframe mounts :
http://www.teamorchard.co.uk/wp-content/DSCF0008.JPGthen once they where welded on , and the first strut brace was done .. i found out that the wheels where in the wrong place !! DOH ..they needed to be 3 inches further forward. I had cut the vauxhall subframe to short ... after swearing allot .. and sleeping .. I started cutting up the 2nd subframe i had ..plus 3 more inches !!
This was then welded onto the end of the subframe forks :
http://www.teamorchard.co.uk/wp-content/DSCF0009.JPG
Then a new strut brace was tacked into place ... then the welder thought it would much about and stop ! .. so thats the end of my long weekend ...
http://www.teamorchard.co.uk/wp-content/DSCF0011.JPG
but now the suspension is fixed .. the wheels are not going to stick out as far as i thought :
http://www.teamorchard.co.uk/wp-content/DSCF0010.JPG
PS . .made a bet with a friend that it would be rolling/driving by the 3rd of December ! .. got lots to do.....

Geehawk

07-11-2005, 07:23 AM

PS . .made a bet with a friend that it would be rolling/driving by the 3rd of December ! .. got lots to do.....

Hope you didn't bet too much :lol: :lol: :lol:

MattG

07-11-2005, 09:41 AM

what you saw yesterday was just a scam .. the real RWD was out back :wink: :lol:

Geehawk

07-11-2005, 09:54 AM

what you saw yesterday was just a scam .. the real RWD was out back :wink: :lol:

With its wheel arches already cut out :lol: :lol:

MattG

08-11-2005, 07:37 AM

got the drivers side subframe brace on last night :
http://www.teamorchard.co.uk/wp-content/DSCF0012.JPG
dont worry if they dont look stright its the camera [wink]
Bought a new tip and shroud for my mig welder and its made the world of difference ..so if you our like me and keep trying to weld with a bad tip .. get a new one !! ( ok maybe there is no one like me :))
At the end of the evening .. started to knock some ideas about for a top strut mount :
http://www.teamorchard.co.uk/wp-content/DSCF0013.JPG
The idea is to have another L shape bracket on the other side .. then a plate will be bolted to the top of them to mount the strut .. this will allow adjustment later on when needed ...
And before anyone asks yes there will be more stength going into them ! lol wait till i have said i am finished before saying it :)
Stopped at bought a 79mm hole cutter this morning so should help me cut some holes for the top strut mount.

MattG

09-11-2005, 07:44 AM

made up a couple of L shaped angle brackets which will hold the top strut plate. :
http://www.teamorchard.co.uk/wp-content/DSCF0015.JPG
Again i know it will need some bracing but I want to make sure position / height and clearance under the wing is going to be ok before going to far ahead.
As i said before I had bought a hole saw to cut some plates for the top .. but then found out my drill chuck is not big enough ! lol
So i spent a bit of time thinking last night ... pretty sure the front is going to work out ok . I then placed a vauxhall subframe under the back of the car and positioned some lower suspension arms to give me somthing to look at :
http://www.teamorchard.co.uk/wp-content/DSCF0016.JPG
I am going to have to turn the subframe around by 180 deg like i did for the front as the suspesnion arms will stick out the back of the mini otherwise ! lol
It looks like i will have to remove the old mini subframe mounting points as the subframe will be forward of them by a few inchs.
Not sure what I am going to do tonight ... dont really want to buy another drill just to cut a few holes ...I might start choping some metal out the back to give me somthing to do untill i can find a drill to borrow !.

strudel

09-11-2005, 03:07 PM

Matt,
What are the consequences of turning stuff around by 180 degrees? Will traling arms still be trailing arms or how will the functionality of this stuff be? I'm just a confused as I don't know diddly about the components you are using. JS

MattG

09-11-2005, 03:20 PM

nor do i JS .. so its not a problem in my mind :lol:
will let you know if it has any effect :) . .. i have my reasons why i dont think it will make much difference .. but dont like to say as i cant be arsed with any arguments :) .. i am doing it this way and thats that :)

Matt

ChadH

09-11-2005, 09:15 PM

Well a trailing arm turned around 180 degrees would be a leading arm :wink: However, the things Matt are using look a bit more wishboney. The only concern I would have (which I'm sure Matt has addressed) is whether the mounts are up to being pushed instead of pulled or vice versa - if that makes sense!

BassAddict

09-11-2005, 09:59 PM

Worst case he can turn the seats around and have a fwd, front engined, 16v mini, or just go in reverse a lot !!! :lol:

MattG

10-11-2005, 08:44 AM

Last nights progress .. not much .. still did not get hold of a drill to cut the top strut mounts .. so decided to use my last two cutting disks to cut a hole in the back ... but i found out you need more than two ! lol ...

sorry no pics today ... going to need to order the roll cage tubing soon i think as well as there will be nothing strong to attach the rear subframe to.

Also i am still after a 2 litre 16v lump ? XE or XEV (ecotec) need full engine loom and ecu , so what do people have .. i have the cash in my wallet and can be over tonight !

Also still need a F18 hydro clutch gearbox ....

off to get some more cutting disks tonight and make a big hole in the back of the car !

MattG

11-11-2005, 07:29 AM

Had to go buy a 15 quid drill from homebase that had a bigger chuck to take the hole saw , so last night i set about cutting a hole in some 3mm sheet metal.I will tell you one thing , a hole saw is lounder than a disk cutter !!my neighbours must love me ! lol , so after a few minutes a had this :
http://www.teamorchard.co.uk/wp-content/DSCF0020.JPG
Think i need to grind it out a little , and maybe put some supports under it to locate the top of the strut .. but i will see ...
So instead of continuing with that job i thought i should finish cutting a hole in the back of the car ... after an 1 1/2 hours later ! i had a hole :
http://www.teamorchard.co.uk/wp-content/DSCF0021.JPG

http://www.teamorchard.co.uk/wp-content/DSCF0022.JPG

http://www.teamorchard.co.uk/wp-content/DSCF0023.JPG

Ok i am sure some more needs to come out , but I will wait till i have the engine / subframe bolted up to see what hits and misses.
At the moment i have left the front rear subframe mounting points in , I am hoping i can leave that whole box secion that runs across the car in , but we shall see.
http://www.teamorchard.co.uk/wp-content/DSCF0025.JPG
it looks like the subframe will fit without cutting the box section away .. but i am not sure if the engine sump / exhaust will hit it ....

but untill i find a XE !!!!!

Not sure how much I can keep this progress up at the moment , funds , wife , injury's are all taking the toll on me ... but i will press on tonight !

QuadCam

12-11-2005, 11:54 PM

Excellent work fella

PaulC

13-11-2005, 10:14 AM

Is this car going to be MOT'd and on he road, or is it just a drag strip weapon?

Paul

MattG

13-11-2005, 10:19 AM

Is this car going to be MOT'd and on he road, or is it just a drag strip weapon?

Paul

why do you ask :lol: I hope to make it road legal ... but lets not talk about that in the public forum :wink:

Matt

MattG

13-11-2005, 02:44 PM

Got it onto two wheels at last ! :
http://www.teamorchard.co.uk/wp-content/DSCF0027.JPG
Ok it may look a little rough ... but should be fine with a coat of paint :) Need to do somthing about the springs ... I have just cut them down for now but will need somthing better before it goes on the road. Again ... more strength will be going into the top strut mounts but for now tacks will do untill i am happy with the positioning etc..

I added some small tabs to locate the strut better :
http://www.teamorchard.co.uk/wp-content/DSCF0028.JPG
Now its on two wheels I cut a hole for the steering rack to come out off , drivers side lines up quite well with the heater inlet hole :)
http://www.teamorchard.co.uk/wp-content/DSCF0029.JPG
Inside the steering rack sits quite well under the dash board , but i have had to remove the pedal box (which i might be able to fit with a bit of cutting or go for a floor mounted pedal box)
http://www.teamorchard.co.uk/wp-content/DSCF0032.JPG
I still might remove the dash rail as its fowling the steering coloumn .. we shall see....
Thats it for this weekend , i have a few more injury's .. and should really see the family ! comments welcome.

niall

13-11-2005, 07:30 PM

My comment . How do you work in a garage with so much stuff in it ? :)

Geehawk

14-11-2005, 08:35 AM

Would the bracing for that frame not be a little better if the braces were a bit further apart?

MattG

14-11-2005, 08:37 AM

Would the bracing for that frame not be a little better if the braces were a bit further apart?

maybe 8) or maybe not 8) I think it should be fine , but could be proven wrong :)

MarkLD

14-11-2005, 09:09 AM

Get rid of the dash rail as it will make life easier and you can then put it back in the right place for the steering column and make it stronger.

MattG

14-11-2005, 09:15 AM

Get rid of the dash rail as it will make life easier and you can then put it back in the right place for the steering column and make it stronger.
2nd person to say that .. its going tonight :twisted:

MattG

14-11-2005, 10:27 PM

Got rid of the dash rail ! :
http://www.teamorchard.co.uk/wp-content/DSCF0033.JPG
rack sits better now .. :
http://www.teamorchard.co.uk/wp-content/DSCF0035.JPG
Still unsure of how best to mount it yet , i might put two cross bars in for now , then take another look at it when the roll cage is in.
Spent allot of time tonight taking track rod ends off , and looking at the rear subframe :
http://www.teamorchard.co.uk/wp-content/DSCF0034.JPG
I am planning on running a L or U shaped channel across the old subframe mounting points , then the vauxhall subframe can bolt to this , But i am not sure how much room i will have for the sump / exhaust ... but it maybe better running the exhaust over the top of the gearbox anyway .. would allow for a bigger box etc in the system... really need an XE , have placed a bid on ebay for one ..so we shall see.

MattG

15-11-2005, 10:48 PM

Ok , i have run two 25x25x2 box sections across from each of the inner wings, and then made some brackets of this to hold the vauxhall steering rack, please dont talk to me about bump steer etc.... but if i need to move the rack it should not be to much of a problem with a few spacers etc... :)
http://www.teamorchard.co.uk/wp-content/DSCF0038_01.jpg
Now the rack was it , it was time to take my office chair as it is needed for bigger and better things ! :
http://www.teamorchard.co.uk/wp-content/DSCF0040_01.jpg
and on with the steering coloum :
http://www.teamorchard.co.uk/wp-content/DSCF0041_01.jpg
Now i think its going to be too long , but will talk more about that in a bit.

Now my office chair is resting in its new home ! :
http://www.teamorchard.co.uk/wp-content/DSCF0042_01.jpg
I dont it will be much of a problem sorting out the seating position...
Now onto the steering column:
http://www.teamorchard.co.uk/wp-content/DSCF0044_01.jpg
How does this come apart ? i am thinking i can just use the top part of the column and remove the black tube ? Also there seems to be a plastic bush stoping it all coming out , is this just pressed in ?
Off to london tommorow so will be late back so no progress tommorow night ....

Geehawk

16-11-2005, 07:27 AM

This is just an educated guess, but I would think that its held by plastic pins which are designed to shear on impact and thus collapse the column. Should Come apart with a bit of force.

BassAddict

16-11-2005, 07:38 AM

Think the desk needs a clean :lol: !!!!

MarkLD

16-11-2005, 08:22 AM

strudel

16-11-2005, 03:33 PM

Armchair critic comment coming up. The lower bar, could it have been raised to incorporate the two bottom mount bolts thus giving a bit more support? I can't tell if it would foul on the right side. Also providing a bit more space underneath if needed. Then a short T could be placed just above the bottom bolt on the bar and then flush up to front of top bar. This would provide a rectangular gris and stiffen it all up. Just a guess on my part. JS

MattG

17-11-2005, 10:12 AM

If you can Matt, I would beef up the members that the rack bolts through. Perhaps some more bits of 25x25 mounted vertically between your horizontal members with some reinforcement tubes through for the bolt holes. As you can image the loads going through the rack mounts are high under hard cornering and any flex will cause some interesting handling characteristics. I assume your going to brace the horizontal members back to the bulkhead?

yep .. will do somthing , will wait till the rollcage is in now and see if i can come off that as well ... for the moment everything is tacked in place with minimum strength untill i am happ with it.

Matt

mick

18-11-2005, 09:24 AM

http://www.valvers.com/phpBB2/viewtopic.php?t=322

hey there some lowerd spring and maybe some parts u need, its abit far thou.

MattG

20-11-2005, 06:06 PM

As its my kids birthday next weekend .. wanted to get allot done this weekend ...
First off got the steering column tacked into place .. again dont worry about this . .as this will all be redone when the cage is in ...
http://www.teamorchard.co.uk/wp-content/DSCF0001.JPG
Speaking of roll cage's .. picked this up at the weekend , thanks Paul ! :
http://www.teamorchard.co.uk/wp-content/rollcage008.jpg
Then picked up this :
http://www.teamorchard.co.uk/wp-content/DSCF0003_02.jpg
http://www.teamorchard.co.uk/wp-content/DSCF0004_02.jpg
Then on sunday did this to it ! :
http://www.teamorchard.co.uk/wp-content/DSCF0006_01.jpg
Have all the loom , ecu etc... i have not bothered to pull the fuel tank out .. as it looked too big for the mini ... so all i need now is a external fuel injection pump...
While the mini was pushed out into daylight .. i took a quick photo :
http://www.teamorchard.co.uk/wp-content/DSCF0002_02.jpg

QuadCam

20-11-2005, 06:22 PM

Brilliant ... good work Matt ...

BassAddict

20-11-2005, 09:44 PM

Damn - same wheels as mine !!!! :lol:

mick

21-11-2005, 06:51 AM

matt, does this model not have an external mounted pump like the older cavs.

mick

MattG

21-11-2005, 08:09 AM

pretty sure it looked like a in tank pump

Matt

JoBu

21-11-2005, 08:11 AM

No there external :wink: NS back corner i think.

Josh

MattG

22-11-2005, 09:18 PM

ok I know i said I would not have much time .. this week , but i sneeked out for an hour to drag the engine under the car and try and get it in the correct position , it still needs to come up and forward yet ... but you get a idea :
http://www.teamorchard.co.uk/wp-content/DSCF0007_02.jpg
http://www.teamorchard.co.uk/wp-content/DSCF0008_01.jpg
I think it will miss the parcel shelf ,but i still might take the shelf out anyway to give me more room.

MattG

27-11-2005, 02:27 PM

ok , kids party is over ... and Mick (sister's husband) help me get the engine into a closer final position.
Was having real trouble trying to jack the engine up into position , then another friend Darren sugested make a frame for the engine to sit on , so thats what i did. Just got two long bars , and welded them together with some anlge.. this allowed us to get the jacks under each side , and the engine was not sliding about etc.... here is a shot of the engine nearly in the correct place :
http://www.teamorchard.co.uk/wp-content/DSCF0009_01.jpg
Had to cut out a section for the exhaust to miss ...i really want to keep this box section on the back of the mini as i think its quite strong .. and i reckon i can bring the engine mounts onto it ....
http://www.teamorchard.co.uk/wp-content/DSCF0010_01.jpg
http://www.teamorchard.co.uk/wp-content/DSCF0011_01.jpg
Now I think i will ditch the front vuaxhall engine mounts ,and try and make my own ... again as allways .. not sure if any of this will work .. but there is one way to find out. Off to local car factors tommorow to get some std engine mounts.

QuadCam

27-11-2005, 06:58 PM

... man that's some pace you're setting there fella! ... !!!

MattG

29-11-2005, 10:07 PM

ok .. after Chip coming round , it was time to get the disc cutter out again , 5 discs later , i had removed the rear valance :
http://www.teamorchard.co.uk/wp-content/DSCF0012_01.jpg
then off inside the car i went ... this bit was a little harder :
http://www.teamorchard.co.uk/wp-content/DSCF0013_01.jpg
cut the rear box section out , engine can easily come forward now , then finally after going deaf i just played around with roll cage position etc.
and looking to see how i could do the front engine mounts :
http://www.teamorchard.co.uk/wp-content/DSCF0014.JPG
Whats next , i want to get the roll cage welded in , then i can start coming off it , to mount the rear suspension etc... have bought another astra subframe so i am waiting for that to turn up.
off to buy some more cutting discs !!

evolotion

29-11-2005, 11:35 PM

one teensy weensy criticism mate, please dont ahte me for beign pickly and pointing it out, i understand teh car is in development and this is nowhere near the final design BUT.. you do realise that relay's are not particularly renound for there stregnth when used as part of a roll cage?

MattG

30-11-2005, 06:02 AM

ChadH

30-11-2005, 10:44 AM

Yep they are - as long as you use the copper contacts to take the load.

Geehawk

30-11-2005, 01:45 PM

PS . .made a bet with a friend that it would be rolling/driving by the 3rd of December ! .. got lots to do.....

Only 3 evenings left :wink:

MattG

30-11-2005, 01:47 PM

PS . .made a bet with a friend that it would be rolling/driving by the 3rd of December ! .. got lots to do.....

Only 3 evenings left :wink:

got an extension untill next week, as kids birthday party stopped work on the car for last week ! :wink:

MattG

30-11-2005, 10:18 PM

now the roll cage I picked was fine for a normal mini , but not reall for a RWD mini , I wanted the rear hoop to be closer to the engine so i can bring the engine mounts off it , So i had to increase the length of the roll cage by sleaving bigger tube over the cage ... then welding :
http://www.teamorchard.co.uk/wp-content/DSCF0015_01.jpg
Then it was a case of making some floor plates , and welding the thing in , not quite finished welding but it will be good enough for me to get on with the next stage. I will be adding diaganals later ...
You can see how far i have moved it back , it should be coming up near the door pillar :
http://www.teamorchard.co.uk/wp-content/DSCF0017.JPG
It may look like rust , but its just brown metal ! :)
http://www.teamorchard.co.uk/wp-content/DSCF0018.JPG
http://www.teamorchard.co.uk/wp-content/DSCF0019.JPG
And while i was out , i started on the gear linkage , as it normally is on the back of the gearbox (which is no good for me as i am now infront of the engine ) .. i chopped the end of the gear selector case , , and turned the selector rod round .. so it now pokes out the front of the gearbox ! jobe done :
http://www.teamorchard.co.uk/wp-content/DSCF0016_01.jpg
off to bed ....

BigAndy

30-11-2005, 10:31 PM

Its taken me just over 2 years to get to almost exactly the same position as you are now you bastard! :lol: I have an engine in the back, custom roll cage all welded in, and suspension almost sorted, well, maybe im a little ahead of you as I have an exhaust sorted and proper engine mounts. Still, its extremely depressing how quick you're getting this done compared to me - so stoppit, stoppit now!

MattG

30-11-2005, 10:38 PM

i am sure yours wont fall to bits once you drive it though :lol:

oh .. just bought a mgf exhaust of ebay .. not sure if its going to fit lol

Matt

BassAddict

30-11-2005, 10:49 PM

...its extremely depressing how quick you're getting this done compared to me - so stoppit, stoppit now!
My sentiments exactly :lol:
Anyone would think you'd done this sort of thing before Matt ?!!! :)

MattG

30-11-2005, 11:03 PM

i think its a mixture of no plans and not messuring ! lol

MattG

01-12-2005, 11:19 AM

and i said i dont do plans ! :

http://www.teamorchard.co.uk/wp-content/DSCF0017.jpg
just a quick design/ plan / scetch of some diagonals for the cage. opinions ?

PaulC

01-12-2005, 12:41 PM

The green clashes badly with the red :roll:

evolotion

01-12-2005, 02:33 PM

matt the door bar pusies onto a vertical pole, if you have a fontal crash the vertical pole will jsut bend. you will either need to add a pole behind that trianggulated to another point on the chassis/frame or lower the door bar to a point where it is nearer/inline with another bar.

i know alot of frames run the setup you have depicted for door bar's but for a home-brew application id try and avoid bendin gloads on the bar's as much as possible, unless your going to sit and go through the hand calc's to work out loading etc. a true space frame design has its bar's in only tension or compression, thats how they get there stregnth. if you try follow this as much as you can the overall structure will be much more rigid.

BigAndy

01-12-2005, 04:46 PM

how about something abit more like this?

http://i9.photobucket.com/albums/a91/ajhmini/DSC_0046.jpg

how convenient i have almost the exact picture on my computer for comparison :lol:

I know mines slightly out of line, but the idea is there, my bar couldnt come down any lower as the one on the other side would foul the OS engine mount.

BassAddict

04-12-2005, 09:49 PM

So come on then Matt - I know you got an "extension" on the deal - but how far did you get by December 3rd since that was yesterday ?!!! :)
Rich

MattG

05-12-2005, 08:30 AM

pics will be uploaded when boss is not looking ... if had a week i could have done it ....

wait till 11:59pm saturday .. thats the deadline....

Matt

MattG

05-12-2005, 08:56 AM

of , picked up a mini clutch slave cyilinder , and mounted that to a piece of angle , which is then welded to the gearbox engine mount.:
http://www.teamorchard.co.uk/wp-content/DSCF0021_01.jpg

Again as all my things .. not sure if it will work .. but only one way to find out ... it is simple so we shall see. Used the threaded end of a clutch cable and that goes into the slave. may just need a nyloc nut to stop it coming off ... and not sure if i need a spring to help the return as well yet.

Next was to make a bigger gear linkage lever , I even used a calculator for this ... the orginal vauxhall one is 150mm long , and this one is 400mm long !! lol , again just all tacked up for now ... and i may need to beef the extensions up as well .. but it seems to be looking like it should work.
http://www.teamorchard.co.uk/wp-content/DSCF0022_01.jpg
He it is in the rough position , need to make a pivot point next , but that should not be a problem. I will wait untill the engine is mounted before I continue:
http://www.teamorchard.co.uk/wp-content/DSCF0023_01.jpg
As for the gear lever , well just took the pivot pin out , lifted out the gear stick and turned it 180 deg , then put it back in , turn the whole lot around and job done ...:
http://www.teamorchard.co.uk/wp-content/DSCF0024.JPG
This gear lever housing even has a reverse notch allready in it , so no more mods are needed. Also i reckon it the arm wont need to be extended / cut either ....

I am hoping that the vauxhall subframe i am waiting for will turn up tonight , as I really want to get the engine mounted tonight !!

PaulC

05-12-2005, 09:32 AM

Next was to make a bigger gear linkage lever , I even used a calculator for this ...

Who'd have thought you can weld a calculator??!!! :shock: :roll: :wink:

MattG

05-12-2005, 10:30 PM

Have made the two front engine mounts , not sure if the way I have done them is strong enough ... but I think it will be fine....
Drivers side :
http://www.teamorchard.co.uk/wp-content/DSCF0027_01.jpg
Gearbox side :
http://www.teamorchard.co.uk/wp-content/DSCF0028_01.jpg
Now that the front mounts where on and holding the engine , i was able to slide the astra subframe in and locate the rear mount :
http://www.teamorchard.co.uk/wp-content/DSCF0032_01.jpg
This fitted under the mini better than i could have hoped for, I will have to make up some mounts for the front of it , i guess a cross tube on the cage ? :
http://www.teamorchard.co.uk/wp-content/DSCF0031.JPG
So , next I need to get the front of this frame bolted up , then get the struts in place and see how the rear diagonals will go in ....

MattG

09-12-2005, 07:55 AM

Ok work was delayed quite a bit because of a slight problem with a neigbour , thats not all sorted and I can get back onto the car.
Ran a cross member from the main cage loop , to hold the front subframe mounts of the rear frame , will gusset these as well once i am happy :
http://www.teamorchard.co.uk/wp-content/DSCF0033_01.jpg
The mgf exhaust got dropped off :
http://www.teamorchard.co.uk/wp-content/DSCF0034_01.jpg
It does go in , but not sure how many mods will be needed to get it to fit properly... could allways have the exhausts coming out of the boot ! ???
Nearly finished the rear cross member for the roll cage :
http://www.teamorchard.co.uk/wp-content/DSCF0035_01.jpg
This bolts to where the roll bar would have gone , again more straping down will be needed , but this should give me a good base for the rear diagonals, which should just squeeze past the alternator , but worst case i will have to move the alternator to the front of the engine.
Started cutting out some bits for the top strut mounts , but cant go anyfurther on those untill i have the rear cross members in.

MattG

09-12-2005, 10:08 PM

Ok , back to work on it .... Next job was the rear diagonals , I found out that my long piece of tube , was not long enough for both sides , so i though i would get on with the drivers side , as that is closest to the engine. They way it has worked out i have had to remove the allternator for now the pully on it was just in the way.

Now for my method of cutting the roll cage to fit nice , take one kitchen roll tube , cut it down the middle , and stick it over the metal tube so its a sung fit. Then remove and cut using scissors untill it fits nice on the pipe you are welding too ... , then slide back on the pipe , and mark with a pen :
http://www.teamorchard.co.uk/wp-content/DSCF0001_02.jpg
Then its just a matter of cutting . grinding and you are left with a tube that fits perfect ! :
http://www.teamorchard.co.uk/wp-content/DSCF0002_04.jpg
took about 5 minutes ...
Then it was time to weld it in :
http://www.teamorchard.co.uk/wp-content/DSCF0003_04.jpg
Hopefully it will hold ! lol
http://www.teamorchard.co.uk/wp-content/DSCF0004_03.jpg
I think tommorow i will try and fabricate a strut mount. And chase up my order of tubing !

QuadCam

11-12-2005, 09:24 AM

Rock and Roll ... :lol:

MattG

11-12-2005, 05:51 PM

Spent allot of time doing nothing ... not sure what i did really .. kept jumping from the rear strut mount , to the gear linkage and not really doing anything.
I started to get a bit arty , so used a bit of old bent roll cage tube to mount the gear linkage on , maybe it could hold the hand brake as well one day ! lol
http://www.teamorchard.co.uk/wp-content/DSCF0005_02.jpg
Also made up a pivot that bolts to the gearbox to hold my extended levers on , used some 6mm plate for this. Again as allways .. only tacked for now !
http://www.teamorchard.co.uk/wp-content/DSCF0007_03.jpg
Gear linkage did work , but needs some work ... will have another bash at it tommorow night.
I am sure i have done more .. but cant think what , so i took a photo of the rear hub sticking out the arch ! :
http://www.teamorchard.co.uk//wp-content/DSCF0008_02.jpg
Should have a nice WIDE feel to it.

MattG

15-12-2005, 09:17 AM

Started on a rear strut mount :
http://www.teamorchard.co.uk/wp-content/DSCF0006_02.jpg
Just clamped into position , There will be a strut brace coming off this over to the other side in the end :
http://www.teamorchard.co.uk/wp-content/DSCF0007_04.jpg
And it will be fully welded to the cage , with some gussets as well.

Then i ran out off mig wire :(

PaulC

19-12-2005, 08:28 AM

any progress over the weekend Matt?

Paul

MattG

19-12-2005, 08:32 AM

nope .. had problems with all the other cars , and also had to go xmas shopping ...

allthough i have found out that the engine / suspension on the rear is 3 inchs to far back .. it will need moving forward ... which i can do quite easily .. i hope ! Lol

Matt

MattG

08-01-2006, 03:22 PM

ok sorry for no updates over xmas , never got much time on the car in the end , most of the time that i did get was spent moving the rear part of the cage forward by 2 inchs to get the wheel base correct .. i must use a tape messure next time ! lol
But once that was done i got onto tacking in the rear strut mounts.
I have added a rear hoop section to the rear diaganals , this should help keep the strut mounts in place :
http://www.teamorchard.co.uk/wp-content/DSCF0008_03.jpg
sorry about the pic , got currupted when uploading , will take another shot soon.
here is a close up of one of the strut mounts tacked into position :
http://www.teamorchard.co.uk/wp-content/DSCF0009_02.jpg
Once that was done i cut a bit of 30mm box and tacked that in accross the to diags to create a mounting point for the track rod arms :
http://www.teamorchard.co.uk/wp-content/DSCF0010_02.jpg
this is when i noticed that the rear cage is quite not in the middle of the car :) but I wont tell no one if you dont ! lol
Really want to get this car on its wheels and roll it out of the garage to get a good look ... but have to do the last strut mount next ....

MattG

23-01-2006, 10:28 AM

Been helping my wife run here business and that has taken all my evenings up at the moment , so not sure of the progress i will make on this car over the next few months ....but...

I did get to spend a few hours on it this weekend , fabricating the last strut mount. But then ran out of mig gas again ! picked up some more this morning at a very cheap price , sure the bloke looked the price up wrong .. but i was not going to argue.

Also connected a battery upto the engine to see if i could get it to turn over ... i did not :( .. not sure why yet , was just touching wires on the X5 connector
to see what would happen ! lol

I will trying and get it on 4 wheels wheels by the end of the month..

Matt

BassAddict

23-01-2006, 11:46 AM

That bet's well and truly lost then !!! :(
Love the previous comment about the subframe not being central though Matt !!! :lol:
http://www.sitevip.net/gifs/cowboy/1411_animado.gif

Yee ha !!!!

MattG

23-01-2006, 11:47 AM

lol , cheers rich , yet bet is lost , owe darren a night out !

aslong as the wheels are in the right place .. does not matter about the cage ! lol ... and from my accurate checks each wheel sticks out 4 fingers on both sides .. so bang on !!!

Matt

BassAddict

23-01-2006, 11:50 AM

:lol:
I know a story about 4 fingers.... !!!! Sorry !!!!! :)
Sure it'll be fine anyhoo - just hope it don't crab !!!!
Rich

MattG

23-01-2006, 11:51 AM

Sure it'll be fine anyhoo - just hope it don't crab !!!!
Rich

well if it goes that will be a start ... crabing is just a bonus ! lol

Matt

MattG

27-01-2006, 06:21 PM

its on 4 wheels ,and out into the day light :
http://www.teamorchard.co.uk/wp-content/P1010019.JPG
http://www.teamorchard.co.uk/wp-content/P1010021.JPG
http://www.teamorchard.co.uk/wp-content/P1010024.JPG
have fixed my drive shaft angle , by lowering the rear subframe mounts !! lol

Matt

Swiftmini

27-01-2006, 06:34 PM

cool ideas very inspiring. :D :D :D
i think your gonna shat yourself the first time u drive :lol:
especialy if u get rear end bump steer. can't wait.

MattG

27-01-2006, 06:36 PM

dont worry about the steering arms on the back, just tacked them like that to allow me to move the car.

Matt

PaulC

27-01-2006, 07:25 PM

Matt,

Please don't take this the wrong way but :arrow:

This is exactly the reason why the DVLA want to ban modified cars!!!! :lol: :lol:

Your working at a very impressive rate of knotts though!!!

Keep up the progress :beer:

Paul

MattG

27-01-2006, 08:33 PM

paul , i am not building this for road use :wink: :lol:
by the time its finished , it will be ready for the scrap heap ! lol

Matt

MikeR33

28-01-2006, 08:59 AM

Looking good Matt, i'm just about to start the front engine for the first time today then it's on to the rear end bits.

I rekon between everybody here we should put a team together for the Scrapheap Challenge tv show, as long as it involved building a car we'd be well away :)

MattG

28-01-2006, 10:40 AM

When is my drive :wink: :wink: :wink: :wink:

thought you chicken'd out ??? :)

STEALTH GT

28-01-2006, 07:50 PM

HOW FUCKING EXCELLNT IS THAT ! :shock:
THOSE WHEELS LOOK FUCKING GREAT 8)

BassAddict

28-01-2006, 11:08 PM

Wish my car could be rolled out on its own 4 wheels :( !!!!
Might try and aim for that by the end of february !!! :)
Rich

MattG

06-02-2006, 08:19 PM

At the weekend i decided that the car needed lowering to help the drive shaft angles , i did this and dropped it by 5 inchs ! lol , this also means the front end is scrap and i would have to re-think that.... but it got worse..

I still can't get the rear struts to squeeze in the mini body , well i can ... but the camber is terriable ....

so really not sure what to do :

1) Scrap the project and take up knitting...
2) put some ugly bumps in the rear windows !
3) Use a different car .. BMW mini ????
4) widen the shell ??
5) think of a different suspension layout that does not cost anything ?

hmmmm ... off to have a good think .. feel free to through ideas at me... (cheap ones) lol

BassAddict

06-02-2006, 08:42 PM

Use a different rear subby - MGTF perhaps ?! :)

EDIT - there's an MGF rear subby just gone in the for sale section :) Can send you a lod of photos of the two if you want to see what they're like :)
Rich

MattG

06-02-2006, 09:09 PM

allways like photos rich ... mg@tstravel.co.uk

Matt

BassAddict

06-02-2006, 10:07 PM

Email is on its way :)

evolotion

07-02-2006, 12:10 AM

geto ne of them kits to make home made coilovers? you know the ones where you get a threaded sleeve to weld to the damper?? alot slimmer than the standard setup. or find a narrower car to take the suspension from? corsa? nova? assumign your useign calibra/chavalier struts and shafts justnow.?

MattG

07-02-2006, 09:14 AM

ok , maybe putting a bulge into the wing would not be to bad ... if i replaced the rear side windows with the opening ones , i would then allways leave them open, and would have to make a bulge something like this wonderfull photoshop :
The green bit would be new metal curved around to miss the coil over.
http://www.teamorchard.co.uk/wp-content/P1010019.jpg

Spag

07-02-2006, 09:56 AM

Can you not just adjust the mounting between hub and strut ?

Move the whole strut inboard by 20mm, or tilt the top inwards, while keeping the hub in it's original position/orientation ?

MattG

07-02-2006, 09:58 AM

not with the cav struts , as they are pressed into the hubs ... maybe i could use nova / corsa struts as they are bolted on ... could then maybe changed the angle of them...hmmm

Matt

MattG

07-02-2006, 10:22 AM

http://www.teamorchard.co.uk/wp-content/DSCF0016.jpg

i could move the bottom nuckle joint inwards by a inch ... Chip did saw he did this on his RWD nova to fix a suspension problem.... wonder how much movment is in the vuaxhall CV joints ?? And can i move it enough?

Rob Hall

07-02-2006, 03:18 PM

mailed a piccy to you Matty

Rob

MK_Bob

08-02-2006, 05:11 PM

Darren, if you can think of a reasonably affordable donor car (or combination of donors) with the correct running gear for mid engined, 4WD, i will have your babies. I've almost come up with a solution, except that the transfer box would send 70% of its power to the front, and 30% to the back. :?

Matt, i have absoloutely no technical advice, but i thought i'd let you know that you're my hero.

Actually i lied, why not weld together a pair of wishbones from some tubing, and make them as short as you need? Rose joints might cost a fair bit though...

sdturbo

08-02-2006, 09:51 PM

89-99 Mitusbishi 4g63 with the transfer case rotated 90deg and the rear end fliped upside down in the front. 60% to the rear mid mounted awd.

Spag

09-02-2006, 05:08 AM

In the grand scheme o things rose joints are not that much...

Like £15 each for 1/2" bore -5/8" stub

BassAddict

19-02-2006, 09:37 AM

Another MGTF rear frame on eBay - looks pretty much complete - lots more with it than the one I bought !!! :)
http://cgi.ebay.co.uk/MGTF-Rear-Subframe_W0QQitemZ4613882860QQcategoryZ10414QQrdZ1 QQcmdZViewItem
Rich

MattG

05-03-2006, 03:55 PM

been quite hasn't it ? :

http://www.power-tool-world.co.uk/makita/images/9069.jpg

to be continued ......

MattG

05-03-2006, 07:42 PM

ok , really did not like how the RWD was progressing , so i did a animal (valvers.com ) , well , maybe i did a little more than him :) After a month of thinking about things , and not doing anything on the car it was time for action.

two main changes have happened to this project now ,

1) The engine is being moved to the front !! still RWD
2) Its going to be a pickup !!!

First take off the F18 gearbox , if anyone wants a F18 , i have one for sale !
http://www.teamorchard.co.uk/wp-content/P1010002.JPG
First find yourself a carlton gearbox :
http://www.teamorchard.co.uk/wp-content/P1010003.JPG
Cut the back off the mini , as i dont need it for a pickup !
http://www.teamorchard.co.uk/wp-content/P1010004.JPG
Then build yourself a bench , yes i know i still have not cleared my garage , atleast i have a bench now to put all the rubish under !
http://www.teamorchard.co.uk/wp-content/P1010005.JPG
sweat trying to get the engine onto the bench ! , i hope the bench is strong enough.
http://www.teamorchard.co.uk/wp-content/P1010006.JPG
Then try and get the cut down shell onto the bench , now owe my wife a new pair of boots, as she has oil on her ones now ! but thanks to my
wife for the lift up !
http://www.teamorchard.co.uk/wp-content/P1010007.JPG
The bulkhead had to go ! , but there lays the new layout , do you like it ?
http://www.teamorchard.co.uk/wp-content/P1010008.JPG
Front end : , engine will come more forward yet. But seems plenty of clearance at the moment.
http://www.teamorchard.co.uk/wp-content/P1010010.JPG
God , its tight ! lol ,
http://www.teamorchard.co.uk/wp-content/P1010011.JPG

ok , a bit more waffle , just to make this update worth reading...
Going to make a space frame chassis out of 25x25x3 box section , will be loosly based on the locost chassis. Will make my own suspension arms (double wishbone) , will try and make my own uprights as well.
Next stage is to order some metal up , get hold of a rear diff , attach the gearbox etc... ! lol

well its been a long day ...... should amuse some people what i have done ! lol