1275GT Mayfair Track Car Build

[andy_s48]

Hi all,

After enjoying a lot of the other builds I thought it was about time I posted my own. I got my 1987 Mayfair when I was 16, then decided it would be a good idea to build a new engine to replace the 998. This somehow turned into a full blown track car build and I'm now 21, been through Uni, and the car hasn't seen the road since 2006!!!

Here's the car as I first got it:
http://i17.photobucket.com/albums/b64/andy_s48/StockMini-1.jpg

After a bit of tinker looked like this (I should have left it like this and never started taking it to bits!!):
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0438.jpg

Interior:
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0635.jpg

Gone:
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0637.jpg

Rear buckets and seat removed. Sound deadining tar removed (pain in th bum but saved me about 10+ kg):
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0710.jpg

Hammerited (some rust patches to remove):
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0704-2.jpg

Decided to go for a fibreglass front- light weight, won't rust:
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0649.jpg

Getting the engine out was a pain, even with a crane:
http://i17.photobucket.com/albums/b64/andy_s48/EngineRemoval.jpg

Wee bit too much negative camber, front brace bars sitting in position:
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0703.jpg

[evolotion]

im going to sound like a bore here, but if this is staying a-series it shouldnt be here :wink:

[andy_s48]

Bought a load of 4mm thick acrylic to replace the windows (all but windscreen). Used the origonal glass as templates, fitted the rear quarters back into their frames so they can still be opened for ventillation and rivetid the front ones in place:
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0724.jpg

N/S door needed replaced:
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0705-2.jpg

Homemade slider so I can still get my Macky Dees at the the drive through. Ran a beed of clear silicone to seal the door:
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0761-1.jpg
Note: Put it as close to the rear of the car as possible, as now that's right in my view line for the wing mirror- oops!


Couple of brakets for the fibreglass boot lid welded in place:
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0753.jpg

Fibreglass boot lid in place. Weighs a LOT less compared to origonal:
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0752.jpg

Welding on a new N/S A panel:
http://i17.photobucket.com/albums/b64/andy_s48/DSCN1603.jpg
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0759-1.jpg

Fibreglass front sitting in place:
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0760-1.jpg

Boot was all junk, so started removing the origonal to replace with a nice carbon fibre one from minispeed:
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0757.jpg

Am going to design an alloy fuel tank and get it made at work, so blanked off the origonal fuel filler hole, marked the surface so filler sticks better:
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0766-1.jpg

Couple layers of filler and smoothed down. More boot gone:
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0767-1.jpg

[andy_s48]

evolotion
PostPosted: Sat Jun 20, 2009 4:57 pm Post subject:
im going to sound like a bore here, but if this is staying a-series it shouldnt be here Wink

Still undecided on engine was going for 1275, but considering VTec, we'll see... Just thought I'd share though...

[andy_s48]

Carbon fibre boot floor to go in soon:
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0768-1.jpg

Found an absolute bargain on the net:
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0776-1.jpg
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0779-1.jpg

Built them up with new hi-los and adjustable bottom arms. Working with all shiny new parts is sooo much nicer. Front subframe now looks actual poodle's plums:
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0777-1.jpg

That's all so far, back up to Edinburgh soon for a few months so hopefully will get a lot done, then it's back to Uni to do an MSc in motorsport engineeing. Hopefully get it rolling, maybe even running by then.

Andy

[evolotion]

im going to sound like a bore here, but if this is staying a-series it shouldnt be here Wink

Still undecided on engine was going for 1275, but considering VTec, we'll see... Just thought I'd share though...

builds are always nice to see but these sections are for hybrid builds, to keep hybrid build information in one place. this helps people putting similar engines into there cars as the forums present a nice dense pocket of very relevant information. Your buidl isnt hybrid, so shouldnt be in the hybrid builds section ( you used to only be able to post in here after approval, was changed due to the administrative overhead, but doesnt meen anything goes!)

the method for this is you post a build diary in the normal sections, and when it becomes a hybrid build, i.e. car+ engine+ some kind of subframe it is then mooved here, to the build sections:)

Ideally will moove this to the general rover secion, if you do then go down the honda-powerd route then itll be mooved to the honda hybrid build section :)

[andy_s48]

OK fair doos, can a mod move this to the appropriate section then please?

[andy_s48]

A little more progress. Have speant the last two weeks doing bodywork on the front alone!! Very boring, but car has gone from this:
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0781.jpg

To this:
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0784.jpg

And now on it's way to resembling a car again:
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0785.jpg

[andy_s48]

Decided to design my own alloy fuel tank. Was just after a small sprint tank, so designed it nice and low and to hold about 15L. Got it laser cut then tig'd up at work. Needs a quick spray, then should look pretty decent.

CAD model:
http://i17.photobucket.com/albums/b64/andy_s48/4.jpg

Needs some paint:
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0788.jpg

Lots of nice ally TIG welds:
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0789.jpg

[project designer]

wow thats a good project! mine is staying fairly original with a series but doing a few mods aswell!
good luck mate i will be watching your progress ;)

[andy_s48]

A few more from over the summer.....

Temporarily rolling:
http://i17.photobucket.com/albums/b64/andy_s48/DSCF1388.jpg

Front end close up, hubs are coming off again to finish re-furb.
http://i17.photobucket.com/albums/b64/andy_s48/DSCF1386.jpg

Pretending to look like a real car.....
http://i17.photobucket.com/albums/b64/andy_s48/DSCF1391.jpg

Rear end. Ran out of paint and Halfords no longer sell it, so have a slight problem as I wasn't planing on doing a full re-spray!
http://i17.photobucket.com/albums/b64/andy_s48/DSCF1392.jpg

That's all, and sadly I'm now at Uni so won't be able to work on the car for a wee while. Some photos I've taken from Uni, have more if people are interested. Sorry for the rubbish quality......

F1 carbon/carbon multi-plate clutch. Weighs nothing!
http://i17.photobucket.com/albums/b64/andy_s48/Carbon-CarbonMulti-plateF1Clutch.jpg
http://i17.photobucket.com/albums/b64/andy_s48/Carbon-CarbonF1ClutchInsideDetail.jpg

NASCAR brake disc- it's quite big:
http://i17.photobucket.com/albums/b64/andy_s48/NASCARDiscRotor.jpg

A straight cut dog box that we got to play with:
http://i17.photobucket.com/albums/b64/andy_s48/HewlandMk94SpeedStraightCutDogBox.jpg

Finally, just some of the cars in the lab:
http://i17.photobucket.com/albums/b64/andy_s48/Photo-0802.jpg

[andy_s48]

Well, have been back home for a couple of months now and have been getting on with the massive list of things to do. Firstly, re-furbishing the front hubs:

Nasty before pic:

http://i17.photobucket.com/albums/b64/andy_s48/460ce87d.jpg

New bearings, lapped ball joints and re-painted:

http://i17.photobucket.com/albums/b64/andy_s48/279a1124.jpg

http://i17.photobucket.com/albums/b64/andy_s48/2aaf86e8.jpg

Rolling again:

http://i17.photobucket.com/albums/b64/andy_s48/95650f83.jpg

Timing in new cam (Kent 286):

http://i17.photobucket.com/albums/b64/andy_s48/6b43bb7d.jpg

Slowly building up new engine (1275 GT A-Series):

http://i17.photobucket.com/albums/b64/andy_s48/23492cb6.jpg

Beginning to come together. Lifted it in myself and almost put my back out! Will be using a crane or a burly mate if ever doing this again.....

http://i17.photobucket.com/albums/b64/andy_s48/66fdbc9d.jpg

Have been playing around with a bit of wet lay-up carbon fibre. Can't recommend these guys enough, really helpful and not particularly expensive:

http://carbonmods.co.uk/Products/Carbon-Fibre-Laminating-Starter-Kit__CMCFLK300.aspx

http://i17.photobucket.com/albums/b64/andy_s48/5bceeab4.jpg

That's all for now....

[Birdman]

Err, either my maths is very poor, OR you are a bit shy on valves? I think this was mentioned earlier. Please say you are going to add 8 more valves or at least put in a different engine other than an "a series".

I am lost here... :rolleyes:

[evolotion]

Err, either my maths is very poor, OR you are a bit shy on valves? I think this was mentioned earlier. Please say you are going to add 8 more valves or at least put in a different engine other than an "a series".

I am lost here... :rolleyes:

the post was mooved already from the builds to rover chat as per the forum norm untill a build becomes a hybrid :)

Good to see progress, but i think you may underestimate the dynamic forces placed on alternator bracketry, atleast with that carbon part i bet you will snap the corner off your water pump in a few hundread miles :( steering arm also should have tabbed washers if you havnt used a quality threadlock :)

[andy_s48]

the post was mooved already from the builds to rover chat as per the forum norm untill a build becomes a hybrid :)

Good to see progress, but i think you may underestimate the dynamic forces placed on alternator bracketry, atleast with that carbon part i bet you will snap the corner off your water pump in a few hundread miles :( steering arm also should have tabbed washers if you havnt used a quality threadlock :)

Yeah, understand what you're saying about the bracket, but to be honest I think I'm going to have to re-think the whole alternator set-up, as it's giving me lots of problems for my front-mounted radiator plan. And yeah, I'll be lock-wiring everything at some point, but think I'm still pretty far off finishing touches!

Working on a carbon timing cover at the moment, so will get some pics up once that's done.

[matt]

Looks like your doing a nice job on the car but the 1275 is g@y. About as exciting as finding sand in a desert!

At least drop a 8v vauxhall in there, only a weeks job if you know what your doing and 130hp and a 5 speed gearbox.

[andy_s48]

Haha, fair point. It's my first build though, so I'm going to get it running first and then if it goes bang/whatever drop a VTEC in.

[andy_s48]

Right, had enough of engine problems at the moment, so have made a start on the rear. The rear will require a lot of work, including replacing the arches at some point.

Have been fitting my Minispeed carbon floor. What a piece of shit this is! ONLY the top layer is actually carbon- the rest GFRP with the bottom ply painted black! the floor has been "reinforced" with what must be either MDF or a very low-grade plywood. Finally, the quality is rubbish with plenty of voids from bubbles in the top-coat of epoxy. The fact that it also requires a lot of cutting to fit seems trivial in comparison. If it had been sold as a “composite” floor I wouldn't have minded so much, but when you're paying carbon prices......

Anyways, rant over. Rusty boot:

http://i17.photobucket.com/albums/b64/andy_s48/photo-1.jpg

A couple of these:
http://i17.photobucket.com/albums/b64/andy_s48/photo5.jpg
http://i17.photobucket.com/albums/b64/andy_s48/photo2-1.jpg

10 mins later:
http://i17.photobucket.com/albums/b64/andy_s48/photo2-2.jpg

"Carbon" floor and fuel tank sitting in place, will fix it properly later.
http://i17.photobucket.com/albums/b64/andy_s48/photo32.jpg

Despite the floor being neither particularly light nor strong, it at least looks pretty!

That's all for now, will hopefully get it fixed and the new subframe on soon.

[andy_s48]

Well, a lot has happened since the last update. I have now left Scotland and am working down on the south coast of England! The Mini has made it down too:

http://i17.photobucket.com/albums/b64/andy_s48/photo5-1.jpg

In its new home:

http://i17.photobucket.com/albums/b64/andy_s48/photo3.jpg

Made a start on tackling the rear. The metal is so bad I've decided to rip it all out and start again. The subframe put up a good fight, but after the best part of 2 hours it was off!!

http://i17.photobucket.com/albums/b64/andy_s48/photo2-3.jpg

Got a bit of a suprise when I found what the subframe has been mounted to all these years!!

http://i17.photobucket.com/albums/b64/andy_s48/photo-2.jpg

The other side is just as bad, looks like I'm on bodywork for the next month. Just need to figure out where to start....