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Old 12-09-2014, 07:10 PM   #1
windymiller
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Default 1.8 vvc - home made frame

I've decided to say goodbye to my Toyota conversion in favour of a 1.8vvc from a Rover 25 Gti. Apparently, these cars are pretty rare and they're about to get even rarer! The donor has 56k on the clock and a documented HG replacement at 36k and runs pretty sweet. EML was on when I got it a few months ago, but swapping the vvc solenoid connectors sorted that.

The plan is to modify a mini subframe and fit it under my existing clubby fg front.

Not much progress so far - I'm in the process of removing the Toyota engine and frame.
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Old 12-09-2014, 07:32 PM   #2
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Here's how it looks now:

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Old 12-09-2014, 11:41 PM   #3
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Why o why?
Nothing against rovers best, but surely you can get this to perform as you want?
Bored or what?
Huw
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Old 13-09-2014, 07:28 AM   #4
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Originally Posted by windymiller View Post
I've decided to say goodbye to my Toyota conversion in favour of a 1.8vvc from a Rover 25 Gti. Apparently, these cars are pretty rare and they're about to get even rarer!
I wouldn't say they're rare, more that no one seems to want them Shame, as they're a great little hot hatch.

Looking forward to seeing what you've got planned for the frame
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Old 13-09-2014, 09:02 AM   #5
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Originally Posted by minimutley View Post
Why o why?
Nothing against rovers best, but surely you can get this to perform as you want?
Bored or what?
Huw
I need something to keep me occupied over the winter. The car needs the bodywork sorting so I thought I'd go the whole hog and change the engine too. I learnt a lot from the first build and I want to use what I learnt in this one.

I'm thinking of making the frame out of sheet steel, probably 1.6mm and a bit thicker in places. I don't know of any done like this before so it should be interesting
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Old 13-09-2014, 09:16 AM   #6
minimutley
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I don't think you have the space to use bent sheet, look how bulky the std subby is, you only get rigidity with depth from the bend. With a k series in there you got no room man.
Always willing to be proved wrong though...
Huw

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Old 13-09-2014, 12:58 PM   #7
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I mean like a monocoque type construction, so the sheet is folded and welded to make a hollow/tubular type frame. Could be a nightmare but you don't know till you try! I'll start saving cereal boxes for templates
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Old 13-09-2014, 05:33 PM   #8
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Like the front chassis legs on a 'normal' car?
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Old 13-09-2014, 05:54 PM   #9
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Like the front chassis legs on a 'normal' car?
Yes, similar to that. Either built of the subby towers or just above them off the bulkhead and use the subframe just for suspension mounting. I've stripped the Rover ready for engine removal so I can start measuring and see how things could look.
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Old 13-09-2014, 05:59 PM   #10
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Interesting idea.
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Old 19-09-2014, 02:03 PM   #11
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Well, slow progress is being made. Engine is out of the mini:



I've also now got the engine out of the donor:



I'm shocked at how light the k-series engine is. I lifted it out on my own by hand! I had all sorts of plans for getting it out like jacking up the car and sliding it out from underneath but it was a doddle. Need to get it in the garage now and see how it looks.
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Old 20-09-2014, 04:42 PM   #12
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K-series now dangling in space:



Going to strip the dash out tonight and hopefully start on the frame.
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Old 22-09-2014, 09:36 PM   #13
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Managed to get a bit done tonight. I've made and fitted the first plate which will become the mounting of the first chassis leg:



The nuts will be welded on as they'll be boxed in eventually. Here's a shot from inside showing the access holes:



Here are the pilot holes. The two on the right needed moving to the right as the heads of the bolts would have fouled on the internal stiffener:



The plan is for the engine and box to hang off the legs. I'll then trim away at a mini subframe until it fits from underneath, then tie the ends of the chassis legs to the front of the subframe. All of it will be made to unbolt.
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Old 23-09-2014, 02:36 PM   #14
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Interesting idea. I have many questions, but shall wait until we've seen more of it
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Old 23-09-2014, 09:21 PM   #15
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Ok, well I'm in the garage and seem to be making good progress. Some shots of the engine being aligned and the 'windymiller engine alignment tool mk1':













Some free offcuts from my friendly local fabricator:



Thats 2mm sheet. 1.6 looked too thin.

Here's the first chassis leg coming together and using the Rover 25 gearbox mount:







Thats it for now, time to crack on
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