CraigJ

Right starting a build diary for this little monster. The chassis is an Onyx Mongoose item which i bought from www.Onyxsportscars.f9.co.uk near Grimsby about two weeks ago. There own car is powered by a rover 1.4 K series lump producing 100bhp and weighed in at a little over 400kg and was quite impressive on the road and track but like most people i wanted more power and less weight. After contacting David at Onyx i was offered there last chassis for £1000 (only 5-6 chassis have been made so far but the company has currently put it on hold to concentrate on other projects)

My first plan was to fit the Mongoose chassis with a Yamaha XJR1300 engine but due to issues i would have had with cooling a mid-mounted air/oil cooled engine would have been more trouble than it was worth. So after a couple of days searching i found a 1988 Kawasaki ZX10 at MP Motor cycles just at the side of the M606 Bradford and got it for £600 with T&T.

The Chassis


The bike

It actually rode quite well and it was sad to break it.

The bike after about 3 hours


All the parts now all over the place


XJR engine now straped to pallet awaiting collect. Its going to Ireland.


The ZX10 lump stripped of its casings and cleaned up. Had 19 years of shit to remove



A few parts removed cleaned and painted up.


Stripping and cleaning the carbs


3 already done just need to polish them up now


The exhaust will be reused. Had a nice stainless system on it with a Micron can



My 3yo nephew liked the bike. He was in tears when i stripped it




Im hoping to have the engine mounts welded in by next weekend and the engine trial fitted. I'll update as more progress is made. The finished product will weigh around 350kg and have around 140-150bhp. should be fun.

rapidcossie

Looks pretty mental

CraigJ

Thats the plan lol

CraigJ

Right should have a few more pics to put up in the next few days. The engine mounts are in, the chain diff is being built i'll get some pics done and posted up in a day or two. My uprights/hub and suspension will be ready to collect from Onyx at the end of next month.

Hopefully this will be build by the end of august.

Charlie Chalk

iTrader: (1)

I would Love something like this! I sometimes think I shouldnt have started my S2, and what I should have done, was a Z-Cars Mid engind Mini...

Good luck mate, Should be the bollocks

CraigJ

I originally wanted to build a westfield/caterham style 7 but when i saw this i just had to do one. The whole build will set me back around 2500-3000 but only because i can make most of the custom parts myself at work.

The power to weight will be great. Ive been out in a friends westfield with a 2.0 Zetec with 160-170bhp, weighing 530kgs and that was fast so i think im gunna need to keep a spare pair of boxers in this one for the brown pant moments.

CraigJ

Thought id put up a few pics of the chain diff im making. Cut out a few parts at work today.

heres the diff from a 1.8 sierra


one side welded


side mounting plates cut from 5mm 316 s/s


I made the bearing housing from 3 rings of 6mm mild steel with a 2mm end plate.


The bearings im using


All together




Ive made this diff from s/s and mild to start with but i plan to make it from ali once ive tested it to make sure it will be strong enough. Once its all ali it will drop a kilo or two.

Will post some more pics on sunday once ive got the engine back in place.

smitsturbo

would love to build a bike engined something or other 1 day, keep us updated mate

CosKev3

Good read

My m8's currently building his third BEC,all been MK Indy's,started with ZX9 Ninja engine in first one,then '98 R1 engine in second,now building a '06 R1 engined one

Very good fun on the road,6 speed clutchless sequential gearshift is shit hot

CraigJ

Little up date today.

Engine is in but not fully fitted yet, its only in so i can mount the chain diff and other components.







The diff built up




Sat in place in the chassis, will be making the mounts this week.





Will be fitting the steering column and rack this week, just need to nip to the scrappers to get a Metro column.

toff

iTrader: (1)

good work, ill be keeping an eye on this

CraigJ

Thanks

ballin

iTrader: (1)

very cool

coco16i

What a great project mate and some great work so far.

Will be keeping an eye on this build so keep the pics and updates coming

CraigJ

Just thought id put up a few pics of my Onyx Mongoose build. Floor and side panels are fitted and the engine is now in and im sorting the loom out. rack and column are also fitted. I have all the suspension in a box out the way for now.

Sorry some of the pics arnt too good, done a 12 hour night shift had 4 hours sleep then been in the gym for 2 hours so im a bit f**ked and cant hold the cam still lol.



















And a very locost pedal box (cost nothing to make)

CraigJ

Here is an Ebay find. a 4 gallon Jazz fuel cell, cost me £46 the other day. Its a perfect fit.









And part of the rear suspension mocked up today





Hoping to have it sat on its wheels by the end of next week. My front suspension are currently been made and should be here soon.

glancy2081

what will this weigh when fully built up

CraigJ

If it all goes to plan under 400kgs. Im aiming for 350kgs but i'll be happy as long as its under 400.

NEEDFORSPEED

MAD EVO 4

This looks like a good project mate

CraigJ

Cheers guys. The tanks now fitted and plumbed in. all the rear suspension is built up but its coming back apart to be painted this week. will get some more pics up next weekend when hopefully it will be rolling. still got the loom to finish though.

CraigJ

small update. moved house few weeks ago so not got a great deal done but heres a few pics of how the car is right now.















Chain diff completed, used the rear diff from a sierra 1.8






fabricated rear uprights/hubs


fabricated front upright


Column attached


my current ride, 2.6 V6

CosKev3

Looking good

Have you fabricated up-rights yourself?????

CraigJ

No i bought them from onyx. just need a claen up and paint now.

CraigJ

Right Heres a small update, after a few weeks of research ive decided to turbo charge the engine. I already had a garrett t25 laying around so i stripped this down and gave it a good clean but unfortunatly its no use for what i need. Good job id not ordered the rebuild kit yet lol.





The problem i had with this turbo was that the turbine housing and wheel were larger than the compressor which on a bike engine will not spool up fast enough so i now need to get either a T2 from a Renault 5 or a TD04 16T from a Volvo. both of these turbo's should give me a turbine housing that is smaller then the compressor for a faster spool up. I will update as soon as i get the turbo i need. Hopefully not long now.

CraigJ

Here's a quite a few pics of some progress over the past few weeks, no real order just lotta pics.
































































I'm now looking at a realistic finish time of about febuary, march now so will be done in time for the summer.

glancy2081

what will you do about the fueling for turbo,use rising rate regulator and also timming side of things

NEEDFORSPEED

brilliant progress!!

kik1.6se

Looks like a nice project.

Its a shame their putting the mongoose on hold as its the best looking car they've made and seems really good value track toy.

Good look with the build.

Kirk

CraigJ

Im not actually turboing the engine now. decided against it.


I'll have more pics and progress this weekend i'm hoping. Keep an eye on this thread as over the next 3 months it will hopefully be finished and on the road.

Onyx are concentrating on this at the min
http://www.onyxsportscars.f9.co.uk/1142ce10.jpg


But im sure they will still do a Mongoose kit for any who wanted one. I highly recomend Onyx as they are very helpful. This is the first kit Ive built and Onyx have been brilliant with me answering every question ive had (ive had a lot lol).

CraigJ

It on its wheels at last, not got a great deal done in the last month or two been too idol lol.

Charlie Chalk

iTrader: (1)

Getting there

purplemonster

love this project

CraigJ

Cheers guys Im getting giddy myself now knowing it will be on the road soon lol

MAD EVO 4

looking good mate

CraigJ

Well i've done fuck all over the past few months but finally pulled my finger out and started doing a few jobs this week,

Air box modified to clear engine mounting rail



Master cyclinder fitted


Pedal box fitted


Hoping to get more done this week and i'll be ordering more parts so progress should pick up again in the next month or 2.

fezzajsy

iTrader: (9)

awesome stuff m8

CraigJ

Not much done at all and will be moving home soon as me and my fiancee are in the process of buying our first house.

Progress has gone back wards lol



Engine has been removed as i wasnt happy with how id installed it so im going to build a new engine cradle.

Empty engine bay





The chain diff i designed and made has been sold to Chris Gibbs and is being used in a new book he is doing for a 60's style racer but with bike power.

I have a new diff which is a LSD from a PG1 box (rover) and i will be turning this into a chain diff soon enough



Mounted dash panel and warning lights.

.

Will update again once the house move is complete and new garage is kitted out with my crap.

craig_007

Hi mate,

I have a locost with an old zx10 lump in it,

Have you got any info on turbo installation,I was thinking of something different for a winter upgrade.


Good build diary btw,wish I had kept pics of progress too !!

Craig

CraigJ

Your best bet is to buy

http://www.amazon.co.uk/Motorcycle-T...9772859&sr=8-3

its a great book and will tell what u need to know.

a blow through design will work ok and is pretty simple to do. I bough tthe book and it was a great help. never got round to doing it though as i have sold the zx10 lump now.