rs_traynor

thinks gonna be an animal mate, keep up the good work

LIMITLESS

Wow im gob smacked just read this from the start , going to be a naughty beast sir

Dimma4x4

Keep up the good work looking beltin been to MK MOTORSPORT an the things he manufactures is top notch an top fella an ordered just about everything for mine

steven mc kay

very nice project , your makeing a nice job of the shell work your self .
thats a nice list of parts you have collected up to.

look forwards to the up dates , keep up the good work .

thanks steven

zetaboostboy522bhp

thanks steven , love your car and also your escort , i thought you was mad for breaking that but i can see why you did as your fiesta will be a real beast

cheers paul

creator

Bumpty bump
Long time no see paul,any updates mate?

zetaboostboy522bhp

little update , as the weather has been that crap hardly any fabrication has been done to the body shell so ive been working on bits in the shed ive also been buying some parts for the car.

first was a set of bilsteins that had custom mounts fitted but not what i wanted but i got them for a fair price



next was to buy all the steering column components

splined shafts



2 roller bearings and 1 spherical bearing



cds 20mm tubing 3.2mm wall thickness



cds 50mm tubing 2mm wall thickness



univeral joint



also got a new rubber donut for the rear prop

so on to the fabrication of the steering column
the 20mm cds tube needed machining out 1mm which a drill did the job to except the splined shaft

before



after



the tube can now except the splined shaft



splined shaft cut in half



cds tube drilled for plug welding to add strenght to the steering shaft



splined shaft mounted ready for welding



plug welded and double welded around the tube



next was to clean the 50mm tube and mark the holes



32mm hole saw at the ready , first of many holes



many holes later



shaft mount in outer column



next was to mount the rear anti roll bar but i was abit limited with space so decided to use the front anti roll bar brackets that i dont need now as the wrc crossmember already has the arb mounts welded on to it. slightly modded by cutting some lugs off



ready to be welded on , cleaned the area for welding



welded on nice and neat







anti roll bar all mounted up



drop link central with with turret tower



i decided that the rear anti roll bar brackets needed streghtening inside the car as the floor is only 1mm thick and could flex under load from the roll bar working , these are the strenghtening plates i made

cardboard template



metal copy



holes drilled



bent and swaged the holes





welded in to the car



next was to modify the bilstein cases for wrc fitment to fit my billet uprights

orginal mounts



far to narrow for the wrc uprights



cut off orginal mounts and cleaned up



this is the shape we wanted



cardboard template



then a hard template out of foamex



a bit of measuring and working out and a double template with wrap around straps like the orginal bilstein wrc cases



metal template



tack weld the metal template to a 50mm tube and heated with a heatgun , i didnt think it would work as the metal was 3mm thick but it did

starting to heat and bend







fully bent around the tube



cut tack welds off and hey presto







holes then drilled to 12mm



then tried on to the bilstein strut



then fitted to wrc upright



then welded on to the strut case and built back up



full strut and wrc upright bolt together





strut leg straight



what strut leg could go to with offset washers



second one finished just needs building back up



and all finished both together



iam still waiting for mk to finish my hubs off and collect them soon so i can then start building the rear end up , i got some more work for mk aswell like engine mounts and gearbox mounts and some trick ohlins suspension so hopefully more updates soon , if the weathers ok there maybe some tomoz but i wont hold my breath.

anyway thanks for looking

cheers paul

NEEDFORSPEED

bloody brilliant! very talented!

robp-tt

iTrader: (1)

nice update paul your making some good progress with the car, looking at all the trick suspension parts makes me think i should have made kgb 4wd lol

zetaboostboy522bhp

hi rob you wouldnt be saying that if you knew how much cash ive chucked at this thing lol

thanks for the kind comments


cheers paul

M K

iTrader: (9)

Nice work Paul, love the fab work you have done

You didn't melt the rubber bush in the bottom of the case when welding them struts did you?

Swamp

When welding/grinding on the struts isn't there any risk of some internal damage or pressure buildup in the strut?

andy escos

iTrader: (1)

lovely bit of fabrication work Paul coming along nicely

zetaboostboy522bhp

mk there is no rubber seal in the bottom just 2 bronze guides , one at the top and one half way down

no there is no risk as the whole inserts comes out so your just welding the cases .

M K

iTrader: (9)

In the bottom of a bilstein case is a rubber bush like a bump stop, that is what can melt if you don't be carefully or remove it first, if yours doesn't have them then they should do

M K

iTrader: (9)

As seen in this pic mate

williamsclio1

Awesome thread, throwing some money at this one.

Will be amazing finished.

AustenW

Good job, looking well

SiST

iTrader: (1)

Any updates fella - always like coming on here and reading how you are getting on.

COLEYST200

iTrader: (3)

looking good mate

rst-g

Crackin work mate

zetaboostboy522bhp

right another little update as again been so busy its been unreal and the weather been really shit down derby way on so i just havent got the car uncovered as its just aint worth the risk even thou its rusty as fuck lol.

first i found a really good set of grpa bilsteins that iam going to use to mock up the front end , not bad as they have brand new springs and inserts



next on the list was to get mk motorsport to make me x2 brand new drive flanges to wrc spec and to fit mk bearings in his upright and to make me x2 brand new drive flanges to 4x4 spec but also to fit mk uprights , mk has machined them up but is having trouble getting them splined but hopefully they should be done in the next month or two. so as i needed to get the rear end all built up and rolling to see if the wheels are ok etc i got mk to turn the drive flange down and stub shafts to fit mk bearings . mk also kindly cleaned them up for me so cheers for that mark

stub flange



drive flange



and both together



and all built up into the upright



mark had forgot that i was using a 2wd rear diff and made me a 4x4 diff cover so he quickly machined me a 2wd diff cover up so i could collect when i collected my drive flanges

nice new shinny cover



also looking at the engine i noticed when i was playing with the front diff the engine wants lifting up and inch if i can as even thou iam running a remote diff and a dry sump the drive shaft would need to go through the sump and i dont want that so thats a job to do. i would want new engine mounts so thats what i got on with today as again it was pissing it down on and off all day

card board templates



made in metal



all tig welded up






2 made up with lids on



edging strip to add strenght



edging strip on and migged for strenght along with the insides also to add a bit more meat





holes drilled into the top and sides



swaging tool



holes swaged up





all cleaned and primed up





hopefully get the rear end all built up now which for me is a milestone and if the good weather comes back i might get more done

thanks for looking

cheers paul

Richie.

iTrader: (5)

Engine mounts look good mate


Are those stub axles machined standard ones??

Gav Diamond

iTrader: (6)

Amazing work bud, keep it up

zetaboostboy522bhp

cheers for the comments , the stub axles are grpa or wrc ones but they was to big for mk bearings he uses (only 1mm as the are 5 different sizes) so they was just turned down

cheers paul

whizzisat114

iTrader: (2)

Great fab work Paul
liking the engine mounts
Do They weld straight to the flitches ?

lanfire

Brilliant work going on in here, makes me want to learn how to weld properly haha

andy escos

iTrader: (1)

any updates Paul

zetaboostboy522bhp

a little update , been waiting for some parts off mk motorsports to get the car rolling but hes also waiting on them so hopefully they will arrive soon as i know mark is a top guy .
ive been trying to do as much as possible before winter really sets in and tbh i really wanted it painted by christmas but i know that its never going to happen as when you build a car like this nothing is never as simply as it seems lol
anyway been busy working out how to fit the wrc crossmember and mount it to the chassis legs so it looks nice and tidy , i had to make a box section with 4 threaded bushes then fully weld them to the chassis legs , i used the big block of wood to stop the chassis legs twisting during welding





wrc crossmember fully fitted





next on the list was to trim the chassis legs to allow the driveshafts to fit with room as it was very close and i wasnt happy so cut out a lump and plated with 3mm thick metal so it nice and strong





i fitted all the suspension to the car and jacked the wheel up so i got the ride height correct with nice equal gaps around the front wing and found because iam running 18x8 alloys with 40mm tyres that i had massive inner wheels arch problems in that i had an inch before the tyre would rub on the inner arch so out came the angle ginder again and cut out all the metalthat i didnt need , i also decided to make some mini wheel tubs for the fronts and this allowed me to follow the arc of the wheel to get a nice shape.

metal work cut ready for welding





cardboard template for the wheel tubs



made in metal





both tubs made



test fitted to the car after some trimming







wheel tubs up welded up and primed





i didnt get chance to take to many pics so i will take some more and hopefully there will be more update soon

thanks for looking

cheers paul

GINGExR2 T

iTrader: (1)

.


Fair play mate, thats some cracking work your doing, love it




Ginger


.

whizzisat114

iTrader: (2)

Great fab work

COCHYN

Awesome! I really want a set of those top mounts off MK

robp-tt

iTrader: (1)

Great update Paul. Looks like your getting there. Have you decided what colour your going to do it yet?

zetaboostboy522bhp

thanks for the kind words , i just wish i had more to show you as it feels like iam going no where fast lol

steven mc kay

looking good paul, your prity handy with this fab work mate .

how did you work out the right hight to mount your x member mounts ect to have the pick up point correct . i am just interested .

thanks steven

andy escos

iTrader: (1)

Great update Paul coming along nicely .

Kizza

fantastic read, i would love to do this to my puma but i just dont have the money

keep up the good work

RS_Rob

its coming on nicely paul,
some proper nice kit being used
have'nt read this for a while,

hope all is well your end,
i'll be in touch soon

zetaboostboy522bhp

a little update , the weather has been really shite and not touched the car since before christmas and work has really got busy so been working all hours to try and gather more money for the car and its been a bonus doing the overtime with the weather being crap.
i have been buying some parts like the hydraulic handbrake , controller unit for the corse power steering that i will be using , comp brake rose jointed track rod ends , a manual ford sierra steering rack that will be fitted with quaife internals.
ive got new extended front drive shafts from automotive unlimited.
ive also been to see mk motorsport today to order my front and rear ap brake kits with marks custom made bells which he said that hes going to make them look like motor bike bells in terms of design so that should be interesting and also bracket etc to fit the billet uprights , iam having black calipers with gold brackets and bells so they should match the rest of the componets ive got. mark is also sleeveing the front drive flanges so i should be able to actually bolt everything up to see if ive got any problems when they are completed.
the 5 mins ive spent down the shed worked out well as iam running a remote front diff set up like ag motorsport did on his focus so without having a part made to fit the crossshaft in i decided to use the cossie sump pan and fittings so cut the sump pan up and ground down all the sides etc and ended up with a ideal piece of equipment to use for the remote diff . it will be strenghtened and have a plate welded to it so it can be bolted to the wrc crossmember.
i have no pics yet but will down load some in the middle of next week and mark from mk motorsport said he will update with pictures of the drive flanges and brakes.

thanks for looking

cheers paul

M K

iTrader: (9)

Good to hear things are still happening Paul

What is your reason for remote mounting the front diff mate?

Will you not going to run into any issues remote mounting the front diff if the engine is in the standard position? Are you going to be dry sump? i have only ever seen it done to a yb set up up Andrew's old car and that engine was mounted a lot further back in the bay and is the reason for going remote front diff i believe? obviously a bonus being able to easily change/remove diff or engine independently, i may be wrong though so interested to see it all done