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 Post subject: Ste's Roadster Build
PostPosted: Thu Jul 04, 2013 4:06 pm 
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Joined: Thu May 09, 2013 6:51 am
Posts: 44
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Hi all, Lifted this straight off rhocar so apologies if it isn't 100% perfect

Hello again :hi:

Some of the older members may remember me and my 2b

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Sold it nearly four years ago now and since getting married I've been allowed to start my new build.

This time I'm going with a scratch built and doing a Haynes Roadster.

After studying the book for a few weeks and familiarising myself with the chassis plans, reading up on the various forums; locost builders, roadster builders and haynes forum. I took the plunge and ordered the steel for the chassis.

6 lengths of 25x25x1.5mm ERW
3 lengths of 19x19x1.5mm ERW
and three 19x1.5mm ERW tube

Built a build table using 18mm phenolic resin ply (was free)

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In the mean time, found a really cheap donor on ebay

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More chassis progress pics

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Top tip, don't brush a bare arm past a freshly welded joint

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 Post subject: Re: Ste's Roadster Build
PostPosted: Thu Jul 04, 2013 4:35 pm 
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Joined: Mon Dec 03, 2012 6:19 pm
Posts: 660
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Ouch. you know all about that when you get in the bath :lol:

Bob


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 Post subject: Re: Ste's Roadster Build
PostPosted: Fri Jul 05, 2013 3:45 pm 
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Joined: Sun Dec 02, 2012 3:59 pm
Posts: 1016
Name: Bruce
Location: Biggleswade
Flying start there, think this will be one to watch :D


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 Post subject: Re: Ste's Roadster Build
PostPosted: Wed Jul 31, 2013 3:51 pm 
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Sorry about the delay in updating...

As I plan on making every panel from carbon fibre I started with the steering column shroud.

Started by blanking off the holes then body filler, sanding, high build primer, more sanding, gloss top coat and more flatting.

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Not got the pics on my phone of the finished bits but they are now ready to take moulds off.



Fabricated the rear uprights. These will accept the sierra hubs and shafts and rear calipers.


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Gearbox was checked over and found to be near perfect inside with no wear so cleaned and painted

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Diff was stripped and casing bead blasted. I'll be fitting an LSD in here so stripped it right back and had to make some special tools to get it apart.

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Rear hubs were treated in the Deox C bath which stripped them of rust, then washed and primed then painted

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Final parts were welded to the chassis minus the engine mounts while I wait for an alloy bellhousing to be made to connect the puma engine to the type 9 box

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Meanwhile, I made the jigs for making the suspension wishbones

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And also started on the plates to make the engine mounts using a broken 1.7 zetec se engine as a guide

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Finally, whole chassis was cleaned, primed and has had it's first top coat

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 Post subject: Re: Ste's Roadster Build
PostPosted: Wed Jul 31, 2013 5:09 pm 
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Joined: Mon Dec 17, 2012 11:22 pm
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Location: Coedpoeth N.Wales
You dont hang about do you?
Great stuff -keep the pics coming .


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 Post subject: Re: Ste's Roadster Build
PostPosted: Wed Jul 31, 2013 7:04 pm 
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Joined: Sun Dec 02, 2012 3:59 pm
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Name: Bruce
Location: Biggleswade
Nice progress indeed :D


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 Post subject: Re: Ste's Roadster Build
PostPosted: Wed Jul 31, 2013 9:36 pm 
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Joined: Mon Jul 29, 2013 7:57 am
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Looking good, can't wait to see this progress..


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 Post subject: Re: Ste's Roadster Build
PostPosted: Thu Aug 08, 2013 4:35 pm 
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Posts: 44
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Been on holiday this weekend just gone so less progress this week.

Fabricated and painted my roll bar. 50mm x 2mm wall seamless tube hoop with a 40mm x 2mm seamless harness bar across it. Into this I welded four threaded inserts for the harnesses.


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Primed then painted with Plasti-kote gloss black. This stuff leaves a finish like powder coating.


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Diff brackets welded up and painted as above but in satin black


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Made the inserts for the suspension bushes. These are seamless stainless steel. 22 of them made then polished up.


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Poly bushes inserted into the lower wishbones, then they were packed away till final assembly.

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Custom alloy bell housing arrived so mated the trial engine and box

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Then fitted it into the chassis to make the engine and gearbox mounts


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 Post subject: Re: Ste's Roadster Build
PostPosted: Thu Aug 08, 2013 7:40 pm 
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Joined: Sun Dec 02, 2012 3:59 pm
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Name: Bruce
Location: Biggleswade
Can I ask what primer you used for the plasticote on the roll bar? also what did you paint the chassis with?

Pictures look great, pls keep them coming


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 Post subject: Re: Ste's Roadster Build
PostPosted: Thu Aug 08, 2013 8:07 pm 
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I use plasti kote primer super in black. Chassis is satin super and roll bar and wishbones are in gloss super. I've used this on a few projects and found it's best to paint it all in one day. Over painting causes it to wrinkle if done once it's cured so I prime then top coat an hour later and then one more coat 20 mins after that.

Sent from my GT-I9300 using Tapatalk 2


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