Hi Robin,
yes, I could drop the back end of the gearbox down a bit but can't go too far or the propsahft will foul on the crossmember. But i'll end up with an extreme angle difference between the gearbox output flange and the diff input flange. All I've read on propsahft theory is the difference should be less than .5 degree and I'm already at 1 degree.
To compensate I would have to rotate the diff casing so it's pointing up at the front, not impossible, but quite difficult to do.
You'll have to come down and take a look...
Hi Mike,
I meant to add a link in my last answer.....
http://www.vibratesoftware.com/html_help/2011/Diagnosis/Propshaft/Propshaft_Angles.htm#Specifications
It seems that you can have large working angles but the difference between the working angles must be < 1 degree.
I wasn't planning on using a rubber doughnut so that was not affecting my thinking.
I'll try dropping the back of the gearbox and see if that gives me enough clearance. Ian's already mentioned that the M50 runs in the BMW at an angle pointing down at the back, so that should not be a problem.
But apart from the price, I am getting quite keen on the Iruna servo option.
I hope to try some more options later this week.....
Week 26 update.
Not a lot to report on this week due to being busy with other things this week.
I did put on the engine compartment sides, the heater cover thingy and the front nose to check for engine clearance issues.
Engine clearance by
marlinpeter, on Flickr
Engine clearance by
marlinpeter, on Flickr
And I'm please to report there are no new issues!
I also made up a cardboard mock up of the Iruna brake servo, thanks to my Blue Peter training.
I'd like to mount it up near the master cylinder but space is a bit tight....
Possible sevo location 1 by
marlinpeter, on Flickr
....but it will easily fit below the inlet manifold and it can sit on the chassis. And probably easier to bleed the brakes in this position as well.
Possible sevo location 2 by
marlinpeter, on Flickr
Not had any time to try out any new engine mounting positions and the angle grinder is locked away for now
.......peter
Week 27 and 28 progress report.
Week 27 saw no physical progress due to some higher priority indoor DIY jobs and some horrible weather outside. But it did give me some thinking time to weigh up the options of modifying the chassis or the GRP bodywork.
In the end I deicide to have a go at the bodywork on the basis that I could put that back together again if it didn't work.
So yesterday I did some thinking and drawing.....the pen marks were to enable me to think about which cuts would be the best and enable me to visualise the different options.
Gearbox tunnel mods by
marlinpeter, on Flickr
I had a go at cutting with a hand held hacksaw blade but quickly decided I needed something bigger. So I went and hired this little beauty. Only £14.90 for a days hire and it was brand new!
Battery Angle grinder by
marlinpeter, on Flickr
With some fully charged batteries and some nice spring sunshine it didn't take very long to have the tunnel cut out allowing me to finally lower the bodywork back on to the chassis.
Gearbox tunnel mods by
marlinpeter, on Flickr
Which left me this....
Gearbox tunnel mods by
marlinpeter, on Flickr
Here you can see my body lifting technique required to get the final trimming for clearance.
Gearbox tunnel mods by
marlinpeter, on Flickr
Next I installed the propshaft and gear change mechanism to check for any issues. The gearbox mechanism will need to be shortened by about an inch.
Gearbox tunnel mods by
marlinpeter, on Flickr
I also checked that the propshaft didn't foul on the handbrake.
Gearbox tunnel mods by
marlinpeter, on Flickr
I originally envisaged just raising the tunnel parallel with the floor but then realised I could mount it at an angle making this joining point much smoother and simpler.
Gearbox tunnel mods by
marlinpeter, on Flickr
I think I'm going to leave those bits overlapping to increase the strength.
Gearbox tunnel mods by
marlinpeter, on Flickr
....to be continued........
............Week 27 and 28 progress report (continued.....)
Clearance at the bulkhead is very tight so I think I'll have to trim this flange back a bit. This is looking down at the back of the engine.
Gearbox tunnel mods by
marlinpeter, on Flickr
In the next shot I'm checking the clearance of the gear mechanism to the propshaft.
Gearbox tunnel mods by
marlinpeter, on Flickr
The propshaft will need lengthening and a different gearbox mounting plate is required. This was not unexpected.
Gearbox tunnel mods by
marlinpeter, on Flickr
No issues at the diff end of the propshaft.....
Gearbox tunnel mods by
marlinpeter, on Flickr
Here is an overall shot with tunnel removed. It's tempting to make the tunnel removable for servicing the finished car but I'm worried there might be too much flex in the body?
Gearbox tunnel mods by
marlinpeter, on Flickr
I've got a few more things to check (like the dashboard!) but I think it's going to fit!
Now.....how do you get rid of the smell of polyester dust from your nose??
....
....peter
Thanks, Robin, that's a good idea that'll I'll take a look at. If not I'll be drilling some holes and/or some access panels because at the current moment I couldn't get the engine out without removing the gearbox (because the sump is trapped behind the chassis cross-member) and I can't get the gearbox bolts out with the tunnel in place
There is always the option of lifting the whole body off on a Sabre but that could be a lot of work once the carpets, seats, doors and hood are fitted again.
If I do glass it in again and then need to get access it would be easier to just cut it out again and glue it back afterwards but a bit of a drastic solution.
The upside of glassing it all back together is in restoring the bodies original structural strength and rigidity.
BTW I forgot to mention, I did try your previous suggestion of dropping the rear end of the gearbox but even at 'full droop' the body was still about 20mm suspended by the gearbox cowling off the chassis.
...peter
Week 29 update.
I've started this week on remaking and refitting the transmission tunnel in it's new position so that it clears the BMW M50 gearbox. I have decided to try and make it removable and will strengthen most of the joins with steel angle.
I started at the rear point first. I've made up a aluminium 'hoop' to join the tunnel at this point. I need to remake it in thicker aluminium and make it slightly longer. I'll probably just use filler to smooth the gap once fixed in place. It provides a good location point before any other fixing.
Transmission tunnel mods. by
marlinpeter, on Flickr
I then made up and fitted strips of steel angle to the floor to provide a fix point for the sides of the tunnel. This is just bolted at the moment but will be screwed and bonded when finalised. The tunnel sides will be fixed with screws into rivnuts and sealed with RTV silicone so that it can be removed, if necessary.
Transmission tunnel mods. by
marlinpeter, on Flickr
I've now extended one side of the tunnel down to the floor.
Transmission tunnel mods. by
marlinpeter, on Flickr
The other side has been 'glassed up this afternoon and is currently setting. All rather time consuming work so it doesn't look like much progress this week.
.....peter
Archive film from 1998
Sorry about the lack of updates but in the meantime I came across this video, so I'd thought I would share....
https://www.youtube.com/watch?v=xorLniPLTdY
the piece on Royale starts at 18 mins 30 secs.
Great bit of film.... I wonder what the 'secret' new car was??
I think the Sabre was launched in 1994 and in the film they say that about 200 had been built, so they were shipping about 1 kit every week!!
The chap featured is a now committee member of the Royale Owners Club.
I can't believe I haven't updated this thread since March!!
Well actually I can because I've been consumed with moving house and taking on a full time work assignment.
I've not had time to work on the Sabre so no progress to report.
But the good news is my work assignment completes this Friday and we are moving house next Friday!!
The Sabre will have to follow on later once I get the new house sorted. Hopefully, I plan to be back in the garage in the spring next year but I'll keep you all posted when I move the Sabre and two lock-ups full of parts!!
If I can I'll grab a picture of the new 'man cave' which needs a lot of work itself so I am going to be very busy.
Thanks for the best wishes.
I think finding stuff after we move is going to be a major problem with so many boxes!!
Not going too far, just a few miles from J9 of the M1.
TBH I had completely forgotten about the 'Ux' in my user name so i'll think i'll leave it the same or I will confuse everybody including myself!
...peter
Hi Steve,
your car looks superb and is a very nice example.
Thanks for the link to wheelwright which coincidental I saw an advert for about the same time you posted this. I do like the look of wires but the cost, the cleaning and potential wheel bearing wear may put me off. The steel wheels do suit your car nicely so may go with steels.
I'm still hoping to re-start my re-build next spring but have a long list of house jobs to do!!
...peter
I've not updated for a while due to moving house. I've still got a long list of jobs to do, not least is to empty and refurbish my garage.
But I couldn't resit this car as a donor car that came up on Autotrader.
It's actually a pretty cool car and I enjoyed the 75 mile drive home around the M25 and up the M1
I plan to give it an oil service and then drive it around for a couple of weeks to see if it has any issues. It'll then be SORN'd and parked up in my back yard until I have time to start work on it.
Now, back to my list of DIY jobs....
P.S. it's a 1995 328i with a M52B28 engine and has clocked up 153k miles.
a bit chilly in this weather
I've also picked from ebay a pair of MX5 seats. It's going to be sometime before I can trail fit them in the Sabre but they came up at £40 and only a few miles from home. They'll be trial fitted and if OK will be recovered or traded in for a pair with new covers.
....peter
I had resisted trying the roof in case it got stuck down but surprisingly all the motors work fine.
...but it seems the clutch is on it's last legs as I had trouble reversing up my drive the last time I parked it, so the car has probably now done it's last few miles
p.s. if anyone wants a complete black leather seats and interior, do let me know!!
p.p.s a Royale Sabre with a motorised hood would be pretty cool, eh?
Hi Anthony,
and a warm welcome to the MAKC forum!
I am a bit surprised that you cannot get a hood frame from Automotive Creations as it's listed in their Parts list on their website? Malcolm (Badger) is usually very helpful to existing owners and at £297.00 I can't see making one yourself makes much sense? But I guess I can see why Malcolm would be sensitive to releasing copies of the drawings to protect his investment.
My hood frame is all in pieces and packed away in one of my 'lock-ups' so it may take me a while to find it all again but I have started to slowly sort things out after moving house last year.
If you have no luck with Malcolm, then send me a PM with your contact details and I'm sure we can work something out.
best regards,
Peter
Still working my way through my 'Honey do' list but made progress this week by demolishing the old log storage shelter to make way for a garden shed. This will free up space in the garage so I can move the Sabre to it's new home. It'll probably be another few months but in the meantime I've been buying and selling on that well known auction site and collecting together some more useful parts. Ford Sierra parts are now definitely becoming scarce and more expensive.
Cheap alloys by
marlinpeter, on Flickr
I bought these wheels just to move the car around on as I'm selling the BMW Type 32's that came with the donor car. They cost me only £50 for 5 including an unused spare wheel and tyre. I've already sold the spare for £35 so they cost me £15!!
Steel wheels by
marlinpeter, on Flickr
These are for the Sabre. Another ebay purchase and even though they are 11 years old they have been dry stored in a shed for 10 years. Colour coded to match the car paint and some nice shiny hub caps and I hope they will create the right effect. (Mark 1, Ford Focus, in case you wondered)
Sierra handbrake cables by
marlinpeter, on Flickr
Sierra handbrake cables
I bought both of these cables from the same seller as they were listed under an obscure Unipart number and only £4.99 each. I need to get one of them shortened, but which one? The one on the left has a manufacturing date of 1995 whereas the one on the right was made in 2000. Was the change in bushes due to cost reduction, automation or an improvement due to failures of the earlier type?
Ford Diffrential/final drive mounts by
marlinpeter, on Flickr
Ford Differential/final drive mounts
On the left is a Granada diff mount compared with a Sierra version on the right. The Sabre chassis can take either type. The Granada version looks like a good option if the polybushed version is too stiff.
Evolution of Ford Uprights. by
marlinpeter, on Flickr
The Evolution of Ford Uprights.
Far left is a Scorpio Cosworth upright and hub, in the centre is Mk 3 Granada knuckle and on the right is the standard Sierra upright. The plan is to try and use the Granada knuckles if the Scorpio hubs will fit. The advantage is that they are a bit more substantial and have 12mm bolt holes for the calipers which means I can use bigger brake discs and calipers. This is a bit of a side trial which has some way to go before I can be sure they will fit and not screw up the geometry, etc.
I'm also cleaning up the rear brake calipers to see if they are refurnishable or will be traded in.
that's all for now...
...peter
Thanks for the feedback and I'm glad you're enjoying the updates. (albeit a little slow progress since moving house last year).
Sorry to hear that you are selling your own car but I'd love to see any old build photo's if you have any?
Unfinished or neglected Sabres do seem to be rather rare but pop up occasionally. I'll let you know if I hear anything!
...peter
Hi Amir,
likewise, it was great to meet you and Peter today.
You are making a very nice job of your car and I really enjoyed the my lift back to the car park
For other followers of these 'bespoke motor vehicles' here is a picture of your super car at the Knebworth Classic car show last week.
Hopefully I'll be back in my garage again soon....
(but I have been saying that for a while now! :sad
Royale Sabre - Knebworth 2014 by
marlinpeter, on Flickr
....peter
Hi Amir,
that sounds very interesting, where are you thinking of mounting them on the chassis?
For posting pictures I always put mine on Flickr first and then add a link in my posts on this forum. I think you can still get a free Flickr account and there is also Photobucket but I haven't used that.
But I believe there are other ways of posting pictures on the forum directly.
I think this thread covers some ways to do it.....
http://www.madabout-kitcars.com/forum/showthread.php?t=3076&page=2
Post #21 has the instructions......for attaching directly to this forum without using Flickr.
....peter
P.S. still no progress on my Sabre but I have started to dismantle the BMW donor. I'm quite busy on ebay selling off bits I don't need