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Vintage and Classic Roadster Kit Car Builds For Vintage and Classic era kit cars. Post your build reports, problems and progress here |
31st October 2015, 15:45
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Exhaust (cont’d)
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31st October 2015, 16:43
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Exhaust (cont’d)
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31st October 2015, 17:25
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Right next instalments tomorrow, I hope you are liking it so far, if anyone has any questions or can shed light on better ways I may have done things please comment, thanks...
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1st November 2015, 11:11
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The Gear Shift
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1st November 2015, 12:57
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Fitting the Alternator
As the original position for the alternator on this engine was at the rear I had to come up with a mod to front fit it, so first I made an aluminium interface plate that would pick up on the lower engine block holes...... Note on the plate’s top right hole, this picks up with a tapped hole in the block and when the bracket is fitted the top right hole of the bracket set itself up perfectly for the belt alignment.
I acquired an alternator bracket from a Honda Prulude which was front mounted, the holes on the interface plate were drilled to suit the holes of the bracket so it could be mounted it the correct position.
Because the alternator I had was smaller in size I wanted to for that rather than a Prelude one so I offered up the alternator to check what mods were required.
The pivot on the alternator was a perfect fit and the belt aligned with the crank pulley just as planned.
The lower hole on the alternator was out of position and didn’t follow the path on the bracket , this I had to slot.
I space out with washers the miss match on the adjuster and later made correct size spacers to replace the washers
All worked fine so I then cleaned the bracket and gave it a coat of paint.
The next thing to do was change the connector on the harness as the harness was for an OBD1 ecu and the alternator was from an OBD2 ecu.
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1st November 2015, 14:17
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Steering
I decided to fit the Honda steering column rather than the mini one so I could use the Honda loom and all the niceties of a later column, this gave a few problems at the rack end because the splines were different.
I gave it a thought and then stripped down a old mini rack I had and removed the pinion, I took it into work, made a heat sink and with the inner bearing race still attached I had my welder build up the end over the existing spline.
Then jumped onto the lathe and turned it down to a size I had experimented with earlier, before this I had done test pieces to get things right before I attempted the pinion
Then I set a medium straight cut knurling tool and put on a new spline
Once completed it was tried into the Honda steering knuckle and hey ho a finished pinion. The reason I left the inner race on was because the new spline was to be larger than original and wouldn’t slip over.
Well that went well so I stripped down a new mini steering rack hoping to fit the modified pinion but all was not well, the pinion was of a diffent pattern than the old one I had done the mod on so back to work to do it all over again with the new pinion
Once done at last the rack was rebuilt and fitted into the car.
Now for the column, as the car was made with a ply-wood shelf which supported the mini column I had to make up various brackets to allow the Honda column to fit, first I fitted the knuckle to the rack but on doing so it fouled the fibreglass around the hole so that was ground back down to allow full rotation
Then the column was fitted to the knuckle and a bracket was made to fix the top of the column to the ply shelf
As the column is adjustable I then made a support for the mid section of the column
Then the ply shelf was drilled and all bolted into place
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1st November 2015, 14:35
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I'm liking this resto/conversion.
Alec
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1st November 2015, 15:09
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Thanks Alec more coming....
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1st November 2015, 15:10
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Throttle
The throttle peddle was the next to be sorted as I was using a Honda cable and due to where the engine sub-frame covered the original cable hole for the mini I had to re-position the hole to miss the sub-frame
As the Fibre glass was thicker than the steel firewall from the Honda I manufactured a carbon-fibre interface plate
The the peddle needed to be altered to suit the new cable position
The peddle then was warmed and bent upwards to achieve enough travel but not so the it sat above the brake peddle
The engine was refitted into the car and the cable run in
The throttle body was the fitted and the throttle was tested for full travel
All good there
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1st November 2015, 16:40
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Your exhaust routing idea and cut section weld techniques for the bends are as inspired as your steering spline mod.
The McCoy I saw was in Brighouse west Yorkshire travelling with a hard top quantum and a mustard coloured allegro towards hebden bridge so they probably came off the M62 so could of been from anywhere. It was odd because when the quantum came out I recall drooling over it particularly the use of Sierra sapphire back lights but yet now it looked very dated and the rear lights looked massive whereas the McCoy looked more like a traditional yet very small sports car lotus élan esque.Ed.
Last edited by a big scary monster; 1st November 2015 at 16:43..
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1st November 2015, 17:01
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The Throttle body
I now discovered a major problem, the throttle body inlet was looking straight at the clutch master cylinder, now that’s not good, I had a few options here, I could either buy a set of individual throttle bodies or go the hard way and modify the one I had..
Well a challenge it was then, there seems to be a theme going on here, if I can go the hard way then that’s the way to go, my thoughts on these things are, anyone with enough money can go and buy all the nice new goodies and bolt them on but I wanted to make this mine so the modification was the way to go.
So here goes (Caution: this part of the build took some time and I want to thank both my welder colleagues for all the work they put in for me here)
First things first, I need to cut and shut the ports to allow the throttle body and chamber to lift up and forward away from the clutch master cylinder, I decided where to cut and then machined both the cut faces flat and square.
After I checked the measurements and angles of the machined part, incase I needed to make further changes after a trial fit.
After checking there became a mismatch of the ports, this was expected and I was going to put in spacers later to compensate for the errors
A trial fit was done and the spacer thickness was determined
Once knowing the thickness the angle for each spacer was measured
Then I manufactured them
Once made all was cleaned and this is where my welders made it all come together, after lots of cursing of course
One side done….now for the other half
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1st November 2015, 17:17
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The Throttle body (cont’d)
Last edited by pompeyal; 1st November 2015 at 17:35..
Reason: .
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1st November 2015, 17:33
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The Throttle body (cont’d)
After fettling a bit more from the fuel rail to allow for the throttle movement the was on last thing to do..
The brake vacuum take of pipe was facing in the wrong direction
So after gently heating the casting around the pipe I managed to rotate it to the required direction
Now it was completely assembled and ready to fir to the engine..
Happy with that…
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1st November 2015, 17:57
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The wiring harness
I acquired a complete Honda harness that I was going to modify to suit the McCoy, It was a harness from a civic so I would have quite a few bits to cut out, first I took the rear harness and rebuilt that, removing the electric window wiring and anything else I didn’t require
Then I started to fit the engine harness and the engine bay harness for the lights etc, this I would cut about removing unwanted bits later.
The parts of the harness I didn’t need were the ABS, Air con etc
I made drawings of the wiring and what was for what, labelled all the ends and then it was ready for stripping, I didn’t want to do that yet because I didn’t know what was required for the ecu, so I started the cabin wiring (Warning: If you have a nervous disposition look away now)
Well if you can make any sense of that lot without getting a head ache please come and sort it out because it has done my head in, I won’t let it beat me but I will be doing it in stages, it had taken an age to get here, looking through wiring diagrams, sorting out what is needed, what may be needed, what isn’t needed or of it was effected by what had been or was going to be cut out…..Hmmmm, needless to say I have left this alone for a while now to get my sanity back
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1st November 2015, 18:07
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The Seats
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1st November 2015, 19:00
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The next episode is covering the headlight choices and front wings....
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1st November 2015, 19:34
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Headlights and Front Wings
Well I have been pondering on and off about the headlight originally fitted to the McCoy, they do start to grow on you after looking at them for so long, but you here from people, clan owners as well that they preferred the rectangular head lights that were fitted to them, well yes I think I agree they do look better than the round ones, I also looked into having pop up headlight so I got some from a Mx-5 but when trying to fit them, I discovered with having the Honda engine in the bay they would not fit, so they are for sale, then I decided I wanted to change the front styling so got a new pair of motorcycle rectangular head lights that would nicely fit..
So I started and cut off one of the healight pods to see how they would look..
OK they would work so I started to put some shape into the wing using expanded foam…
Hmm that may work.. but I would have liked them lower in the wing so I reworked the foam and glassed in flush following the wing shape
No.. I had another thought, that’s trying to be too much like a clan, so the I thought about twin projectors, so I ripped out what I had done and had a re-think…
So out came the card..
That could work, it measures up and a pair should fit in there.. but first I had to build up the inner wing which had previously cut away to accommodate the sub-frame to cover the near side engine mount..
With that done I set off to reshape the wing, firstly getting some perforated aluminium, cutting it to shape, covering it in cling film and clamping it in place
Then fibre glassing in…
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1st November 2015, 19:53
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Headlights and Front Wings (cont’d)
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1st November 2015, 20:21
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Headlights and Front Wings (cont’d)
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1st November 2015, 20:43
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Headlights and Front Wings (cont’d)
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