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Author: Subject: New Furore Formula Build
russbost

posted on 24/4/17 at 04:42 PM Reply With Quote
Day 15, all starting to slow down a bit now. Today was occupied with finishing off the cooling system (there's a further pipe to be added for the temp sender for the Acewell, but I haven't got it yet, cooling system is at least full of water & leak checked for the moment!). Fuel pressure reg & return all in & started on fitting the chain drive diff & reverse provided by the Toyota starter motor


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Furore Formula Car - the only two seater modern Formula Car lookalike. Acewell dashes, projector headlights, dominator headlights, indicators, mirrors etc, best prices in the UK! Take a look at http://www.furoreproducts.co.uk/ or find more parts on Ebay, (see link below) discounts available for LCB users.
Don't forget Stainless Steel Braided brake hoses, made to your exact requirements in any of around 16 colours. http://shop.ebay.co.uk/furoreproducts/m.html?_dmd=1&_ipg=50&_sop=12&_rdc=1

NOTE:This user is registered as a LocostBuilders trader and may offer commercial services to other users
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russbost

posted on 25/4/17 at 06:16 PM Reply With Quote
Day 16, a bits 'n'bobs day. Finish fitting diff, driveshafts & sprocket cover, fit throttle bracket & cable & gearshift cable & bracket at engine end

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Furore Formula Car - the only two seater modern Formula Car lookalike. Acewell dashes, projector headlights, dominator headlights, indicators, mirrors etc, best prices in the UK! Take a look at http://www.furoreproducts.co.uk/ or find more parts on Ebay, (see link below) discounts available for LCB users.
Don't forget Stainless Steel Braided brake hoses, made to your exact requirements in any of around 16 colours. http://shop.ebay.co.uk/furoreproducts/m.html?_dmd=1&_ipg=50&_sop=12&_rdc=1

NOTE:This user is registered as a LocostBuilders trader and may offer commercial services to other users
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russbost

posted on 26/4/17 at 06:23 PM Reply With Quote
Day 17. Almost at the point where I can start the engine & then start the laborious job of remaking the loom. But first need to make up the front end of the exhaust, if I ran it at this stage I think I'd be deaf fairly rapidly! The back end is a unit I use for IVA as it's nice & quiet & has a CAT in it, this late engine probably doesn't need the additional CAT, but that's something to play with further down the line.

Here you can see the bike CAT, I have cut away the rear section of the exhaust where it splits into 2 on the bike, I weld a new section onto this to connect with the rear part of the exhaust


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Furore Formula Car - the only two seater modern Formula Car lookalike. Acewell dashes, projector headlights, dominator headlights, indicators, mirrors etc, best prices in the UK! Take a look at http://www.furoreproducts.co.uk/ or find more parts on Ebay, (see link below) discounts available for LCB users.
Don't forget Stainless Steel Braided brake hoses, made to your exact requirements in any of around 16 colours. http://shop.ebay.co.uk/furoreproducts/m.html?_dmd=1&_ipg=50&_sop=12&_rdc=1

NOTE:This user is registered as a LocostBuilders trader and may offer commercial services to other users
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russbost

posted on 27/4/17 at 06:30 PM Reply With Quote
Ok, apparently Day 18 is where I have to bite the bullet & get down to some serious wiring work with the loom, for the older ZZR1400, pre around 2014/15 I have made myself a great set of instructions which tells you everything you need to do to the loom to get rid of sidestand/clutch/kill/bike down switches & allow startup with the car in gear (bikes don't start unless in neutral for fairly obvious reasons!) & also to prepare the ZZR loom ready to fit to our own ready made loom.
However, the 2016 loom is different - DOH!!! I did know this b4 I started, but it's still a pain, you have to keep the original key & barrel as there is something which identifies the key to the ECU & you can't bypass it in the normal way, I even looked at getting the ECU flashed to remove the immobiliser, but apparently you can't - at least not on the ECU I have anyway)
Hence I am entering a somewhat unknown area, so will proceed with caution. I have got the car to the point where I can fire the engine up with all the old bike loom in place & will only remove one circuit at a time to ensure I don't suddenly find myself with a dead engine & no idea what killed it.

Watch this space!

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That's the ABS plug in the pic above - that's something that's got to go for starters!

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All connected & ready for startup

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Ok, gonna admit to a schoolboy error here - wasted half an hour trying to start it & wondering why the heck it now wouldn't go, when was running perfectly in the bike b4 I stripped it??? I'd decided not to wire around the "tip over" or "bike down" sensor until I had it all running, however as I had clipped the sensor on upside down the ECU thought I had therefore crashed & killed the fuel! Once inverted all was good! Even more annoying my instructions for removing that sensor were all correct for the 2016 ECU & had I done it first I wouldn't have wasted time scratching my head! These little things are sent to try us - at least so I'm told!

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Furore Formula Car - the only two seater modern Formula Car lookalike. Acewell dashes, projector headlights, dominator headlights, indicators, mirrors etc, best prices in the UK! Take a look at http://www.furoreproducts.co.uk/ or find more parts on Ebay, (see link below) discounts available for LCB users.
Don't forget Stainless Steel Braided brake hoses, made to your exact requirements in any of around 16 colours. http://shop.ebay.co.uk/furoreproducts/m.html?_dmd=1&_ipg=50&_sop=12&_rdc=1

NOTE:This user is registered as a LocostBuilders trader and may offer commercial services to other users
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russbost

posted on 3/5/17 at 06:36 PM Reply With Quote
We're on the 19th day, & getting thoroughly entrenched in the wiring. I have gradually removed circuits & bypassed the various kill switches etc. without a problem, still removing wires that are for circuits no longer required like ABS, hence the big pile of wiring!

Sometimes you need to go backwards b4 you can go forwards - I do understand why some people get daunted by wiring, all I would say is that calm & methodical wins the day!

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Furore Formula Car - the only two seater modern Formula Car lookalike. Acewell dashes, projector headlights, dominator headlights, indicators, mirrors etc, best prices in the UK! Take a look at http://www.furoreproducts.co.uk/ or find more parts on Ebay, (see link below) discounts available for LCB users.
Don't forget Stainless Steel Braided brake hoses, made to your exact requirements in any of around 16 colours. http://shop.ebay.co.uk/furoreproducts/m.html?_dmd=1&_ipg=50&_sop=12&_rdc=1

NOTE:This user is registered as a LocostBuilders trader and may offer commercial services to other users
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russbost

posted on 9/5/17 at 06:41 PM Reply With Quote
Ok, I won't bore you stiff with loads of pics of bits of wire - loom work is not the most exciting, but a necessary evil!
This represents days 20 thro' to 24, you can see the loom gradually getting tidier! I won't case it all up until all lights & dash etc. is all in & everything running from the key & switches as it should - tends to save a lot of swearing if you have to cut loom casing back open when you realise you've forgotten something or there is something not working as it should!


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The very observant amongst you (c'mon, you all missed it, admit it!), will have noticed that the temp arrangement of the fuel reg setup has now been more permanently fitted, all the fuel hoses still need final fitting with rubber spacers etc.

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Furore Formula Car - the only two seater modern Formula Car lookalike. Acewell dashes, projector headlights, dominator headlights, indicators, mirrors etc, best prices in the UK! Take a look at http://www.furoreproducts.co.uk/ or find more parts on Ebay, (see link below) discounts available for LCB users.
Don't forget Stainless Steel Braided brake hoses, made to your exact requirements in any of around 16 colours. http://shop.ebay.co.uk/furoreproducts/m.html?_dmd=1&_ipg=50&_sop=12&_rdc=1

NOTE:This user is registered as a LocostBuilders trader and may offer commercial services to other users
View User's Profile E-Mail User Visit User's Homepage View All Posts By User U2U Member   russbost 's Aim
russbost

posted on 10/5/17 at 06:43 PM Reply With Quote
Days 25, 26 & 27 still wiring, plus a couple of other jobs, added the dash (ok that's still wiring!) & fixing points, added the front light bar (will be replaced later), & mounted the horn, most circuits are in now, 2 days at most should see the back of nearly all the wiring jobs, I'll leaving extending the rear loom until the wing struts that the lights mount to are in & as already said won't finalise all loom coverings etc. till a little further on just in case!

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[Edited on 10/5/17 by russbost]





Furore Formula Car - the only two seater modern Formula Car lookalike. Acewell dashes, projector headlights, dominator headlights, indicators, mirrors etc, best prices in the UK! Take a look at http://www.furoreproducts.co.uk/ or find more parts on Ebay, (see link below) discounts available for LCB users.
Don't forget Stainless Steel Braided brake hoses, made to your exact requirements in any of around 16 colours. http://shop.ebay.co.uk/furoreproducts/m.html?_dmd=1&_ipg=50&_sop=12&_rdc=1

NOTE:This user is registered as a LocostBuilders trader and may offer commercial services to other users
View User's Profile E-Mail User Visit User's Homepage View All Posts By User U2U Member   russbost 's Aim
russbost

posted on 11/5/17 at 06:18 PM Reply With Quote
Day 28 & 29, finally all wiring is in, mounted the speedo pickup today & also the reverse switches & solenoid for the electric reverse provided by the donor Toyota starter motor, the engagement of which is also all adjusted & now setup. I still need to make a mounting panel for the lights, fog & reverse switches, but that's the only wiring left to do other than the rear light loom to be added when I fit rear wing supports (that's where the lights mount). You have now caught up to where I actually am with the build, so everything from here on will be pretty much as it happens!

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I've included these last couple of pics specifically as I know some people struggle with knowing how to fit the speedo sensor on the Acewell speedos, last pic shows it perfectly, the magnet should pass along the line at either one end or the other of the sensor - it MUST NOT run down the length of the sensor as this will cause multiple & erratic signals, I have embedded the magnet in the head of a bolt so it is adjustable to get the correct airgap to the sensor

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[Edited on 11/5/17 by russbost]





Furore Formula Car - the only two seater modern Formula Car lookalike. Acewell dashes, projector headlights, dominator headlights, indicators, mirrors etc, best prices in the UK! Take a look at http://www.furoreproducts.co.uk/ or find more parts on Ebay, (see link below) discounts available for LCB users.
Don't forget Stainless Steel Braided brake hoses, made to your exact requirements in any of around 16 colours. http://shop.ebay.co.uk/furoreproducts/m.html?_dmd=1&_ipg=50&_sop=12&_rdc=1

NOTE:This user is registered as a LocostBuilders trader and may offer commercial services to other users
View User's Profile E-Mail User Visit User's Homepage View All Posts By User U2U Member   russbost 's Aim
Mash

posted on 11/5/17 at 06:55 PM Reply With Quote
Looking really good mate, excellent job you're making there
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russbost

posted on 16/5/17 at 07:07 PM Reply With Quote
Thanks Mash!

Ok, we're 30 days in & wiring is finally (almost!) finished, back on the bodywork

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Unfortunately b4 I can do final fit of O/S sidepod, just need to encase the loom first! (so much for "finished the wiring!)

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The "bonnet" is made to fit both old & new style sidepods, so, to fit to the new style ones we have here, the rear section needs to be removed

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Quite time consuming as to get a neat fit requires careful trimming

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New bracket made to support rear of bonnet

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Furore Formula Car - the only two seater modern Formula Car lookalike. Acewell dashes, projector headlights, dominator headlights, indicators, mirrors etc, best prices in the UK! Take a look at http://www.furoreproducts.co.uk/ or find more parts on Ebay, (see link below) discounts available for LCB users.
Don't forget Stainless Steel Braided brake hoses, made to your exact requirements in any of around 16 colours. http://shop.ebay.co.uk/furoreproducts/m.html?_dmd=1&_ipg=50&_sop=12&_rdc=1

NOTE:This user is registered as a LocostBuilders trader and may offer commercial services to other users
View User's Profile E-Mail User Visit User's Homepage View All Posts By User U2U Member   russbost 's Aim
russbost

posted on 18/5/17 at 05:06 PM Reply With Quote
Day 31, steady progress on the bodywork, supports/locators made to fit rear edge of "bonnet" to sidepods, now bonnet has been drilled for rear mounting, the Acewell can now be mounted up (yes, b4 anyone comments, the bracket has now been squared up since pic was taken!



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Rear lower engine cover is cut away to match new sidepod end, cut piece used for template for opposite side to ensure all equal

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Furore Formula Car - the only two seater modern Formula Car lookalike. Acewell dashes, projector headlights, dominator headlights, indicators, mirrors etc, best prices in the UK! Take a look at http://www.furoreproducts.co.uk/ or find more parts on Ebay, (see link below) discounts available for LCB users.
Don't forget Stainless Steel Braided brake hoses, made to your exact requirements in any of around 16 colours. http://shop.ebay.co.uk/furoreproducts/m.html?_dmd=1&_ipg=50&_sop=12&_rdc=1

NOTE:This user is registered as a LocostBuilders trader and may offer commercial services to other users
View User's Profile E-Mail User Visit User's Homepage View All Posts By User U2U Member   russbost 's Aim
russbost

posted on 24/5/17 at 05:14 PM Reply With Quote
It's day 32 & starting to look the part!

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Preparing the rear wing sides, both sides clamped & drilled together to ensure uniformity

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Once ready, it's a simple matter to bolt them in place, these have to go on prior to final fit of rear "deck" (lower half of engine cover) as they affect how the deck sits on the rear chassis arms

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The 2 rear wing blades are then bolted in between to give a stiff structure

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Rear deck can now have final fit & fixings fitted

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& suddenly it starts to look like a Furore!

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[Edited on 24/5/17 by russbost]





Furore Formula Car - the only two seater modern Formula Car lookalike. Acewell dashes, projector headlights, dominator headlights, indicators, mirrors etc, best prices in the UK! Take a look at http://www.furoreproducts.co.uk/ or find more parts on Ebay, (see link below) discounts available for LCB users.
Don't forget Stainless Steel Braided brake hoses, made to your exact requirements in any of around 16 colours. http://shop.ebay.co.uk/furoreproducts/m.html?_dmd=1&_ipg=50&_sop=12&_rdc=1

NOTE:This user is registered as a LocostBuilders trader and may offer commercial services to other users
View User's Profile E-Mail User Visit User's Homepage View All Posts By User U2U Member   russbost 's Aim
russbost

posted on 25/5/17 at 09:26 AM Reply With Quote
Day 33 & last post for a little while as off for a hard earned break! Rear indicators are on, location for upper engine cover bolted in whilst bonding paste cures, & further fittings to the front of the upper engine cover ready to accept the passenger seat cover. The 2 are then mated together & temporarily clamped & bolted to fit accurately together, when fitting the upper engine cover & passenger seat cover to the car they are best fitted as one piece & only separated once a satisfactory fit is achieved, from experience fitting the rear half followed later by the front half is a recipe for a poor fit. Once all in place fittings left to cure overnight. They are initially bonded in with Siraflex, once cured this will be overlaid with fibreglass mat bonded in place to ensure all stays where it's meant to

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Furore Formula Car - the only two seater modern Formula Car lookalike. Acewell dashes, projector headlights, dominator headlights, indicators, mirrors etc, best prices in the UK! Take a look at http://www.furoreproducts.co.uk/ or find more parts on Ebay, (see link below) discounts available for LCB users.
Don't forget Stainless Steel Braided brake hoses, made to your exact requirements in any of around 16 colours. http://shop.ebay.co.uk/furoreproducts/m.html?_dmd=1&_ipg=50&_sop=12&_rdc=1

NOTE:This user is registered as a LocostBuilders trader and may offer commercial services to other users
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Mr Whippy

posted on 25/5/17 at 11:45 AM Reply With Quote
good post

like everything bar the location of the fuel tank, I'd want that behind the driver seat like the real cars rather than have the passenger seat

side pods are much better though do tend to make the car seem higher than before, a side skirt might look good

surprised you don't sell more as I'd want one of these much more than a 7

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russbost

posted on 25/5/17 at 01:56 PM Reply With Quote
Relocating the fuel tank would be simple.

When it's got its wheels on most people say the new pods make it look lower, makes the higher ground clearance (than F1) less obvious, one customer did an extended flat floor & carbon covered it, looked brilliant & did make it look lower, tho' was actually only lower by about 8mm

TBH, when I built the first car that was purely for myself, never intended to go into business with it, then it got on the front cover of Kitcar mag, national papers & BBC TV (plus Fuji TV in Japan!) & the rest as they say, is history. Even then I never anticipated it being more than a hobby business, but I've sold 5 complete cars, finished builds on 2 others & sold quite a few kits, this one will be chassis no. 17 (plus the original twin engined car) & I have chassis 18 waiting to start when this ones done, tho' that will be a much more relaxed build. If I was younger & still hungry I'd be pushing much harder for sales, as it is, I'm very happy for it to be a hobby business

I think it's too much of a niche market to sell loads, tho' if anyone could be bothered to put the time & money into getting type approval I have people all over the world wanting cars - the problem is invariably local regs, tho' we have one on the road in the States, one in Canada, & at least one on the road in Germany, passed TUV (might be 2 or more, not sure). There are 4 cars in Germany, two ZZR1400 engined cars regularly used for trackdays - they actually put paying (read novice!) drivers in the front & an instructor in the back - the instructors must be braver than I am, I'd want at least a kill switch & dual control brakes! I'm sure one reason I don't sell loads is that they're not as cheap as a 7, but unfortunately the bodywork/wings etc all have moulds that need to be paid for .........





Furore Formula Car - the only two seater modern Formula Car lookalike. Acewell dashes, projector headlights, dominator headlights, indicators, mirrors etc, best prices in the UK! Take a look at http://www.furoreproducts.co.uk/ or find more parts on Ebay, (see link below) discounts available for LCB users.
Don't forget Stainless Steel Braided brake hoses, made to your exact requirements in any of around 16 colours. http://shop.ebay.co.uk/furoreproducts/m.html?_dmd=1&_ipg=50&_sop=12&_rdc=1

NOTE:This user is registered as a LocostBuilders trader and may offer commercial services to other users
View User's Profile E-Mail User Visit User's Homepage View All Posts By User U2U Member   russbost 's Aim
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