well after 4 years i have now some time i can start my build its going to be a haynes based zzr1100 track only car i hope to do a first shake down in may-june but subject to race commitments colected most of the running gear and steel and just brought a new invertor mig pluss i have a small tig
i realy want it to be sub 450kg but will be a challenge





[Edited on 16/9/13 by rick1962uk]

Nice welder. Where did you bring it from?

i got it from R-techwelding.co.uk cost just over £440 but i will use it a lot and its an inverter so should run a lot better i was just fed up will all the diy welders i brought over the years

A few more parts ready to paint




ZZR1100 engine to go in



nice little mill for cutting and facing the box steel



[Edited on 17/9/13 by rick1962uk]

Build Table built now to start cutting and welding

cutting starts this makes it easy






Not bad for half a days work

Looking good and a nice strong engine choice. I ran that engine in my single seater without any oiling problems due to the pickup design. Forgive me if I’m teaching you to suck eggs but are you aware that fitting the GPZ 900 sump and pickup will allow you to lower the engine?

many thanks and yes i will use the gpz sump and pick up pluss its only for track days so new oil every time the plan is to cut my teeth on this one then go for a zzr1400 one mid engine

Had a good morning after sorting out that sodding front frame it went together quick but ran out of steel so more ordered

had a good day on the chassis







decided to clamp the chassis down to the board and make sure its 100% true with no twists as im sure when the diagonal bars go in it will be almost impossible to get back square

veiw from the rear

You're about at the same stage as me

I noticed your u7 is in the wrong place, making the transmission tunnel wider. Don't know if this is by choice but would have thought you'd have made it smaller, if anything, with a bike engine?

Had another good morning on the car got most of the chassis done its starting to look like a 7 now







http://i1298.photobucket.com/albums/ag52/rick1962uk/Haynes%20kitcar%20Build/Picture014_zps56e6c8a1.jpg


i clamped every corner with these angle bars with 10mm studding to try to keep the warping down as low as i can im going to leave the wishbone brackets untill last that way i can make sure they are all level even if the chassis is a bit out




Trouble is i have to get on with building some bikes so the kit will slow down for a few weeks

quote:

---

Originally posted by joneh
You're about at the same stage as me

I noticed your u7 is in the wrong place, making the transmission tunnel wider. Don't know if this is by choice but would have thought you'd have made it smaller, if anything, with a bike engine?

---

Managed to get all the welding on the chassis done today just the rear end to do then onto the arms but might leave them untill the Christmas holidays as the race bikes are behind schedule so need to catch up then back on the kitcar

Had a bit of time today to kill so got the diff frame made starting to look like june target will be achieved

quote:

---

Originally posted by rick1962uk
Had a bit of time today to kill so got the diff frame made starting to look like june target will be achieved

---

Rear end Done wishbones next

After a few months off due to work managed to get back on with the haynes


Front Lower Wishbone Arm Getting Machined





all jigged ready to weld

All welded and reamed the bushes out now onto the top ones

Keep it up

Another good morning managed to ream out the wishbones greased and fitted bushes and popped a coat of paint on getting on so well if i can have a good day tuesday i might have enougth time to go to the kitcar show

Looking good there fella, keep it up.

I'm over at Brize Norton if you fancy chewing the fat?

Regards Dan.

I would advise putting another spar in for the fuel tank to sit on

it will only have a 2 gallon one so should be ok but will test first many thanks

quote:

---

Originally posted by scutter
Looking good there fella, keep it up.

I'm over at Brize Norton if you fancy chewing the fat?

Regards Dan.

---

quote:

---

Originally posted by scutter
Looking good there fella, keep it up.

I'm over at Brize Norton if you fancy chewing the fat?

Regards Dan.

---

Engine in place




Exhaust has clearance




Prop should have enough clearance



Lower Mounts Done




Started to make the top cradle but ran out of steel




Bonnet fits but is tight

Finnished off the engine cradle




front bracket done with crush tubes




also started with the seat brackets

Front end done

A little crossbracing in there can't hurt.

ATB Dan.

i know will have a go at working it out a bit later when i know it wont get in the way of anything the amount of times i have built something then have to remove braces or brackets to let other items fit must be in the hundreds

Had a slow weekend on the car had a lot planed but had an sos from a fellow 7 owner just about sorted that one so on with the roadster so far spent about 3 hours trying to get the seat and steering wheel in the right place sort one then the other comes up wrong but think im there

Hi nice work there.
One thing , I've noticed on the last picture upper wishbone is on the wrong side or upside down.
Cause transit drag link goes down . should look up.




[Edited on 18/5/14 by Darek32]

Many thanks have moved them around so many times will check tonight

Managed to get the steering column done looks like i will have to change the rack to get a decent angle




http://i1298.photobucket.com/albums/ag52/rick1962uk/P1010062_zpsb4265f69.jpg

Welded up the rear uprights today got the stick welder going to cope with the thick plates



put a coat of paint on




now its starting to look like a kitcar and not a pile of parts

Almost finished the pedal box going for a motorcycle rear cylinder for the clutch as car ones seem to have to big pistons and i want a smooth clutch action im going for a 12mm one

Managed to have a few hours on the car so cracked on with the steering its a bit tight but will have a go at modifying it for a few mm of clearance

Had a good morning on the kit got the rad fitted and almost sorted the gear linkage

Looking great mate! Can't wait till I'm up to your stage

its taken nearly 2 years on and off but going to have a big push to finnish it this winter

had almost a full day on the car today so managed to pull it all apart a bit sole destroying but knew it had to be done finished welding all the bits i couldnt get to with the engine in ground down the welds and even got a first coat of paint on so now feeling great as 1 more coat then it can go together for the final assembly babby sitting the grankids sunday so might take them down and get them working 4 and 11 should have a few uses even if its getting into small gaps

Feeling a lot better now its going back together again floor and back panel in i now hate rivets

Pedal Box al done



it was a bit tight




Scuttle was a bit to short




Now to cut the front end to fit




Roll bar tacked ready to cut the supports




Suport plate welded




Brakes and wheels fitted to see how they look going for 15s

First support bar tacked in place took ages to get the joints right

Looking sweet!

Just picked up yhese with 888 tyres on

Looking good there fella. Making much better progress than me.

ATB Dan.

Dan take heart it stagnated for ages i was working on it but getting no ware then it just started to come together i found that making a plan of work with loads of small tasks worked IE i didnt make a list and put make wishbone armes i instead put down cut tube , make bush tubes ,make jig etc it makes you feel a lot better and it looks like your getting there

quote:

---

Originally posted by rick1962uk
Dan take heart it stagnated for ages i was working on it but getting no ware then it just started to come together i found that making a plan of work with loads of small tasks worked IE i didnt make a list and put make wishbone armes i instead put down cut tube , make bush tubes ,make jig etc it makes you feel a lot better and it looks like your getting there

---

Cheers buddy, Mines slowed somewhat because mof leaving the RAF and having to sort out a Job/house!!

ATB Dan.

the build is llooking great...

(love the gear knob )

Thats the roll Bar done many thanks http://www.tube-bender.co.uk/ only £100 pluss vat i had to cut the fish mouths and weld up but what a great price

Another productive day plumbed in the hard brake lines and started to fit the rear tub at last starting to look like a track car

had a go at making the dash it has all what i need as its for track day only but just not to happy with it so im sure it will get changed many times before im happy

coming on nicely mate!