I hope this is in the correct place. A few more photo's of my build. I started about 12 months ago.

you start off the weekend with this.......the very last time Stella will be started with the big bruiser Vauxhall engine.
https://www.youtube.com/watch?v=FdLN3_cu270

then it was on with the strip down


and you finish the weekend like this







I'm so happy i decided to go the space frame route. The shell is really rotten around the sills
this is how i started the day off








I started cutting and found my sills rotten and about 5kg's of sand and rust in them




with the floor gone i had to make a temporary stand so i can move it about






That's where i left it for today. i'll finish cutting the bulkhead out tomorrow and try and make a start on the floor. Its good to be back in the garage

Paul

I had a good day today, bulkhead removed and i'm where i wanted to be at the end of the weekend. There is a bit of work to do to the shell to tidy it up but only a weekends work i think





Started on the space frame base but i can't really do much more till i get the MX5 and see where the prop shaft and exhaust tunnel are going to go.



nothing is permanent yet so its just sat on the box section



I modified my stand so i can get it a bit higher to crack on with the body work









My space frame bits should be here in a few weeks but i really need the doner car to crack on.

Paul

I decided to add a bit more mini to my mini The inner wing hinge panels were very badly corroded so i replaced them.

I'm also going to have to add a bit of bulkhead back so i can mount a windscreen wiper motor. A repair panel isn't available for this though i don't think?





Paul

Bulkhead bit added.....this took longer than i thought it was going to so didn't get time to finish the space frame base.





I worked out the turbo i'm going to fit and have settled on a Garrett GT2560r. A nice modern ball bearing unit that spools very quickly and should be good for 200 to 230bhp on standard internals. Should be good for 280 if i choose to rebuild the bottom end and push the boost up.

Paul

[CENTER][B][SIZE="7"][COLOR="Red"]Turbo Porn Alert![/COLOR][/SIZE][/B][/CENTER]

It arrived.......or i should say i collected it







I started the day off on Sunday at 7.00am to a nice empty garage.


I went to collect Bill's trailer in Lincoln and went here


some of you might remember it They were having there Festival of motor sport yesterday. I had a look but couldn't find any of you guys there your invite must of got lost in the post along with mine......ok maybe not mine as i'm not a member anymore

Big thanks to Joey who came to the track with me just in case they didn't let me in on my own


I towed the MX5 home to Leeds and then set off back to Lincoln to return Bill's trailer and then did the return trip back to Leeds. It was a long day and i finally got back at 6.00pm







Not much going to happen over the next few weeks

Paul

The MX5 is gone I weighed it in on Saturday along with the floor pan and bulkhead from Stella. I tidied up at last and i can sleep again.

Spent the day sorting out all the running gear and stripping the bearing out of the uprights. I've got one drive shaft and CV joint that will not separate from the hub. CV joint is fucked........well it is now after i tried to persuade it out with a BFH

I had a look at where the engine is going to sit





I think it needs to be back a bit further as you can see the indent on the oil pan where the steering rack needs to be.







That's all for a while anyway as i'm off on holiday in a few weeks, i might get next weekend in.

Paul

I got a lot done today Its all just tacked up at the minute.

















I need some more box section to complete the diff carrier and add some more triangulation.

Paul

Not much to see really but I've made quite a lot of progress.

Engine mounts made.


I was able to use the existing MX5 mounts but added the trusted Land Rover bobbins.


I got the base welded up as well




Engine is in and sat on its mounts. The mounts need a bit more bracing adding but I'll wait till the engine is out again to have a bit more room.




Gear box attached as well and this needs another fastening somewhere on the other side but its really solid as it is.


If you look at the photo i have shortened the gearbox selector.......or at least i have started as i need a new selector housing as the casting broke when removing it out of the Mazda. Thanks to Richard Cole for this link http://the-mite.com/mite18.htm. I have been able to move the engine back and still keep a good position for the shifter.







Paul

I love xmas holidays you get so much done

got around to altering the diff and getting rid of those big ears





getting the wheels where i want them and removing loads of arch



got the diff cage all tacked up





shortened the diff







i got a bit more done than i thought i would so i should get around to the roll cage and i can tie the front subframe and diff cage into it. I also need a bit more bracing on the diff as i'm not happy with just 3 bolts and it hanging. I already know how i'm going to do this.....maybe tomorrow.

Paul
This seemed like a perfect place to end the year. Stella looks like a mini shaped vehicle again



Frame is now welded





Loads of room for a radiator intercooler and oil cooler now. I had to shorten the frame by 100mm today. I'm getting rid of the front mounted thermostat housing and relocating it to the rear of the engine, which is well known coolant reroute option.



See you all next year..........well tomorrow Happy new year everyone

Paul

Started again with the welding. I've got the main cage fully welded up and it just needs to be tied into the front and back subframes and get a bit more triangulation in there.




And sat the shell over the climbing frame





Should get a moving a bit quicker now

my next issue is measuring up for the wishbones? Anyone got any thoughts?

Paul

A bit of an update....I've been really busy in the garage but doesn't look like much. I'm down to what i didn't realize was going to be so complicated and that is making the wishbones. Making them is easy, measuring and testing isn't. There is tons of stuff to take into account and I've learnt so much about suspension geometry.

I have to say a big thank you to to Richard Cole who has helped me immensely and found a brilliant bit of kit www.racingaspirations.com. Once you have measured you enter the data into it and you can see what effects what and see what happens to the roll center and camber in a corner.

I've made brackets for one side......mirror image for the other side. The racing Aspirations site has helped withe the placement of the brackets.





The start of a jig for the upper control arms that's just welded to the bench



Paul

Front wishbones are done. Pickup points are still only tacked on. They are fully adjustable on car so setting it up should be easy:rolleyes:













I made a start on the backs today but didn't get much done. I need some short coil overs.

Its taken me a lot more time than i thought it would. I hoped to have all the wishbones finished by close of play tomorrow but this isn't going to happen. I should have a full weekend on her though.

Paul

Reet, this seamed a good point to take a break from building for a few weeks. I've been on it for about 6 weeks now doing the wishbones which took way longer than i thought.

I thought it better to do a bit of a walk round before stripping it down and welding all the mounts and pick up points. I have to alter the gearbox mount as its way over engineered......(too heavy). The diff is also going to be changed for the same reason, still keeping the MX5 diff but getting a custom cover from Talon Motorsport that will be easier to mount.

https://www.youtube.com/watch?v=oZ2wUZtXCFE

And this is where she sits waiting







More updates in a few weeks

Paul

I started off the day with this lot


All went together really well, its the first time all of my fabricated parts have been added to the frame and fastened on properly.































Engine fitted





Prop shaft fitted



Diff fitted. This is the diff cover i bought from Talon motorsport and its a really nice bit of kit. It looks so much better that the mx5 OEM item. Its much neater as well........i like neat and tidy









A bit of an extension although i'm not sure i'm going to use it but i'll leave it on for now.







And the shell fitted over the frame. I need to alter the scuttle panel or the rocker cover as it interferes a bit.



Thats the frame almost done. I need to triangulate the from a bit more and weld in some anchor points for the seat harness.

Paul

Doesn't look like I've got much done but its the little bits that take fookin ages

Brake lines and brake calipers are in albeit without the handbrake and pedal box........i'm skint so they will have to wait a few months

Fuel tank and lines are in here is a few photo's







I'm running out of cheap things to do but don't want to start on the shell yet. The next time i strip everything back off will be the last time before i build it up for good. Loads of finish welding to where things are still just tacked in place.

right.......nuff said go and talk to your wives

Paul

Still doing the cheap stuff

Front end is almost done, i'm going to have to have a mould made for the front end.









I'm also going to have to make my own arches. GRP 101 coming up

Paul

Well i thought i would teach my self composites

I had to cut about 6" out of the middle of the front end and was going to just use it as it was with the grafted on splitter. I then thought if i prang it i'll never be able to make it again. The cost of getting a mold made was a bit too much so i thought i would have a go myself.

So here is the plug being made





I've blanked off the lights and grille area and the holes in the splitter









plug made for the arches as well i could have them 12" wide if i wanted.

I have to make the molds now but that wil have to wait till October as i'm going away for a while

It took me 2hrs to clean the garage as well


First a bit of an update

Pedal box, master cylinders and reservoirs are in. All the brake and fuel lines have been run and are complete.







Thats it really

oh no hang on. I bought another engine, this one is a year 2000 mk2 engine its done less miles and hasn't been strangled round a track for the last part of it life. The plan is to run the new engine NA to gain the signatures i need to upgrade my licence so i can then go turbo. The other one i can build as the turbo unit next year



I have a bit of a problem though. My wiring harness is MK1 and my PnP mega squirt is for a 94-95 MK1 to suit.

There is a few very subtle changes to some of the sensors such as the MK2 runs a crank trigger wheel (MK1 doesn't) Mk2 runs a different CAS although i reckon i could retro fit the MK1 as the cylinder head on the MK2 still has the hole but blanked off.

I thinking about selling the PnP unit and just buying a V3 megasquirt and making my own harness. I might be able to get rid of the myriad of vac pipes if i do this as well and not have to pick through the MX5 harness to get to the bits i want.

I almost regretted selling the DTA S40 but it would not of done what a megasquirt can do once set up.

What are your thoughts particularly mininut who i know has an MX5 to transport his photo stuff as well as having a mobile hair do business on the side

[B][CENTER]The end [/CENTER][/B]

Mean while back in the present day 26-10-15 I'll keep it updated

Paul

looking forward to the updates

Great thread .keep the updates coming

This is what i took out to make the new one

https://www.youtube.com/watch?v=FdLN3_cu270
230 bhp red top really good fun

https://www.youtube.com/watch?v=LdZkWW3ITJg this was on crappy michelin slicks

Paul

Very impressive, similar to my project

quote:

---

Originally posted by maccmike
Very impressive, similar to my project

---

Extra post while I was replying bonus. Love the wheel, I have a set on my car in orange.

quote:

---

Originally posted by mini-sprite

quote:

---

Originally posted by maccmike
Very impressive, similar to my project

---

have you got a build diary Mike?

---

Lovely to see your handy work. Well impressed.
Dread to guess how many hours work to get it to this stage.
Look forward to seeing the finished project.

I've been a bit quiet lately, work keeps getting in the way of play but back on it.

My aluminium radiator turned up this week so I've got that to do next week.

Exhaust manifold and exhaust is done. Its a bit of a Frankenstein creation as i'm only going to use it for one season while i run N/A. Its got a bit of Mazda a bit of unknown Stainless and a lot of Jaguar X type. It was all free so i can't complain. The silencers are not exactly light weight but it saves me altering my Carbon cans that i will eventually be using off old Stella.









I used some sophisticated CAD design to mock up my Rad as well



Paul

An awesome build Paul. I love the way you seem to build and design at the same time. I'm planning (long term, when I finish my PhD) to use the running gear from an MX5 in a tubular chassis with a fibreglass body so I'm intrigued by your approach. What is the idea behind your suspension? Is it close to MX5 geometry with added adjustability or completely redesigned?
Cheers
Ross (in NZ)

There wasn't a plan really, i new what i wanted to do and your right i kind of design as i go. I do research a lot off the internet when i get to a different stage. I don't make notes though as i would new follow them as it evolves during the build.

The wishbones were the hardest part to do by a long way. They are not any way the same dimensions as MX5 as the track was way too wide to use standard. I am not an academic person more a 'monkey see monkey do'. I used this for the calculations to start with http://www.racingaspirations.com/apps/suspension-geometry-calculator and my measurements seem to work out quite well on paper. It is still a 'suck it and see' project though.

Paul

Thats a great resource! Have you seen Jim McSorely's youtube description of how he fine tunes a suspension design using adjustable bits in-the-flesh?

https://www.youtube.com/watch?v=6crOSs6LCTQ

cheers
Ross

Exhaust is in i just need to sort out some hangers.





My Radiator is in as well, I need some softer bushes than the poly ones i used as they are rock hard. I'll sort them later after i've finished mock up.







Header tank too do this weekend and then.......erm, not sure really

Paul

Brilliant thread! Keep the updates coming..
Mark.

quote:

---

Originally posted by MsD
Brilliant thread! Keep the updates coming..
Mark.

---

A bit o wiring:-?

Coolant system is all done so i thought i would crack on.

Great Thread

I haven't posted much for a while as ive been cracking on with the wiring. This always takes ages and i used to hate it but the last 2 cars ive done have been good and have enjoyed the process and learnt so much. Anyway after messing about a bit today here a video of not quite the first start but a clean version as the first one has some robust language in it, although its quite funny as my mates were still there.

https://www.youtube.com/watch?v=FeKmqz9zLwk

looking good and I really enjoy this thread, its a great feeling when you get em running stupid smile n all
crack on that man.....

A little update

Got it running and did a bit of tuning.........work got in the way again

Bought a new tow vehicle to replace my T4









Bought some new wheels so its fat arse fits on the trailer







then took it all apart again





Did some finish welding on the underside and bit i forgot to finish weld



Forgot that welded bits get bloomin hot



Primed the climbing frame



And the other stuff





Added some colour to the other stuff and got into trouble for using the spare room to store my crap......as the wife put it.





paint it black.......song in there somewhere





Found out how frustrating it is spraying a chassis and trying to get the spray gun in all the little areas.

Reet your back up to date. Aluminium floor is being installed this weekend and the rest of it will be built up over the next few weeks. I will have much more garage time as my missus is off on holiday with her mum for 2 weeks..................2 weeks

Paul

[Edited on 18/4/16 by mini-sprite]

Fantastic build thread, I'm not entirely sure how I've missed it all this time but I'm definitely going to keep an eye on it now!!

One question, the front upper wishbones, they're not very 'triangular' are they? I appreciate there's not much loading meant to go through them, but they do seem to put bending forces on to the weld joints. The lower ones look better as they have bracing on them.

quote:

---

Originally posted by Slimy38
Fantastic build thread, I'm not entirely sure how I've missed it all this time but I'm definitely going to keep an eye on it now!!

One question, the front upper wishbones, they're not very 'triangular' are they? I appreciate there's not much loading meant to go through them, but they do seem to put bending forces on to the weld joints. The lower ones look better as they have bracing on them.

---

Had a really good few weeks my missus has been away on holiday with her mum so had the long bank holiday weekend and last weekend and the weekend coming

This is the results so far





I love CAD







Diff went in as well







And my nice new coil overs











And finally on floor with the coil overs instead of my temp steel tube





A bit of neg camber





See what else i can do this weekend

Paul

Started on my bulkheads









Rear one will get done this weekend all being well

Paul

Rear bulkhead finished. It just needs sealing around the bottom and around the bars









seat and harness went in as well





Paul

Please tell me there is going to be a diff NOSE MOUNT and your not just going to rely on the main plate of the diff cover??? It was not intended to work on it's own the main plate only stops the diff twisting it DOES NOT stop the diff from bucking when you put torque through it!!!

[Edited on 10/7/16 by Talon Motorsport]

Great build thread .... Keep up the top notch work loving every update