Hi guys,

I've stalked this site for many years but never really thought my project or skills worthy!

But anyway - here I am, and here's my wee Turd!

I bought it "partially built" in 2011, after having a hankering for one since seeing them for sale in mini world in about 1998!

Long since out of production and an advanced staring place for a bug.



Fiddled about with it with the goal of "get an IVA"





By adding and adding and adding....



Here it is on the day of the IVA!


[Edited on 12/12/17 by Freestyle_998]

scary times...




Failed my first go - mostly for sharp edges and I had a loose suspension nut

But on the second shot - wooo!



Passing in may 2012, where, promptly the engine ("fully reconditioned" when i bought it) let go, along with my enthusiasm.

From there I parked it up and spend the next 5 years "getting round to it".

First I considered full bore 998 A-series turbo, and manically started collecting bits.

Then the engine on my other project let go, and I punted on the collection to fund the 1.8T replacement for that.


Next I bought a 2.8 VR6 engine to put in the buggy, for all out bonker-ness

But then I got distracted rebuilding Project #2, and Project #3....

and one fateful day at a hillclimb late in 2017 I got ye old grey matter working...

I sold Project #3

and bought an 2006 R1, with the intention of shitting it up to put as much as I can into the buggy.


(Project #2 on left)

Meeting Douglas - minitici confirmed my ideas were sound and now I am moving forwards with the build!

Hope you don't mind me dropping in on your vastly superior build forum (this is going to be rough and ready )

First task: out with the boat anchor





The A series weighs 127KG with no diff and all ancillaries, Dry. The R1, 74KG full of oil.

(p.s. did i mention a diet at this stage? No I didn't. I want to get sub 400kg )

Nice project and great pics

The R1 engine will be under half the weight of that A-Series

[Edited on 11/12/17 by CosKev3]

Thank you, not sure why the last ones are so MASSIVE

Well, thinks are improving without the boring "legal" tat - the diet version is looking much better!

[img]https://i.imgur.com/fUxxyqg.jpg?1[/img]

[img]https://i.imgur.com/pKJKEW1.jpg?1[/img]

General plan....

Loose the chrome
Loose most of the wheel arch
Chopchop anything unnecessary
More aluminium
More carbon....
Rewire with yamaha loom
Mc battery
R1 rad up front
Lose the fuel tank and reposition a new one
Extended rear by a bit
New steering wheel
New lights
De blue
Chopchop a bit more
Possibly replace side tubes with new round side tubes
Hide all wires
New brake lines
Maybe go discs at rear....
New dash
New exhaust

Then after that little lot, re suspension

a day of messing about with drills n stuff...

stage 1 - 50x50 box - mitered into a few sizes (30 degree cut and also 45 degree cut) depending on position. I'm going to use the longer ones at the front where i have removed more steel underneath to save double weight.... or something...

stage 2 - box linished to a nice profile then drilled 10.5.

stage 3 - 25mm bar, cut to 44-45mm length, linished to size, then drilled to 10.5

m10 10.9 bolts to finish.


Mounts with next stage - bracing for subframe and engine end - 5mm plate, welded onto the end of 32mm tube, again 10.5 hole for bolts.



Subframe progressing. bracing next


T45 for the new rear end

No going back now!! rear end has been detached



Spent a while messing about notching the tubes... exact length TBC


Think this time i'm going add bracing. never really liked how it was originally, in my structural engineering mind... will I hit the tyres though....?


Also need to consider the seat belt brace too. Air box might be in the way

Trial position


Mor T45.... Going to make a kind of triangulated tube thing to hold in the motor


More soon

still attempting to push on diff-less

webs added to complete the extension piece



much time spirit leveling


and my general engine mounting plan


small but exciting update - Diff stage 1....



10 week back order from Minispares - came after 7

and we are about up to date after a chilly eve in the shed last night!!

R1 Cradle Stage 1

Great to see some interesting work going on.
Keep them coming

Glad you think its interesting, the internet is a but rubbish and quiet on the forum / project front lately

That mount is looking really good

quote:

---

Originally posted by Freestyle_998
Glad you think its interesting, the internet is a but rubbish and quiet on the forum / project front lately

---

This weekend I mocked up my diff cradle from a drawing supplied by the Westgarage.





Its maybe a little too tall, but i'm thinking it'll just about work if its "upsidedown" at a jaunty angle. It cant really be much smaller (required cog size to get a half reasonable gearing), and then it gets complicated with angles of drive shafts.





Need to strengthen the subframe back up before I can continue.... uuugh more ££££

As said above, it looks a good project and it's always a pleasure to see some fabrication work in progress.

You may have shown us before (I don't recall), but the Caddy looks rather nice as well. My Dad had a plain one for work many moons ago. Didn't think much of it at the time, but have a strange hankering for one these days.

Thanks

The Caddy? old shitter, been in my life far too long!!

Nothing much going on unfortunately.

Have sourced a new alloy fuel tank and done some wiring.

Found this great site for metals! https://www.materials4me.co.uk/

This looks fun!

Caddy looks mint

Built it yourself?

What's the spec of engine?

Thanks Kev,

Yes, that is engine #4 or #5 I think (1.6 diesel, 1.6 diesel, 1.9 TD diesel, 1.8 19VT ( ) and now 1.8 20Vt)

I would think it is around 180hp, with a couple of small mods ie FMIC, 3" dp etc.



Nothing much to report buggy-in, been a bit under the weather and a bit skint lol!

However my fuel tank I ordered some time ago arrived





Which I am almost pleased with - seems to have been a little measurement error somewhere..... sigh.

I intend on welding in the R1 sender unit, which will give me my low fuel light, baffle, and pump.

And on the top is a manual level gauge

Also you can see "diet" mudguards in progress....

Tank looks nice

Love the gauge!

That's looking great.
As It happens I've just got myself a freestyle too to fill a gap while I'm getting the van diemen sorted.
Needs a bit of tlc bit shouldn't be an issue. I'm sticking with the engine that's in it.

picture




[Edited on 22/1/18 by jamriggsy]

hiya mate - good to see you over here too.

I'm thinking I may take that suspension set up

Great project, good,luck.

Thank you

Bit more progress not involving spending

First up - sump for the pump...







Bastard bit of alloy took some cutting. I was going to get it cnc'd but then i went at it one afternoon, and stupidly wouldn't let it defeat me!!!



Next - something that has always upset me - the pedal box.
You can see in this old pic, the clutch pedal was almost in the passenger foot well when I bought it - made for a nasty driving position, but it was a job i thought i'd leave post IVA.


you might notice it's had a hard life




Even being moved over 30mm to the right (lol look how squint the throttle pedal is too) the spacing was still crap.



Everything wonkily welded


So some cutting, grinding, drilling later, the pedal was now secured in its new position on the pivot


and at 90degrees!

Need to de tigerseal the rubbers and fix the throttle and we should be all level

Budget sequential shifter


(and 3/4 of budget corner weighing set )

[Edited on 8/2/18 by Freestyle_998]

Been a funny year.... SLOW progress.

Feel i should put some pics up of something at least.....




There - 22kg lost! I am going to replace this with aluminium, which i intend to run all the way back under the engine as one piece

Like this,

Everything is holey and had the poo drilled out of it, so I'm replacing a lot of it, like the center console

Just needed my T45 to arrive.... been 7 weeks on order !


Eventually it arrived






Made it outside inbetween fitting a new kitchen

New centre "console" knocked up for the hand brake and gear shifter.



Hehe....

Had a look at this little problem... I'm no one to criticise anyone's welding, so I won't





Getting ancy waiting on bits.... i got grinder happy



Spent a considerable about of time lining up everything for a more comfortable seating postion - but as you know the controls are a bit skewed..


but then decided I'd cut more out first... add some tabs and an alloy floor with some mouldy old treadplate I had.


more weight saving : :




And added some bracing for the next job....


along with these feet


Meaning I can get the whole thing nice and level


Bringinng me to approximately concept v3.963

Been a wee while.... haven't actually done much Happy new year everyone!

Love is....



Thanks to Westgarage Engineering




I'm beginning to understand why people build chassis from shs!!



Anyway, chipping away, motor is level and almost in after about 4 days of measuring and adjusting




using my method of "dangling"




*excuse the mess of the garage