Brad's rocket build.

[golftdibrad]

Well, guess its time to get a build thread going.

I may have gotten my donar. I say may because this car has some issues, and if i put it in the kit i may kill myself.

240 hp turbo ford focus.

part of add:
"ALL VF motor mounts
Spec STG 3 clutch
Fidanza aluminum Flywheel
2.5 " Trubendz exhaust and flex pipe, magnaflow muffler
CFM adjustable STS (best shifter ever put in a focus)
quaife LSD
CFM TB
custom turbo kit using SPA manifold, SPA turbo (sold in CFM's DIY kit), custom intercooler, custom pipes all mendrel bent with silicone couplers, Gready Type RS BOV, and custom 2.5" downpipe.
Car made 240whp and 240wtq on 12psi with a conservative tune.
The good: Car runs very strong and handles great. No problems with the engine or any suspension.
The Bad: While changing axles the mechanic knocked a piece out of the differential. The differential still works fine, the piece knocked out was there to keep it quite, now it is fairly noisy above 65mph.'


IMHO the diff is fine, its just road nose from polyurethane....everything.

It needs a tune, quite badly. it likes three things: cruise, WOT, off. Also the adaptive learning fuel bullshit requires the ecu to need a reflash every few times its run.... this is a risky proposition on a fnord.

The PVC system is.... nonexistent. engine bay has lots of oily residue all over everything.

It leaks oil pretty bad. no biggie since i'd have to pull the motor and change a few things anyway. (like rods :coolnana:, can we say 300hp?) Good things cannot come for a 1k lb car with that much power though, so it would be more of a reliability thing. Need to improve on the drivability of the tune to convince me to keep the thing.

Thats right, its for sale. I should have known better then, and indeed do now. Kinda broke the budget on the donar too... but not bad. I'm going to try and flip it for a profit, or close to break even point. If it does'nt sell It has alot of suspension goodies that will fetch good prices on the aftermarket. I just learned to that Jackson racing discontinued their supercharger kits for zetech engines.... booooo. centrifugal blowers a shit for all but a few specific applications. So that is some motivation to NOT sell it and get and pay for a better tune/smaller turbo.

anywho I'm pretty happy. I'll either sell it and make some cash or have a wicked ride anyways. Now, for suffering through all that text here are some pics!!

[cordycord]

Congrats Brad! Good luck with the build--I guess the tear down comes first.

[golftdibrad]

I've been tinkering with this over the last week, and with a few vacuum leaks fixed and the wastegate and boost controller hooked up correctly, it drives way way better and is a blast. I may keep it after all....

[Gage]

If everything went perfectly it wouldn't be nearly as memorable.

[golftdibrad]

With the new found power and drive ability, I have broken a motor mount!

Think I'ms gonna keep it too BTW

[Karlo]

Your engine looks like the 2.0 Zetec with the MTX trans?

[golftdibrad]

Your engine looks like the 2.0 Zetec with the MTX trans?

that is correct!

[Karlo]

Brads Rocket frame with and shipping box.

[golftdibrad]

Sweet!

[thebionicman]

Wow you must be so excited. That has to be about the best present to open.

[golftdibrad]

I'm stoked. Got a pic of the crate.

[stiggymills]

Please ignore th LMC box label, it has the front uprights in it. Will include a gear lever for you FOC, just the lid to nail on, soon be over to you Brad. Plastic Rocket in the picture is now on my truck. Now that attracts more attention than the cars. It's off to the big U.K kit car show this weekend. Bed now long weekend coming. Oh no all that bear I will have to drink again!

[golftdibrad]

Spent time this weekend cleaning the garage for the build. The garge was a MESS from the 240sx lemons build I'm doing with some friends. I wish i had a before pic to illustrate how much it improved.

Miata will have to take up an outside sleeping position.... :( . Other than that very clean :D

A box I will probally become more familiar with than i'd like. But hey, goodies! lets see whats inside....


Sealing multi depth large head 3/16 rivets (250) from summit, and cleclo fasteners in 3/16 and 1/8 inch and a tool. First received part and tool purchase.

Gentlemen, The project has started. I'm stoked :D

-Brad

[cheapracer]

The more I see of the MEV stuff the more I'm impressed especially for the landed price all the way from corr blimey land.

Good luck to ya, should go like a, errr, rocket!

[Karlo]

Brads Rocket ships Monday.

[golftdibrad]

Brads Rocket ships Monday.

that is awesome!!

Like giving the thumbs up huh?
:D


:thumb2:

I got and tested the 50 dollar ebay pneumatic rivet gun. Its very yellow, and will not make my forearms huge.

[cheapracer]

Not only do they look cold but that picture makes me wonder why England is the center of kit cars and convertable sports cars!

[golftdibrad]

unpacked rollbar

GRRR!!!

Parts room.

And since we all love action shots!

http://www.youtube.com/watch?v=Sb965Ao0_vE

[thebionicman]

I like your thanks :)

[cordycord]

Jeez, you're unpacked and already ahead of me...

[Karlo]

Great Video Brad!!!:cool3:

http://www.youtube.com/watch?v=Sb965Ao0_vE

[golftdibrad]

Jeez, you're unpacked and you're already ahead of me...

wanna race? :codrive:

j/k.

[Pagester]

great video Brad - you need to keep that going through the entire build!

[golftdibrad]

great video Brad - you need to keep that going through the entire build!

thats the idea, i just need a better place for the camera...

[golftdibrad]

I did the floor sunday. Pics and maybe even video later.

edit:

I just bought about 80 bucks worth of hardware..... gonna have me some mounted wishbones by the weekend.

[golftdibrad]

Preparing to fit

Starting to drill holes

more holes

While the floor was off to de-burr the holes.

finished

Carnage

All bushings pressed.

So.... some actual text on how things are going. Ill start with the floor

Do yourself a favor..... dont use the harbor freight drill bits. I went through a ten pack and was still not finished. I had some other 1/8 inch bits so i was in luck. I expected to break a few... but TEN??? the 'other brand' ones that i think were craftsman did not break... even one after 15 holes. I was averaging I guess five with the HF ones.
Cutting the floor was straight forward, just use a sharpie at a fixed angle and use the chassis to trace. I drilled all the holes 1/8 first, then 3/16. Get and use the clecos, they are a huge help - as well as a center punch. I worked from one end to the center, then from the center out. I stood on it today and it holds my big ass so i guess i did something right.
I did the floor first for two reasons: Its step one, and i've never done anything but read about sheet metal work so i wanted to hide my crappy work. It turned out beautiful. all the rivets line up and are nice and geometric. Too bad no one will ever really see it again.

The bushings.... step TWO. Who knew i'd read the directions?

As usual with polyurethane, it was a royal pain in the ass. Didn't get any pics doing this... opps. Some things we learned that will make your life easier:
1. You absolutely have to file off the powder coat on the a-arm, get a nice smooth finish
2. Chamfer the edges of both the bushing and the insert.
3. Use lube, but not too much.
4. We stopped mid way to go get a vice (I needed one anyways), but the deadblow hammer worked the best. The vise helps with the sticky ones though.
5. This is important.... you HAVE to use the wire wheel on the (bench) grinder to finish the surface of the steel inserts. There was some leftover scale, oil from packing, and other things it did that made it SO much easier. The first two were a pain and once i discovered this the rest went smooth.

Well.... hardware is on order, should be able to start bolting things together Thursday.

Sheetmetal work in timelapse.
http://www.youtube.com/watch?v=QdXmx1m5Djc

-Brad

[cordycord]

Where'd you get those big-ass rivets?

[cheapracer]

[

Do yourself a favor..... dont use the harbor freight drill bits. I went through a ten pack and was still not finished. I had some other 1/8 inch bits so i was in luck. I expected to break a few... but TEN???

-Brad

Your lucky to have only used 10. Some of the stuff here is so bad you wouldn't believe it, well after your drill bits maybe you would.

[golftdibrad]

Where'd you get those big-ass rivets?

Summit racing 3/16 multi depth sealing rivets. good stuff so far.

Your lucky to have only used 10. Some of the stuff here is so bad you wouldn't believe it, well after your drill bits maybe you would.

I'm pretty sure my drill bits came straight from china :thumb2:

[cheapracer]

. Foo was here!!

[cordycord]

Do me a favor and slow down a bit--you're giving me a complex.

[golftdibrad]

I will be held up by parts in short order.
edit:
i should elaborate.

Parts for the brakes are still probably a week or two out. I misunderstood the options.... I really didn't want Al uprights and hubs but the cortina ones used solid rotors and didn't come with calipers. After some research i found that the upgraded brakes are a separate option, so the wilwood fronts and correct rotors with any needed brackets are on zee way. I need to clean and refurb the spindles.

And... I drove the donar car to work today. I may be selling that car back to the guy i bought it from.... 'making' a little coin. I'd end up with a donar for under a grand. I'd then be free to get a blower kit separately as well as the LSD. So, I cant even begin to do that stuff until that deal gets a yay or nay and get the other car the dude has. I also need to get the hubs redrilled....and get rear hubs to re-drill....

plus, our 24 hours of lemons is in less then 2 weeks.

Should give you time to catch up :D

[B-T]

Looks good Brad! Keep up the work, and have fun at the 24 heurs de Lemons...
:)
BT

[golftdibrad]

Looks good Brad! Keep up the work, and have fun at the 24 heurs de Lemons...
:)
BT

Thanks! We drove our lemons car around the block last night.... that POS is running way better and is quick.

[cordycord]

I will be held up by parts in short order.
edit:
i should elaborate.

Parts for the brakes are still probably a week or two out. I misunderstood the options.... I really didn't want Al uprights and hubs but the cortina ones used solid rotors and didn't come with calipers. After some research i found that the upgraded brakes are a separate option, so the wilwood fronts and correct rotors with any needed brackets are on zee way. I need to clean and refurb the spindles.

And... I drove the donar car to work today. I may be selling that car back to the guy i bought it from.... 'making' a little coin. I'd end up with a donar for under a grand. I'd then be free to get a blower kit separately as well as the LSD. So, I cant even begin to do that stuff until that deal gets a yay or nay and get the other car the dude has. I also need to get the hubs redrilled....and get rear hubs to re-drill....

plus, our 24 hours of lemons is in less then 2 weeks.

Should give you time to catch up :D

I've got an alternate (of course!) Wilwood option that will go on the Cortina spindles--Wilwood hubs for a 70's Barracuda, 5x4.5 bolt pattern, and the ability to run 12"+ rotor with 6 piston calipers up front. Big. Honkin'. Brakes. Maybe too much, but brakes are a category where too much is MUCH preferable to too little.

[golftdibrad]

Well, after LeMons I can get back to working on the car again. I hung the a-arms.
http://www.exocars.net/attachment.php?attachmentid=2080&stc=1&d=1245108385

Stripped, cleaned, and painted the Cortina hubs.
http://www.exocars.net/attachment.php?attachmentid=2077&stc=1&d=1245108385
http://www.exocars.net/attachment.php?attachmentid=2078&stc=1&d=1245108385
http://www.exocars.net/attachment.php?attachmentid=2079&stc=1&d=1245108385
http://www.exocars.net/attachment.php?attachmentid=2085&stc=1&d=1245108385
http://www.exocars.net/attachment.php?attachmentid=2086&stc=1&d=1245108385

One of the front wheel bearings in the front was bad. Its the little one.... i did some digging and here is what i came up with for Ford Cortina hub bearings:

Outer cone bearing # LM11749 / Cup LM11710

Inner cone bearing # L44649 / Cup L44610

cite sources.... http://www.jensenhealey.com/forums/view_topic.php?id=266&forum_id=8
verified by the NTN catalog and my measuring stick. http://www.ntnamerica.com/pdf/A1000/A1000IX_Tapered.pdf

http://www.exocars.net/attachment.php?attachmentid=2081&stc=1&d=1245108385

You can search rock auto with the part numbers. Little under 15 bucks... best price I found quick. The Bearing store was WAY cheaper but shipping was $$$ so it total would have been more; if one needed all four sets they would be more cost effective.

http://www.exocars.net/attachment.php?attachmentid=2082&stc=1&d=1245108385
http://www.exocars.net/attachment.php?attachmentid=2083&stc=1&d=1245108385
http://www.exocars.net/attachment.php?attachmentid=2084&stc=1&d=1245108385

So, I was gonna use Dzus fasteners to attach the rear engine cover, but as you can see it is not a good application for them. I am no wondering what direction to take here. I am thinking along the lines of an elastic strap at 4 locations, or a metal attachment point, like a fire extinguisher strap. I'll think about it some more and bounce any ideas off you guys. Some time in the McMaster catalog is warranted....

Focus is still not out of gas either. Maybe by Thursday? The thing gets really good millage when your not thrashing it.

-Brad

[cheapracer]

Focus is still not out of gas either. Maybe by Thursday?

-Brad

LOL! So we have to wait for your build until the donor runs out of fuel, now thats a first!!

[golftdibrad]

LOL! So we have to wait for your build until the donor runs out of fuel, now thats a first!!

haste makes waste. :D I am doing other things... just not the ones I perhaps should be. I'm gonna miss that little car(the focus).... its a blast. such a sleeper.

[Gage]

I love all the pictures and updates. Your zeal for the project in inspiring. Keep it up!

[cheapracer]

I'm gonna miss that little car(the focus).... its a blast. such a sleeper.

Just keep thinking whats going to happen when you half the weight then :-)

[golftdibrad]

Just keep thinking whats going to happen when you half the weight then :-)

I'm already there. I decommissioned the focus last night by removing the steering column and mounting it in the car :D

[cheapracer]

Well at least you can sit there and make vroooom, vroooom noises!

[golftdibrad]

Well at least you can sit there and make vroooom, vroooom noises!

done, and
done. :thumb2:

[golftdibrad]

Last week the gas ran out the car, so i needed an easy, one night project that de-commissioned the focus.

http://www.exocars.net/attachment.php?attachmentid=2122&stc=1&d=1245810577
I kinda want to mount a ps2 controller just to throw passers by off.

http://www.exocars.net/attachment.php?attachmentid=2123&stc=1&d=1245810577
http://www.exocars.net/attachment.php?attachmentid=2124&stc=1&d=1245810577

My steering fit fine, thank goodness. The only thing was the M6 holes were clearanced to roughly M8 to use stock style/available hardeware.
The car has tilt and telescope, and vroom vroom noises were made.

http://www.exocars.net/attachment.php?attachmentid=2125&stc=1&d=1245810577
http://www.exocars.net/attachment.php?attachmentid=2126&stc=1&d=1245810577
http://www.exocars.net/attachment.php?attachmentid=2127&stc=1&d=1245810577

Today I started to disassemble the the car more aggressively. The turbo kit is being traded for a Jackson racing roots blower kit. I was going to pull the turbo today, but it turns out there is ONE bolt that you just cant get to with the turbo mounted to the mani. But... you can with the PS bracket removed. So the plan is to now pull the drivetrain, split the motor form the tranny, and remove all that stuff (that's coming off anyway) and get said bolt off. That should happen over the course of this week and be finished by Saturday.

The radiator form a US spec foci, as expected since they all have ac, does not fit since the kit is for a non-ac car. A junkyard trip is in order armed with some measurements.

I have decided to part out the focus. When I'm tired (or my neighbors!) of looking at it I'll sell it to a salvage yard if they give me some cash.... if not the sawzall will be broken out.

Buying stuff... did alot of that too. I got me some Dzus for the cover and hood. ordered hubs and wheel bearings for the rear. Got a replacement bearing for the front. ordered brake rotors. Should have all the parts at least for the 4X100 re drilling operation in a week or so. I was thinking 6UL's for wheels.... http://949racing.com/index.asp?PageAction=VIEWCATS&Category=33
http://949racing.com/ProductImages/36BsW.jpg

Thats it for now... for the next few weeks I'll likely be elbow deep in focus dis assembly.

-Brad

[golftdibrad]

The focus, that is.

This is by far, far, far the most dirty car I have ever worked on, mostly due to PO issues. A solid two layers of PCV/oil/road grime was on everything, and places where it could build up need wire brushing. The below, semi final result is after several hours and the better part of 2 cans of engine degreaser. Much improved.

http://www.exocars.net/attachment.php?attachmentid=2172&stc=1&d=1246234618

parts shelf starting

http://www.exocars.net/attachment.php?attachmentid=2173&stc=1&d=1246234618

turbo, radiator ac condenser/compressor

http://www.exocars.net/attachment.php?attachmentid=2174&stc=1&d=1246234618
lots of pipe.

http://www.exocars.net/attachment.php?attachmentid=2175&stc=1&d=1246234678


Big hole, BIG HOLE. I'm going to try and keep cruise :D You can see some of the grime in this pic

http://www.exocars.net/attachment.php?attachmentid=2176&stc=1&d=1246234678

http://www.exocars.net/attachment.php?attachmentid=2177&stc=1&d=1246234678

http://www.exocars.net/attachment.php?attachmentid=2178&stc=1&d=1246234678

How it sits now. I'm going to try and drop it off stands (since i don't want to mess with the focus much for a week or so) so it looks like a car tomorrow.

not getting much action on the part out....

I have also found the major oil leak, in the pan. the front and rear mains are not leaking, and frankly starting to change out parts is a slippery slope and used motors are 500 bucks. Based on that, I dont even think I'm gonna split the trans from the engine.

Tired. Hands hurt. Going to go watch new Top Gear.
-Brad

[cheapracer]

First we have to wait till it ran out of petrol now we have to wait while you watch Top Gear???
:)

[golftdibrad]

First we have to wait till it ran out of petrol now we have to wait while you watch Top Gear???
:)

ummmm..... yes :thumb2:

[cheapracer]

............says Andy.

[golftdibrad]

I got tired of looking at the focus, and i want my other parking space back. 85 percent stripped. Tired, dehydrated, sore. more later next week.

For the wait you get a crappy vid of a focus being disassembled and cut up :D

I want to find a use for the cable operated vent and heater controls too.

And how the **** do you get the shifter cables out? or the heater core/evap/blower assembly? There is exactly one bolt and that bitch in in there SOLID. I could use the Jeremy Clarkson method but id rather not...

[Nigel]

.......... And how the **** do you get the shifter cables out? or the heater core/evap/blower assembly? There is exactly one bolt and that bitch in in there SOLID. I could use the Jeremy Clarkson method but id rather not...

Take the whole dash out :spin:

http://i177.photobucket.com/albums/w232/NigelP21/MEV%20Sonic%207/Donor%20Car/IMG_4921.jpg

The two nuts under the heater :thumbdown2:

http://i177.photobucket.com/albums/w232/NigelP21/MEV%20Sonic%207/Donor%20Car/IMG_4923.jpg

What great fun and games I remember it so well :spin:

[golftdibrad]

Take the whole dash out :spin:

http://i177.photobucket.com/albums/w232/NigelP21/MEV%20Sonic%207/Donor%20Car/IMG_4921.jpg

The two nuts under the heater :thumbdown2:

http://i177.photobucket.com/albums/w232/NigelP21/MEV%20Sonic%207/Donor%20Car/IMG_4923.jpg

What great fun and games I remember it so well :spin:

Ok. Mine looks like pic 1 without wires right now. Thanks.

[golftdibrad]

no pics today from the weekends work.

Most of the weekend was spent tearing down the donor to the bare shell. 90% there. Sold alot of stuff for a good amount of money today. Might have the suspension sold. I definitely have it off if it were not to the bonehead previous owner that ran the lugs on with an impact. Broke tools, am pissed. Drills come out tomorrow. That is such a stupid thing to do... when will people learn?

I was REALLY hot. I am beat. Can't wait till this is done and I can get back to working on the car itself.

-Brad

[golftdibrad]

You guys are media deprived, and I is sorry but it has been hot as shit AND i've been working my ass off. I actually had to wring out my clothes today.

But... here is a taste :D

http://www.youtube.com/watch?v=TQ7zHA_RMkg

-Brad

[cheapracer]

A vid of you wringing out the sweat from your clothes?? :nervous:

eewww, for the first time I'm actually glad I can't get Youtube!

[golftdibrad]

A vid of you wringing out the sweat from your clothes?? :nervous:

eewww, for the first time I'm actually glad I can't get Youtube!

Thats not in the vid. ewwww

[B-T]

Good work! You made some great progress in one day on that video. So what is the current donor cost (initial cost minus the proceeds of the parts sales)? I'm looking forward to the finished product!!! Do you want a Richard Simmons motivational cassette??? It is sure to make you extra pissed just hearing that voice, and the project will move along rapidly.
:coolnana:
BT

[golftdibrad]

Well its gone. not including the parts sales, disposing of the metal was not a cost effective venture.... but I haz vin.


Good work! You made some great progress in one day on that video. So what is the current donor cost (initial cost minus the proceeds of the parts sales)? I'm looking forward to the finished product!!! Do you want a Richard Simmons motivational cassette??? It is sure to make you extra pissed just hearing that voice, and the project will move along rapidly.
:coolnana:
BT

The donor cost is still pretty high, but i still have more stuff to sell. I'll do some figuring this weekend.... cause I'm certinally not doing anything other than driving a car.

Richard simmons.... no. just no.

-Brad

[golftdibrad]

if you look closely you can see whats left of a ford focus around the fridge.

http://www.exocars.net/attachment.php?attachmentid=2208&stc=1&d=1247266541
This was not cost effective. $42 and change for the metal (over 1k lbs!!!!)

truck was about 50, gas was 6.50, $20 in sawzall blades, plus a ton of work.

But.... well lets say i kept the digits. :D
-Brad

[golftdibrad]

So what is the current donor cost (initial cost minus the proceeds of the parts sales)?
BT

so far, 4274.20 for the car, this includes travel, transfer fees, etc.
512.59 on parts.
so 3761.61.

keep in mind that the car has a quaife, had turbo that is being traded for SC, performance clutch, etc. the first two things are 3000 alone new.

[cheapracer]

Has a "Quaife" what? Gearbox or diff or both?

[golftdibrad]

Has a "Quaife" what? Gearbox or diff or both?

the diff.

[B-T]

so far, 4274.20 for the car, this includes travel, transfer fees, etc.
512.59 on parts.
so 3761.61.

keep in mind that the car has a quaife, had turbo that is being traded for SC, performance clutch, etc. the first two things are 3000 alone new.

Sounds like a good price to me. I'm looking forward to the finished project. What's your color scheme???
Any specific performance targets, or just going to build it and see how it goes???
Keep up the good work!
:)
BT

[golftdibrad]

Sounds like a good price to me. I'm looking forward to the finished project. What's your color scheme???
Any specific performance targets, or just going to build it and see how it goes???
Keep up the good work!
:)
BT

colors are silver frame with black panels and fenders. Might have to make wider fenders..... they might end up red. We'll see.

Performance targets... Well i don't have any specific and im trying to keep expectations as low as reasonably possible so im not disappointed. Lets put it this way.... I'd be disappointed if it didn't do the sprint to 60 in under 5 seconds and pull .95g on a track on street tires.

-Brad

[cheapracer]

colors are silver frame with black panels and fenders. Might have to make wider fenders..... they might end up red. We'll see.

Performance targets... Well i don't have any specific and im trying to keep expectations as low as reasonably possible so im not disappointed. Lets put it this way.... I'd be disappointed if it didn't do the sprint to 60 in under 5 seconds and pull .95g on a track on street tires.

-Brad

To 60 in under 5 secs will be very easy, more than 0.9g won't be (depending on how 'street' your tyres actually are).

[golftdibrad]

To 60 in under 5 secs will be very easy, more than 0.9g won't be (depending on how 'street' your tyres actually are).

one of the several extreme performance summer offerings. I can do .9g with those in the Miata, so hopefully I can at least match that.

[cheapracer]

Cool and at almost half the weight you would rightfully expect some improvement. Are you looking at sprint stuff or fast road?

[golftdibrad]

Cool and at almost half the weight you would rightfully expect some improvement. Are you looking at sprint stuff or fast road?

not sure I understand. as a type of tire im not familiar with that termonology.

[cheapracer]

Sprint stuff = hillclimbs, track days, lap dashes, autokarna, etc. using something with softer compounds and weaker sidewalls.

Fast road = hooning around your streets, mountain roads on Sunday mornings, club tracks days but for standard'ish street cars etc. more budget type sport tyres with comfort, noise and wear considerations.

[golftdibrad]

Fast road, but may change to racing tires for autox events.

[cheapracer]

Ok, well getting 0.95 without aero assistance may be a struggle then, but good luck anyway :thumb2:

[Nigel]

I just love this thread :spin:

I'm using Yoko A539's :) OK there 205/40 17's (a little to wide really) and I struggle to get them warm except on a hot day. Have thought of going to Yoko 888's but going to persevere with the A539's for the time being. (save some money)

My biggest problem at the moment as far as going round corners, is the flexing of the seats, so I'm going to have to rope rib and put another layer of fiberglass over the backs.

I've just got that feeling that I'm going to have to hand the car over to a more experienced driver at the track to get a 2nd opinion, regarding handling settings, as I'm finding that zero camber on the front is the most optimum.

Just wish this bad weather would change :(

[cheapracer]

I just love this thread :spin:

I'm using Yoko A539's :) OK there 205/40 17's (a little to wide really) and I struggle to get them warm except on a hot day. , regarding handling settings, as I'm finding that zero camber on the front is the most optimum.

(

Quite possible, if your a bit wide/light at the front and cant get heat then a little positive camber allows the outer shoulder to 'dig' in more. Otherwise it's possible you have too much caster. I think you mentioned 8+ degrees caster? Back the caster off 2 degrees and add 1+ degree camber maybe.

I would strongly suggest you try a range of tyre pressures start from around 45psi and go through to 20psi in steps of 5 and see what results you get. Probably a constant of around 35 in the rears while you do it then once you are happy with the front do the rears as well. Please take care.

Many people adjust pressures but mistakenly just throw the same pressures in front and rear.

[golftdibrad]

Quite possible, if your a bit wide/light at the front and cant get heat then a little positive camber allows the outer shoulder to 'dig' in more. Otherwise it's possible you have too much caster. I think you mentioned 8+ degrees caster? Back the caster off 2 degrees and add 1+ degree camber maybe.

I would strongly suggest you try a range of tyre pressures start from around 45psi and go through to 20psi in steps of 5 and see what results you get. Probably a constant of around 35 in the rears while you do it then once you are happy with the front do the rears as well. Please take care.

Many people adjust pressures but mistakenly just throw the same pressures in front and rear.


I'm sure you know this chearacer, but as an FYI for others...

Once you have optimized your tire pressures for wear and temp anything else is a band-aid. By wear and temp I mean that your using all the tire and the temps are even across the surface with out rolling onto the sidewall and overheating the tire.

Adjusting the pressure away from this point is a band-aid for two things:

1. contact patch size. More applicable in autox than track or street, but increasing pressure on the end with more grip and vise versa to reduce/increase the contact patch size can improve balance and transitional behavior.

2. adjust effective spring rate. more applicable to the track. increasing pressure increases spring rate and vise versa.

These are band aids per say, but an extremely effective way to fine tune the balance of a well set up car for conditions and courses.

I do disagree about running going as high as 45 psi. On such a light car the optimum set up should be in the 20's. 30's is a BIG band-aid. Hell, I only run about 25 on the miata, its 2700ish pounds race weight on 205's. for comparison we ran between 10 and 12 psi on our 600lb (with driver) FSAE car. My gut tells me that these 1000-1500 lb cars will end up being most happy in the high teens to low twenty's of psi. More than that.... time to change spring rates. YMMV

-Brad

[Nigel]

I would strongly suggest you try a range of tyre pressures start from around 45psi and go through to 20psi in steps of 5 and see what results you get. Probably a constant of around 35 in the rears while you do it then once you are happy with the front do the rears as well. Please take care.

Many people adjust pressures but mistakenly just throw the same pressures in front and rear.



I do disagree about running going as high as 45 psi. On such a light car the optimum set up should be in the 20's. 30's is a BIG band-aid. Hell, I only run about 25 on the miata, its 2700ish pounds race weight on 205's. for comparison we ran between 10 and 12 psi on our 600lb (with driver) FSAE car. My gut tells me that these 1000-1500 lb cars will end up being most happy in the high teens to low twenty's of psi. More than that.... time to change spring rates. YMMV

-Brad

You were getting me worried there Cheapracer :nervous: I've done lot of playing with the tyre pressure and I've settled on 16 psi front and 20 psi rear, I found the Sonic especially sensitive to front pressure, you feel the difference of as little as a 2 psi change.

Caster is pre-set on the Sonic (no easy adjustment) so I'm leaving that at 8 deg, dose provide reasonable self centreing for such a light car and good stability at speed 90mph hands off straight as a dia.

I'm currently trying to borrow a set of 185/45 16 wheels shod with R888 CG just to see the difference the reduced contact patch makes and soft R888's. :thumb2:

Have been making many modifications to the car over the last X weeks since my shakedown and hope to get a list up on my website in the next week or so but now starting to get to the point of planning an engine upgrade for a winter project (2ltr Duratec ST170) :spin: I love this game :thumb2:

[golftdibrad]

Speaking of tires,

Despite my best efforts with trying to keep track of pointy fasteners.... i grabbed what looks to be a framing nail from the in one of the miata tires :( I also discovered that they are very near the end of their useful life.... bad camber wear. Going to use the tire machine at a friends shop to rotate them.

[cheapracer]

You were getting me worried there Cheapracer :nervous: I've done lot of playing with the tyre pressure and I've settled on 16 psi front and 20 psi rear, I found the Sonic especially sensitive to front pressure, you feel the difference of as little as a 2 psi change.



Oh no, don't worry, I expected you to be around the 20's eventually and if I had to guess before you wrote this I would have predicted 20 front and 25 rear in those 5psi steps.

I'm a little worried about the 2psi sensitivity, I'll think about that a bit, can you tell me what happens if you go 2 down and 2 up from 16? - more later, got to go.

[golftdibrad]

Ok, here is how to make your ac/ps delete the B-R-A-D way.

Parts need: an old, but working focus tension pulley, mazda 929 belt tensioner, < 1 foot piece of 1" X 1" angle iron, various fasteners

Step 1, go to you local u-pull it and find a 90's mazda 929 with the v6

http://www.exocars.net/attachment.php?attachmentid=2224&stc=1&d=1248661975

They apparently like to blow timing belts some someone will have removed alot of stuff to allow you to see the part with no effort. I saw at least 4, three had lost a timing belt and one was missing an engine

http://www.exocars.net/attachment.php?attachmentid=2225&stc=1&d=1248661975

Get some engine degreaser that makes Al Gore cry. That belt didn't go for no reason.

http://www.exocars.net/attachment.php?attachmentid=2226&stc=1&d=1248661975

Get your focus pulley taken off.

http://www.exocars.net/attachment.php?attachmentid=2227&stc=1&d=1248661975

All cleaned up

http://www.exocars.net/attachment.php?attachmentid=2223&stc=1&d=1248661975

Mount using 929 hardware with extra washer so the full range of adjustment is available.

http://www.exocars.net/attachment.php?attachmentid=2228&stc=1&d=1248661975

Mock up with angle iron to use PS bracket. Realize that you nifty adjustable 929 tensioner will not work. Have beer, relax. Pulley can mount straight to angle iron with 929 nut and washer. Hey, it was 5 bucks at the pick and pull... and it will work, get over it.

BTW Al Gore is now BALLING because you didn't even use the bracket that got cleaned :D

http://www.exocars.net/attachment.php?attachmentid=2229&stc=1&d=1248662076
http://www.exocars.net/attachment.php?attachmentid=2230&stc=1&d=1248662076
http://www.exocars.net/attachment.php?attachmentid=2231&stc=1&d=1248662076

Align the pulley carefully in all dimensions so the damn thing doesn't squeak. I suggest measuring your holes from the edge of the angle iron so its at least perpendicular to the belt path. Use a center punch before you drill. I used body fasteners to mount the angle to the PS bracket and a TORX from one of the seat belts for the pulley

Clean edges, paint, mount, DONE. Get a beer.

[golftdibrad]

The engine is in.... kinda

http://www.exocars.net/attachment.php?attachmentid=2234&stc=1&d=1248664468
http://www.exocars.net/attachment.php?attachmentid=2235&stc=1&d=1248664468
http://www.exocars.net/attachment.php?attachmentid=2236&stc=1&d=1248664468

There is a severe alignment issue in terms of both front to rear and up and down. The shifter also hits the trans mount, but this problem may go away when i fix the alignment. I believe the trans needs to be raised and moved to the rear a touch.

http://www.exocars.net/attachment.php?attachmentid=2237&stc=1&d=1248664468

blower is on too :D

http://www.exocars.net/attachment.php?attachmentid=2238&stc=1&d=1248664468

Good thing I decided against the turbo.... It just would not have fit without some SERIOUS modification.

Well, I am tired, the garage is a mess, and a whole lot was done. I'll work on the solution for the engine mount issue as I continue work on the car. Wont be much in the coming weeks though. I have a trip to the tail of the dragon in 7 days that I need to get the miata ready for and I'll be there for a week. I'll tinker this week though and be ready to jump back in with renewed motovation after the Smokey mountains provide inspiration :thumb2:

[cordycord]

You are now officially my hero--you made Al Gore cry.

[B-T]

Enjoy your ride at Deal's Gap. If you have the time, NC 215 from US 64 up to the Blue Ridge Parkway is a great road, as well as Georgia 348 (Richard Russell Scenic Highway) about 5 miles south of Blairsville, GA.
That SC is looking good!!!
:)
BT

[golftdibrad]

Enjoy your ride at Deal's Gap. If you have the time, NC 215 from US 64 up to the Blue Ridge Parkway is a great road, as well as Georgia 348 (Richard Russell Scenic Highway) about 5 miles south of Blairsville, GA.
That SC is looking good!!!
:)
BT

thanks for the tip! Probally going to avoid going through hot-lanta though..

[swingdancr]

Wish I had seen this sooner. I live in Knoxville and would have gladly met you up there.

BTW, have you been to MATG? It's the last weekend of July every year. Had 410 cars sign the registration this year, so 450 Miatas is a reasonable expectation of actual turnout.

[apalumbo]

I think the hardest part about the build process is almost over. I have an agreement with the wife! I have to give her my current car, trade in her car for a really cheep daily driver and then I am allowed to buy the MEV Rocket!

Brad - I've been following your build. I am looking for some purchasing advice. I have very limited experience with this type of thing but I have built a sand rail with a friend and I owned a 53 chevy pick up with a 327. My brother is an automotive engineer with International so I will need to rely on his experience quite a bit. I plan on using the KISS (Keep It Simple Stupid) principle throughout this build so I am wondering what purchases can I make to keep my build as simple as possible?

Cheapracer - I have a good idea what your comments would be so you will not need to add anything to this thread.

[golftdibrad]

Wish I had seen this sooner. I live in Knoxville and would have gladly met you up there.

BTW, have you been to MATG? It's the last weekend of July every year. Had 410 cars sign the registration this year, so 450 Miatas is a reasonable expectation of actual turnout.

Never been to MATG, I go with a bunch of friends that I met 5 years ago when we were (or still are?) water cooled VW people. We all go...em... a little harder than the miata guys would.

And most of the soltiace/sky crowd... those guys were SLOW, save for the one guys that was too fast... RIP passenger and hope the driver recovers.

We had a ton of fun this year. polished off a set of falkens and lots of gas. That blown miata is expensive.

I think the hardest part about the build process is almost over. I have an agreement with the wife! I have to give her my current car, trade in her car for a really cheep daily driver and then I am allowed to buy the MEV Rocket!

Brad - I've been following your build. I am looking for some purchasing advice. I have very limited experience with this type of thing but I have built a sand rail with a friend and I owned a 53 chevy pick up with a 327. My brother is an automotive engineer with International so I will need to rely on his experience quite a bit. I plan on using the KISS (Keep It Simple Stupid) principle throughout this build so I am wondering what purchases can I make to keep my build as simple as possible?

Cheapracer - I have a good idea what your comments would be so you will not need to add anything to this thread.

I'll send you a pm.

[cheapracer]

Cheapracer - I have a good idea what your comments would be so you will not need to add anything to this thread.

errr??

Is there some post within Brad's thread thats out of place, non constructive etc?

[golftdibrad]

Guys, please keep that personal shit out my build thread.

kthnxbye.

[Nigel]

Hi Brad, just wondering how the builds getting on, have just learn't that someone here in the UK has this summer put a supercharged 2Ltr Zetec powered Rocket on the Road. :spin: I'm currently trying to track them down and find out more, will keep you posted. :thumb2:

[golftdibrad]

Hi Brad, just wondering how the builds getting on, have just learn't that someone here in the UK has this summer put a supercharged 2Ltr Zetec powered Rocket on the Road. :spin: I'm currently trying to track them down and find out more, will keep you posted. :thumb2:

Been on a bit of a break from the build since/during/after my vacation. Plan is to get back to business this week and weekend after i clean my damn house up!

LMK if you dig anything up on the supercharged car; it would help!

-Brad

[golftdibrad]

got in the garage a little yesterday. Mounted my vise. Cut tubing to space up the trans mount. got it level horizontal was at least.

[Gage]

Keep it up! I have new appreciation for the time needed to make things happen.

[golftdibrad]

Keep it up! I have new appreciation for the time needed to make things happen.

yea. Next is to get the other mount measured up so i can weld it up.

[golftdibrad]

Well, after a long absence I got myself back in the garage today. Main goal was to measure and fit the engine so the mounts can be modified. The transmission was easy, just used some one inch square tube to space up the inch needed. the motor mount is a little more tricky, but will moved to the front of the car about 1.25 inches

http://www.exocars.net/attachment.php?attachmentid=2298&stc=1&d=1251861211

http://www.exocars.net/attachment.php?attachmentid=2299&stc=1&d=1251861205

As you can see the motor was removed so the mount can be fixed. I plan on cutting the vertical support out, fashioning something similar an inch or so to the front of the car, and welding plate to the whole back side to box it in on the side nearest the motor. Will be very strong. Going to try and do that this week sometime but over the weekend at the latest.

-Brad

[Karlo]

Any better pics of your wheels?

[golftdibrad]

Any better pics of your wheels?

Those will actually be for the Golf. They are stock scion TC wheels. :awais:

[golftdibrad]

So today I finally got the new mount welded in. I will provide measurements/directions later when it is finalized.

Video time!

http://www.youtube.com/watch?v=nzkWAqfOYO4

-Brad

[Nigel]

I see you've been a little quite of late, how's the car going ?

The cars, Rocket and Sonic are gathering pace here in the UK with quite a few builders sharing there experiences on the MEV web forum.

Tim has been doing some tunning and thought this might interest you http://forum.allcarclub.co.uk/index.cgi?action=display&board=mevmodifications&thread=1182&page=1 Refer

I've not managed to contact that other Rocket owner with a supercharger but will keep trying.

Looking forward to hearing your cars running

Nigel

[golftdibrad]

I see you've been a little quite of late, how's the car going ?

The cars, Rocket and Sonic are gathering pace here in the UK with quite a few builders sharing there experiences on the MEV web forum.

Tim has been doing some tunning and thought this might interest you http://forum.allcarclub.co.uk/index.cgi?action=display&board=mevmodifications&thread=1182&page=1 Refer

I've not managed to contact that other Rocket owner with a supercharger but will keep trying.

Looking forward to hearing your cars running

Nigel


Been busy with work and stuff. I was hoping to get some work in this week but the weather has sucked it up. I hope to be rolling in a week or two.

[golftdibrad]

So, I've gotten some work done. The engine is ALMOST completely mounted. It can no longer fall out that is for sure.

One of the front uprights is assembled and loosely bolted to the car. Just need to get some castle nuts or something to secure it and I'll be close to having front wheels.

[golftdibrad]

Soooo... Been awhile since the last update. Progress is slower than i'd like but alot of stuff has been holding me up. I still get work on it done though so its all good.

I got the front wheels mounted. big mental step here.
I had previously built one of the front hubs so it was kind of on. I decided to not redrill everything to 4X100 for a couple of reasons. First, it would have been alot of machine time since the rear has to have the rotors done as well. Second, parts are expensive and in the case of the front hubs rare as shit stateside. Third, not even sure I could do the fronts due to possible interference issues. and finally, adapters are relatively cheap.

I did have to replace one bearing as outlined in an earlier post. I got the dust covers from autozone but they were a little small so they were modified with channel locks and a vise.

Also, since the hubs did not come with a way to lock the nut for bearing preload, I used some castle nuts from lowes installed upside down with the nut they came with and a cotter pin.

I also had the pleasure of doing the hub in the video twice.... forgot to attach the brake rotor. I was very pissed at myself but it was not as bad as I thought.

Also got the rack painted.

http://www.exocars.net/attachment.php?attachmentid=2411&stc=1&d=1256694592

http://www.youtube.com/watch?v=XiFPROSgies

[cordycord]

Brad, I think it's time you retire those pants... :)

[golftdibrad]

Brad, I think it's time you retire those pants... :)

work pants, you know :)

[VMV Cars]

Brad. Very closely look at where the brake and clutch pedals are. Then, with the center console in place, try to find a spot for the gas pedal. That's what I was referring to the other day. Your LHD chassis suffers from the same unfortunately placed brake/clutch mount. Fix that and the lower control arm mount while you have the torch hot ;)

Oh, and good taste in music!

[golftdibrad]

Brad. Very closely look at where the brake and clutch pedals are. Then, with the center console in place, try to find a spot for the gas pedal. That's what I was referring to the other day. Your LHD chassis suffers from the same unfortunately placed brake/clutch mount. Fix that and the lower control arm mount while you have the torch hot ;)

Oh, and good taste in music!

Thanks man. I think that picture suffers from bad perspective, the pedal mounts look about right. In fact they couldn't go more to the outside by more than about an inch.

I'll try to get better pics of my LCA mount but it is a different style than yours. I don't think I'm initially going to mess with it.

[golftdibrad]

My goal for the weekend was to get it rolling chassis.

Not as productive today as I hopped....

It started innocent enough. Go to the LSU shop where the arbor press is and make rear spindles, bearings, and hubs one part. Well, they have alot of construction going on so there was no light. Then, the tolerances on the spindles are kinda tight so the 2 ton arbor press was a no go. the hydrolic one was out of order....crap.

So, I go to harbor freight to get the 6 ton hydro press. Hell its only 70 bucks and i can use it for lots of stuff. Nope, sold out. 12 ton was 129. So I was like screw it, I WANT rear suspension. Buy that crap and go home.

Assembled press, pressed parts, disassembled press, shower, return press*, watch the refs loose the LSU game for us, and I'm home.

Work continues tomorrow....

*I had a bad experience using a shop to press FWD bearings. I do it my self now whatever it takes... even if its a bit sleazy.

[VMV Cars]

My goal for the weekend was to get it rolling chassis.

Not as productive today as I hopped....

It started innocent enough. Go to the LSU shop where the arbor press is and make rear spindles, bearings, and hubs one part. Well, they have alot of construction going on so there was no light. Then, the tolerances on the spindles are kinda tight so the 2 ton arbor press was a no go. the hydrolic one was out of order....crap.

So, I go to harbor freight to get the 6 ton hydro press. Hell its only 70 bucks and i can use it for lots of stuff. Nope, sold out. 12 ton was 129. So I was like screw it, I WANT rear suspension. Buy that crap and go home.

Assembled press, pressed parts, disassembled press, shower, return press*, watch the refs loose the LSU game for us, and I'm home.

Work continues tomorrow....

*I had a bad experience using a shop to press FWD bearings. I do it my self now whatever it takes... even if its a bit sleazy.

I heated up the bearing bosses with a heat gun, froze the bearings in the beer fridge's freezer, and used a 33lb "weight" to get those bearings in. It was all of about 1 hour work per bearing, but it worked. If you start putting them together at the same temp, it really seems like there is no possible way the bearing will go in the bearing boss. Congrats on getting them put in!

[golftdibrad]

Well, I missed my goal of making a rolling chassis today but just a little. FYI 15 inch alloy wheels don't fit the rear of the car :( Will 16's? I hope. 17's are too big for this thing IMHO.

I figured out the steering after looking at the instructions, who knew? Didn't get a chance to fab it though.

Pretty un eventful, just a bunch of work. Pics for your enjoyment.

http://www.exocars.net/attachment.php?attachmentid=2450&stc=1&d=1257730916

http://www.exocars.net/attachment.php?attachmentid=2451&stc=1&d=1257730915

-Brad

[VMV Cars]

The 17s I have on my car BARELY clear the rear fender mount. There might be a millimeter or two clearance. If you are hell bent on 16s, you are either going to need to bend the hell out of the fender mounts to make them work. Since the fenders travel with the wheel, you can get them pretty tight. 17s with low profile tires look great (see my site).

[golftdibrad]

I heated up the bearing bosses with a heat gun, froze the bearings in the beer fridge's freezer, and used a 33lb "weight" to get those bearings in. It was all of about 1 hour work per bearing, but it worked. If you start putting them together at the same temp, it really seems like there is no possible way the bearing will go in the bearing boss. Congrats on getting them put in!

Congrats to you for getting that to work on FWD bearings! I heard of many failed attempts, none that have worked. Interference fit rule of thumb is one thousandth of an inch per inch of diameter. I dont have measuring tools that accurate so I went on faith.

The 17s I have on my car BARELY clear the rear fender mount. There might be a millimeter or two clearance. If you are hell bent on 16s, you are either going to need to bend the hell out of the fender mounts to make them work. Since the fenders travel with the wheel, you can get them pretty tight. 17s with low profile tires look great (see my site).

Ha, fender stays. Like I've even unpacked those :D I'll be keeping my eyes on used wheels of Focus fanatics I guess. Really crappy thing is I have ANOTHER set of wheels that dont 'fit' any of my cars...

[golftdibrad]

Well, I think I'm close to connecting the steering wheel to the front wheels. Got my adapter fabed up with the help of a friend and it *just* kisses some frame. After some work with the flap wheel it should fit fine.

sorry no pics today :D

-Brad

[Gage]

Great progress! (clapping)

[cordycord]

I saw that Longacre kit and considered getting it myself. I assume that you're going for the -3 (dash 3) size. I'm trying something interesting with the master brake cylinders--instead of plumbing straight in, I'm running a banjo bolt with a bleed screw at the end. On my car the reservoir's are the highest point, so I figure I'll be doing a lot of bleeding at that point. Although I've used banjo bolts directly into master cylinders before on motorcycles, I don't see it much in cars--don't know if I'm missing something...

Let's see some more pictures and video!
__________________

[Lynn]

I saw that Longacre kit and considered getting it myself. I assume that you're going for the -3 (dash 3) size. I'm trying something interesting with the master brake cylinders--instead of plumbing straight in, I'm running a banjo bolt with a bleed screw at the end. On my car the reservoir's are the highest point, so I figure I'll be doing a lot of bleeding at that point. Although I've used banjo bolts directly into master cylinders before on motorcycles, I don't see it much in cars--don't know if I'm missing something...

Let's see some more pictures and video!
__________________

if you use a pressure bleeder from the brake caliper up thru the master cylinder you do not need the bleeders. all the air will go up and out into the reservoir.

[cordycord]

if you use a pressure bleeder from the brake caliper up thru the master cylinder you do not need the bleeders. all the air will go up and out into the reservoir.

It never did on the motorcycles, but then again, the handlebars were never level. Hmmm.

[golftdibrad]

I assume that you're going for the -3 (dash 3) size. I'm trying something interesting with the master brake cylinders--instead of plumbing straight in, I'm running a banjo bolt with a bleed screw at the end. On my car the reservoir's are the highest point, so I figure I'll be doing a lot of bleeding at that point. Although I've used banjo bolts directly into master cylinders before on motorcycles, I don't see it much in cars--don't know if I'm missing something...

Let's see some more pictures and video!
__________________
I did go with -3.

if you use a pressure bleeder from the brake caliper up thru the master cylinder you do not need the bleeders. all the air will go up and out into the reservoir.

This is true in theory and practice to a point. The first bleed of any hydrololic system with be a royal PITA, brakes especially. Once the system is bled you can do what you suggest just to change the fluid. But cord, the way the MC works is that if the resiviour is above the intake no bleeding is necessary up to that point. They air will likely collect in the caliper and be bled at the highest point of it. IF you keep all your lines below this point (impossible!) its easy. If like the rest of us mortals your MC's are above your SC's you just have to use an obscene amount of fluid for that initial bleed and/or elevate the car to ridiculous angles. :) Its the lesser of two evials IMHO... residual pressure valves (suck) or mount the MC higher than the SC and hate your life on that initial system bleed.



I may not be able to post pics or videos for awhile because my house got robbed today. I still have the snapshot camera and web cam.... but I'll clearly be preoccupied for at least a few days. :(

[cordycord]

CRAP!!!! Sorry to hear about that. Good luck...

[golftdibrad]

Well, going to start in on the car again this weekend now that things are falling back into place.

I got wheels :D

[cordycord]

WHEELS!!!! I'm looking for wheels!!! Show pics, and confirm backspacing please. If I'm going to run 8.5" or 9" on the Sonic, I'll need close to zero backspacing, and very few suppliers seem to carry them--at my price point...

[golftdibrad]

WHEELS!!!! I'm looking for wheels!!! Show pics, and confirm backspacing please. If I'm going to run 8.5" or 9" on the Sonic, I'll need close to zero backspacing, and very few suppliers seem to carry them--at my price point...

Cord, been sick sorry it took awhile to get back to ya. They are these: http://www.fordracingparts.com/parts/part_details.asp?PartKeyField=7005

Thats pretty high offset for your application I think.

[golftdibrad]

And I have too many wheels in my garage....

http://www.exocars.net/attachment.php?attachmentid=2808&stc=1&d=1264264919
http://www.exocars.net/attachment.php?attachmentid=2809&stc=1&d=1264264919
http://www.exocars.net/attachment.php?attachmentid=2810&stc=1&d=1264264919
http://www.exocars.net/attachment.php?attachmentid=2811&stc=1&d=1264264919

[Nigel]

Fantastic Brad :clap:

I do like the Black wheels, what tyres ?

With Christmas over and the summer just over the horizon it won't be long now :D

nigel

[cordycord]

Ahead of me again. :)

[golftdibrad]

Fantastic Brad :clap:

I do like the Black wheels, what tyres ?

With Christmas over and the summer just over the horizon it won't be long now :D

nigel

tires are yoko avids, they came with them. I'll be running something alot more grippy, but those are fine for now.

[golftdibrad]

So, wow it has been forever since I've has a change to work on the car. Life get in the way i guess. But despite feeling like crap for the last two weeks (alergies..oak trees are in bloom) I got my butt in the garage saturday and worked on the brakes.

http://www.exocars.net/attachment.php?attachmentid=3157&stc=1&d=1269833735

The fronts dont really come with directions per say, but they are pretty self explanatory. The only issue I had was the spacer washer for the Rally design parts was a little small; probably due to the difference between standard and metric. While I didn't have a drill to clearance the hole, weirdly enough I had the right tool.... a reamer. Reamed those suckers out and they fit like a champ.


http://www.exocars.net/attachment.php?attachmentid=3158&stc=1&d=1269833735

Still need to flip the e-brake brackets, will do tomorrow.

Other: I beat on my bent wheel relentlessly with a dead blow hammer and a piece of wood. I think I got most of the bend out.... if the tire is dismounted the rest will be easy, but it may balance anyway.

In other news on of the jam nuts for the tie rod ends is frozen on. PB blaster failed. Next is the heat wrench. If that fails, me and Mr. dremel will spend some quality time cutting the nut off with the hope of not damaging the treads....much.

So nice to be working on it again in a CLEAN garage.

-Brad

[golftdibrad]

Just got back from using the heat wrench on that jam nut. Success! now on to cleaning the threads and getting the wheels somewhat straight.

[swingdancr]

Congrats!!! I just sold my Miata yesterday, so I'm on the hunt for a donor car. Then I'll order the kit. Can't wait!

[golftdibrad]

Congrats!!! I just sold my Miata yesterday, so I'm on the hunt for a donor car. Then I'll order the kit. Can't wait!

as you can see in previous pics....I just couldn't sell the miata.:D

[swingdancr]

The money from the Miata is paying for the kit, so I was willing to part with mine. Wife has a Mk V GTI and I also have a Samurai, so I've still got a few toys to play with until the kit is done....

[cordycord]

Brad, I can sympathize on the lack of time and feeling like crap. I've got allergies now that make me feel like I've got walking pneumonia.

[golftdibrad]

Well, next big thing is almost done. got all the hard lines run. It was not as bad as i thought.

http://www.exocars.net/attachment.php?attachmentid=3232&stc=1&d=1271729008

As previously mentioned, I used the lonacre kit. It said, in big red letters, THIS KIT SHOULD NOT BE USED ON RAD VEHICLES. Furthermore, the AN-3 flex lines declared that "FOR OFFROAD USE ONLY, NOT DOT APPROVED" My view on that is Stainless lines don't rust and if AN lines are good enough for racecars, the FAA, and the military I'll take my chances.

The kit came with nice metal brackets that you screw the adapters in. Some days, having a car made of round tube sucks. some creative work with the hammer, two drill bits, and a coat of primer and paint later I got this:
http://www.exocars.net/attachment.php?attachmentid=3233&stc=1&d=1271729008

I also ordered new master cylinders from wilwood. Why would I do that?

1. The remote mount kits are 50 ish dollars.
2. There is an identical part that in every way is the same except that the resivor is cast into the MC.

Now I know room is a bit limited in the rocket nose but I really don't know why MEV went with the compact MC's that need a remote mount vs the ones that don't; they cost almost the same. I can for see that the clutch may need a remote mount but its gonna be close so i only got two for now. One could argue that it be nice to have the compact MC's fed by one reservoir. I disagree, if a leak develops its better to have the two circuits independent of one another.

pic of ones kit shipped with:
http://www.wilwood.com/Images/MasterCylinders/Master%20Cylinder%20Photos-Large/260-6088-lg.jpg

ones i ordered:
http://www.wilwood.com/Images/MasterCylinders/Master%20Cylinder%20Photos-Large/260-6579-lg.jpg

wilwood part number is 260-6579

I still have to tighten all the fittings and figure out how to secure the rear lines to the floor so they don't vibrate to pieces but all in all that is minor stuff. Honestly the rear may need to be redone to accommodate the fuel cell, something else i kinda forgot about :/

One more big step is completed though :D

[golftdibrad]

Well, got the clutch MC in and mounted up the new MC's. To use these you have to take the pedals apart, but its no big deal really. Tips for anyone using this set up:
1. Take brake pedal off.
2. Install clutch MC
3. Put on the middle brake to your disassembled adjuster, slide adjuster through hole
4. install other MC
5. rebuild brake pedal and secure MC's to pedals...must do this last.

I also built a welding cart for my welder finally. First time MIG welding so not too pretty but it'll do.

http://www.exocars.net/attachment.php?attachmentid=3238&stc=1&d=1272152104
http://www.exocars.net/attachment.php?attachmentid=3239&stc=1&d=1272152104
http://www.exocars.net/attachment.php?attachmentid=3240&stc=1&d=1272152104
http://www.exocars.net/attachment.php?attachmentid=3241&stc=1&d=1272152104

[VMV Cars]

It still looks like your clutch pedal is in the center of the steering column. You might want to test fit a gas pedal with the center tunnel just to make sure there is space. From looking at those pictures, I still think you are destined to reweld the pedal assembly brackets (which will keep you from using that new clutch MC as it gets up under the frame).

[golftdibrad]

It still looks like your clutch pedal is in the center of the steering column. You might want to test fit a gas pedal with the center tunnel just to make sure there is space. From looking at those pictures, I still think you are destined to reweld the pedal assembly brackets (which will keep you from using that new clutch MC as it gets up under the frame).

well, i'm not married to the center console either.... most important thing is comfort. I sat in it and the pedals/steering feel like they are in a good place. Plus....wide load here may have to ditch the console anyway for the 18" wide seat. I'll def report on how it goes.

Thanks for the cable info too dude. How is your car? get it all fixed up and running? enjoying it? I saw that MEV issued a fix for all the cars like yours...good deal.

-Brad

[golftdibrad]

I bought seats. They barely fit, but they fit. They were expensive, ~500. They are ultrashield pro drag seats, with blue covers to be ordered cause race shop didn't have them. They are 18" wide.
http://www.ultrashieldrace.com/nControl/showpic.php?id=34&rnd=1274058494

I take pics, but in epic irony....
After waiting YEARS to get a camera mount for the car I finally did, so I bring it to the autox and try to video a run (with awesome spin recovery I might add) and its dead. D-E-A-D. some luck, huh?

So this week i get to mount SEATS!!!!

-Brad

[cordycord]

Autocross run in the Rocket?! You're done? Wassup with that?!

[golftdibrad]

Autocross run in the Rocket?! You're done? Wassup with that?!

heh, I wish. This was in my supercharged miata.

[VMV Cars]

http://www.ultrashieldrace.com/nControl/showpic.php?id=34&rnd=1274058494 http://www.freewebs.com/acorn-games/Diddy_Kong.jpg

For some reason, Diddy Kong came to mind. :spin:

I've never seen those seats. Very cool! I've done some mods to the car after the repair. I hope to take some pics, soon.

[cordycord]

heh, I wish. This was in my supercharged miata.

I'm going down to AWR today so I'll be sure to take a couple of pictures that will give you some ideas for your Miata. :thumb2:

[golftdibrad]

been busy. Seats almost ready to go in.

http://www.youtube.com/watch?v=DEXtlNrcXm0

[Nigel]

Hi Brad,

Been very quite of late, interested to know how your getting on with the Build :)

RTR have got approval from the 750 motor club here in the UK to start a MEV Rocket Race Series.

Going to be a very exciting year hear in the UK

nigel :thumb2:

[golftdibrad]

My little usb camera died so not alot of motivation for updates. And, honestly it has been slow, but I've got some parts in recently that need to be put on so I can start working again.

[golftdibrad]

sup bitches. been not too busy with the car but want to get re-motivated on this project. So, motivate me.

I need to get a list going. I got my radiator (from a dirty-d honda!).

Miata is out the garage for the next couple of days so i want to clean it up and re-organize it to make it a happy place to work again. Of course I want to turn a wrench or two on the car :D.

The car really is a lot closer to being done than it was when i got it, i just need to make the final push to the end of the project.

So what else has been up around here?

-Brad

[VMV Cars]

Not much. I have my Rocket up on Ebay right now. Need to move onto the next projects (78 VW Bus.)

Where are you on the build? Are you on the MEVOwners board? In the Tech section?

[golftdibrad]

Not much. I have my Rocket up on Ebay right now. Need to move onto the next projects (78 VW Bus.)

Where are you on the build? Are you on the MEVOwners board? In the Tech section?

saw that your car was for sale. I am on the MEV board, have not checked in in awhile.

I think I'm about 60-70% done with build. Too many irons in the fire to fully concentrate, i need to just put all that other shit out my mind and git'r'done.

Sucks that your selling your car, doesn't seem like you had alot of time to enjoy it!

[VMV Cars]

saw that your car was for sale. I am on the MEV board, have not checked in in awhile.

I think I'm about 60-70% done with build. Too many irons in the fire to fully concentrate, i need to just put all that other shit out my mind and git'r'done.

Sucks that your selling your car, doesn't seem like you had alot of time to enjoy it!

Ha! I had plenty of time to enjoy the build. Plus 400 miles to play with it and work out any bugs. I'm sure I have ADD or something and it kept me from finishing the car as quick as I wanted. I just had to power through it, doing it more and more, day by day. It also kinda sucked that ~40 wires needed to make the engine run were cut by the morons that pulled the drivetrain from the donor. Ford Service DVD was priceless, there.

And trust me, the bus build will be plenty fun. I've got my eyes on a Subaru SVX 3.3L Flat6 for it.

Hit me up on the MEV forum if you need any help, too.

-Chris

[golftdibrad]

Ha! I had plenty of time to enjoy the build. Plus 400 miles to play with it and work out any bugs. I'm sure I have ADD or something and it kept me from finishing the car as quick as I wanted. I just had to power through it, doing it more and more, day by day. It also kinda sucked that ~40 wires needed to make the engine run were cut by the morons that pulled the drivetrain from the donor. Ford Service DVD was priceless, there.

And trust me, the bus build will be plenty fun. I've got my eyes on a Subaru SVX 3.3L Flat6 for it.

Hit me up on the MEV forum if you need any help, too.

-Chris
will do. Subie into aircooled vw=fun. I'd kinda like to do that to a formula vee.....

[golftdibrad]

just had a brain storming session with co-worker about the freaking steering, going to use some shaft collars and a rod end. Cant believe i didn't think of it before!

[golftdibrad]

OK, been doing work, Son. First, clean up. Many projects have been started and finished in the garage besides the rocket and it was time for a cleanup.

before:
http://www.exocars.net/attachment.php?attachmentid=5461&stc=1&d=1302909619
after:
http://www.exocars.net/attachment.php?attachmentid=5460&stc=1&d=1302909619

now, to actual work. In order to avoid a fiery death I'm redoing the steering AGAIN. I was never really happy with it.

START. get shaft from england. 15mm, expensive, not compatible with anything.

Lucky for me, i have a buddy with a lathe and i know how to use it :D
center drill
http://www.exocars.net/attachment.php?attachmentid=5462&stc=1&d=1302909619

chuck it up
http://www.exocars.net/attachment.php?attachmentid=5463&stc=1&d=1302909619

turning shaft down to 9/16th or 14mm
http://www.exocars.net/attachment.php?attachmentid=5459&stc=1&d=1302909619

finished
http://www.exocars.net/attachment.php?attachmentid=5464&stc=1&d=1302909619

now for the focus end of things. Did you know....that shaft that goes to the column is not round? previous attempts have screwed the end up alot too.

so, make a hole in the center of it:
http://www.exocars.net/attachment.php?attachmentid=5466&stc=1&d=1302909619

skipped alot of steps on the lathe again here, but here is the result:
http://www.exocars.net/attachment.php?attachmentid=5465&stc=1&d=1302909619

also did alot of investaging about shifting the thing..... did you know mcmaster sells 6 ft push pull cables, and that the distance from the shifter to the trans is.....6ft :D

[golftdibrad]

So, I got the steering welded up in its final incarnation. I'm going to pull it off again tonight to paint it and then we'll put that shit to rest.

Steering feels smooth, very minimal wiggle, strong.

http://i510.photobucket.com/albums/s342/golftdibrad/car%20work/Rocket%20Build/th_VideoApr2190305PM.jpg (http://s510.photobucket.com/albums/s342/golftdibrad/car%20work/Rocket%20Build/?action=view&current=VideoApr2190305PM.mp4)
http://i510.photobucket.com/albums/s342/golftdibrad/car%20work/Rocket%20Build/PhotoApr2190255PM.jpg

I'm going to get on my soapbox here for a minute. This has been a HUGE sticking point for me on this project. I think that in order to make the kit easier for the end user (esp us state side guys that can't get this stuff on this side of the pond) the parts and/or directions for interfacing the focus column to the rack more complete. I spent about an extra 100 bucks on parts and shipping from Europe. I was lucky to have access to machine tools or it would have been another several hundred dollars for machine work.

Here is a picture of the part that should be included or have instructions on how to make it: http://i510.photobucket.com/albums/s342/golftdibrad/car%20work/Rocket%20Build/mevsteering.jpg
It was pretty much all I had to go by from the build manual.

I know some time has passed since I got my kit and perhaps this has been improved, I just wanted to post my comments and impressions. Stuff like this is going to come up in any build.

So... the list... in order.

1. mount seats
2. do things necessary to start the engine.
3. ??????
4. Profit.

but seriously, after the engine runs and I bleed the brakes the damn thing can drive. :D

[cordycord]

The cars are a definite case of "live and learn". It's almost like the lust of owning an E-type Jag, knowing that beneath lurks a temperamental 12 cylinder with Lucas electrics. :D

Not that it matters now, but I've seen past steering columns welded up where the welded connections were cut diagonally. In other words, the outer weldment is cut at an angle so there's more weld area, and if any weakness were created by the weld it would be spread across a greater area.

[golftdibrad]

The cars are a definite case of "live and learn". It's almost like the lust of owning an E-type Jag, knowing that beneath lurks a temperamental 12 cylinder with Lucas electrics. :D

Not that it matters now, but I've seen past steering columns welded up where the welded connections were cut diagonally. In other words, the outer weldment is cut at an angle so there's more weld area, and if any weakness were created by the weld it would be spread across a greater area.

yea, i saw some shit at a custom car show awhile back that made me cringe. This is way strong, way stiff; i am way happy with it.

Tome to go mount stuff... like seats, radiator, gas tank.

[golftdibrad]

So, did lots of random projects today. First on the list: gas. The suplied fuel tank look kinda small to me so I measured it. It will hold 6.5-7 gallons. Assuming a cruise mpg of 30, that a decent range of 180 miles or so. Thrashing..lets say 10 mpg (this is realistic based on the miata....) so thats 60 miles. Motorcycles do about that and this is like a big bike so i'll roll with it.

So we have to extend the focus fuel.....thing to fit the deeper tank. THe instructions say to use 6mm threaded rod but here in 'amerika we use 1/4-20 like a boss.

http://www.exocars.net/attachment.php?attachmentid=5494&stc=1&d=1303609285

Also took of the steering for the LAST time (hopefully) to paint it.

http://www.exocars.net/attachment.php?attachmentid=5495&stc=1&d=1303609285

That is about as long as it gets and its just enough. I am worried about leaks. If this all sucks the car will get a standard return style fuel system, MAP/VE tuning via megasquirt, and an FIA fuel cell with extreme quickness.

http://www.exocars.net/attachment.php?attachmentid=5496&stc=1&d=1303609285
(TWSS)

The 'extender' to get the transmission at the right height is weak sauce now with no sleeves and open ends. Been on the to do list for awhile.

http://www.exocars.net/attachment.php?attachmentid=5497&stc=1&d=1303609285

and now its on the 'DONE' list

http://www.exocars.net/attachment.php?attachmentid=5498&stc=1&d=1303609285


Other things I did that are not pictured: I took out the seats and sliders to paint where i welded them in, drilled all the holes in the drivers seat, cleaned floor of the car, made a list of hardware to order, and flipped the brake calipers in the rear right side up.

This is actually interesting, I'm not going to use the handbrake setup. I'm going to use a manual line lock for a parking brake. I don't need 'emergency' brakes since I have to completely independent hydraulic circuits with independent fluid reservoirs. the only way the brakes could fail is if the pedal breaks and if that happens your pretty much boned anyway.

So....maybe some more work tomorrow, but maybe not. Definitely more this week :D

[Nigel]

If you wish to get full use of the tank capacity I suggest you fit the slush plate.

nigel

[golftdibrad]

If you wish to get full use of the tank capacity I suggest you fit the slush plate.

nigel

looks like the focus stuff has one built into the pickup?

[Nigel]

Hi Brad,

Below are some pictures, I found that to get full use of the tank I had to remove the plate that is bonded/stuck inside the original fuel tank and attach it to the pot. (See Below)

http://i177.photobucket.com/albums/w232/NigelP21/MEV%20Sonic%207/Modifications/P1000123.jpg

http://i177.photobucket.com/albums/w232/NigelP21/MEV%20Sonic%207/Modifications/P1000118.jpg

http://i177.photobucket.com/albums/w232/NigelP21/MEV%20Sonic%207/Modifications/P1000112.jpg

nigel :)

[golftdibrad]

First off, thanks for all the pics and advice.

I think perhaps this is one of those 'detail' parts where the focus is not a world car.

this bottom part on your car:
http://i177.photobucket.com/albums/w232/NigelP21/MEV%20Sonic%207/Modifications/P1000112.jpg

and on mine

http://www.exocars.net/attachment.php?attachmentid=5496&stc=1&d=1303609285

are a little different, but they seem to do the same thing. the little slit is the suction of the pump that overlaps with the inside of the baffle, and the discharge is into that baffle. the bottom is otherwise sealed, and overflow through the discharge is through the top. Conceptually they work the same even if the parts are a little different :D

Hi Brad,

Below are some pictures, I found that to get full use of the tank I had to remove the plate that is bonded/stuck inside the original fuel tank and attach it to the pot. (See Below)

http://i177.photobucket.com/albums/w232/NigelP21/MEV%20Sonic%207/Modifications/P1000123.jpg

http://i177.photobucket.com/albums/w232/NigelP21/MEV%20Sonic%207/Modifications/P1000118.jpg

http://i177.photobucket.com/albums/w232/NigelP21/MEV%20Sonic%207/Modifications/P1000112.jpg

nigel :)

[Nigel]

How was the pot attached inside the Focus tank then ?

nigel

(PS:- How's the build going ?)

[golftdibrad]

How was the pot attached inside the Focus tank then ?

nigel

(PS:- How's the build going ?)

I don't remember.... I think it just might have hung there from the top only.

[petik]

Brad, how's the build going? She running yet?

Just wanna say you're my hero man. I've been doing DE's with my turbo-focus around texas for a while now and when I discovered to Rocket I was super excited. This thread is an excellent reference for a build as I've never done a kit car build before though I've done enough fabbing and welding to tackle it. I'm getting ready to place my order for one and will definitely be talking to MEV about the issues you ran into and see if they've addressed them. I may bother you over PM if you don't mind.

[golftdibrad]

feel free to send a PM. The kit has a price on it right now, IE for the right price its for sale. I've already had a few offers, so if your interested we should chat.....

[golftdibrad]

sold to petik.

[Nigel]

Its a very sad day when one has to sell ones part finished kit :cry: but lets wish the new owner every success with his or her new dream build :D

nigel

[petik]

Thanks Nigel. I definitely plan on keeping up with documenting my progress as Brad had. For now I barely managed to roll the chassis into the garage last night - now I have to go lay some hardwood floor in my house as a "payment" imposed by my darling wife for this toy :)

I'll start a new thread with the goings as I get working. I'm sure I'll have lots and lots of questions...

All loaded up on the truck yesterday morning
https://lh5.googleusercontent.com/-GudwK-MEpw0/Tpx5y8IlaWI/AAAAAAAACvY/i6WgM0Llvco/s640/IMG_20111016_083119.jpg

-pete