The hubs have been machined to accept standard Corsa B solid discs rather than machine the discs to fit the hubs. This will make life easier in the future as the discs are a consumable parts and this way standard replacements can be fitted. I am using Punto MK2 front callipers and VW passat rears. I am going to have to machine the rears to fit under the wheels but I am still going to have to go up a wheel size to 13".
After much deliberation I decided on using MG Midget wheels as they are the correct stud pattern and there is not much room under the arches for anything bigger. Regrettably the down side to these wheels is that I had to use spacers to clear the callipers.
The standard master cylinder is not man enough to power the callipers so I acquired one off a 05 Mondeo. This was a bad move as it has some funny sort of return valve on the end that goes into the servo (that I am not using) so a day was spent machining bits to make it work with the rod that comes off the Reliant brake peddle. Think If I did it again I would but a better solution than make the free one work!
Used AtoCAd to design the brackets for the callipers. The brackets are 6mm thick steel and only required a little filing to make them fit although this was probably down to my drilling inaccuracies rather than the drawing. I had square plates cut at a local fab shop and used a hole cutter, drills and angle grinder to make the shape. Total cost of brackets including buying the drills and hole cutters was £16 each.
Machined Callipers off e-bay. told they would fit under 13" wheels but had to take more meat off them to get them to fit.
I got the car off a friend of mine who didn't have the time to do it. I then tied him and his workshop up for a couple of day by getting him to help me machine some bits up. Ironic I know. Thanks Chris Buxton.
Next job was to remove the back and put the bulk head in as I want it a s a pick up. Also started rubbing it down ready for paint.
Rubbing down old paint has to bee the most boring job ever so i decided to make a little cross piece for the back of the bulk head to square it off and provide a support for the bed cover.
Also removed all the wiring from under the bonnet to tidy things up and make security a little better.
Every thing is now sanded and ready for primer. I was really lucky that the bodywork was in great condition with no crazing.
Couldn't resist a little mod to the fog lamp at the rear.
Finally in primer! In fact this is why I am posting these photos as I am waiting for the primer to go hard before I rub it down and do the base coat and clear coat.
Thanks Speedle but I can't really take too much credit for the bed as these things are designed to be an Estate, Van, Pickup or "Sports convertable just by bolting or un-bolting different bits provided.
Hi Qwerty, Other than the brakes and nice paint job the engine has been reconditioned by the previous owner who I know. he tells me that it has over sized pistons and a hot cam. They use these engines in Formula Rebble racing, I think they are getting around 50BHP out of them reliably. Not big numbers but quite respectable in something that is around half a tonne. I was tempted to put a bigger engine in but quite like the idea of somthing fun that still does 50mpg!
Got the base coat and clear coat on now so paint work done with the exception of the tail gate and bonnet. Also found a way of getting the pictures to stay (had to open a Photobucket account). It took me longer to sort the photos than it did to paint the car!
The engine was nice and clean before I started the epic rub down so should clean up easy. Think I will paint the rocker cover and radiator black and replace some of the long rubber pipes with copper to tidy things up.
The sun roof has a red coating on the inside that is stronger than dried on weetabix! It won't come off with paint stripper or 120's sand paper so I will either have to get it sand blasted (If the glass wont shatter?) or maybe get a vinyl chequered flag to go over the top. Any suggestions welcome.
A bit more work to report. Firstly these things never came with a cowling for under the steering column so always looked as if they had just been stolen with wires hanging down. I decided to address this by fitting a Mini one as I had one or ten hanging around. Thought it would be quite a simple job bit turned out to be an epic one. I had to move the ignition switch further up so no steering lock any more. Then as the stalks are different I had to elongate the holes for them, cut a hole in the top for the column mount and finally make a bracket for the two pieces to screw through. Done, not quite as the dash will not fit now so had to completely modify the dash by cutting it to bits riveting a strengthener in over the column and making an aluminium plate to house the gauges as they are now in a different location. The knock on effect is I now have to put all the switches in the centre console as no room on the dash. On the up side I did get to fit a rev counter just in case I can't here the engine! Next job is to fit a head lining, another thing these never had. This was quite simple but had to use contact adhesive and that always brings out the turrets. I then went on to build the doors up and window frames giving all the individual bits a coat of satin black along with fitting the windscreen and a few other bits an bobs.
Not far off completion now. Will paint the front and rear bumpers next and finish of the modified centre console for the switches. I may even take the dash back out and spray it all black?
I ended up making ally hubs from scratch on my kitten as the lack of meat on the original hubs to support the disc means a tiny imperfection on the face becomes a big vibration when you brake hard I did a disc conversion for a 10" wheel using a laser cut disc and spigot welded on the back of the hub that worked perfectly
Post by composimmonite on Nov 24, 2014 8:50:12 GMT
Ensure you carefully check the roll type bar that is bonded into the bodywork and the seat belts attach. It's open at the bottom end and rusts badly. On my Fox the rust was so bad the seat belt upper mount simply pulled though the bodywork so in the event of an accident the seatbelt would have given way