2005 Kia Sorento into a 1932 Ford Hot Rod

I don't know how to multi-quote but to answer most of the questions in one post: 

Chassis has been modified, both ends have been cut off to fit the body so unfortunately I can't just call it a rebody.

Even if this wasn't in need of an IVA I'd still be using the rules as a build guide so it's safe for the road.

A man called Kev Rooney has created some very useful legal guides and if he doesn't know it isn't worth knowing.


It's really humbling to see all the different conversation concerning all parts of this build, gives me confidence that should I have a problem somebody on here will have a solution!

Now then where I had got up to? Ah yes starting to reconnect controls because for some reason everything is too long or too short...

Having made and fitted the grille stay bars it was time to tackle re-connecting the steering wheel to the steering rack. There was part of the column which bolted in between the two so the plan was cut that up, make an additional flange, find and weld some thick wall tube in and viola done... this then escalated.

Extension shaft was made and welded up, but the length meant it was a bit wobbly (so many innuendoes...). The distance between the two fixed points was a bit too far apart now, so the extension shaft was cut, round bar fitted inside, welded and cross bolted into one half and just bolted into the other so it can have a flanged bearing fitted over it. 







Added an upright to mount the bearing too and bolted it top and bottom and after aligning the CV joints the steering feels just as smooth as before so super pleased with this. Will be fitting high tensile bolts when I come to do final assembly ofc. 

Braithwaite. 

Yes if you get an age related plate you can then transfer a private plate on to it.
Ask Kev if you need any specific info on it.

Loving the discussions going on here, for once it hasn't descended into madness, the fact we all have a differing view on the rules screams that they need to be reviewed and 100% clear.

I am loving the build the more I read the better its getting. All the looks and all the MPG's and all the power to weight! What's not to love.

I think getting in contact with them and getting the word as they see it would be the best thing to do.

Build to their word, then if an inspector fails/complains, drag out the written reply and "it says here . . ."

Non-transferable means the original VRM allocated to the vehicle can't be transferred off onto another vehicle. However it doesn't stop you applying a private plate "over the top".

Lots of people confuse - sometimes deliberately - the car's physical identity and the attendant BIVA concerns, with the registration number.

Anyway... leaving the legalities to one side. 

Now that we could steer the thing and make it much easier to push around the workshop it seemed a sensible idea to look at making the damn thing stop.

One benefit of using something big and heavy like the Korean Escalade (as I affectionately call the black tow rig) is the brakes on it are gurt huge and won't need upgrading. If they can stop 2 tonnes of 'fun' then something half the weight is no bother. 

While the wheel end of things is fine the foot end provided some head scratching... as you can probably guess, a '32 Ford firewall is narrower than a Kia Sorento's and someone has put an engine right close to it. The original Master Cylinder (M/C from here on) and servo were huge, the servo must have been the size of a dinner plate if not larger prevent us from moving the clutch over to clear the engine. Fortunately in the family we have a few cars laying about, first we pillaged my 1982 Morris Ital (that's the next project and thread.) for it's brake parts but that was too long as the M/C sits almost directly under the steering column. Measured a few more modern cars but all the servo's were huge, then we found a Micra K11 servo is smaller in depth and diameter. 

I ordered one and by sheer luck I discovered it bolts straight onto the Kia pedal assembly! I had to shorten the clevis but otherwise is a bolt on fit!! RESULT... almost... 



Next I had to find a M/C because I can't use a K11 one as they are drums rear and the Kia is discs all round. I did some reading on Micra forums and they suggested a Citroen C3 M/C but it meant opening up the servo to rotate the stud alignment, but then eBay suggested another M/C and it was smaller, meant for an all disc car and the stud holes appeared to be in the right place, off a 2016 Nissan Pulsar. Took a gamble and after massaging the hole (  Lol) it turns out it bolts right together! The push rod may need some adjusting but that's easy enough to do! 

So that's 2005 Kia Pedal assembly, bolted to a Micra K11 Servo which is then mated to a 2016 Nissan Pulsar Master Cylinder... hopefully this works otherwise it could be a right shitemare! 










Obviously only attached to the mock up bit of wood as the bulkhead shenanigans are a story for another night! 

Braithwaite.

Next job, well another job as I've got a little out of sync with everything whoops.

Once we'd made the frame the body sits on we used some plywood to make two floor templates, plan is to make the floors out of 1.2mm steel but for the time being we're using the ply so we then know what size and shape to cut out. 

The front seats being used for mock up are from my Morris Ital as well as the handbrake lever and mount... The reason for cutting it out is that the tunnel in the Ital isn't big enough for what it's going to be getting shoe-horned into it but that's a project thread for another day. The hand brake took some positioning as the mock seats are about as wide as we can sensibly get away with and the gap between them is only big enough for the seatbelts, not sure what the real seats will be, bomber seats feel over played but if that's the only thing we can get that'll fit then it is what it is.




There was a bit of clamp mocking up with the Kia handbrake but it was just too big and bulky.



We used all this to get a better idea of where everything needs to be in terms of controls being as comfortable as it can be, it won't be continent cruiser but I aim to make sure it's comfortable enough for a long drive to and from a car show. 

In case you can't tell I'm enjoying this project, I've rebuilt cars and while you have to over come problems there's more constraints, the solutions are much more straight forward. The downside is you'll create a solution then have to cut it up as something else has conflicted with it hahaha! 

Braithwaite (not sure why I keep signing these off, but just feels right...)