Kit Car 4×4

I now have all the pieces cut ready to take to the specialist TIG welding company. It’ll look much better once all the sticky tape is removed!

There was a stage when I was worried that the assembly would be a little weak, yet this mock-up is roughly stuck together with tape and is so totally solid, minor adjustments in the structure are impossible. There is no rattle, squeak or flex even when I resort to the rubber mallet to adjust alignment. If a bit didn’t fit, the only option was the file or start again. It’s light and sits flat and true on the chassis.

It’s not finished, but I’m pretty chuffed 🙂

On Friday it was -9.5°C in the workshop, so progress hasn’t been lightning quick.

Building a 4×4 Kit Car isn’t going to be easy. Building a 4wd sports car is going to be even harder. Modifying the Sierra front differential has been slow; so far; but surprisingly easy. The only hard part has been moving around in a thick coat and gloves.

There are a few more pictures in the gallery.

Published: 5th February 2012

Sierra Front Differential Part II

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I'm getting better at the CAD stuff. The latest item to get drawn up is the Sierra Group N front stub axles. When I started learning AutoCad this would have taken me days if not weeks to draw. These took about under an hour to measure up and they ...

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I've started to mock up the front 4x4 system. In CAD everything looked extremely tight. I spent ages moving components back and forth to get everything to fit. So far, in the mock up. There looks like bags of room. When I say 'bags' I mean a good 6-7mm! ...

Seventh Heaven

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Ford Sierra Front Differential 4x4
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