Plan of Attack

Having built and modified several cars in the past, with this build I knew it was vital that I laid out exactly what I wanted to do before I even picked up a saw or file.

I’d had projects that started with live axles, swapped for IRS then back to live. They’d had Pinto’s, Nissan Turbos, Rover V8s and Chevy Smallblocks before even a key had turned in the ignition. I am my own worse enemy.

Before I designed this chassis, I had some initial investigation and purchasing to do.

I always wanted Sierra Cosworth 4×4 running gear. With adapter plates available for the Ford gearbox to fit almost anything, I’d have a large engine choice.

However, Sierra 4×4’s are getting thin on the ground and prices for even rough ones are starting to rise quite swiftly. Staying with the Ford family, the Jaguar X–type is a satisfying car to drive. The only problem is the Mazda derived Duratec V6 is mounted sideways and the only box to fit it longitudinally is the Getrag 221 (from the S–type) and that is 2wd. Size, weight and power wise the V6 is perfect (lighter than a pinto and twice the power). The MT–75 4wd gearbox from the Sierra is a great box but the bellhousing is integral. Therefore, a custom adapter plate would need to be sourced or fabricated to mate the two together. Rumour has it, some Transit based V6 ambulances have such an adapter plate.

So it’s either Cosworth 4×4 or a Jaguar Duratec v6 / Sierra combo….

I’ll let Fleabay be the decision maker. (I hope it’s a Duratec ☺)

Rover V8 Sierra Clutch

As you can see in the picture above the Rover V8 Clutch (right) is much bigger than the Sierra clutch left. How did I quickly and very cheaply solve this problem? The Rover V8 has a 272mm clutch. The Sierra has a 241mm clutch. The splines are also different between ...

Rover V8 to MT75 Adaptor - part 4

This is an MT75 4x4 gearbox from a 2.0lt turbo Sierra Sapphire Cosworth. The bell-housing bolt pattern is much smaller than that of the Rover V8. Unfortunately, the bell-housing is not removable, so I am cutting it off with a hacksaw. It may seem a little Low-Tech and indeed there ...

Kit Car Tube Chassis

This Haynes Roadster Kit Car Tube Chassis is a 44-0.2 4 inches wider 4 inches longer -0.2 inches less tall The gearbox tunnel hasn't quite ended up as I would have hoped. No doubt it will look better once the front section has been re-added. I think this exercise has proved to ...

Rover V8 to MT75 Adaptor Plate - part 3

I've been having fun converting my Rover V8 to Sierra Cosworth MT75 4x4. When you find  the correct solution to a problem, sometimes it makes previous efforts look like a waste of effort. Rover V8 to MT75 gearbox using LT77 bell-housing - Part 1 Rover V8 to MT75 gearbox using BW35 ...

Rover V8 to MT75 Adaptor Plate - part2

Will the Borg Warner 35 Auto bellhousing mate to the MT75 manual? Can I cut it up to make a Rover V8 to MT75 adaptor plate? I was having one of those mental blind-spots. For some reason, because I was trying to mate the Sierra Cosworth MT75 manual gearbox to the ...

Rover V8 to MT75 Adaptor Plate

The goal is to mate the Rover V8 up to a Ford MT75 gearbox. Therefore I had 2 choices: Use an Rover V8 to MT75 adaptor plate Use a complete LT77 bell-housing and remove the integral MT75 bell-housing and weld on a mounting plate. Seeing as I could not find anyone ...

Haynes Roadster - Gearbox Tunnel

Strength wise, I always thought the standard Locost gearbox tunnel was a neglected area. I've tried to add as much triangulation as I can. Obviously, given the size of the Cosworth MT75 gearbox and the already limited interior space, there were quite a few design limitations. Luckily, the missus and ...

Sierra Front Propshaft

The 4x4 Ford Sierra Cosworth Front propshaft needs to be extended. Because of the 19” front wheels the front diff is mounted higher in the chassis. This means the propshaft now travels upwards towards the front of the car. If I angled the front diff down 1.5 degrees then I could gain ...

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