Side tracked

Not wanting to simply bolt together a bunch of components from a list of donor vehicles, just because they fit, the intention is to use modern suspension analysis software such as Kangaloosh to model all I can.

In order to analyse anything, it became annoyingly obvious that I would need every single part of the suspension first hand. Every single, seemingly trivial dimension became a stumbling block. Luckily, I now have everything measured and modeled. – I think

To complicate and lengthen the process of measuring everything, I decided to implement 4×4. Why? Not because I want to go rallying, simply because I live down a muddy track that ices over 4 weeks a year.

The goal is to use all around A-arms and rising rate, push rod suspension.

Forgetting that the body will not look anything like a Locost or Haynes Roadster, the suspension design will be directly compatible.

Once I have the front suspension modeled, I can search for the last vital component – the steering rack. It’s a little more tricky being 4×4, as the rack may want to pass right through the Sierra Cosworth front diff or custom front prop-shaft.

Sierra 4x4 Cosworth Front Suspension

In this case, the venerable MK2 Ford Escort Rack might not fit the bill. It maybe a front rack, a rear rack, long short – only time and sums will tell.

The rear suspension will be a little tricky too, as it’s asymmetrical. Luckily, there should be a small amount of play in the c.v. joints.

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.

MT75 4x4 Haynes Roadster

I've had a trial fitment of the MT75 Ford Cosworth 4x4 gearbox and it was a little tighter than I hoped. The gear selector mechanism; which will be removed and replaced; fouled the tunnel but this was a known issue. More importantly, the gearbox's transfer casing is a

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

Step One

The rear of the chassis originally had the most twist and dimensionally bore little resemblance to the drawings. New tubes were cut, from heavier gauge steel and then welded into place. By entering all of the design into CAD first, it was simply seconds to gain any position

Starting Again - Cutting It Up

It was decided that, although individual measurements often had small errors compared to the drawings, all these minor errors added up to huge errors. There were 27mm differences from one side of the chassis to the other and it had over 30mm of twist. Our goal was to have less

Chassis Type

Having quickly established that most pairs of measurements were different, the next task was to check all measurements against those published. In the process, establish exactly what type of chassis I´d purchased. The fact that measurements were different to those published would not be of major concern; as no

Chassis Collection

Having debated building a 'super seven' style car for decades, when a chassis came up on ebay with a reserve of only £0.99, temptation and curiosity took hold. The auction finished with only 3 bids at £56.55. Surely this was a bargain??!? A 550mile round trip would

Suspension Mounts

I've done the mounts for the front suspension A-arms and the Sierra Front 4x4 mounts. I'm not the first to mount a 4x4 front diff into a Haynes Roadster and at the speed I work at it's not surprised. It's not just a case of

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