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 in 3 planes. This would not be possible with paper drawings without hours of trigonometry. I cannot recommend using CAD drawings enough, I’d say they were essential.

Using this method was initially extremely slow, but as the number tubes grew, the time for each tube dropped considerably. We were surprised that by using this method, we were often less than 0.5mm out, on dimensions not initially marked on drawings.

Tools that I found definitely worth the investment, were digital angle finding protractors and digital spirit levels (available cheap on Fleabay). Other much simpler and traditional devices such as large internal and external calipers were an almost instant way of comparing dimensions.

 

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 ...

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 little close ...

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 ...

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 ...

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 answer that. The unfortunate answer ...

Haynes Roadster - Rear Chassis

Now I have a flat table, progress on the chassis has been swift. In fact I surprise even myself. With only 4 hours work, Saturday and 7 hours Sunday the rear of the chassis has totally transformed. Armed with a bunch of tubes I'd cut and filed during the week, the chassis ...

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