Haynes Roadster/MX5 scratch build

[ianrobb]

I've wanted to build a Lotus 7 type car for several decades now. I'm pushing 40, and no better time than now to start.

 

I started with a McSorley 442E, Figuring that the bigger it is, the more likely that my "larger" friends could fit. After I built the basic frame, I started looking into the suspension design, which was giving me anxiety, since I wanted to use NA/NB Miata diff, axles, uprights, etc. I was told that the 442 was too wide to use stock axles. I didn't want to go down the rabbit hole of custom length axles, designing my own control arms, mounting points and geometry. I have a full time job, a 10 year old son, and a baby girl, I don't have time for all that.

 

So, I cut it all up, and used the pieces to build a Haynes Roadster, using the Saturn Sports Car plans to adapt to MX5 running gear. This way, most of the work was done for me. Planning on using a Ford Duratec 2.3, NC Miata 5-speed, NB Miata rear diff, axles, uprights, brakes, steering column, and other small bits.

 

Oh, and don't worry, the irony isn't lost on me, that the time spent cutting up one frame, and building another probably took longer than just sticking with the first frame.

 

Anyway, I'm almost ready to start fabbing up some control arms.

 

 

[JohnCh]

What are your plans for the engine? Are you keeping it stock or going with changes to the induction or internals?  Do you know yet what you’ll use for the ECU?

[ianrobb]

34 minutes ago, JohnCh said:

What are your plans for the engine? Are you keeping it stock or going with changes to the induction or internals?  Do you know yet what you’ll use for the ECU?

Stock internals, for now at least. It's rated at 160 crank HP stock, but I'm planning on using Cosworth style intake, freer flowing exhaust, plus without power steering and A/C, I'm expecting to be around 180 crank HP. Not planning on turbo or supercharger, I want to keep it light and simple. My ultimate goal is about 200WHP, all motor, probably with a 2.5L Duratec. 

 

Stock ECU, with immobilizer delete, possibly a mild tune. 

[IamScotticus]

I would like to know how Haynes goes from Ron Champion to Chris Gibbs, for the same car.

I found out.  The Champion build is escort based.  The Gibbs is Sierra based.

I do hope there is a nod to Ron in the later. 

Edited September 13, 2024 by IamScotticus

[ianrobb]

8 minutes ago, IamScotticus said:

I would like to know how Haynes goes from Ron Champion to Chris Gibbs, for the same car.

I found out.  The Champion build is escort based.  The Gibbs is Sierra based.

I do hope there is a nod to Ron in the later. 

The Gibbs car is also referred to as a +221, 2" longer and wider, 1" taller, than the Ron Champion version.

[MV8]

I found the Gibbs plans to be the same length as the 442 in overall chassis length. Have all the chassis dims compared in my sig on locostusa, which has once again crashed.

[ianrobb]

4 minutes ago, MV8 said:

I found the Gibbs plans to be the same length as the 442 in overall chassis length. Have all the chassis dims compared in my sig on locostusa, which has once again crashed.

Interesting. I've never compared the 2 dimensionally. I just know they Haynes is 2" narrower than the 442. The seatback is also lower on the 442.

[MV8]

A few years ago,I thought it would be interesting to compared all the plans I could find for a few basic dims, but I don't think I ever posted it:

 

 

 

[ianrobb]

Ok, time for an update.

 

Progress has been slow. Shortly after my initial post, I acquired a $200 2006 Mercedes S-Class project. Really nice car, had some shifter/transmission issues. This car consumed a lot more of my time than I wanted. Then, on January 15th, that car was rear-ended and totaled while driving to buy suspension parts for the Locost build. I got the insurance payout for that today.

 

Anyway.

 

I bought a new welder, a Primeweld with TIG capability(TIG not yet used). I finalized the front/rear suspension geometry, built 1 front lower control arm(partially built in photo), and am almost done with the rear section of the frame, just need the rear "hoops". I have set September 1st as the deadline to have a rolling chassis. I hope to beat that time.

[MV8]

You may want to get your bushing order in to MK if they can ship quickly.

https://www.mksportscars.com/collections/bushes-601?page=2

[ianrobb]

I will be using Energy Suspension bushings. I do need to place that order though.

[IamScotticus]

Whatever you do,

 

DONT STOP!

 

Kids national championship game, 

Nope.

House fire,

keep perishables in a shed.

Wife wants a Hawaii trip 

Nope

Cancer diagnosis 

It can wait a few more months 

Parent dies,

Tell them they can't die until you finish 

 

If only I took my own advice. 

The curse is real.  Everything imaginable will pop up to divert you from the project.  

[MV8]

4 hours ago, ianrobb said:

I will be using Energy Suspension bushings. I do need to place that order though.

Did you change the Haynes bush shell dims? Which Energy set? Are they a direct replacement for the MK bushes in the Haynes shells or will you be turning the Energy bush set to fit? Inner sleeves?

[anduril3019]

1 hour ago, IamScotticus said:

Parent dies,

Tell them they can't die until you finish 

Great minds...

One of my goals is to get mine done while my dad can still drive, or at least go for a ride in it. Seems to have a few years in him still. Photo is circa 1967.

[ianrobb]

9 minutes ago, MV8 said:

Did you change the Haynes bush shell dims? Which Energy set? Are they a direct replacement for the MK bushes in the Haynes shells or will you be turning the Energy bush set to fit? Inner sleeves?

I'm using the 9.9107 bushing. The shell is 1.5x0.125, I think. 1/2" bolt.

[ianrobb]

1 hour ago, IamScotticus said:

Whatever you do,

 

DONT STOP!

 

Kids national championship game, 

Nope.

House fire,

keep perishables in a shed.

Wife wants a Hawaii trip 

Nope

Cancer diagnosis 

It can wait a few more months 

Parent dies,

Tell them they can't die until you finish 

 

If only I took my own advice. 

The curse is real.  Everything imaginable will pop up to divert you from the project.  

Filling my social media and YouTube with cars like this helps keeping me motivated. Plus, I have other projects that cannot be started until this is done. I have plenty of drivers to keep me going. Adhd meds don't hurt either.