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Andy’s Starter Kit build


Yorkshire_Pudding

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Yorkshire_Pudding

Also collected some more parts recently. 
 

The main item being the caterham (MX5) gearbox. This means I don’t have to cant the engine by 10 degrees to use the standard NC MX5 gearbox but instead can run everything vertical and inline. The caterham gearbox uses the standard MX5 NC internals and ratios but is housed in a slimmer and lighter aluminium casing with a separate bell-housing. 
 

The gearbox I got was from a Sigmax race car so had the bell-housing for a sigma. This has a slightly different starter fitment and bolt spacing  to the Duratec.

 

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The next big purchase was a Quaife ATB diff with drive flanges for a steal!. I’m planning on getting this fitted in the upcoming weeks.

 

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I have also decided to go with polybushes kit for the rear suspension. I made a pressing tool to push the metelastic bushes into where the lower wishbone attaches to the upright. It was a fairly simple design and works a treat.

 

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I have run into a problem with fitting the rear wishbones. The wishbone seems to be slightly wider set than the wishbone mounts meaning the crush tube needs to be pushed in more towards one side. This means the nylon washers can’t fit on both sides of the crush tube. After speaking to Westfield they have suggested opening the brackets up by around 0.5mm as they have already been tightened up to check the wishbones fitted by Westfield.

 

Cheers 

Andy

 

 

 

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Hi Guys   Well, I decided to place the order with Westfield for my MDV Starter kit on the 28th February 2020 which was due for collection on June 26th. However, due to the current situation

Got round to doing more work on the car today. I started with fitting the rear (right) upper wishbone and then the shock absorber. I intended on fitting the uprights and hubs but ran into a problem wh

Well I’d like to have thought I was well into the build by now but due to an increasing work and college load progress has been super slow. So, this update is just to share what parts I’ve been collec

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Yorkshire_Pudding

I have finally got round to fitting the rear suspension. I decided to go with poly bushes on the rear (this may be a poor option as the polyurethane wall thickness isn’t very thick for shock absorption). The first job was to flash the inside of the wishbones with a wire brush. I had to be quite careful doing this as too much material off means the wishbones would be scrap 😬

 

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I then pressed the outer polyurethane sleeve into the wishbone with the help of red rubber grease. Once in, I then pressed the crush tube into the polyurethane sleeve with the power flex grease. I had to slightly bend out the brackets to ensure everything would fit. The lower wishbone was a bit of a dog to get on as the nylon washers kept falling off when placing the wishbone into the brackets. 

 

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I then cleared the rose joint threads on both wishbones using a 1/2” UNF taper and plug tap. The top wishbone went on without a hitch thankfully.

 

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The next job was to fit the rear shock absorber. Am I right in thinking the Protechs with the bush shown above don’t need the two washers between the bush and the bracket? Anyway it’s fitted up now for the time being.

 

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Next job was to fit the upright. Quite worryingly I found some aluminium shavings in the back of the upright which would make quite the mess of the bearings if they got into them. 
 

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The upright also went on without a hitch which went down well 😂 it’s been pointed out I have missed the tank brace bar out which I’ll get on with fitting tonight.

 

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Anyone got any advice for the torque settings for poly bushes when it comes to being on all 4 wheels?

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corsechris

You can torque up the poly bush fixings at any stage as the crush tube rotates freely in the bush, unlike a metallastic type where it’s bonded.

 

Don’t know the figure though, soz. :)

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Dave Eastwood (Gadgetman) - Club Secretary

You’re right re the packing washers, the two washers are normally needed with the standard Gaz dampers, but others have wider ends to them so may not need any washers, or sometimes just one, to take up the slack.

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jonjh1964
12 hours ago, corsechris said:

You can torque up the poly bush fixings at any stage as the crush tube rotates freely in the bush, unlike a metallastic type where it’s bonded.

 

Don’t know the figure though, soz. :)

Should be the same as the elastomerics as you torque against the centre tube

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Yorkshire_Pudding
On 18/10/2020 at 21:14, corsechris said:

You can torque up the poly bush fixings at any stage as the crush tube rotates freely in the bush, unlike a metallastic type where it’s bonded.

 

Don’t know the figure though, soz. :)

 Ah right yeah that makes sense, I’ll get that done tomorrow then, thanks 👍🏻
 

22 hours ago, Dave Eastwood (Gadgetman) - Club Secretary said:

You’re right re the packing washers, the two washers are normally needed with the standard Gaz dampers, but others have wider ends to them so may not need any washers, or sometimes just one, to take up the slack.


Cheers Dave, there is no room to fit any washer in so thank you for clearing that one up.

 

12 hours ago, jonjh1964 said:

Should be the same as the elastomerics as you torque against the centre tube

I’ll give Westfield a ring tomorrow to double check but that sounds about right, thank you 👍🏻

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Yorkshire_Pudding

Got round to doing more work on the car today. I started with fitting the rear (right) upper wishbone and then the shock absorber. I intended on fitting the uprights and hubs but ran into a problem when the 9.5” long 7/16” stud wouldn’t go through the metalastic bush or the rose joint. I spoke to Westfield about it and they are sending me another stud out to try. 
 

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It turns out I had forgotten about fitting the tank brace when I fitted the top wishbone up. A quick fix turned into a little bit more work as the tangs on the tank brace had the holes too far apart by about 4mm.

 

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To fix this I bored out both holes until it fit. Before fitting it again I sprayed the bare metal with Dinitrol ML just to give it some sort of protection and left it to dry.

 

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I also trial fitted a rear wheel to see how that would go. I am going to try some 12mm spacers first and then see how long the studs need to be if that clears everything as it’s currently hitting the bottom of the shock and the bottom rose joint.

 

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The next job on the list was to build the driveshafts. As I had only being supplied the bar shafts with my kit, I ordered the CV joints from J&R and set to work once they arrived.

 

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it’s a good idea to get both boots fitted first.
 

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Pack plenty of grease into the bearings on the boot side of the CV.


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Fill the boot with the same grease and the seating face to the CV itself.

 

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Then place the CV onto the splines with the scored circumference to the boot. Then fit the circlip.

 

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I then packed the outside face with grease and sealed the lot up with a plastic bag and cable tie so that no foreign objects can get in while they aren’t mounted. (My mum wasn’t best please when I told her the sandwich bags had gone to good use 😬)

 

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I also received my rear light pods back from being carbon skinned and they look amazing.

 

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I finally took delivery of all my front suspension from Siltech, and can I just say WOW. The quality is amazing and they are so light. A credit to Dennis and Andy at Siltech 👍🏻👍🏻👍🏻
 

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Gary Taylor - Scotland AO

Great to see you getting on but it’s infuriating when those little things go wrong, you really do expect to pick the piece up and it fits ! Different if you were doing your own thing but from the kit ....

Still someone made a great job of the carbon skinning and those front hubs are stunning .

keep up the good work 

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Yorkshire_Pudding
2 hours ago, Gary Taylor - Scotland AO said:

Great to see you getting on but it’s infuriating when those little things go wrong, you really do expect to pick the piece up and it fits ! Different if you were doing your own thing but from the kit ....

Still someone made a great job of the carbon skinning and those front hubs are stunning .

keep up the good work 


yeah you’ve got it Gary I was spitting feathers. Especially something as small as a stud being oversized 😡 yeah I got them done by Classic Carbon as I have a few mates with Caterham’s and they rated them. Cheers Gary 

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Yorkshire_Pudding
38 minutes ago, Steve (sdh2903) said:

Light pods look great. Can I ask a ball park figure to get them done?


cheers 👍🏻 And £200 it was I think 

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Rush Motorsport the 2nd
21 hours ago, Yorkshire_Pudding said:


cheers 👍🏻 And £200 it was I think 

But if the Mrs asks it was £15

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Chris King - Webmaster
1 hour ago, Rush Motorsport the 2nd said:

But if the Mrs asks it was £15

Crickey. Yorkshire Wives are tight!
 

My missus fully understands that the individual component cost for all things Westfield is £30 (unless it’s an Xmas present whereby a factor of 10 is allowable)

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Yorkshire_Pudding
2 hours ago, Rush Motorsport the 2nd said:

But if the Mrs asks it was £15

Lol 😂 I promised her a holiday after it was built. Hope she doesn’t mind camping about a mile away from where we live 😂.

 

1 hour ago, Chris King - Webmaster said:

Crickey. Yorkshire Wives are tight!
 

My missus fully understands that the individual component cost for all things Westfield is £30 (unless it’s an Xmas present whereby a factor of 10 is allowable)

Think I’m going to need some lessons in this 😂😂

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Yorkshire_Pudding

Only got chance to do a couple of bits on the motor today. I decided to fit the Siltech lower wishbones ready for when I get the shock absorbers back from Procomp.

 

Same as the rears, I de-greased the brackets to eliminate the rust protection, I then put a spare 7/16” bolt through the brackets to ensure the powder coating wasn’t too thick in that area. Then fitted the wishbone.

 

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Excuse the Barnsley spec shock absorbers, but they’ll be reyt for the time being 😂. I’m getting quite excited now even though it’s only a small step getting it onto four wheels.

 

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I also removed the steering wheel and boss as I am going to have a go at designing a boss cover on CAD and have my mate 3D print it.

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