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Post by pocketrocket on Oct 28, 2015 0:34:58 GMT
Figured I should start a build thread.
Based in West Australia, with a significant background in racing (predominantly circle track/speedway). Now that my own racing days are done, I figured I needed something to do, in my shed.
I've been keen on the Lotus 7 type cars for many years, but figured there must be something more "up-to-date" available, out there, somewhere. So after months of searching, researching & weighing up all the pros & cons of many different "kits", as well as the option of simply building my own, I settled on the MEV Rocket.
I bought this "base" kit in June 2014, through the Australian agent, Southam Engineering. They're located in Perth, West Australia, which is the state's capitol. Its about a 4.5hr (450kms) drive south. That was actually one of the factors that weighed heavily on the decision to go with one of the MEV cars. Southam are a registered engineering facility, of vehicle modifications & ICVs (Individually Constructed Vehicles), for the registration/licencing authorities. The Australian authorities require the chassis of such vehicles to have completed & passed specific tests. These are beam & torsion tests. Basically there is a minimum amount of deflection permitted, within the chassis, in bending (length ways) & twisting. Southam Eng, have already completed these tests & the chassis they supply already have the neccessary additional bracing, allowing them to pass the test. So that is another significant reason behind my decision. All this is already done, passed & is essentially included in the purchase price.
Being the perfect size for a racing car driver (I measure in at just barely 5ft & 50kgs) I requested the chassis come with the seat, column & pedal mounts be only tacked into place, incase I needed to move them.
As there is a chance I might choose to use the car for competition, I also optioned the CAMS (Confederation of Australian Motorsport) spec roll bar. But I had them just tack this together too, so that the height could be adjusted, if needed.
I wanted to be able to use the latest model engine I could, so had them just tack the engine/transmission mounts in place too.
Total cost was $12925 AUD including tax
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Post by pocketrocket on Oct 28, 2015 0:43:26 GMT
  The Donor. Purchased as a statutory "write-off", from an insurance company auction for $1775 AUD inc tax. 2012 Ford Focus. 23000kms. 2lt Duratec w/5 speed MTX75 transmission. |
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Post by pocketrocket on Oct 28, 2015 0:51:43 GMT
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Post by pocketrocket on Oct 28, 2015 0:59:08 GMT
In the past 12 months, I didn't really do much to it. But instead, extended my shed, including insulating the entire thing (with the view of installing an air conditioner at a later date) & lining the interior walls with aluminium composite panels. It gets ever so hot here in summer (40+deg C for days on end), hence the insulation. The extension is one of those projects I've wanted to do & been going to do, since I bought the place in 2000. its now 16M wide/long x 6M deep (equivilent of 5 car bays)     |
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Post by pocketrocket on Oct 28, 2015 1:16:23 GMT
While that was all happening, I started accumulating some parts Cosworth Intake  Billet oversize throttle body  Aluminium flywheel & heavy duty clutch  |
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Post by pocketrocket on Oct 28, 2015 1:23:50 GMT
Nearly 12 months later, started trial fitting a few things. First up, the engine & transmission   It became evident that there are variances in the engine mountings between Duratec Focus'. The mounts fitted by Southam weren't even close. Lucky I had them only tacked in place. So cut them off & started again. Initially, purchased a full set of Steeda billet/urethane mounts, for a 2012 Focus out of the US. They were ever sog expensive & wouldn't you know it.... there was no way I was going to be able to adapt them. Have since bought another set (FS Works this time), for a 2007 Focus. They're much more compact & look neater. As I own a cnc waterjet shop, I profiled some neat mounting points & have since welded them in place on the chassis. Just need to finish dressing a few edges up with the die-grinder (there is another story to that). |
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Post by pocketrocket on Oct 28, 2015 1:38:31 GMT
Then came the front end. I optioned the car/kit with the Rally Design aluminium uprights. Later, I bought the 265mm slotted rotors & Wilwood calipers direct from RD.  You'll probably all have seen, in another thread regarding uprights & alignments etc. In summary: I'm not sure what RTR have done, but the geometry is all messed up with regards to the minimum amount of caster achievable. When the upper control arm is spaced all the way forward, it has about 14deg of positive caster. This should be the absolute maximum amount. And the shock mount on the lower control arm doesn't line up directly with the upper mount, so you have to kind of flex the shock into position. Both of these issues are quite simply crap in my opinion. Supposedly fabricated in a jig. This is what I spent all the money for. Anyways, it is what it is & I guess it might explain why RTR are no longer in business. So, I just need to find a solution to the problem. End result, I am in the process of making new lower control arms, with the lower ball joint moved back 20mm. I couldn't find the same tube as RTR used, so I have gone up in size to "err" on the side of caution. The tubing is 25mm OD x 0.120" (3mm) wall thickness DOM (Drawn Over Mandrel) tube - commonly used in race car fabrication. This should give the correct range of caster adjustment & also give me the opportunity to relocate the lower shock mount so that everything lines up correctly. I'll post photos a bit later |
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Post by pocketrocket on Oct 28, 2015 1:51:46 GMT
Started coming up with a plan for the fuel system. The RTR fuel tank doesn't fit in the Australian spec chassis, due to the additionaldiagonal tube bracing. Southam offer a tank of their own design, but I didn't like the look of it so decided to go my own route (not sure this was the correct decision, but I'll go with it for now). I bought 2 x 3 Gallon dragster fuel tanks by JAZ Products & a 2L surge tank, which would give a combined capacity of abot 21L. I know alot of clubman racers use a low pressure pump to pull fuel from the main tank, filling the surge pot, then use a high pressure pump for the fuel injection. I wanted to try & avoid having 2 pumps, if I could, because I think its just one more thing to go wrong. So the plan was to have the 2 drag tanks, gravity feed to the surge pot & have the EFI pump pull from there. I messed around with this for days & in the end have abandoned the idea. I can't get the drag tanks up high enough, to ensure good feed to the surge pot, while still maintaining enough clearance at the top, for the filler neck. So the idea has been scrapped & the parts are now added to the growing pile of new, unused parts, that will later be sold off for probably a 3rd of what they cost.... just to rub salt into the wound.  I have since bought an aluminium 19L tank by Aeroflow, that I'll use with the surge pot & may end up just conceding defeat & fitting 2 pumps |
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Post by pocketrocket on Oct 28, 2015 1:57:10 GMT
I should also take the opportunity to thank Rob the Kiwi.
I had the idea of making up some "dummy" bushes for the suspension, so everything could be trial fitted without having to fit the Urethane units, only to have to remove them for the painting/powder coating process.
Anyways, following Kiwi's build, turns out I wasn't the only one with the idea. Once he had finished with them, he was kind enough to forward them onto me, to use too. Saved me a heap of time & effort.
He's also been very forth coming with information & drawings.
So, cheers Kiwi
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Post by kiwicanfly on Oct 28, 2015 2:27:28 GMT
Wonder if you will still be saying that Sunday morning  |
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Post by pocketrocket on Oct 28, 2015 2:28:22 GMT
In the process of making new front lower control arms First up, I created a drawing of an arm, as supplied  Then I moved the lower ball joint section 20mm & joined the parts back up  Then I took just the ball joint/shock mounting plate & added the locating tags for the tube, allowing for the wall thickness of the tube, the additional diameter of the tube I'm going to use, and the thickness of the plate itself, so it'll actually fit up the inside of the tube. Even added a "lightening" hole (actually just there to make it not look like its just a bit of plate - give it some character)  And finally, some shock mounts in a flat layout, including notches to indicate bending points  |
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Post by mawdo81 on Oct 28, 2015 6:56:45 GMT
Great write up; keep it coming...
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Post by pocketrocket on Oct 28, 2015 7:12:03 GMT
Wonder if you will still be saying that Sunday morning Its ok, we'll teach you how to play cricket over the next few months |
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Post by kiwicanfly on Oct 28, 2015 8:19:46 GMT
Mind you I shouldn't speak too soon, I was the one who changed my user name to kiwicansail when we were 8:1 up in the Americas Cup, look how that ended  There was an Aussie at the helm then! |
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Post by mawdo81 on Oct 28, 2015 8:47:56 GMT
Note to self: Try to avoid Rugby based banter with the Southern Hemisphere :-(
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