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Thread: SFS 447V Harrier Project

  1. #81
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    Re: SFS 447V Harrier Project

    It's been a long time since the last update on the car, a huge amount of time has been spent on the front end of the car.

    Rust has been found in the normal places, new wing fillers have been fitted along with repairing the rust underneath. I did get a new front panel from Magnum but wasn't happy with the quality of it, a friend had an old front panel that had bits missing. Luckily the original panel had the bits we need to repair this newer panel, the weight difference between this old stock panel and the Magnum is incredible.

    The both inner wings have been pulled out from a previous accident, the drivers side was much worse it need 20mm pulling out. Properly should have replaced both front inner wings really because all the tabbed areas that the front panel welds too also needed rebuilding. Rivnuts have been put into the A panel just because its a nicer way of bolting up the wings.





















































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  3. #82
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    Re: SFS 447V Harrier Project

    Front suspension fitted up to get a wheel fitted, the Whiteline antiroll bar is really nice it gives you caster adjustment by using spacers in front of the TCA's

    The arches and spoiler are from Ralloy, can't recommend them enough they're very nicely made and fit really well with very little effort.











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    Re: SFS 447V Harrier Project

    Some more progress made this weekend, wings have been cut out and a return edge has been put into the wing to give it some strength back.

    Found it quite hard to see what other people do with the excess that needs removing from the front panel, so we have done a nice swapping curve to give the wheel enough clearance.






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    Re: SFS 447V Harrier Project

    Loads more progress has been made over the last week, the front has been taken down to bare metal all the lows filled and flatted then etch primed before the arches and spoiler where fitted.

    Found a good quality 120-degree countersink on eBay for a reasonable price if anyone is looking for one or about to fit arches to there car. The 8.3mm size is perfect for the rivets

    https://www.ebay.co.uk/itm/Exact-TiN...m/264853998651


















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    Re: SFS 447V Harrier Project










    Next up are the new rear arches, using these large magnets are brilliant for aligning and holding the arches in place









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    Re: SFS 447V Harrier Project

    Little update for you guys

    On to the rear quarters and arches, the drivers rear quarter had two bad dents which were hidden by over 10mm thick filler. A panel beater friend came in to help repair the damage, he used a spot weld dent pulling machine and carbon shrinking rods to remove the dents.

    The rear arches have been shaped and fitted to the car after the quarters were filled, flatted and etch primed.

    The shell is looking really good now

















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    Re: SFS 447V Harrier Project

    Good progress. Keep the pics coming as always impressed with others fab skills.

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    Re: SFS 447V Harrier Project

    She is looking fine and taking shape nicely. Rear wings came out well and you must be chuffed, know I would be

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    Re: SFS 447V Harrier Project

    Quote Originally Posted by dt36 View Post
    Good progress. Keep the pics coming as always impressed with others fab skills.
    I'll try and upload a few more photos tonight, the gearbox mount and brackets on the tunnel are all made and finished off last night


    Quote Originally Posted by donnie View Post
    She is looking fine and taking shape nicely. Rear wings came out well and you must be chuffed, know I would be
    Thanks Donnie, I couldn't be happier with how the rear quarters and arches have turned out.

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    Re: SFS 447V Harrier Project

    Next job on the list was the gearbox brackets and 6 speed mount. I brought some universal brackets from Motorsport Tools but they didn't suit the angle of my tunnel, it's a shame they're not square so you can cut your own angle into them but ended up making these from a CAD template, 2-inch box, 3D printed bushes to sacrifice for the tack welding and some 4 link bush cups. It's tuned out alright considering its made from offcuts and scrap

























    Last edited by SimonD; 20-01-2021 at 19:57.

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    Racer Decade Plus User wildo105e's Avatar

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    Re: SFS 447V Harrier Project

    Is that the mazda 6 speed ? I am running a mazda 5 speed and thats exactly the same idea i was thinking of with slightly different tunnel mounts due to my current setup. Nice to know i am on the right path.

    Great work as usual.

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    Re: SFS 447V Harrier Project

    Yeah its the 6 speed from mk3 mx5, the plan is to only use 2nd to 6th turning it into a 5 speed with a dogleg 1st.

    The gearing looks really good it should make a nice close ratio box, let's hope it works out like that

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    Re: SFS 447V Harrier Project

    SimonD, amazing work, really nice weldings. The sidewall looks really neat and perfekt now!
    How do you manage the angle of the gearbox? Or will the gearstick be straight without angle to the left side?

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    Re: SFS 447V Harrier Project

    Quote Originally Posted by skmotorsport View Post
    SimonD, amazing work, really nice weldings. The sidewall looks really neat and perfekt now!
    How do you manage the angle of the gearbox? Or will the gearstick be straight without angle to the left side?
    Hi sk,

    Thank you, my welding is self taught and I have quite bad OCD but my welding is getting better all the time. The angle is designed into the gearbox by Mazda because the engine has 10 or 15 degree tilt, it's a comprise unfortunately but NC 5 and 6 speed gearbox are really good for the little money they demand.

    Your car is looking really awesome btw

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    Racer Decade Plus User wildo105e's Avatar

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    Re: SFS 447V Harrier Project

    Quote Originally Posted by SimonD View Post
    The angle is designed into the gearbox by Mazda because the engine has 10 or 15 degree tilt, it's a comprise unfortunately but NC 5 and 6 speed gearbox are really good for the little money they demand.

    Your car is looking really awesome btw
    I was watching vid on youtube of the brand new mk2 escort that MST have had built. They mentioned about a gearlever extension they have made for the 6 speed. I couldn't see if it took out the tilt tho (on my phone) maybe worth looking into. I suspect for the cost i may put up with the angle it does seem that bad

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    Racer Decade Plus User wildo105e's Avatar

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    SFS 447V Harrier Project

    Doesn’t seem that bad


    Sent from my iPhone using Tapatalk

  23. #97
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    Re: SFS 447V Harrier Project

    Quote Originally Posted by wildo105e View Post
    I was watching vid on youtube of the brand new mk2 escort that MST have had built. They mentioned about a gearlever extension they have made for the 6 speed. I couldn't see if it took out the tilt tho (on my phone) maybe worth looking into. I suspect for the cost i may put up with the angle it does seem that bad
    I've not seen the GBS video until now, the part they have made is very interesting. It looks like it does straighten the gear lever up and it also moves the lever right back, I didn't think the position of the lever was any different from a type 9 if anything a little further back. Makes me want to put the seats back in to find out.

    Like you say I wonder how much it would be.


    Quote Originally Posted by wildo105e View Post
    Doesn’t seem that bad


    Sent from my iPhone using Tapatalk
    Tapatalk isn't working again, I'm guessing this is the image you have posted up?


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    Re: SFS 447V Harrier Project

    I'm going to try and keep doing smaller more frequent updates on the car now.

    Earlier on last year we started looking at the 4 link, toe correction and brake caliper brackets, now the gearbox is mounted in the car the next job is to centralise the axle to the car and the 4 link boxes and also set the brackets angle 2 degrees down. (Gary aka Retromotorsport, recommends around 2 degrees nose down works well for tarmac cars)

    My dad had a great idea to make a jig that's square to the brackets, this has made it really easy to set the 2 ish degrees









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    Racer Decade Plus User wildo105e's Avatar

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    SFS 447V Harrier Project

    Quote Originally Posted by wildo105e View Post
    Doesn’t seem that bad


    Sent from my iPhone using Tapatalk
    Apologies that was correcting my last statement about the gear-lever angle. Having it at 15degs angle doesn’t seem so bad. On the 5 speed nc box the lever came about an inch further forward than the type 9 on the pinto


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    Re: SFS 447V Harrier Project

    Quote Originally Posted by wildo105e View Post
    Apologies that was correcting my last statement about the gear-lever angle. Having it at 15degs angle doesn’t seem so bad. On the 5 speed nc box the lever came about an inch further forward than the type 9 on the pinto


    Sent from my iPhone using Tapatalk
    Oh sorry , yeah I don't think its the end of the world. That's interesting it's about an inch shorter, looking at the GBS photo they have moved it about 3 - 4 inches back. I'll definitely have to try my seat back in the car and see what it's like, I can see another little cad project coming on

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    Spanner Monkey SimonD's Avatar

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    Re: SFS 447V Harrier Project

    I don't think anyone has noticed that we have removed the watts towers that had been fitted to the car, I have been working on an adjustable roll centre watts kit for well over a year. All the inspiration has come from a kit that's available from Australia but with the cost of the kit and shipping/import costs, it's well out of reach.

    How hard can it be right I'll try and make my own, as it turns out its been really hard. The centre swivel has been a complete pain because I have tried to avoid the expense of having this part CNC machined, the centre bearing lockups when the bolt is torqued up. I have tried all sorts and ended up getting a machined billet version with billet spacers that take the pressure off the bearings, all of the alloy parts have been made from T6 grade aluminium. There still a tone of design work left to get the axle brackets to fit together nicely but it's definitely getting there.


























  29. #102
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    Re: SFS 447V Harrier Project

    Make more progress over the weekend on the watts setup, printed out the first tower and made a cardboard version to try before the flatted shape is ordered from the laser cutters. It looks pretty good, just need to start working on the other side now.

    The first chassis bracket has been made using a good old contour gauge and some threaded inserts, making these brackets is so time consuming to get them at the correct height and level but it's satisfying to see it all come together















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  31. #103
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    Re: SFS 447V Harrier Project

    Some more progress made at the weekend, the watts tower brackets for the chassis are all finished ready to be welded on. I have sent off the drawing to the laser cutters for the axle brackets until they arrive we can't really make any more progress with the watts.



    Finished off a little job for the harness, put the seat back in and worked out where the 6 point locations need to be and welded in four spreader plates





    Picked up an eBay bargain last week, Corsa C power steering column for £35. Going to make my own kit to mount this in the car by adding a dash tube to the roll cage, should be interesting how that goes.

    Does anyone know where I can get the main power in connector, preferably new?


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  33. #104
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    Re: SFS 447V Harrier Project

    Great progress with the rear set up and plenty adjustment available. She’s going to be a belter

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    Re: SFS 447V Harrier Project

    Thanks Donnie, I'm trying my best to make the car as good as it can be and future proof it.

    We are getting so close now to applying the stone chip/painting the underneath, just need to get all the little finishing touches in place before we can't do anymore welding on the floors

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  36. #106
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    Re: SFS 447V Harrier Project

    Still waiting on the laser cut parts to arrive for the watts tower, so started looking at the Corsa power steering. Had a right laugh trying to get the plastic housing off that the stalks connect to, ended up cutting it off and then realizing it had an alloy sleeve and bearing inside the plastic. It needs this bearing because the inner shaft doesn't have any support without it

    Ordered a small bit of CDS tubing to make a new steel sleeve, it's been bored out to the OD of the bearing with a step for the bearing to press against. Then ID of the tube has been bored out again to be a nice fit over the original column. Once it's all welded up should look alright. I really do like making little bits on the lathe it's very satisfying











  37. #107
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    Re: SFS 447V Harrier Project

    Christmas has come early, game on now to get the rear suspension underway again.


  38. #108
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    Re: SFS 447V Harrier Project

    Huge moment for the car, the tunnel and other new bits were going very rusty. All of last week was spent rubbing down and keying up all the interior for a light coat of epoxy primer. Still have welding to be done on floor but this will stop the surface from getting worse, plus it looks really good being all one colour.




















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  40. #109
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    Re: SFS 447V Harrier Project

    A little update for you guys, we are still working away like mad to get the shell ready for paint, I haven’t really updated the post with photos of the shell being cleaned and prepped for paint because no one what’s to see that. The boot has been up in epoxy primer and the engine bay is back to bare metal ready for primer

    Oil line routing is done now, made up a 3D printed tool that was superglued to the bench vice to put a 30deg bend in a load of washers to create cable tie points. To save on buy loads of bulkhead fitting I’ve used long slots and thick rubber trim for the pipes to pass through. The clear plastic pipe was used because 3 meters was really cheap and it saved damaging the proper AN-12 pipe




















    Last edited by SimonD; 09-06-2021 at 12:23.

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  42. #110
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    Re: SFS 447V Harrier Project

    Bit more done the past few evenings, made a start on the customer radiator mounts. They will be bolted in place top and bottom with little brackets welded to the inner front panel.








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  44. #111
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    Re: SFS 447V Harrier Project

    Moving onto the fuel line, the watts tower mount is right in the way for the fuel bulkhead fittings to be in front of the fuel tank.

    They have gone behind the tank which will make the fuel lines in the boot look nice and neat, hopefully with have all the fixing points done for the fuel this week








  45. #112
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    Re: SFS 447V Harrier Project

    The fuel pump I've gone for is an integrated fuel swirl pot, friends with the same style tank in escorts have had problems with fuel starvation so this should stop that problem and the Bosch 044 style of pump should ideally be emerged in the fuel to reduce the load on the pump and overheating

    I'm still working on the design for the mount for this swirl pot and Redtop lift pump but that should be finished soon




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    Re: SFS 447V Harrier Project

    Interesting solution ! And from it, I assume the tank you are using doesn't have an integrated sump although the mounting plinth allows for one? Submerging the pump will make no difference to it operation as the internal workings are submerged in fuel in normal operation. I too, use a swirl pot, fed with a bike interrupter type fuel pump which makes it a little quieter in operation, but it can 'clatter away' on occasion LOL!

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    Re: SFS 447V Harrier Project

    Quote Originally Posted by katana View Post
    Interesting solution ! And from it, I assume the tank you are using doesn't have an integrated sump although the mounting plinth allows for one? Submerging the pump will make no difference to it operation as the internal workings are submerged in fuel in normal operation. I too, use a swirl pot, fed with a bike interrupter type fuel pump which makes it a little quieter in operation, but it can 'clatter away' on occasion LOL!
    Hi Katana,

    The tank I have does have a built-in swirl pot unfortunately it's far too small and on the wrong side of the tank for circuit use. I know it's a common problem when driven very hard on slicks, this should stop me from having any fuel starvation. The pumps do become noisy and hot when asked to pull fuel through small pipe from the tank (typically 6AN), having the pump completely submerged opens up the inlet to 8AN min and cools the pump. It's a win-win in my eyes, it's also great value if you are looking for a swirl pot and pump setup

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    Re: SFS 447V Harrier Project

    Quote Originally Posted by SimonD View Post
    A little update for you guys, we are still working away like mad to get the shell ready for paint, I haven’t really updated the post with photos of the shell being cleaned and prepped for paint because no one what’s to see that. The boot has been up in epoxy primer and the engine bay is back to bare metal ready for primer

    Oil line routing is done now, made up a 3D printed tool that was superglued to the bench vice to put a 30deg bend in a load of washers to create cable tie points. To save on buy loads of bulkhead fitting I’ve used long slots and thick rubber trim for the pipes to pass through. The clear plastic pipe was used because 3 meters was really cheap and it saved damaging the proper AN-12 pipe




















    Excellent love the cable tie solution even better than project Binky!!!!!

  49. #116
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    Re: SFS 447V Harrier Project

    Ha, another binky fan here.
    www.instagram.com/thehighclassescort/

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    Re: SFS 447V Harrier Project

    Quote Originally Posted by rustyshell View Post
    Excellent love the cable tie solution even better than project Binky!!!!!
    Project Binky is something else, I can only dream about getting to their level of bracket creation and engineering

  51. #118
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    Re: SFS 447V Harrier Project

    Last night's effort on the fuel pipes, decided to weld the washers together to make it easier to align them up and look more consistent. I've gone with a 25cm spacing on the mounting points, that seemed sensible without being over the top










    Last edited by SimonD; 17-06-2021 at 09:03.

  52. #119
    Racer Decade Plus User wildo105e's Avatar

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    SFS 447V Harrier Project

    Quote Originally Posted by Baron von Teuchter View Post
    Ha, another binky fan here.
    Ditto that.


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  53. #120
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    Re: SFS 447V Harrier Project

    A little update from the weekend just gone, got the rad mounts all finished up. They are bolted top and bottom to allow for future changes, not my best welding but they will look ok once powered coated








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