|
Up-dating my McCoy
In the beginning
I first heard from a friend about the car, he told me that a friend of his was selling a mini based kit car but couldn’t give me any details of it, I arranged to go and view the car thinking it may be a Mini Midas or similar but when I first saw it, it reminded me of a car I was familiar with from the 70’s, the Clan Crusader but it didn’t look quite right and I knew the Clan had an Imp engine, looking around it had stick on letters saying McCoy which then I was not familiar with, I asked the price, he told me £200 and I gave him the money. It wasn’t running very well so I organised a trailer to get it home. http://i652.photobucket.com/albums/u...g/Image000.jpg I got the trailer and went to collect the car to bring it home… http://i652.photobucket.com/albums/u...way%20home.jpg The next day I had a good look over the car and didn’t look too bad but had mechanical issues which I decided it was time for an overhaul, engine, gearbox rear sub-frame, the usual mini problems and later purchased a donor mini. http://i652.photobucket.com/albums/u...g/DSC00006.jpg http://i652.photobucket.com/albums/u...g/DSC00007.jpg http://i652.photobucket.com/albums/u...g/DSC00010.jpg http://i652.photobucket.com/albums/u...g/DSC00012.jpg http://i652.photobucket.com/albums/u...g/DSC00013.jpg The interior was shabby but nothing that couldn’t be improved. |
carry on, I'm enjoying this....
|
Stripping out
I had the car a few years before serious work was started, women’s requirements got in the way, you know what I mean, get married fix up house, move, fix up house etc etc….
Well I got the car on the 20th January 2004 so work out how much time I havn’t been able to get on with it. Anyway, I was helping my eldest son put a Vtec Honda engine into his mini but he wasn’t putting enough effort into it due to him working 50 miles from home and it looked like I was going to do it for him, there he was wrong, I had other thoughts, I gave him a deal which let me have all the parts he had for the Vtec conversion which I could then put into the McCoy but I never made the deal until we had the engine running because a lot of work would be needed to get it to fit the McCoy and I wasn’t prepare to cut the car to get it to fit with knowing it was a runner. In the mean time in slow time I started stripping out the McCoy to fit the parts from the donor mini just in case. http://i652.photobucket.com/albums/u...t/IMG_0188.jpg This had to come out…. http://i652.photobucket.com/albums/u...t/IMG_0183.jpg and this along with several other parts that had seen better days… http://i652.photobucket.com/albums/u...t/IMG_0288.jpg The engine bay was stripped and cleaned… http://i652.photobucket.com/albums/u...t/IMG_0283.jpg On doing this showed a problem with the firewall suffering from heat off the mini exhaust, that would need repairing… http://i652.photobucket.com/albums/u...t/IMG_0005.jpg The door cards were removed along with the rest of the interior and the part have been stored until I get back to them. http://i652.photobucket.com/albums/u...t/IMG_0198.jpg The fuel tank would also need some work…. http://i652.photobucket.com/albums/u...t/IMG_0197.jpg None of this would be needed as I would be fitting a beam axle with new swinging arm assemblies that my son had got new for the mini, but I would refurbish the swinging arms as spares… http://i652.photobucket.com/albums/u...t/IMG_0256.jpg This lot had to go… and it would become apparent that the front valance would need cutting to allow the Vtec exhaust to fit. http://i652.photobucket.com/albums/u...t/IMG_0284.jpg I am not sure what my son was thinking here but I think it would probably be ‘This will be a monster with my Vtec in’ http://i652.photobucket.com/albums/u...t/IMG_0287.jpg |
The engine inspection
I said to my son ‘It would be a good idea to inspect the engine before we bench tested it’ because it was bought off E-Bay and collected from the back of a van somewhere in London and we didn’t have any history of it. All he knew that the engine was from a Honda Del Sol and it was a 1.6 B16A2 Vtec unit with gearbox.
We emptied the sump and with horror about a litre of water came out with the oil and sludge, so the sump was to be removed for further investigation http://i652.photobucket.com/albums/u...n/IMG_0156.jpg On removal of the sump the bottom end looked surprisingly clean but the sump itself was full of sludge. http://i652.photobucket.com/albums/u...n/IMG_0168.jpg http://i652.photobucket.com/albums/u...n/IMG_0159.jpg The small amount of emulsified oil was removed…. http://i652.photobucket.com/albums/u...n/IMG_0166.jpg The main and big end bearing shells and crank were inspected and only a small score was found on one of the shells.. http://i652.photobucket.com/albums/u...n/IMG_0167.jpg http://i652.photobucket.com/albums/u...n/IMG_0164.jpg http://i652.photobucket.com/albums/u...n/IMG_0165.jpg http://i652.photobucket.com/albums/u...n/IMG_0163.jpg http://i652.photobucket.com/albums/u...n/IMG_0162.jpg So all was cleaned and rebuilt.. While the engine was out a new clutch assembly was fitted along with a new timing belt and tension pulley. |
Sub-frame build
The sub-frame was purchased from a company that manufactured them to suit minis with other engines, as the McCoy was mini based this sub-frame was also suitable, the following was progressed when it was being destined for my sons Mini, the majority of the parts were brand new and other donor part came from the mini and we refurbished…
These were some of the new parts.. http://i652.photobucket.com/albums/u...4%20Engine.jpg http://i652.photobucket.com/albums/u.../14a%20Sus.jpg http://i652.photobucket.com/albums/u...ld/9%20Sus.jpg http://i652.photobucket.com/albums/u...d/13%20Sus.jpg http://i652.photobucket.com/albums/u...d/DSC01137.jpg And some of the refurbished or made parts.. http://i652.photobucket.com/albums/u...ld/8%20Sus.jpg http://i652.photobucket.com/albums/u...ld/6%20Sus.jpg http://i652.photobucket.com/albums/u...nearlyfin1.jpg It was a struggle to say the least to get the engine into the sub-frame and had to be support from a crane while the sub-frame was put onto it, just like putting on a coat. As this was the easiest way of fitting them together the hole assembly would have to be removed from the car if any major work had to be done http://i652.photobucket.com/albums/u...7%20Engine.jpg Finally the engine was in and then the suspension, drive shafts steering components etc was assembled. http://i652.photobucket.com/albums/u...8%20Engine.jpg http://i652.photobucket.com/albums/u...2%20Engine.jpg Later in the build it was apparent that the heater hoses would clash with the sub-frame so it had to be redesigned to sort it out.. http://i652.photobucket.com/albums/u...d/IMAG1560.jpg http://i652.photobucket.com/albums/u...d/IMAG1563.jpg http://i652.photobucket.com/albums/u...d/IMAG1566.jpg http://i652.photobucket.com/albums/u...d/IMAG1571.jpg That done the trick, it shouldn’t have had to be done if the sub-frame manufacturer accommodated it and there were a few other clash issues I had to deal with, with regard to the sub-frame. |
Engine bench test
Heath Robinson would have liked this, I pulled a bench out into the garden and clamped the sub-frame, complete with engine and mini fuel tank a radiator and wiring harness, stuffed an old silencer into the manifold with fire gum attached a battery and tried to fire it up…
http://i652.photobucket.com/albums/u...t/IMG_0169.jpg http://i652.photobucket.com/albums/u...t/IMG_0185.jpg http://i652.photobucket.com/albums/u...t/IMG_0182.jpg http://i652.photobucket.com/albums/u...t/IMG_0181.jpg http://i652.photobucket.com/albums/u...t/IMG_0180.jpg http://i652.photobucket.com/albums/u...t/IMG_0179.jpg http://i652.photobucket.com/albums/u...t/IMG_0178.jpg http://i652.photobucket.com/albums/u...t/IMG_0174.jpg http://i652.photobucket.com/albums/u...t/IMG_0171.jpg Go here for first trial video https://www.flickr.com/photos/383774...7658176284393/ The problem was the immobiliser within the ecu, the steering column was from a different car than the ecu, so the internet was called for, I went searching for possible solutions and it came up trumps, a guy on a Honda forum described in depth on how to by-pass the immobiliser circuits in the ecu, this meant opening it up cutting a couple of resistors out and putting in a few links, after doing this, this is what happened next Go here https://www.flickr.com/photos/383774...7658176284393/ |
Well that's the first 5 episodes of 27 to date, more to come, watch this space....
|
Engine bay mods
Well the deal was done and I had most of the parts to complete the job so I thought, time to make it fit.
The engine was removed from the sub-frame and then the engine bay was cut about to make it fit http://i652.photobucket.com/albums/u...s/IMG_0304.jpg I set up a pair of straps around a piece of 4x2 straddling the wings and the sub-frame and started to lift into position, cutting material from the car allowing it to raise into the correct position, this is how I envisaged the hole assembly would have to be installed. When putting it in the mini there was a removable flip front so no problems were there, I did at one stage consider flipping the front of the McCoy but changed my mind. Finally after removing material from the inner wings and the front valance it was in.. http://i652.photobucket.com/albums/u...s/IMG_0306.jpg The sub-frame was bolted at the top but the two lower mounts where sitting off the body, The area around the mounting plates on the car were cleaned back to the glass and pads were glassed into position, the sub-frame mounts were dressed in cling film, the sub-frame was re-fitted and the pads were shaped to fill the gap. http://i652.photobucket.com/albums/u...s/IMG_0317.jpg http://i652.photobucket.com/albums/u...s/IMG_0305.jpg http://i652.photobucket.com/albums/u...s/IMG_0199.jpg The sub-frame was forward of the front valance so some cutting was required there. http://i652.photobucket.com/albums/u...s/IMG_0319.jpg Now for the frame and the engine, the engine was refitted into the sub-frame and the whole assembly onto a trolley I had made earlier, the car was jacked and the lot was slid under. http://i652.photobucket.com/albums/u...s/IMG_0190.jpg Then the car was lowered and more bodywork cut away to allow passage… http://i652.photobucket.com/albums/u...s/IMG_0191.jpg Don’t fit….. http://i652.photobucket.com/albums/u...s/IMG_0195.jpg More cutting…, as you can imagine the car has been going up and down like a fiddlers elbow by this stage.. http://i652.photobucket.com/albums/u...s/IMG_0197.jpg Do fit…phew.. Next was the issue with the exhaust manifold and front sub-frame cross mount plates, something had to be done with the front valance to tidy that up http://i652.photobucket.com/albums/u...s/IMG_0207.jpg More cutting in order then, gees this car was light before but at this rate there will not be much left… http://i652.photobucket.com/albums/u...s/IMG_0209.jpg That’s better now to put some strength back.. http://i652.photobucket.com/albums/u...s/IMG_0229.jpg That’s better. |
The Fuel Tank
On removal of the fuel tank it didn’t look too bad and there was no sound of rust rushing about inside, if I were to use it again it would have to either be run with an external or an internal fuel pump and as I like a challenge I decided for the latter, a pump from the same car the engine came from, I obtained a pump from a civic with the same engine and checked it out against the tank, depth was a perfect fit and the rest of it seemed to be too, the only problems I had now were where are the baffles in the tank and how do I remanufacture the opening for the pump to fit…
After browsing the net I fortunately came across these images, result… http://i652.photobucket.com/albums/u...affles%201.jpg http://i652.photobucket.com/albums/u...ffles%202a.jpg Brilliant the pump will fit between the baffles and I know where to cut the hole… Hmmm next was how to fit it, I could either cut a civic tank up and use the interface from there and weld it into the tank or I could do it the hard way and do it properly so I opted again for the latter… First I had to design and make a tool to create the swaged edge for the gasket to seal against, so into work, knocked up a tool and then done this… http://i652.photobucket.com/albums/u...k/IMG_0198.jpg Get old tank… http://i652.photobucket.com/albums/u...k/IMG_0734.jpg Mark out and cut holes… http://i652.photobucket.com/albums/u...k/IMG_0735.jpg Trial fit pump.. http://i652.photobucket.com/albums/u...k/IMG_0736.jpg Fit tool and tighten, loosen, turn, tighten, loosen turn etc … http://i652.photobucket.com/albums/u...k/IMG_0737.jpg Remove the tool and hey presto a nice swage…now for the fixings… http://i652.photobucket.com/albums/u...k/IMG_0743.jpg Clean interface in and out and clean fixings. http://i652.photobucket.com/albums/u...k/IMG_0744.jpg Silver solder fixings In one by one allowing to cool at each fixing.. (NOTE: Ensure the tank has been completely cleaned off any fuel vapours if you want to try this at home, I will take no responsibility if you blow yourself up) http://i652.photobucket.com/albums/u...k/IMG_0745.jpg http://i652.photobucket.com/albums/u...k/IMG_0747.jpg All done and pump now fits.. now to make it clean and sealed inside and nice on the outside http://i652.photobucket.com/albums/u...k/IMG_0748.jpg http://i652.photobucket.com/albums/u...k/IMG_0749.jpg http://i652.photobucket.com/albums/u...k/IMG_0750.jpg http://i652.photobucket.com/albums/u...k/IMG_0757.jpg |
Fuel tank (cont'd)
Now that’s done it only seemed right to give the filler the same respect..
http://i652.photobucket.com/albums/u...k/IMG_0773.jpg http://i652.photobucket.com/albums/u...k/IMG_0774.jpg http://i652.photobucket.com/albums/u...k/IMG_0775.jpg http://i652.photobucket.com/albums/u...k/IMG_0776.jpg http://i652.photobucket.com/albums/u...k/IMG_0782.jpg That’s better, now to fit the tank into the car.. http://i652.photobucket.com/albums/u...k/IMG_0795.jpg First mark out the position of the pump and chain drill a series of holes http://i652.photobucket.com/albums/u...k/IMG_0796.jpg Cut out the middle.. http://i652.photobucket.com/albums/u...k/IMG_0797.jpg Clean up the edges and now the tank was ready to fit.. http://i652.photobucket.com/albums/u...k/IMG_0798.jpg http://i652.photobucket.com/albums/u...k/IMG_0800.jpg Done.. rubber seals were placed between the tank and the boot floor on assembly, now for the filler.. http://i652.photobucket.com/albums/u...k/IMG_0801.jpg Ok next job.. |
Excellent, thanks for putting all this effort into the thread a most pleasant surprise when I logged on. That swage tool is a work of art you should hire it out, I followed a McCoy last week they look better as they get older Ed
|
Hi Ed, I thought I should as I have been teasing for a while, I don't think you will reckonise mine when its finished, if you see that McCoy again would you mind taking its reg no as I am trying to make a database on them, cheers..
|
Rear end
Now for the back, the old sub-frame was in serviceable condition believe it or not but not for me, I wanted to use the beam axle my son had for his mini, the problem with these after market items they do no cater for everything and the beam was no different, it did not have provision for the handbrake cables so as its what I do I made that right…
http://i652.photobucket.com/albums/u...n/DSC02033.jpg http://i652.photobucket.com/albums/u...n/DSC02034.jpg Having that sorted the beam was drilled for fit and powder coated.. http://i652.photobucket.com/albums/u...n/DSC02037.jpg The beam was offered up and centralised, the car drilled and then bolted into place, I will be strengthening the heal plate it fits to later… http://i652.photobucket.com/albums/u...n/IMG_0250.jpg Nice new coil overs.. http://i652.photobucket.com/albums/u...on/7%20Sus.jpg Refurbished swinging arms with new brake parts and bearings were then fitted to the beam, all the geometry will be set up at a later date.. http://i652.photobucket.com/albums/u...n/IMG_0249.jpg I was going to have it sit on revolution 12” wheels… http://i652.photobucket.com/albums/u...n/IMG_0247.jpg But decided on these 13” Starmags.. http://i652.photobucket.com/albums/u...n/IMG_0252.jpg The problem with all McCoy’s they sit high in the arch at the rear, even using hi-lo coil overs, I have thoughts on righting that later. |
Rear Lights
Now the car was back on wheels I could put it back in the garage, even though the garage was small it would do for a while as I had planned a much bigger garage when I had my extension built.
The rear lights were tired so I searched E-bay for some suitable replacements, as my ideas were not for going modern on the looks at this stage I got some from a Triumph Dolomite, because the rear panel on the car is flat it lent itself to 70’s lights. http://i652.photobucket.com/albums/u...s/IMG_0758.jpg http://i652.photobucket.com/albums/u...s/IMG_0759.jpg First the old lights were removed and a template for the hole positions for the new lights was made. http://i652.photobucket.com/albums/u...s/IMG_0761.jpg http://i652.photobucket.com/albums/u...s/IMG_0762.jpg http://i652.photobucket.com/albums/u...s/IMG_0765.jpg Holes were cut… http://i652.photobucket.com/albums/u...s/IMG_0763.jpg http://i652.photobucket.com/albums/u...s/IMG_0764.jpg New lights and number plate trial fitted, looking better.. http://i652.photobucket.com/albums/u...s/IMG_0766.jpg http://i652.photobucket.com/albums/u...s/IMG_0767.jpg A few coats of paint.. http://i652.photobucket.com/albums/u...s/IMG_0777.jpg http://i652.photobucket.com/albums/u...s/IMG_0785.jpg A few stripes… http://i652.photobucket.com/albums/u...s/IMG_0803.jpg And that looks good, the paint colour was decided to celebrate the routes of the car where the designer ‘Arthur Birchall ‘ was originally an engineer for the Lotus Racing Team.. |
The boot lid
Next was the boot lid, first thing was to flat back and fill the hole that some previous owner drilled for a hideous ill fitting spoiler, maybe he liked it but not my cup of tea, I have other plans on that front and I am considering integrating an air brake…hehe
http://i652.photobucket.com/albums/u...d/IMG_0808.jpg http://i652.photobucket.com/albums/u...d/IMG_0809.jpg A few coats of primer.. http://i652.photobucket.com/albums/u...d/IMG_0814.jpg And a couple of top and that will do for the time being.. http://i652.photobucket.com/albums/u...d/IMG_0818.jpg |
On show at the McLaren show in 2011
As my eldest boy works at McLaren, he got me an invite to their yearly show for employees, so onto a trailer, 50 miles up the road and then on show, It got quite a lot of attention as people thought it was a Clan Crusader but couldn’t work out why it had a engine in the front…
http://i652.photobucket.com/albums/u...4_364781_n.jpg http://i652.photobucket.com/albums/u...1/IMG_0248.jpg http://i652.photobucket.com/albums/u...1/IMG_0249.jpg We had a good day talking about the car and putting people right about the car and also enjoyed walking around all the other cars owned by employees, we also had the privilege walking through the factory….I wish my garage was so spotless… |
In it’s new home
During the long time working on this car my house extension including my new garage was build, the garage boasts carpets and central heating, power and light, now things can really get started and I would not have the weather, lack of light and the cold to stop me, but there is always the wife and a new kitchen and dining room had to be done before I could get on…
http://i652.photobucket.com/albums/u...e/IMAG1484.jpg http://i652.photobucket.com/albums/u...e/IMAG1485.jpg but after I had satisfied I was allowed to continue with my quest… http://i652.photobucket.com/albums/u...e/IMAG0934.jpg http://i652.photobucket.com/albums/u...e/IMAG0933.jpg http://i652.photobucket.com/albums/u...e/IMAG0935.jpg Engine out again…. http://i652.photobucket.com/albums/u...e/IMAG0936.jpg And started on the engine bay harness.. |
Some future mod’s
I have along the way had a few ideas to modify the car and acquired parts to do them, here are a couple
http://i652.photobucket.com/albums/u...0mods/dash.jpg A Honda Del Sol dash to be altered to fit, http://i652.photobucket.com/albums/u...s/IMAG0928.jpg http://i652.photobucket.com/albums/u...s/IMAG0929.jpg http://i652.photobucket.com/albums/u...s/IMAG0930.jpg A rear spoiler from a Mazda Rx-7 FD and a Subaru air intake http://i652.photobucket.com/albums/u...s/DSC_0377.jpg http://i652.photobucket.com/albums/u...s/DSC_0378.jpg And a rather large turbo…..no seriously the car will be fast enough without that and anyway that’s what we fitted to my son’s Rx-7 which took the BHP to 423.. |
The exhaust
It all started of with me going to use the standard manifold with me fabricating the exhaust centre pipe as I already had a 2” bore stainless back box for a mini van, first I got some 2” stainless tube and flared the end to fit the manifold gasket and made a flange to suit..
http://i652.photobucket.com/albums/u...t/IMG_0659.jpg http://i652.photobucket.com/albums/u...t/IMG_0660.jpg http://i652.photobucket.com/albums/u...t/IMG_0661.jpg Then I decided I wanted a full stainless system so I got this http://i652.photobucket.com/albums/u...t/IMAG1153.jpg Unfortunately it gave too many clash problems and only 20mm road clearance and I couldn’t fit it with the engine in the car and I couldn’t fit the engine in the car with it previously fitted so I sent it back http://i652.photobucket.com/albums/u...t/IMAG1189.jpg http://i652.photobucket.com/albums/u...t/IMAG1191.jpg http://i652.photobucket.com/albums/u...IMAG1192_1.jpg So then I got this it was a pattern copy of the original cast manifold, I could split it to remove it whilst in the car and also take the engine and sub-frame out of the car with it still fitted so that was a go from there. http://i652.photobucket.com/albums/u...t/IMAG1194.jpg http://i652.photobucket.com/albums/u...t/IMAG1195.jpg http://i652.photobucket.com/albums/u...t/IMAG1196.jpg http://i652.photobucket.com/albums/u...t/IMAG1245.jpg This one didn’t go that easily though, it didn’t snuggly fit under the engine and the rear support bracket had to be modified so it was time for the disc cutter, I measured them marked with tape how much to be removed, cut it off and cleared the stubs from the flange http://i652.photobucket.com/albums/u...t/IMAG1197.jpg http://i652.photobucket.com/albums/u...t/IMAG1215.jpg Put the pieces together and checked clearances before having it welded http://i652.photobucket.com/albums/u...t/IMAG1217.jpg http://i652.photobucket.com/albums/u...t/IMAG1218.jpg http://i652.photobucket.com/albums/u...t/IMAG1220.jpg http://i652.photobucket.com/albums/u...t/IMAG1221.jpg All was good so I prepped the surfaces and as it happens I have very good welder colleagues where I work so it was then welded back together http://i652.photobucket.com/albums/u...t/IMAG1224.jpg http://i652.photobucket.com/albums/u...t/IMAG1226.jpg http://i652.photobucket.com/albums/u...t/IMAG1227.jpg Nice job… |
Exhaust (cont’d)
The next problem I incurred was a clash with the sub-frame cross member
http://i652.photobucket.com/albums/u...t/IMAG1240.jpg http://i652.photobucket.com/albums/u...t/IMAG1238.jpg http://i652.photobucket.com/albums/u...t/IMAG1248.jpg http://i652.photobucket.com/albums/u...t/IMAG1247.jpg so rather than spacing it out I dealt with that by making a new one and again called on the services of my welder http://i652.photobucket.com/albums/u...t/IMAG1368.jpg http://i652.photobucket.com/albums/u...t/IMAG1378.jpg http://i652.photobucket.com/albums/u...t/IMAG1379.jpg http://i652.photobucket.com/albums/u...t/IMAG1381.jpg I also had a small issue with the clutch slave fouling the new cross member so I dealt with that as well while I was at it http://i652.photobucket.com/albums/u...t/IMAG1471.jpg http://i652.photobucket.com/albums/u...t/IMAG1474.jpg Finally got the rear exhaust bracket to fit.. http://i652.photobucket.com/albums/u...t/IMAG1450.jpg http://i652.photobucket.com/albums/u...t/IMAG1243.jpg And I have a small issue with the lamder sensor clashing with the sub-frame and will need to deal with that before long http://i652.photobucket.com/albums/u...t/IMAG1244.jpg http://i652.photobucket.com/albums/u...t/IMAG1562.jpg That’s nothing for a cutting disc |
Exhaust (cont’d)
I had to manufacture some exhaust hangers for the back box and fit them with the back box into position
http://i652.photobucket.com/albums/u...t/IMG_0805.jpg http://i652.photobucket.com/albums/u...t/IMG_0807.jpg The next on the menu was to make a template between the exhaust manifold and the back box so I came up with a cunning plan and used these http://i652.photobucket.com/albums/u...t/IMAG1254.jpg A length of 15mm copper tube and 5 nylon rings http://i652.photobucket.com/albums/u...t/IMAG1255.jpg By bending the copper pipe into an approximate shape require for the centre pipe, then placing two of the rings at one end and then inserting them into the manifold parted to get alignment I could see where to adjust the copper pipe for best fit http://i652.photobucket.com/albums/u...t/IMAG1257.jpg http://i652.photobucket.com/albums/u...t/IMAG1260.jpg http://i652.photobucket.com/albums/u...t/IMAG1261.jpg By placing the fifth ring (the one with the blue marker on)which was a slip fit over the pipe and the outside diameter of the exhaust I could then place the template back into the exhaust at both end and run the fifth ring along the copper pipe to see there was enough clearance along its length and adjust the copper pipe where required http://i652.photobucket.com/albums/u...t/IMAG1262.jpg http://i652.photobucket.com/albums/u...t/IMAG1260.jpg http://i652.photobucket.com/albums/u...t/IMAG1257.jpg Once satisfied I could then use the template to manufacture the centre pipe http://i652.photobucket.com/albums/u...t/IMAG1265.jpg Marking as I went along I cut the pipe at the bend positions taken from the template and shut each in turn to form the shape http://i652.photobucket.com/albums/u...t/IMAG1267.jpg http://i652.photobucket.com/albums/u...t/IMAG1269.jpg http://i652.photobucket.com/albums/u...t/IMAG1271.jpg http://i652.photobucket.com/albums/u...t/IMAG1296.jpg Once all done my welder tacked each bend and off I went to check it against the car just in case I had to make slight alterations http://i652.photobucket.com/albums/u...t/IMAG1297.jpg http://i652.photobucket.com/albums/u...t/IMAG1300.jpg http://i652.photobucket.com/albums/u...t/IMAG1304.jpg http://i652.photobucket.com/albums/u...t/IMAG1306.jpg Once satisfied my welder completely welded each cut http://i652.photobucket.com/albums/u...t/IMAG1310.jpg OK that’s the exhaust system complete, next item …. |
Right next instalments tomorrow, I hope you are liking it so far, if anyone has any questions or can shed light on better ways I may have done things please comment, thanks...
|
The Gear Shift
The gear linkage from the Honda was longer than that of the mini and had to be shortened
http://i652.photobucket.com/albums/u...e/IMAG1364.jpg To go about shortening the linkage I cut the ends of and fitted the to the car and then reshaped the link tubes in turn to fit between the ends http://i652.photobucket.com/albums/u...e/IMAG1316.jpg http://i652.photobucket.com/albums/u...e/IMAG1318.jpg http://i652.photobucket.com/albums/u...e/IMAG1319.jpg http://i652.photobucket.com/albums/u...e/IMAG1346.jpg When each of the link tube had been bent into their new shape I trial fitted each in turn, setting the gear stick to a mid position and checking clearances under the car. http://i652.photobucket.com/albums/u...e/IMAG1325.jpg http://i652.photobucket.com/albums/u...e/IMAG1343.jpg To hold them in place I cut some flexible split cable conduit and used that to hold the ends, I rotated each to their best fit and then marked them. http://i652.photobucket.com/albums/u...e/IMAG1345.jpg The areas to be welded were cleaned and the services of my welder were again called upon. I had them tacked first then checked them in the car and then once satisfied they were positioned correctly I had them fully welded. http://i652.photobucket.com/albums/u...e/IMAG1355.jpg http://i652.photobucket.com/albums/u...e/IMAG1363.jpg I then cleaned back all the old paint and then re painted. http://i652.photobucket.com/albums/u...e/IMAG1371.jpg http://i652.photobucket.com/albums/u...e/IMAG1372.jpg http://i652.photobucket.com/albums/u...e/IMAG1375.jpg All I would need to do then was re-glass the original cut out for the mini gearshift. |
Fitting the Alternator
As the original position for the alternator on this engine was at the rear I had to come up with a mod to front fit it, so first I made an aluminium interface plate that would pick up on the lower engine block holes...... Note on the plate’s top right hole, this picks up with a tapped hole in the block and when the bracket is fitted the top right hole of the bracket set itself up perfectly for the belt alignment.
http://i652.photobucket.com/albums/u...r/IMAG1212.jpg I acquired an alternator bracket from a Honda Prulude which was front mounted, the holes on the interface plate were drilled to suit the holes of the bracket so it could be mounted it the correct position. http://i652.photobucket.com/albums/u...r/IMAG1211.jpg Because the alternator I had was smaller in size I wanted to for that rather than a Prelude one so I offered up the alternator to check what mods were required. http://i652.photobucket.com/albums/u...r/IMAG1207.jpg The pivot on the alternator was a perfect fit and the belt aligned with the crank pulley just as planned. http://i652.photobucket.com/albums/u...r/IMAG1204.jpg The lower hole on the alternator was out of position and didn’t follow the path on the bracket , this I had to slot. http://i652.photobucket.com/albums/u...r/IMAG1210.jpg I space out with washers the miss match on the adjuster and later made correct size spacers to replace the washers http://i652.photobucket.com/albums/u...r/IMAG1129.jpg http://i652.photobucket.com/albums/u...r/IMAG1385.jpg All worked fine so I then cleaned the bracket and gave it a coat of paint. http://i652.photobucket.com/albums/u...r/IMAG1431.jpg The next thing to do was change the connector on the harness as the harness was for an OBD1 ecu and the alternator was from an OBD2 ecu. |
Steering
I decided to fit the Honda steering column rather than the mini one so I could use the Honda loom and all the niceties of a later column, this gave a few problems at the rack end because the splines were different.
http://i652.photobucket.com/albums/u...n/IMG_0845.jpg I gave it a thought and then stripped down a old mini rack I had and removed the pinion, I took it into work, made a heat sink and with the inner bearing race still attached I had my welder build up the end over the existing spline. http://i652.photobucket.com/albums/u...n/IMG_0844.jpg http://i652.photobucket.com/albums/u...n/IMG_0849.jpg http://i652.photobucket.com/albums/u...n/IMG_0853.jpg Then jumped onto the lathe and turned it down to a size I had experimented with earlier, before this I had done test pieces to get things right before I attempted the pinion http://i652.photobucket.com/albums/u...n/IMG_0855.jpg http://i652.photobucket.com/albums/u...n/IMG_0856.jpg Then I set a medium straight cut knurling tool and put on a new spline http://i652.photobucket.com/albums/u...n/IMG_0857.jpg Once completed it was tried into the Honda steering knuckle and hey ho a finished pinion. The reason I left the inner race on was because the new spline was to be larger than original and wouldn’t slip over. http://i652.photobucket.com/albums/u...n/IMG_0861.jpg http://i652.photobucket.com/albums/u...n/IMG_0859.jpg Well that went well so I stripped down a new mini steering rack hoping to fit the modified pinion but all was not well, the pinion was of a diffent pattern than the old one I had done the mod on so back to work to do it all over again with the new pinion http://i652.photobucket.com/albums/u...n/IMAG0938.jpg Once done at last the rack was rebuilt and fitted into the car. Now for the column, as the car was made with a ply-wood shelf which supported the mini column I had to make up various brackets to allow the Honda column to fit, first I fitted the knuckle to the rack but on doing so it fouled the fibreglass around the hole so that was ground back down to allow full rotation http://i652.photobucket.com/albums/u...g/IMAG0944.jpg Then the column was fitted to the knuckle and a bracket was made to fix the top of the column to the ply shelf http://i652.photobucket.com/albums/u...g/IMAG0972.jpg As the column is adjustable I then made a support for the mid section of the column http://i652.photobucket.com/albums/u...g/IMAG1376.jpg Then the ply shelf was drilled and all bolted into place http://i652.photobucket.com/albums/u...g/IMAG0973.jpg |
I'm liking this resto/conversion.
Alec |
Thanks Alec more coming....
|
Throttle
The throttle peddle was the next to be sorted as I was using a Honda cable and due to where the engine sub-frame covered the original cable hole for the mini I had to re-position the hole to miss the sub-frame
http://i652.photobucket.com/albums/u...e/IMAG0965.jpg As the Fibre glass was thicker than the steel firewall from the Honda I manufactured a carbon-fibre interface plate http://i652.photobucket.com/albums/u...e/IMAG1427.jpg http://i652.photobucket.com/albums/u...e/IMAG1430.jpg The the peddle needed to be altered to suit the new cable position http://i652.photobucket.com/albums/u...e/IMAG0961.jpg The peddle then was warmed and bent upwards to achieve enough travel but not so the it sat above the brake peddle http://i652.photobucket.com/albums/u...e/IMAG0969.jpg The engine was refitted into the car and the cable run in http://i652.photobucket.com/albums/u.../IMAG1432A.jpg The throttle body was the fitted and the throttle was tested for full travel http://i652.photobucket.com/albums/u...e/IMAG0966.jpg All good there |
Your exhaust routing idea and cut section weld techniques for the bends are as inspired as your steering spline mod.
The McCoy I saw was in Brighouse west Yorkshire travelling with a hard top quantum and a mustard coloured allegro towards hebden bridge so they probably came off the M62 so could of been from anywhere. It was odd because when the quantum came out I recall drooling over it particularly the use of Sierra sapphire back lights but yet now it looked very dated and the rear lights looked massive whereas the McCoy looked more like a traditional yet very small sports car lotus élan esque.Ed. |
The Throttle body
I now discovered a major problem, the throttle body inlet was looking straight at the clutch master cylinder, now that’s not good, I had a few options here, I could either buy a set of individual throttle bodies or go the hard way and modify the one I had..
http://i652.photobucket.com/albums/u...e/IMAG1131.jpg http://i652.photobucket.com/albums/u...e/IMAG1130.jpg Well a challenge it was then, there seems to be a theme going on here, if I can go the hard way then that’s the way to go, my thoughts on these things are, anyone with enough money can go and buy all the nice new goodies and bolt them on but I wanted to make this mine so the modification was the way to go. So here goes (Caution: this part of the build took some time and I want to thank both my welder colleagues for all the work they put in for me here) http://i652.photobucket.com/albums/u...d/IMAG1139.jpg http://i652.photobucket.com/albums/u...d/IMAG1135.jpg First things first, I need to cut and shut the ports to allow the throttle body and chamber to lift up and forward away from the clutch master cylinder, I decided where to cut and then machined both the cut faces flat and square. http://i652.photobucket.com/albums/u...d/IMAG1137.jpg http://i652.photobucket.com/albums/u...d/IMAG1141.jpg http://i652.photobucket.com/albums/u...d/IMAG1142.jpg After I checked the measurements and angles of the machined part, incase I needed to make further changes after a trial fit. http://i652.photobucket.com/albums/u...d/IMAG1140.jpg http://i652.photobucket.com/albums/u...d/IMAG1139.jpg http://i652.photobucket.com/albums/u...d/IMAG1143.jpg After checking there became a mismatch of the ports, this was expected and I was going to put in spacers later to compensate for the errors http://i652.photobucket.com/albums/u...d/IMAG1150.jpg A trial fit was done and the spacer thickness was determined http://i652.photobucket.com/albums/u...d/IMAG1146.jpg http://i652.photobucket.com/albums/u...d/IMAG1144.jpg Once knowing the thickness the angle for each spacer was measured http://i652.photobucket.com/albums/u...d/IMAG1146.jpg Then I manufactured them http://i652.photobucket.com/albums/u...d/IMAG1186.jpg http://i652.photobucket.com/albums/u...d/IMAG1187.jpg http://i652.photobucket.com/albums/u...d/IMAG1188.jpg Once made all was cleaned and this is where my welders made it all come together, after lots of cursing of course http://i652.photobucket.com/albums/u...d/IMAG1314.jpg http://i652.photobucket.com/albums/u...d/IMAG1311.jpg http://i652.photobucket.com/albums/u...d/IMAG1312.jpg One side done….now for the other half |
The Throttle body (cont’d)
This is where the cursing came in
http://i652.photobucket.com/albums/u...d/IMAG1348.jpg http://i652.photobucket.com/albums/u...d/IMAG1347.jpg As you can imagine it was very difficult for him to get to some of the weld areas but he kept at it and produced this.. http://i652.photobucket.com/albums/u...d/IMAG1354.jpg http://i652.photobucket.com/albums/u...d/IMAG1353.jpg Now to machine the distortion from the flange face http://i652.photobucket.com/albums/u...d/IMAG1351.jpg http://i652.photobucket.com/albums/u...d/IMAG1352.jpg With that done the bores were ground flush to remove any welding and rough edges then it was back to the car to see how it looked http://i652.photobucket.com/albums/u...d/IMAG1361.jpg http://i652.photobucket.com/albums/u...d/IMAG1362.jpg That done the trick, well that was the first saga over with.. On assembling the air temp sensor fouled the injector rail so that had to be dealt with, I ground away the rail but that wasn’t enough, if I went much deeper then I would have broken through into the fuel gallery so other thoughts had to be made. http://i652.photobucket.com/albums/u...d/IMAG1417.jpg What I needed to do was machine the boss at an angle to allow clearance, make a new boss so back to the milling machine and then speak nicely to my welder again.. http://i652.photobucket.com/albums/u...d/IMAG1424.jpg http://i652.photobucket.com/albums/u...d/IMAG1420.jpg http://i652.photobucket.com/albums/u...d/IMAG1422.jpg http://i652.photobucket.com/albums/u...d/IMAG1425.jpg http://i652.photobucket.com/albums/u...d/IMAG1426.jpg http://i652.photobucket.com/albums/u...d/IMAG1427.jpg http://i652.photobucket.com/albums/u...d/IMAG1433.jpg http://i652.photobucket.com/albums/u...d/IMAG1434.jpg All done now to fit it all together.. http://i652.photobucket.com/albums/u...d/IMAG1435.jpg http://i652.photobucket.com/albums/u...d/IMAG1436.jpg http://i652.photobucket.com/albums/u...d/IMAG1437.jpg Just right…. |
The Throttle body (cont’d)
After fettling a bit more from the fuel rail to allow for the throttle movement the was on last thing to do..
http://i652.photobucket.com/albums/u...d/IMAG1428.jpg The brake vacuum take of pipe was facing in the wrong direction http://i652.photobucket.com/albums/u...d/IMAG1438.jpg So after gently heating the casting around the pipe I managed to rotate it to the required direction http://i652.photobucket.com/albums/u...d/IMAG1440.jpg http://i652.photobucket.com/albums/u...d/IMAG1441.jpg Now it was completely assembled and ready to fir to the engine.. http://i652.photobucket.com/albums/u...d/IMAG1445.jpg http://i652.photobucket.com/albums/u...d/IMAG1447.jpg Happy with that… |
The wiring harness
I acquired a complete Honda harness that I was going to modify to suit the McCoy, It was a harness from a civic so I would have quite a few bits to cut out, first I took the rear harness and rebuilt that, removing the electric window wiring and anything else I didn’t require
http://i652.photobucket.com/albums/u...s/IMAG0993.jpg Then I started to fit the engine harness and the engine bay harness for the lights etc, this I would cut about removing unwanted bits later. http://i652.photobucket.com/albums/u...s/IMAG0937.jpg http://i652.photobucket.com/albums/u...s/IMAG0936.jpg The parts of the harness I didn’t need were the ABS, Air con etc I made drawings of the wiring and what was for what, labelled all the ends and then it was ready for stripping, I didn’t want to do that yet because I didn’t know what was required for the ecu, so I started the cabin wiring (Warning: If you have a nervous disposition look away now) http://i652.photobucket.com/albums/u...s/IMAG1486.jpg http://i652.photobucket.com/albums/u...s/IMAG1485.jpg http://i652.photobucket.com/albums/u...s/IMAG1484.jpg http://i652.photobucket.com/albums/u...s/IMAG1483.jpg http://i652.photobucket.com/albums/u...s/IMAG1482.jpg http://i652.photobucket.com/albums/u...s/IMAG1490.jpg http://i652.photobucket.com/albums/u...s/IMAG1497.jpg http://i652.photobucket.com/albums/u...s/IMAG1502.jpg Well if you can make any sense of that lot without getting a head ache please come and sort it out because it has done my head in, I won’t let it beat me but I will be doing it in stages, it had taken an age to get here, looking through wiring diagrams, sorting out what is needed, what may be needed, what isn’t needed or of it was effected by what had been or was going to be cut out…..Hmmmm, needless to say I have left this alone for a while now to get my sanity back |
The Seats
As the seats in the car were so tatty I got some from seats from a Ford Fiesta Si, I have had a lot of Fords in the past and I know their seats are good for comfort and as these were from a sport model they lent good support
http://i652.photobucket.com/albums/u...s/IMAG1398.jpg The problem with them were the framework underneath was too high so I made some new sub-frames, took the rails from the cars original subframe and fitted them onto the seats lowering them by about 50mm http://i652.photobucket.com/albums/u...s/IMAG1387.jpg http://i652.photobucket.com/albums/u...s/IMAG1388.jpg http://i652.photobucket.com/albums/u...s/IMAG1390.jpg http://i652.photobucket.com/albums/u...s/IMAG1391.jpg http://i652.photobucket.com/albums/u...s/IMAG1392.jpg Once done I test fitted into the car, they were much better for height and as I am over six feet I didn’t do too bad.. |
The next episode is covering the headlight choices and front wings....
|
Headlights and Front Wings
Well I have been pondering on and off about the headlight originally fitted to the McCoy, they do start to grow on you after looking at them for so long, but you here from people, clan owners as well that they preferred the rectangular head lights that were fitted to them, well yes I think I agree they do look better than the round ones, I also looked into having pop up headlight so I got some from a Mx-5 but when trying to fit them, I discovered with having the Honda engine in the bay they would not fit, so they are for sale, then I decided I wanted to change the front styling so got a new pair of motorcycle rectangular head lights that would nicely fit..
So I started and cut off one of the healight pods to see how they would look.. http://i652.photobucket.com/albums/u...IMAG1559_1.jpg http://i652.photobucket.com/albums/u...IMAG1577_1.jpg http://i652.photobucket.com/albums/u...IMAG1578_1.jpg OK they would work so I started to put some shape into the wing using expanded foam… http://i652.photobucket.com/albums/u...s/IMAG1579.jpg http://i652.photobucket.com/albums/u...s/IMAG1580.jpg http://i652.photobucket.com/albums/u...s/IMAG1581.jpg http://i652.photobucket.com/albums/u...s/IMAG1582.jpg Hmm that may work.. but I would have liked them lower in the wing so I reworked the foam and glassed in flush following the wing shape http://i652.photobucket.com/albums/u...s/IMAG1590.jpg http://i652.photobucket.com/albums/u...s/IMAG1591.jpg http://i652.photobucket.com/albums/u...s/IMAG1592.jpg http://i652.photobucket.com/albums/u...s/IMAG1594.jpg No.. I had another thought, that’s trying to be too much like a clan, so the I thought about twin projectors, so I ripped out what I had done and had a re-think… So out came the card.. http://i652.photobucket.com/albums/u...s/IMAG1624.jpg http://i652.photobucket.com/albums/u...s/IMAG1622.jpg http://i652.photobucket.com/albums/u...s/IMAG1625.jpg That could work, it measures up and a pair should fit in there.. but first I had to build up the inner wing which had previously cut away to accommodate the sub-frame to cover the near side engine mount.. http://i652.photobucket.com/albums/u...s/IMAG1600.jpg With that done I set off to reshape the wing, firstly getting some perforated aluminium, cutting it to shape, covering it in cling film and clamping it in place http://i652.photobucket.com/albums/u...s/IMAG1601.jpg http://i652.photobucket.com/albums/u...s/IMAG1602.jpg http://i652.photobucket.com/albums/u...s/IMAG1603.jpg Then fibre glassing in… http://i652.photobucket.com/albums/u...s/IMAG1604.jpg http://i652.photobucket.com/albums/u...s/IMAG1605.jpg |
Headlights and Front Wings (cont’d)
Once set I could trim the glass back to follow the shape of the bonnet
http://i652.photobucket.com/albums/u...s/IMAG1611.jpg http://i652.photobucket.com/albums/u...s/IMAG1612.jpg http://i652.photobucket.com/albums/u...s/IMAG1613.jpg Now to even up and put in some strength.. http://i652.photobucket.com/albums/u...s/IMAG1630.jpg http://i652.photobucket.com/albums/u...s/IMAG1631.jpg And now to build up the top of the wing.. http://i652.photobucket.com/albums/u...s/IMAG1632.jpg http://i652.photobucket.com/albums/u...s/IMAG1633.jpg http://i652.photobucket.com/albums/u...s/IMAG1634.jpg http://i652.photobucket.com/albums/u...s/IMAG1635.jpg http://i652.photobucket.com/albums/u...s/IMAG1638.jpg http://i652.photobucket.com/albums/u...s/IMAG1640.jpg http://i652.photobucket.com/albums/u...s/IMAG1641.jpg http://i652.photobucket.com/albums/u...s/IMAG1642.jpg Well I at this stage finally decided what I wanted to do, I had seen the technique done years ago with the custom boys and what they did to there rear lights on the hotrods, so out again with the cardboard and a piece of ducting of the right diameter and come up with this.. http://i652.photobucket.com/albums/u...s/IMAG1718.jpg http://i652.photobucket.com/albums/u...s/IMAG1721.jpg So I took some measurements and made this template mould and covered it with lino.. http://i652.photobucket.com/albums/u...s/IMAG1650.jpg http://i652.photobucket.com/albums/u...s/IMAG1649.jpg http://i652.photobucket.com/albums/u...s/IMAG1648.jpg http://i652.photobucket.com/albums/u...s/IMAG1743.jpg Then I clad the whole thing in cling film and cut the glass to suit, mixed up the resin and….. http://i652.photobucket.com/albums/u...s/IMAG1729.jpg out popped this |
Headlights and Front Wings (cont’d)
Next was to cut it to fit and glass it in..
http://i652.photobucket.com/albums/u...s/IMAG1732.jpg http://i652.photobucket.com/albums/u...s/IMAG1733.jpg Then to cut the inside to suit the light, http://i652.photobucket.com/albums/u...s/IMAG1734.jpg http://i652.photobucket.com/albums/u...s/IMAG1735.jpg http://i652.photobucket.com/albums/u...s/IMAG1736.jpg http://i652.photobucket.com/albums/u...s/IMAG1738.jpg oh I forgot to say I had got some Hi-Lo Hid units from E-Bay.. http://i652.photobucket.com/albums/u...IMAG1717_1.jpg http://i652.photobucket.com/albums/u...IMAG1716_1.jpg http://i652.photobucket.com/albums/u...s/IMAG1742.jpg Now to cut for final fit and glass it in.. http://i652.photobucket.com/albums/u...s/IMAG1740.jpg http://i652.photobucket.com/albums/u...s/IMAG1745.jpg http://i652.photobucket.com/albums/u...s/IMAG1746.jpg http://i652.photobucket.com/albums/u...s/IMAG1747.jpg Add a build of glass to bring up the height,, http://i652.photobucket.com/albums/u...s/IMAG1750.jpg http://i652.photobucket.com/albums/u...s/IMAG1751.jpg http://i652.photobucket.com/albums/u...s/IMAG1752.jpg And cover with gel coat, this is where it all went wrong, the gel coat didn’t harden for some reason, I applied heat, left it for a week but still it was a sticky mess.. http://i652.photobucket.com/albums/u...s/IMAG1753.jpg So I ended up having to scrape it all back, cleaning up the mess and I applied filler instead.. http://i652.photobucket.com/albums/u...s/IMAG1754.jpg http://i652.photobucket.com/albums/u...s/IMAG1755.jpg Rubbed it all back and applied a few coat of high build filler primer http://i652.photobucket.com/albums/u...s/IMAG1757.jpg |
Headlights and Front Wings (cont’d)
In the mean time back at work I had to come up with a way to adjust the headlights so out came the cardboard again…
http://i652.photobucket.com/albums/u...IMAG1691_1.jpg Well that was the idea for the brackets now for some adjusters, so I knocked the up.. http://i652.photobucket.com/albums/u...s/IMAG1683.jpg Then some pivots and fix it all together and see what happens.. http://i652.photobucket.com/albums/u...IMAG1687_1.jpg http://i652.photobucket.com/albums/u...s/IMAG1688.jpg http://i652.photobucket.com/albums/u...IMAG1692_1.jpg That all seemed to work so to make them in stainless http://i652.photobucket.com/albums/u...IMAG1696_1.jpg http://i652.photobucket.com/albums/u...s/IMAG1697.jpg http://i652.photobucket.com/albums/u...IMAG1698_1.jpg http://i652.photobucket.com/albums/u...IMAG1700_1.jpg http://i652.photobucket.com/albums/u...IMAG1701_1.jpg http://i652.photobucket.com/albums/u...s/IMAG1702.jpg http://i652.photobucket.com/albums/u...s/IMAG1703.jpg http://i652.photobucket.com/albums/u...IMAG1704_1.jpg Had the corners welded and then assembled them.. http://i652.photobucket.com/albums/u...IMAG1706_1.jpg http://i652.photobucket.com/albums/u...IMAG1707_1.jpg http://i652.photobucket.com/albums/u...IMAG1709_1.jpg http://i652.photobucket.com/albums/u...s/IMAG1711.jpg The base bracket is only a temporary one until I finish the wing and can come up with a plan to fit them under the wings. A few more coats of filler primer and rub down http://i652.photobucket.com/albums/u...s/IMAG1766.jpg http://i652.photobucket.com/albums/u...s/IMAG1764.jpg http://i652.photobucket.com/albums/u...s/IMAG1768.jpg Yeah well pleased with that.. |
| All times are GMT +0. The time now is 09:38. |
Powered by vBulletin® Version 3.8.9
Copyright ©2000 - 2024, vBulletin Solutions, Inc.
Copyright Madabout Kitcars 2022