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-   -   Ray Hutchings Formosa project (http://www.madabout-kitcars.com/forum/showthread.php?t=6659)

lancelot link 16th March 2018 20:18

Ray Hutchings Formosa project
 
A couple of weeks ago , after a few phonecall's , Ray went to see Graham Alexander , who very kindly gave him an hour or two of his time showing him around his car and even took Ray for a little cruise around Melksham outskirts ..
As a result of that viewing , I was asked to try and locate a suitable Vitesse donor for him ...

I asked a couple of guys who I know play with Vitesses and Heralds , ran a wanted advert ...and then one of my phonecall's paid off ....

Andy from Wales dropped this to me end of last week ....

http://preview.ibb.co/gAT2cx/IMG_20180307_134031.jpg

Its a Mk2 2000 with overdrive , rotoflex and has a 6 branch , servo , a couple of other tweaks and sounds great ...

I set about stripping it and now we are at this stage ....

http://preview.ibb.co/jKzfVH/IMG_20180316_094709_1.jpg

The chassis is very good ....It had a tiny hole on a centre rail , a crack on top of a boot outrigger and a small slice from me cutting through the floor and hitting the outrigger as well as a bit of damage on the passenger side outer rail from seized in bolts holding the rear tub in refusing to budge ...

I welded the hole, crack and slice and then changed both outer rails to boxed in rails using 3mm thick box to add strength and give me enough meat to drill and tap as required ...

http://preview.ibb.co/b7euPc/IMG_20180316_124442.jpg

http://preview.ibb.co/hgDzqH/IMG_20180316_124453.jpg

Just before I left for the day ...this arrived ...

http://preview.ibb.co/mcQCAH/IMG_20180316_133035.jpg


This is going to be a full build , going down pretty much the same route as Grahams ....I have 3 ongoing builds now , Erics , Barry's and this one ...so I am officially booked up for the forseeable ...

I do have an established builder who can take on a turnkey , if anyone reading this wants one ...but it will be a few months before I can do a full one ....

Ray is coming down Monday and , between us , we will be pulling the engine and box , so I can turn the front turrets around to reverse the engine mounts and lots of cleaning up and paint prep etc...

Barber 16th March 2018 21:10

Well done Gary, a true open top is not for me, but they are lovely looking cars, and seeing them go from rusty chassis to shiny end product is fascinating.

Alex 17th March 2018 08:33

Great work mate, I know Ray is really looking forward to the build so hope all goes well and possibly a bit easier than mine as we should have ironed out the first build issues we encountered. The doner car looks great and look forward to watching the progress with interest

lancelot link 19th March 2018 19:38

Ray turned up today and is going to spend a couple of days staying in Bournemouth and 'mucking in '

So by lunchtime we were at this stage ....

http://preview.ibb.co/guw4Uc/IMG_20180319_134329.jpg

Engine and gearbox out and chassis cleaned up ...

By the end of play , the rack was off , stripped and cleaned up .....new parts being fitted tomorrow .
The turrets were off , brake pipes etc all stripped off and then Ray put a coat of paint on the rear section of the chassis ...

http://preview.ibb.co/dkEKvH/IMG_20180319_182757.jpg

tomorrow should see turrets re-fitted opposite each other , further cleaning and painting etc. whilst I tackle patching up the bulkhead ..

RayHutch 23rd March 2018 13:48

Hi everyone, I'm Ray. I saw Gary's eBay advert and responded based on the fact that I had just seen a Miglia sold at Ascot Historics auction.

I am very grateful to Graham (Alex) for showing me around and taking me out for a run in his gorgeous Formosa. I have owned Caterhams for about 20 years and going out in the Formosa was like driving the Caterham for the first time - or like getting a new bike as a kid !

Gary has been kind enough to let me assist in the non technical work to allow him to use his skills more productively. It's a bit daunting at the moment (I didn't build my Caterham) but Gary is leading me through the process and helping all the way. He also appears to be a bit of an eBay Ninja as he somehow finds stuff that I can't.

It's good to start a build thread. The Vitesse is a good quality donor car in the areas that we need it to be. As Gary mentioned, I'm hoping to be assisting weekly and getting thoroughly immersed in the project !

Barber 23rd March 2018 17:28

:welcome:

micky1mo 23rd March 2018 17:51

RayHutch :welcome:

lancelot link What's the advantage of swapping the front suspension turrets? :icon_confused:

Paul L 23rd March 2018 18:41

RayHutch - Welcome to the forum Ray. :cool:

I like the idea of helping out with the build, I'm sure you will learn a lot.

Good luck, Paul. :)

redratbike 23rd March 2018 18:58

Quote:

Originally Posted by micky1mo (Post 93903)
RayHutch :welcome:

lancelot link What's the advantage of swapping the front suspension turrets? :icon_confused:

Moves the engine mounts further back needed on this car due to the long bonnet

lancelot link 23rd March 2018 19:39

Quote:

lancelot link What's the advantage of swapping the front suspension turrets?
Quote:

Originally Posted by redratbike (Post 93908)
Moves the engine mounts further back needed on this car due to the long bonnet

Half right REDRATBIKE ... It moves the engine back about 8'' by simply putting the engine mounts at the rear of the turret rather than the front ...its an old racing trick , nothing new or cleverly designed by myself ...on Heralds its pretty straightforward , the Vitesse with overdrive brings a little clearance issue to the table and I have to nibble a little bit to get clearance on the chassis rail .....

Although shifting the weight back is better for weight distribution , with the Formosa , its more about getting the gearstick in a better position ...approx 48'' ( not fixed in stone ) from the centre of the rear axle to the gearstick is what's required for my bodyshell ...
This can also be achieved by leaving the engine where it is in its standard format and fitting an extended shifter to the gearbox ...like the Spartans and Miglia's etc. The bonnet has plenty of clearance with a 6 cyl. in its stock mounting place ...

Obviously different engine options will have different locatory properties ...but 47-49'' approx gearstick to centre rear axle location will be your datum line , so to speak ....

redratbike 23rd March 2018 22:15

Quote:

Originally Posted by lancelot link (Post 93909)
Half right REDRATBIKE ....

:hail::hail::hail::hail:

lancelot link 24th March 2018 18:09

Pictures to follow.... after several fits and removal of engine and gearbox , its evident that Rays 6 branch exhaust system is fouling the chassis where it goes past the bellhousing , I have , therefore , had to mount the engine on the front of the engine mounts and fit a smallish spacer between engine mount and turret , so we are looking at about a 6.5'' shift backwards now and a 49'' axle to gearstick measurement .... I have had to modify the exhaust slightly to tuck it in to the engine a bit more too ....still good though ..so happy days

lancelot link 27th March 2018 18:39

HERE'S THE MOD i DID ON THE EXHAUST... The piece just in front of the bellhousing was reduced in size to an internal fit of the existing tube and welded in place ...these few mm. were crucial , its so tight in that area ...I also tucked the piece behind it in a bit and fitted a joining strap holding the two pipes together and a strap that affixes to a bellhousing bolt so it can't knock against the gearbox ...

http://preview.ibb.co/f9SuQS/IMG_20180326_171108.jpg

I then flipped the chassis over , did the welding that was required underneath and painted the underside to match the rest ...after putting the engine back in and fitting some 'bedrock' temporary shocks and putting the wheels back on, I got it back to a rolling stage ...

http://preview.ibb.co/cuob5S/IMG_20180327_152706.jpg

I then shortened and refitted the propshaft .....followed by first fit of the frame to enable me to position the bulkhead correctly .
The front floorpans were trimmed back to allow the bulkhead to slide backwards from its stock position ..the frame attaches to the top hinge mount on the original A pillar at this point.
I have got to adjust the frame slightly as Ray has aftermarket shock mounts fitted that change the location of the rear frame mount , also a boot outrigger has been replaced previously and is slightly out of line , so I may slice that and tweak it in a bit too ...

http://preview.ibb.co/dyr7C7/IMG_20180327_152730.jpg

final job today was to make the new bulkhead support pieces , made and roughly located but not fully fitted as I ran out of time ...

http://preview.ibb.co/gLjYkS/IMG_20180327_160343.jpg

tomorrow should see these fitted , fuel tank trial fitted , some seat belt mounts etc...

Alex 27th March 2018 18:45

Looking good Gary, hard to think that a year ago we were going through exactly the same with mine, keep up the good work and hope Ray is enjoying the build

RayHutch 29th March 2018 18:15

Great progress Gary, see you on Tuesday for some fun with brake pipes !

lancelot link 30th March 2018 10:51

Bit more done .... Pedals refitted with new m/cylinders , servo refitted but centralized a bit more to give room for a battery.

http://preview.ibb.co/f4kGs7/IMG_20180329_111056.jpg

Fuel tank in , Spitfire one , and some extra bracing added to the frame to support it ...

http://preview.ibb.co/jZzgQS/IMG_20180329_111115.jpg

RayHutch 30th March 2018 12:06

Don't forget to leave room for the turbo ;-))

lancelot link 6th April 2018 19:27

FEW MORE JOBS DONE THIS WEEK ....Nothing particularly exciting , unless you are Ray !!
Rear brakes stripped out , all metalwork cleaned and painted and rebuilt using new cylinders and shoes ...
Anti-roll bar refitted on reversed suspension arms with new bushes fitted ...
Some welding that got missed welded on the frame , seatbelt mounts added and steering column mount made - steering wheel looks to be in a weird position in this picture ...its just the angle !! Its nicely centralized ...

http://preview.ibb.co/kbscwc/IMG_20180406_174730.jpg

Brake pipes started , new pipes made , main ones run and clipped to the chassis , new flexi's ready to go on .....

Steering sorted out ... I fitted a TR6 U/J in place of the standard Vitesse knuckle at the steering rack , then a second U/J half way up to deal with the change in angle required on the column , between the 2 U/J's on the lower section is a rose joint that will support that section ...

http://preview.ibb.co/bYVQhH/IMG_20180406_174655.jpg

The rose joint is going to be bolted through a section of the front tubework ...I started this today as well , mounting the Lotus Radiator and creating a front section that will tie the bulkhead to the front framework and shock towers to add strength ...all bolted and fully removable to get access to engine if ever required ...

http://preview.ibb.co/cDEFGc/IMG_20180406_174537.jpg

Hopefully get this framework and steering mount finished tomorrow ...

lancelot link 11th April 2018 07:00

Frame work and steering shaft mount all finished and painted ...

http://preview.ibb.co/gsA4zx/IMG_20180409_173830.jpg

Fully bolted to bulkhead , suspension towers and original rad mounts and fully removable to enable access to engine removal etc.

http://preview.ibb.co/cJcv6c/IMG_20180409_173854.jpg

lancelot link 11th April 2018 18:22

Mounted Rays Handbrake today ...Ray bought quite a stylish little handbrake on Ebay and I fitted it and the compensator bracket to the frame this afternoon ...

tomorrow I will make some cable guides to lengthen the rear handbrake cable ...it needs to travel a longer distance to get to the compensator because I don't want to shorten it ...
I will also modify the front cable as well , as we have moved the lever back a bit over its stock location ....

I made the mount a bit heavier duty than probably necessary , braced and boxed etc. ...but it is nice and strong ..which is always good ...

http://preview.ibb.co/g98LPx/IMG_20180411_171633.jpg

lancelot link 20th April 2018 18:57

Ray ''Don't call me Raymondo'' came down yesterday and painted his frame with POR15 ..I have not had any dealings with it before and its a little bit time and preparation critical , but it is quite impressive ..it has the look and feel of a plastic coating finish on the frame ...

https://preview.ibb.co/nF2EHS/IMG_20180419_164553.jpg

I have allowed it to cure today , but tomorrow morning its going back on the car ....body is going to be ready on wednesday morning ...so it's all going to start shaping up quite quickly now ...

RayHutch 20th April 2018 20:05

Also managed to POR15 parts of my hands, arms and head. Impossible to remove (good sign), even with petrol.... I’m sure it will wear off !

While the first coat of the POR15 was drying Gary took me to the fibreglass fabricators where they were making the bonnet - highly recommended to see the body coming together. Once Gary trains me how to post photos to l’ll put them up.

Quick shout out to Gary’s neighbour Dave who’s hospitality is peerless :-))

molleur 20th April 2018 22:26

Have a look at "Rust Bullet" Very similar, half the price.

Paul L 21st April 2018 05:46

I know I keep saying it, but the internal framework does look impressive. :cool:

Good luck, Paul. :)

lancelot link 21st April 2018 07:19

Quote:

Originally Posted by Paul L (Post 94450)
I know I keep saying it, but the internal framework does look impressive. :cool:

Good luck, Paul. :)

Thank you ...

lancelot link 8th May 2018 18:40

Having pretty much drawn a line under Barry's car , it meant that today I could get back to Ray's example.
I fitted the frame back on properly , first fit since painting it , bolted everything back as it was ....fitted his wheel adaptors and put his 15'' wires on .

I dropped it off the jacks and put the body in place for it's first trial fit ....

https://preview.ibb.co/fZ7Sm7/ray2.jpg

I need to remove the body , fit fuel tank etc and hopefully after a bit of a roll about the rear wheels will level up ...the front wants raising a bit as it's a bit low ...soft springs I suspect as they all get cut a similar amount initially ...

https://preview.ibb.co/k1TmDn/ray3.jpg

The body was pinned in place at the bulkhead and clamped at the rear to check frame fit / wheel arch centreing etc... and all is good ..little bit of fettling and alignment required on final fit but thats normal at this stage ....

https://preview.ibb.co/me0cKS/ray4.jpg

lancelot link 9th May 2018 17:54

Fuel tank has gone back in and was plumbed up in the process ...fuel line runs along its stock route through the outriggers . The Spitfire fuel tank really is perfect for this type of conversion .

https://preview.ibb.co/nAf8uS/320893...91998464_n.jpg[/url]

The steering was hooked up and body re-instated so that I could fit the exhaust system.
The front section was fitted when I shifted the engine back , but the rear section is too long as a result of the shift backwards and less overhang than the stock Vitesse bodyshell.
So approx 57cm was removed and piece of slightly larger exhaust section ( actually a piece I removed from Grahams car ! ) was welded to the end to enable it to sleeve over the front section .

Then I made a rear crossmember....

https://preview.ibb.co/kxRsMJ/321166...74007552_n.jpg[/url]

and when it was bolted across the two boot outriggers , it gave me two mounting points for the rear tail pipes . The crossmember laps under the outriggers to stop it twisting as well ...

https://preview.ibb.co/jsUAad/320872...35284992_n.jpg[/url]

Ray wanted some subtle peek-a-boo tail pipes , not sticking too far out but just showing themselves subtlely at the rear ....hopefully this is what he asked for !

https://preview.ibb.co/cTj1Fd/321701...94648064_n.jpg[/url]

RayHutch 9th May 2018 18:03

Looks good Gary, I like the link between Graham’s and mine :-)

Looks like some complicated challenges overcome.

lancelot link 10th May 2018 18:14

I went round the bodyshell fixing it in place and moved the rear body mounts outwards a bit

https://preview.ibb.co/mpeAty/321884...96863744_n.jpg[/url]

With the body in place , I turned my attention to the front end ...I trimmed back the inner wing section and started to look at mounting the bonnet

https://preview.ibb.co/k1kdfd/322223...38530304_n.jpg[/url]

I made up a framework using my standard bracketry and tube method I have used before ...I also made the little hinge brackets and bolted them to the lower edge of the flip front ....Ray now has a opening bonnet..........

https://preview.ibb.co/hzGC6J/321874...37068288_n.jpg[/url]

https://preview.ibb.co/kqQB0d/321606...29543680_n.jpg[/url]

I will cut the grille opening out fully and the headlamp sections in the morning ....

RayHutch 10th May 2018 18:21

Wow, really coming together !

Alex 10th May 2018 20:03

Looking good mate, brings back memories :icon_razz:

lancelot link 16th May 2018 18:26

Managed to get Ray's door frames done and first fitted ...The frames are pinned on at present , I have ordered some 7.9mm aluminium spacers from my engineer mate to mount them properly ..

https://image.ibb.co/fdYxiy/IMG_1573.jpg

https://image.ibb.co/nDVhGJ/IMG_1572.jpg

I used my pattern doorskins that I use to make the frames to ensure the frames are seated properly in the gaps ..

https://image.ibb.co/gqhOOy/IMG_1571.jpg

Then I turned my attention to the bootlid ....

molleur 16th May 2018 18:39

looking great! Well done.

lancelot link 16th May 2018 18:47

Ray wanted hidden hinges , like Grahams , so I made up another pair of hinges and also made a pair of pivots that are linked together with a bit of strap iron and two corner braces ...

https://image.ibb.co/bDXbAd/IMG_1570.jpg

This was then bonded and bolted onto the inner lip area of the boot aperture ...it will also be bonded to the rear deck area to ensure it is nice and strong. I then took another pair of hinge plates , welded 4 countersunk 8mm bolts into each plate and joined them together with a piece of 30x30mm box...these were bolted to the hinges and will form the brace and mounting points for the bootlid.

https://image.ibb.co/dawsiy/IMG_1569.jpg

I trimmed the bootlid right back to virtually a single skin , but the advantage of starting with a deeper panel means you get a gel coated edge rather than the raw edge of a cut out panel ...The the boot brace was supported underneath by an axle stand in the right position to line it up with the boot skin .I then gunned a load of bonding adhesive onto the brace bar , heaping it on nice and generously ...the boot skin was then bedded down into the adhesive and weighted and propped overnight to allow it to dry in position

https://image.ibb.co/dJbWbJ/IMG_1568.jpg

lancelot link 16th May 2018 19:26

I have been working on some bespoke bonnet and boot pins , I haven't run them past Ray yet ..so at present , not sure what latch style we are going for ....

lancelot link 17th May 2018 19:42

weight and props removed , inner lip trimmed back ....

https://image.ibb.co/fEbC3y/IMG_1574.jpg

Also managed to make a start on the inner arches ...will box the rears tomorrow morning when they are cured ...

https://image.ibb.co/d2qiAd/IMG_1575_1.jpg

Barber 18th May 2018 06:27

Quote:

Originally Posted by lancelot link (Post 95033)
weight and props removed , inner lip trimmed back ....

Gary, I think you are just quoting random bits from 50 Shades of Grey.

lancelot link 18th May 2018 18:59

https://image.ibb.co/mHyQQo/IMG_1577.jpg

The rear edges have been rounded off and all wooden areas were coated in resin ...

lancelot link 19th May 2018 18:05

4 hours in the workshop this morning got a few jobs done ...I managed to raise the front suspension a bit ...I think it's ok now , but when the rear settles a bit more ..its come down a bit already ..I will be in a stronger position to get the ride height how we'd like it ...

I put some extra fixings through the space frame augmentation and down into the chassis ...these will hopefully double up as mounting points for seat belts too ...

Then I started to fit the aluminium bulkhead ...its been bonded and rivetted every 50mm around its outside edge ...I'll clad the rest a bit further on in the job ..I'm expecting the rear bulkhead on Monday , so would like to get that area finished before I come back to the front ...

Although it doesn't show in the picture very well , both sides of the aluminium panel have swaige lines pressed into them ...

https://image.ibb.co/e3Z1Y8/IMG_20180519_150839.jpg

lancelot link 22nd May 2018 19:21

Spent some time yesterday , tying the front footwells into the chassis ...when the bulkhead shifts back , the footwells need to have the back edge removed . This means the rear edge no longer sits on the front outrigger , as it did ...an addition of a 'vertical'Z' shaped piece of folded steel , welded , riveted and bonded into place ties it back together and adds some real strength to this area ...A fibreglass tunnel will cover the edges and centre area ..

Today , I made a steel frame from 20x20 mm box , 25x30mm angle and 25mm flat bar to support the expansion/filler tank. We didn't want to mount it to the bulkhead as the exits weren't working for us ...but spacing it off in a frame that is bolted through the bulkhead shelf area where the heater used to be and back into the upright bulkhead area , is perfect for us ...nice and high to be efficient and really sturdy.

https://image.ibb.co/hkaLWT/IMG_1595.jpg



I also marked out most of the dash area and cut the holes for gauges ..

I also managed to get the filler cap fitted ...measurements were taken from front and rear of filler neck on the tank , transferred to the rear deck and then an investigative pilot hole drilled just large enough to get a thin screwdriver through ...this is to check the hole centre is in the right place ...it's easier to deal with an extra pilot hole in the bodyshell , if its wrong , than a 50mm hole saw opening cut in the middle of the rear deck !! I was bang on -exactly in the centre of the tank filler ...so I proceeded to open up the hole to accept the cap fitting ring ...

https://image.ibb.co/gPu8J8/IMG_1594.jpg


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