This is a read-only archive of the old Madabout Kitcars forum. New posts and replies are no longer possible, but every thread is still here to browse and read.
3 new pictures today! One very shiny rocker cover, now polished and painted black. Inlet manifold slowly cleaning up. Not sure how much more I will do on this one. Click me
Construction began properly for the first time today. Already I am having issues. The rear spring seats dont line up - its worse on one side than the other.
Rear suspension test fit. Although the rear spring seats dont align properly the springs seem to go in ok. I'm not 100% happy with this but for the moment it will do. I installed new suspension top mounts from an E46 Cabrio, an E30zone recommendation. Please see new pictures in the gallery: http://www.msportster.co.uk/detail.asp?cat=7
The AVO rear dampers are working very well. Although I had to use the standard plastic covers as the ones that came with the dampers were not quite long enough.
After waiting on missing ball joints, it turns out they're not part of the kit. So ball joints ordered from Marlin.
Steering Wheel should be here soon, all that is needed now is the steering rack (on order) and front shocks (also on order) to test fit the front and get everything in the right place.
Having some issues with the brake lines. I have finally figured out where all the braided hoses are supposed to go, but none of the copper tubes seem to have the correct connectors on them. That means I will need a joiner, if such a thing exisits, or get new pipes made up
Some more pictures of the progress. I've installed ball bearings from the donor car on both the brake and clutch pedal. Needed a bit of lathe work but it got there in the end.
Front suspension is together! Just need the steering rack now for final test fit. I've put pictures up of the progress. Also test fitted the front antiroll bar. I still need to fabricate brackets for them. http://www.msportster.co.uk/detail.asp?cat=7&offset=24
Test fitting front roll bar with donor braket (need to make some for the Sportster)
Got my hands on a 3.91 LSD this weekend! So cleaned it up, removed all the rust and painted it. Also completed cleaning up the front calipers. Need a new dust cap before I do the other side.
Test fit of engine. Got bored waiting for steering rack so we thought we'ed "chuck" the engine in and see how it fits - very nicely from the look of it. The gearbox mount bracket is a bit off so its being held up with a jack until thats bent in to the right shape and had one hole moved a bit.
Since the last post we've fitted the gearbox cross member - that was bit of pain getting the holes in the right place!! Got there in the end though so the car is movable on the build stands again!
The brake servo/master cylinder/pedals are clamped in for test fit. I think I am going to have to move the whole assembly to the left over the standard location. There's not much room for the accelerator to move, and i would like a bit more room for my feet too. I think I am going to have to bend the brake pedal bit so there is more gap between it and the accelerator.
Also today we recieved new rear brake spash plates so I went about installing them. Needed holes cutting in them - this was due me not wanting to take the hubs off. Enough has been take off for the plate to go past the back of the hub leaving all the handbrake assembly parts and the brake hose braket in place.
Also eye'd up where to put the gear lever, i think I am going move the handbrake handle a bit to give more room for the gear lever. I am waiting for Marlin to send the steering rack back to me again then I can position the wheel, hand brake and gear lever all at the same time
Dropped the car on its wheels and took it out on the driveway as it was nice and warm. Not done a great deal except play with the alignment of the steering column now that the rack is in place. Its also the first time it's been on the wheels with the engine in. The front suspension feels good! The steering is very direct the smallest movement from the steering wheel translates instantly to a small movement at the wheels. I can't wait to drive it! It'll be a fare few months yet though! I've taken a few pictures of the whole car as I dont have many of those yet:
No pictures today, but the pedal box is now securly mounted on the car. I've also mounted the back of the gear lever assembly. Decided to keep it simple and used a P-clip. I may revise this to something more sturdy. I've also decided that the Z3 1.9 gear lever I bought is not stubby enough so I am going to get my hands on one from a Z4 3.0ltr. Still awaiting confirmation on part numbers as there are two different types.
Mounted the tank, We had to make up some spacers to bring it all the way back. I dont have any pictures yet - watch this space!
Also done a bit more work on restoring parts off the engine. The wiring loom got a clean as well as all the water pipes. The metal pipe off the front of the engine was rotten through so I ordered one from a breaker to replace it. The replacement had a bit of surface rust but other than that very good. Thats also been cleaned up and painted.
A friend sourced a fuel pump for us so thats ready to go. I have to place an order for fuel pipes, filter and oil cooler. Also a few bits and pieces for the car. I've decided to get a full new set of OEM disks and pads from Motormec. Still making a list for all that! I will get some more pictures up soon.
Another week end another few bits and pieces done. The fuel tank is mounted, the brake pipes are back from our local garage flared, the steering rack is nicely in placed with the column in a trial position. 4 meters of vinyl from Marlin are on their way to Cobra seats for a set of custom Roadster 7 to be made up.
We're having some fun with the radiator. We've established that is a BMW rad from Marlin but we've got no idea how to mount it. The brackets from Marlin don't seem to work with the rad, further conversations with Marlin will be need to figure this one out! One thing that is certain is that the stock water pipes are not all the right length to work with the new radiator. So custom ones will need to be ordered.
We have taken the engine out to do some work that can not be done while its in place. This includes the radiator mounting, clutch pipe, brake pipes and fuel pipes. Fuel pipes still need to be done but the rest is complete. The radiator is now in place along with all the brake and clutch pipes. We have made our own mounts for the radiator as the Marlin ones wouldn't work with electric fan - not enough room for it. There are pictures of the Marlin mounts and our custom ones on the construction section.
A lot of new parts through including a full set of disks and pads, alternator mounting bracket, Z4 3.0ltr shift level, and various O rings for the engine all from motormec.co.uk. Also in fuel pipe, battery clamp, kill switch, light switch, and various other bits from Car Builder Solutions (nfauto.co.uk). We''ve got to be almost there for parts now!
Finally a comparison between shift levels original on the bottom, Z3 1.9 in the middle and Z4 3.0ltr (early model part number) at the top. The Z4 has the shortest shift of all of them.
Put the E36 wheels with Bridgestone RE720's on this weekend. The clearance at the back is now much better with the stud adapters. They look good too! Rain has stop us taking the car outside to get good pictures.
Also now under construction an adpater plate to fit the steering column. The steering feels very good even on the spot.
(more pics on [url]www.msportster.co.uk[/url]) 
True 
Am enjoying your posts.
Got my hands on a 3.91 LSD this weekend! So cleaned it up, removed all the rust and painted it. Also completed cleaning up the front calipers. Need a new dust cap before I do the other side.
[/url] 
