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R1 Fwd Build..let The Games Begin


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#31 mr_conrod

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Posted 06 May 2008 - 12:45 PM

Hello to all....

Just like to say im loving all the builds that are currently in progress, its great to see the mini kept alive and especially with
all sorts of exotic engine conversions being undertaken. Our build progress is steady but sure at the moment.
A lot of time is often taken up thinking, measuring, drinking tea and ordering parts, so the actual fabricating of late hasn't been
too time consuming. We are currently on with the gear selector mechanism and the latest pics (www.flickr.com/r1manx)
show the almost complete working design. We just need to fab the main selector rod which passes through
the bulkhead from the steering column shifter to the engine bay. The next step will be the diff housing and James
is already on to the bearing blocks and giving his old school lathe plenty of stick! We need to finish the bearing blocks,
fabricate an oil can, fab a sprocket adaptor plate and press in the main bearings and driveshaft oil seals. The jobs after that will
be the diff/chain tensioner once the diff is in place, custom exhaust header, custom length driveshafts and then wiring loom setup.
So far the build is looking good and we are happy with the design, we just hope it performs well when we finally get round to getting her lit!

I'll be posting plenty more pics as more parts are made/fitted so feel free to take a look and any comments/advice etc...
is more than welcomed.

Cheers

#32 mr_conrod

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Posted 09 June 2008 - 09:53 AM

Morning guys,

Well the 'R1 Manx' is coming along nicely now. I have had a full on weekend removing the engine and box from my rally car aswell as attending to the mini project. We made good progress last week and I spent a fair bit of time doing non R1 mini bits. I have now got the rear subframe built up to go into the car for when we start testing. I replaced the wheel cylinders, brake shoes and springs, drums for minifins, new cones and hi lo's at the back (the current ones had siezed solid), new knuckle joints and new handbrake cables. The radius arms are in good condition and have been cleaned and painted up and I will also renew the rear wheel bearings.

As for the R1 mini parts of the project, we worked on the differential/sprocket setup some more. I now have a D.I.D. race spec chain and a 39 tooth Renthal rear R1 sprocket to fit. After a few hours of discussion and measuring the bearing blocks and diff, James and I drew up some part specs in Autocad. These were for the sprocket adaptor ring and the oil can and its mounting ring. The drawings were sent off to westgarage in the UK and they are fabricating the parts for us. When they are here we will bolt the diff parts together and then build the steel cradle around the diff and hang it off our engine frame.

Meanwhile, this week we will look at the exhaust. Due to engine position, the stock header sticks out too far so we will fabricate a custom header which will run tight to the block and then underneath the motor where the downpipes will meet the collector. The tricky part is getting the downpipes the correct length so as to maximise performance. I will update the website when we have more pictures together so please take a look if you're at all interested in our build. I hope we can have a running prototype by the end of the summer, it's going to be a mint day when we finally get her lit!

Cheers

Ben
www.r1manx.com

#33 mr_conrod

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Posted 27 June 2008 - 02:35 PM

Hello to all,

Its been a while since my last post but we have made good progress on the R1 Manx build. I haven't got round to updating the
website yet but will do soon. So, we have made a start on the exhaust header in stainless steel, and after chopping up the
downpipes from the stock bike header, we made a start on the bending and welding the custom manifold. It is proving
quite a challenge with the header as there is very little clearance for the flip front and not much room underneath the sump
to run the downpipes into the collector. I have been restoring both subframes over the last month or so and now have the rear
subframe in ready for testing, with new knuckle joints, cones and hi lo's installed. On the front end, I have replaced the wheel
bearings and top and bottom ball joints, installed rose jointed heavy duty bottom arms and heavy duty tie rods. The car is now ready
to be on wheels so we can test the car once the build is complete in prototype form. s for the diff, we designed an oil can and sprocket
adaptor ring using Autocad and had it sent to Westgarage in the UK who have done a mint job of fabricating the parts. When they arrive,
we will be ready to make the diff cradle and hang it from the engine frame, and then measure up for custom driveshaft lengths. I have
posted new pictures up (www.flickr.com/r1manx) so please take a look...they are now in separate categories (ie. engine frame, diff, exhaust)
to make it easier to navigate around. I will keep everyone posted soon on how the diff assembly goes, can't wait to fire it up and drive the beast!

Cheers

Ben
www.r1manx.com

#34 supermotolee

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Posted 27 June 2008 - 07:02 PM

sounds really good have you thought of running the headers around the side of the engine? as you say if you run the car low you will struggle with ground clearence

i think z cars have done this as they have revised their engine mounts to bring the engine lower

#35 mr_conrod

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Posted 27 June 2008 - 10:33 PM

sounds really good have you thought of running the headers around the side of the engine? as you say if you run the car low you will struggle with ground clearence

i think z cars have done this as they have revised their engine mounts to bring the engine lower



Hi,
Yeah we have considered running the downpipes round the side of the engine but due to the eventual
radiator position and the diff tensioner, one side of the motor is definitely not an option. With us running the
pipes underneath we can at least still get the downpipe lengths matched so as to maximise performance and
engine running. It is always a trade off with these custom builds, but with the stock sump guard in place, we found
that the downpipes will still fit underneath the motor, even if the engine is sat a little higher than I would have
preferred.

#36 mr_conrod

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Posted 09 July 2008 - 11:19 AM

Hey guys,

Loving some of the rare build projects on the forum, its great to see people trying there hand like we are. We now have the diff parts back from westgarage (www.westgarage.co.uk) and I have to thank Douglas Anderson there for fabricating the bits exactly to our design, top bloke. Yesterday, we got the rear engine mounts installed which attach to the rear bulkhead and have pressed in the peugeot 205 bushes. The engine is basically in its desired location now so we made a start on the diff cradle. This is being made from strip steel and will brace the diff and bearing blocks and the whole unit will hang from the engine frame via rose joints. This is so the chain tensioner can work as the whole diff can pivot on the rose joints off the frame. We hope to have the diff assembled with the oil can and sprocket on within a couple of weeks. Then we measure up for shafts and get them cut, and meanwhile have been looking at the cooling system. I am going with a mini Mpi radiator and need to decide on what fan(s) to use. Only time will tell if the rad is up to the job. I have now updated the website (www.r1manx.com) and new pictures are up too so feel free to check them out, much appreciate any advice/comments on our build.

Cheers

Ben




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