Mac#1 Motorsport Worx Build

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jason61c said:

Cheers for that, how long are the pins? Does the bonnet feel secure?

450kg would be some going

I've not measured the pins but they were about 100mm/4" long.

The bonnet feels quite secure the way it is, but will feel better when the rubber bushes are slid over the top of the pins, then the bonnet will be held down tight against them.

Well 450kg is the target, will find out when it's on the road, to be honest even if it is a bit heavier I don't think i'll really notice, lol.

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I've been doing a bit of thinking and have came up with this plan for the cooling system, as i'd like to run a header tank instead of an expansion bottle.

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I didn't do anything on the car yesterday due to feeling a bit unwell but I did manage to take delivery of some parcels...

First off some rose joints and misalignment spacers for the exhaust support hanger.



If you've been reading the thread you'll remember the standard oil/water heat exchanger has been removed to make space for the turbo, meaning no oil cooling at all, so I've been doing a bit of research and I have been unable to find an upgraded oil cooler kit for a Kawasaki ZX10R.

The Kawasaki oil filter thread is M20x1.5 and the oil filter seal is I.D. 54mm and O.D. 62mm.

I found on ebay a Mocal sandwich plate with built in thermostat intended for Peugeot 106/206/306 GTI, the dimensions looked suitable so I ordered it.

Here it is...



The oil filter screws on nicely and seals nicely against the sandwich plate, result... well it will be if it fits to the remote oil filter mount, but there doesn't look to be any reasons why it will not.

Edited by Red16 on Saturday 8th January 13:21

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Another parcel arrived this afternoon, some braided fuel hoses and fittings

Mabbx said:

I think your 450Kg is very achievable with engine weight. I am currently building a MEV Rocket and aiming for simular BHP/ton. Doing my best to keep the weight down also - wheels weigh 5kg each and are 15 x 8 on rears (225 tyre)and bucket seats weigh 2 kg each - all carbon fibre and no GRP or ali panels. The engine is a supercharged new 2.0 Zetec - forged pistons, rods, head work etc. As long as I can match you build quality i'll be happy.

The ZX10R engine and gearbox weighs in at 67kg if i remember correctly, which is pretty light really, so should help a lot

Do you have a build thread of your car? I'd love to see it if you do, sounds a nice all round package, supercharged zetec should be very responsive!

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Mabbx - your build looks great, love the clean look of the chassis. The carbon/composite floor is a lovely touch... is it expensive?

Loosely fitted some parts today, here's how the fuel hoses and filter fit between the regulator and rail.



and with the inlet in place



Cut to length and then made up the hoses, here's the Bosch 044 pump outlet



Return hose to tank, it will fit a lot better than this when it's routed and fastened down properly.



and finally the feed/return hoses connected to the fuel pressure regulator.



I'll get round to fastening the hoses securely to the car tomorrow.

Edited by Red16 on Sunday 9th January 21:38

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Today I tidied up the fuel hoses and secured them to the chassis







and took delivery of a non return valve to use on the breather outlet of the petrol tank

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I've been too busy playing on the PS3 today to progress the car, but I did manage to accept a parcel from the postman.

Steve_D said:

Is that a roll over valve or just a one way valve?

If it is just one way then it will not allow the tank to breath.

Cheers for pointing that out Steve, I completely overlooked the air expanding inside the tank!

procomp said:

Your front dampers are fitted upside down. They do not work that way. Do some research with other Mac owners.

Matt, they were sold to me by Mac#1 as revalved to work the way they are fitted to my car.

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Ponk said:

Can I ask why you are using push on fittings for the FPR to rail but braided for the rest? You've done a great job routing the hoses, it's not easy keeping them neat.

Sorry Ponk, I forgot to reply yesterday, the reason is I already had the hose and fittings in the garage, but I'll be replacing it with braided hose because it doesn't look right being different to the rest of the fuel hoses.

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I marked out and then cut the top panel for the transmission tunnel. Once rested in position the edge trim pieces were laid on top and then drilled to accept rivots.



At the moment I'm not sure wether or not to use small rivots like the ones in the photos or use rivots with larger heads.



The pedals were fitted along with the clutch cable, will fit the accelereator cable tomorrow.



Work was interrupted when one of the neighbours pets, a.k.a. garage kitty, decided to pop in for a mooch around.





I eventually got round to cutting the bulkhead panel to accomodate the steering column



The silver section at the top of the steering column has now been painted black, which blends in with the dash a lot better. Heres how the passenger compartment is looking... starting to take shape nicely now

Edited by Red16 on Thursday 13th January 20:15

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Yesterday I cut the holes in the transmission tunnel upper panel for the handbrake and gear change levers. The trim edging was then marked out and drilled so it could be fitted to the inside edge of the outer sides of the cockpit.

Once all that was done I gave the parts a lick of etch primer



The intercooler pipework needed to be altered again, for the last time this time (hopefully) so I set about cutting the old pipes off and prepping the new ones



This morning I have been to see a local lad to have the intercooler pipes TIG welded onto the intercooler, while he was busy I got an extra 10mm pipe welded to the hot side of the radiator, this pipe is for the turbo cooling water water return.



A couple of parcels have been delivered too

One set of oil cooler fittings and push fit hose



A custom made propshaft to suit bike engine at the front and Freelander rear differential.



a gear linkage kit



One piece of the linkage kit wasn't painted, so I done that



and finally, a 300mm alcantara steering wheel

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Jason I prefer to use MIPA etch primer, great stuff, comes in a rattle can too, for the other coats I use 2k paints and lacquer, applied with a Devilbiss spray gun via a small compressor.

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plasticpig said:

You do know that spraying 2 pack is illegal outside of a proper filtered spray booth? Isocyanate is nasty stuff and there is a good reason for it's controlled use.

I know of it's toxic nature and the need for adequate PPE, but I didn't think it was illegal.

Toyless said:

Is that a Bailey Morris prop ? Doesnt look like its got the cush drive section built in ?

I don't know who made it, I bought it from Mac#1, it hasn't got a cush drive section.

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Done a little bit today...

Fitted the radiator fan



One completed exhaust support rod, will fit it tomorrow



Loosely fitted the prop





Remote oil filter mount and oil cooler sandwich plate secured to the chassis



Steering wheel drilled and loosely fitted to the quick release boss to get a photo taken, need to get hold of three 5/16" UNC bolts to properly secure it to the boss.

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CPDMotorsport said:

Can you tell us who made that for you please? I need an almost identical prop' for a car with a Freelander Diff and ZX10R Engine.

I've sent you an email with details mate.

I painted the panels black this morning, but they look grey in the photo, ready to be lacquered tomorrow



I also made up a plate to mount to the top of the oil cooler, which was then welded to the intercooler, finally the intercooler was given a flash of black paint to make it more discreet.



I started making up the oil cooler hoses using Aeroquip fittings and socketless hose, but gave up and came indoors after the first one, what a bd they are to push on to be continued...

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eliot said:

I assume the Fuel rail is dead-headed. And you have the inlet/outlet of the fuel pressure regulator round the right way?

Yeah that's right.

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Not done much on the car today, been preoccupied with it being the wifes birthday, but managed to nip out and lacquer these panels

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*Al* said:

Wow i'm slowly reading through your build, awesome work! I feel like a cheat now, owning a MAC#1 and not building it! Mine was built by MAC for a customer.Keep up the good work.

Haha, you cheat! Thanks for the kind words

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Intercooler/oil cooler/radiator fitted to the car this morning, you can see the 10" rad fan is the biggest I was going to squeeze behind the radiotor.



With the nose cone fitted, the intercooler is now looking very discreet



Exhaust support fitted



I then set about fitting the finished trim strips to the outside edges of the passenger compartment





I had to nip out to buy some more rivots this afternoon, I got sidetracked and time passed by, when I returned home I couldnt be bothered to do much else, so I quickly trial fitted the rest of the panels.

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Jason... I'm not sure where it originally comes from or what its called, I bought it from Mac#1, they buy it in and cut/bend it to suit the shape of the car.

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Some RS4 mesh destined for the opening in the nose cone