Mac#1 Motorsport Worx Build

[Red16]

Some more new parts arrived today

One Sierra master cylinder



A hydraulic switch for the brake lights



A Freelander rear differential



Finally got round to fitting the steering rack and quickly mocked up the suspension to see how it looks







PS Yes I know the track rod end should mount underneath the upright not above like I had it, I only realised after I had taken the photos, doh!

No drama though as nothing is tightened up, and it all needs to come off so I can finish cutting the side panels.

Looking back through those photos really hits home how messy the garage has become, I'll be sorting that out tomorrow too!

[Red16]

The doorbell went this morning and I was greeted by the posty with a parcel from Mac#1

Two new custom driveshafts and tri-lobe bearings



The stockpile of parts is getting really big, it's about time i pulled my finger out and got some of it on the car!

[Red16]

Tried to fit my Freelander rear diff yesterday but didnt realise until it was nearly in the car that the casing needed a little mod, doh!



Once the notch was cut out of the casing, the diff bolted into the chassis easily.





I then set about a quick mock up of the rear suspension, which looks something like this

[singlecoil]

I notice you are using 4 pot calipers at the rear, with the Sierra dual circuit master cylinder. Is this a known combination? It seems to me there would be a risk of too much braking effort at the rear.

[Red16]

Thanks for your concern mate, but no need to worry. This braking combination has been used on many Mac#1 customers cars and found to be trouble free, the front and rear calipers have different sized pistons in them and they work nicely together, with no need to fit a brake bias adjuster into the rear brake line.

[singlecoil]

Red16 said:

the front and rear calipers have different sized pistons in them

Could I touble you for the sizes, it would be useful infomation for the future.

[Red16]

The pistons have diameters of 35.1mm in the front calipers and 25mm in the rear calipers.

[singlecoil]

Red16 said:

The pistons have diameters of 35.1mm in the front calipers and 25mm in the rear calipers.

Thanks, I'll make a note of that, it could crop up quite soon.

[Red16]

singlecoil said:

Red16 said:

The pistons have diameters of 35.1mm in the front calipers and 25mm in the rear calipers.

Thanks, I'll make a note of that, it could crop up quite soon.

No problem hope it helped.

Todays progress goes like this...

One new Sierra brake fluid reservoir



Driveshafts built up, but still requiring securing around each end of the cv boots



Drivers side driveshaft fitted, suspension assembled with upright, bushes fettled to rotate nice and easily, no squeeks







List of jobs for next time i venture out to the garage...

1. Brake caliper brackets to paint and fit.
2. Copper slip and other crap to wipe from the chassis, it looks filthy in the photos
3. Spring to fit to coilover strut.
4. Couple of nuts/bolts to torque up.

Then the other side can be assembled.

The rear hubs are away being machined to 134mm diameter to allow the rear brake discs to be fitted.

Edited by Red16 on Monday 5th July 23:35

[Red16]

Been assembling the rear end today





Fitted the brake caliper brackets to the uprights.

Drivers side





Passenger side



Then done a small amount of work to the front end, fitted the arms to the steering rod and secured the rubber boots.



Hoping to get my rear hubs back tomorrow, then the brakes can be fitted.

[Red16]

Small update of the weekends work, nothing spectacular just a spot of painting, also fitted a set of longer wheel studs to suit the Pro Race 1.2 wheels.



The rear hubs are now back from being machined and are painted but not dry, hence the lack of photos.

[Red16]

Rear hubs and brake caliper brackets fitted, driveshaft nuts need to be torqued up once the brakes are operational.



Rear brake discs and calipers fitted and it started to look like this





With my mate, Decka, acting as a temporary wheel nut a wheel was tried on the back, starting to look quite wide now



The side panels were trimmed for the final time, or so i thought, i now think i'll merge the steering rack hole with the front lower wishbone hole, as most people do.

The passenger side front suspension was then built up





Drivers side



Took the nose cone off to fit it in the garage, need to move my vice stand to get the car further back... job for another day



Thanks to Decka for the assistance today, I'm dead happy with the kit, it's really starting to look like a car now

[Red16]

This afternoon i took the suspension off the front of the car and decided to do the final trimming to the side panels

Before



After



All the steering/suspension fitted back to the car again. The washers in the upper wishbone mounting brackets are temporary until i get some bushes knocked up.



I done a quick little job while the side panel was off and fitted the master cylinder.

[rdodger]

Before you make up the bushes. Is the space there to allow the adjustment of the caster angle?

[Red16]

rdodger said:

Before you make up the bushes. Is the space there to allow the adjustment of the caster angle?

Yes it is, the washers are being used until I decide on the dimensions of the bushes needed to achieve the caster angle I want/need, which at the moment I have no idea about... something else to learn and speak to Mac about.

[rdodger]

That is some seriously neat cutting! Did you use a hole saw and file?

[Red16]

rdodger said:

That is some seriously neat cutting! Did you use a hole saw and file?

Thanks

Yeah, I used a holesaw kit, flat and half round file, hacksaw and junior hacksaw.

[Red16]

Well after ages of not doing much, I've been in the garage making progress today...

The beginning of the bulkhead/pedal cover panel



How it looks resting in position



The steering column goes through the bulkhead/pedal cover panel, so I made this wedge to cover the steering column in instead of it being exposed, not sure if I'm going to use it or redesign and remake it though.



How it'd look if I used it as it is.

[jason61c]

Keep up the good work, looks like a nice build

I wish I could keep my workspace that tidy!!

[MH]

Tidy work there, it's looking good.

I like your vice mount too!

Mike