My 205 4X4 Cosworth

[Caddyshack]

Furyblade_Lee said:

That is one of the most beautiful cars I have ever seen.

Wow. Thank you.

To me it is too, I love it.

[F1natic]

Have you had it near any weight scales recently? Curious about the final power to weight you are targeting. Also just wanted to chip in with some encouragement, really good to see your progress. 80% there, only 80% to go!

[Caddyshack]

F1natic said:

Have you had it near any weight scales recently? Curious about the final power to weight you are targeting. Also just wanted to chip in with some encouragement, really good to see your progress. 80% there, only 80% to go!

Not yet. I was expecting 1000kg but a very similar fiesta was weighed and was 850kg, my car has thinner steel and has carbon fibre panels so I expect 850/900.

My old gti was in the 860kg wet with full interior and metal panels. Their rear beam is really heavy so I have saved a bit there and on body panels; doors were a net saving of 26kg, bonnet was net 10kg and boot lid was a net 12kg. I have a stripped interior but added the t45 cage. My rear diff is heavy and the turbo Cosworth engine and box are a fair bit heavier than the gti. My seats are probably a net 8-10kg lighter than road car seats for both. But things like having 4 drive shafts and not 2 all add up. So, under 1000kg a given but could be 800’s or low 900’s.


I will eventually swap to an alloy rear diff which will save a chunk and the Smith and Jones alloy block is 25kg lighter than the block I have if I go that route (nice saving off the front axle weight)

I do not really have a target, I just want it to be light.


What do you think?….expectations are off?

[Caddyshack]

More sanding and filling today, this was the largest area of damage on the wing. I cannot feel any deviations to the touch now so probably one more coat of high build and block it back and that area should be done. There are about 7 repair areas on this wing as it popped 4 of the filled rivets where it joins the car, another crack like the one in the pic and then a crack up the door pillar and along the window ledge. Nearly all sorted now….I hate body work.

[take-good-care-of-the-forest-dewey]

alfa-alex said:

Caddyshack said:

alfa-alex said:

I’d be interested to see what cost they come back with, if they haven’t done one before then there’s a lot of research and drawing time required before you get anywhere near printing or fitting the vinyl

They have said around 1300 which seems good to me. Warranty on their work, 3m warranty too.

Feel free to pop the quote over to me on email to make sure all looks right

Is that about right? I had a look on 3M's site and looked at few approved installers... Seemed to be 3 to 5k for a complete and complex (e.g race livery wrap)

[Caddyshack]

take-good-care-of-the-forest-dewey said:

alfa-alex said:

Caddyshack said:

alfa-alex said:

I’d be interested to see what cost they come back with, if they haven’t done one before then there’s a lot of research and drawing time required before you get anywhere near printing or fitting the vinyl

They have said around 1300 which seems good to me. Warranty on their work, 3m warranty too.

Feel free to pop the quote over to me on email to make sure all looks right

Is that about right? I had a look on 3M's site and looked at few approved installers... Seemed to be 3 to 5k for a complete and complex (e.g race livery wrap)

They have suggested plain white wrap and then apply the decals on top, I had that advice from a few sources. I think the car will be quick and simple to wrap and they can have it stripped if they like, all of the door shuts etc will be painted white as will engine bay etc.

I paid £900 for my Twizy which is much smaller but a whole lot harder to wrap.

Edited by Caddyshack on Thursday 26th May 21:28

[take-good-care-of-the-forest-dewey]

Caddyshack said:

take-good-care-of-the-forest-dewey said:

alfa-alex said:

Caddyshack said:

alfa-alex said:

I’d be interested to see what cost they come back with, if they haven’t done one before then there’s a lot of research and drawing time required before you get anywhere near printing or fitting the vinyl

They have said around 1300 which seems good to me. Warranty on their work, 3m warranty too.

Feel free to pop the quote over to me on email to make sure all looks right

Is that about right? I had a look on 3M's site and looked at few approved installers... Seemed to be 3 to 5k for a complete and complex (e.g race livery wrap)

They have suggested plain white wrap and then apply the decals on top, I had that advice from a few sources. I think the car will be quick and simple to wrap and they can have it stripped if they like, all of the door shuts etc will be painted white as will engine bay etc.

I paid 900 for my Twizy which is much smaller but a whole lot harder to wrap.

Edited by Caddyshack on Thursday 26th May 21:28

Thanks. Could tempt me in to getting a tommi wrap on my VII RS for a couple of years. Needs some paint anyway.

[Caddyshack]

take-good-care-of-the-forest-dewey said:

Caddyshack said:

take-good-care-of-the-forest-dewey said:

alfa-alex said:

Caddyshack said:

alfa-alex said:

I’d be interested to see what cost they come back with, if they haven’t done one before then there’s a lot of research and drawing time required before you get anywhere near printing or fitting the vinyl

They have said around 1300 which seems good to me. Warranty on their work, 3m warranty too.

Feel free to pop the quote over to me on email to make sure all looks right

Is that about right? I had a look on 3M's site and looked at few approved installers... Seemed to be 3 to 5k for a complete and complex (e.g race livery wrap)

They have suggested plain white wrap and then apply the decals on top, I had that advice from a few sources. I think the car will be quick and simple to wrap and they can have it stripped if they like, all of the door shuts etc will be painted white as will engine bay etc.

I paid 900 for my Twizy which is much smaller but a whole lot harder to wrap.

Edited by Caddyshack on Thursday 26th May 21:28

Thanks. Could tempt me in to getting a tommi wrap on my VII RS for a couple of years. Needs some paint anyway.

I don’t know how soon mine will be ready, will let you know when I book it and how it comes out.

[Caddyshack]

I found a door bar weld had not been completed, luckily I can get in there with the welder.

[Caddyshack]

I added an L plate where I had to cut away the cage leg base that was too close to my ankle and way over what was needed for msa regs (not that I am building to regs) I left 3mm of the old box protruding up from the floor and then welded the plate to that….then I welded along the old base as it had only been tacked in place on that side.

[Caddyshack]

Realised the join above had a missed weld too…done now.



Above, quick release spit….quick released.



Front bar will come out, that was an old rad mount. Will make something better.



Above, ready for test fit of engine and gearbox but I am going to have a few days off the car for a rest now…hopefully offer up next week…fingers crossed the tunnel doesn’t need much work to fit it???

[take-good-care-of-the-forest-dewey]

Does that mito have twin pipes?

[Caddyshack]

take-good-care-of-the-forest-dewey said:

Does that mito have twin pipes?

The black one does, it is a tzr 250 swap. , the red one has a cr500 in it tuned to 74hp and64ftlb. I have a 125 mito as well and a rolling chassis ypvs 350. And an Aprilia supermoto with rotax 257.

250 during build.

Below is cr500 mito.

Edited by Caddyshack on Friday 27th May 23:23

[Caddyshack]

Above is the supermoto and my 125 mito. I built the mito during lock down from a box of rusty old bits in a box.

[take-good-care-of-the-forest-dewey]

Those mitos are great. I sat on one at the NEC bike show years ago (I'm 6' 5") and it was weirdly comfortable. More so than a lot of bigger bikes.

That said, my mate observed I looked like a frog perched on smarty tube.

Always fancied one ever since as it felt right.

That CR powered one must go like stink.

[Caddyshack]

take-good-care-of-the-forest-dewey said:

Those mitos are great. I sat on one at the NEC bike show years ago (I'm 6' 5") and it was weirdly comfortable. More so than a lot of bigger bikes.

That said, my mate observed I looked like a frog perched on smarty tube.

Always fancied one ever since as it felt right.

That CR powered one must go like stink.

I find much more than an hour and my shoulders ache if I haven’t been used to riding them.

The 500 mito will wheelie in 4th without provocation.

I can imagine 6’5 would not fit on many bikes unless big adventure bikes?


I think I will get the new Aprilia RS660 at some point.

[PhillipM]

Caddyshack said:

I'm gonna be *that guy* and say that wants grinding out and rewelding - it's been welded far too cold and it's not tied into the floor plate bar superficially at all.
Crank the amps up a bit more or slow down some.

[Caddyshack]

PhillipM said:

Caddyshack said:

I'm gonna be *that guy* and say that wants grinding out and rewelding - it's been welded far too cold and it's not tied into the floor plate bar superficially at all.
Crank the amps up a bit more or slow down some.

Thanks, that weld was never meant to tie in to the floor, that weld ties the plate to the 3mm upstand. After this was done I did a much more Amps weld to tie that weld to the floor. The old box was cut off so I left 3mm sticking out of the floor and welded the plate to that.

In the pic below you can see what I welded the plate to…that is the weld you are commenting on, not the one that connects it all to the floor.

Edited by Caddyshack on Saturday 28th May 10:19

Edited by Caddyshack on Saturday 28th May 12:33

[chippy348]

HI Toby, are you using a Mig welder with gas ? if so what gas are you using ?

[Caddyshack]

[quote=chippy348]HI Toby, are you using a Mig welder with gas ? if so what gas are you using ?[/quote

Hi, yes 180 amp mig with hobby weld gas. Huge bottle of it. It’s a rent free bottle but you pay about 150 to “deposit” then a full charge each time which is 95 for the number 5 which is the mix, I believe. Using it at 10cfm ( think that’s the measurement)

This is the place:

https://www.cranleighgas.co.uk/