Discussion
Enjoyed reading that. I can sympathise re: the bloody iso mounts fir the exhaust. Lost count of how many I fitted. Terrible design.
Re: tall drivers. I'm 6'5" and you can increase the steering column angle and lengthen it. It meant I had plenty of room in mine. Funnily enough, quite a feel that drove it at Westfield preferred the driving position over the normal set-up - for normal height drivers it was similar to modern WRC position. Wheel close to your chest - very bent arms.
Looking fwd to where you get to with engine power.
Re: tall drivers. I'm 6'5" and you can increase the steering column angle and lengthen it. It meant I had plenty of room in mine. Funnily enough, quite a feel that drove it at Westfield preferred the driving position over the normal set-up - for normal height drivers it was similar to modern WRC position. Wheel close to your chest - very bent arms.
Looking fwd to where you get to with engine power.
On with the final finishing touches now ready for IVA. Started on the interior panels, covered with vinyl.
Carpets cut and then dropped into the trimmers for binding
Stuff like this is where you can save big money on the build vs buying from the factory (when it was open), i reckon I saved around 70% on retail. I tried to stick to this plan throughout the build, save money in some areas to allow the nice upgraded parts in others.
Then it was time to get the IVA application in.
Carpets cut and then dropped into the trimmers for binding
Stuff like this is where you can save big money on the build vs buying from the factory (when it was open), i reckon I saved around 70% on retail. I tried to stick to this plan throughout the build, save money in some areas to allow the nice upgraded parts in others.
Then it was time to get the IVA application in.
Finished off the boot box area, the boot 'lid' needed some strengthening to support the hinges.
Interior coming together, seats and harnesses in.
I heard back from DVSA and had an IVA date booked for 18th march 2020, great, only to hear a few days later that the tester was actually on leave so was pushed back to 14th April, then another phonecall to move back to 2nd April, and then another to move back to the original date but 1 hour later!! At this point according to the email I had 3 valid appointments booked as only one was showing as cancelled!
I was just glad to get in asap as it was now early march 2020 and the world was just starting to go a bit crazy.
Car ready in 'IVA trim'.
So the car was ready, eldest lad had been roped in to escort with a car full of tools, spares, edge trim, cable ties etc just incase. It's a 50 mile drive to the IVA test centre at Livingston, I always prefer to drive them there, everything gets nicely up to temp and you can get the brakes bedded in nicely.
Interior coming together, seats and harnesses in.
I heard back from DVSA and had an IVA date booked for 18th march 2020, great, only to hear a few days later that the tester was actually on leave so was pushed back to 14th April, then another phonecall to move back to 2nd April, and then another to move back to the original date but 1 hour later!! At this point according to the email I had 3 valid appointments booked as only one was showing as cancelled!
I was just glad to get in asap as it was now early march 2020 and the world was just starting to go a bit crazy.
Car ready in 'IVA trim'.
So the car was ready, eldest lad had been roped in to escort with a car full of tools, spares, edge trim, cable ties etc just incase. It's a 50 mile drive to the IVA test centre at Livingston, I always prefer to drive them there, everything gets nicely up to temp and you can get the brakes bedded in nicely.
So the day of the test, left mega early to allow for any issues, A Mcd's breakfast and to allow for M8 traffic.
Sadly before i even left the street I knew Id failed, the speedo wasnt registering on the AIM dash
. Gutted, never mind crack on get to the other end and see if we can sort it befor the test starts. After an uneventful drive through to test still no joy, the speedo sensor was reading the target as the indicator light on the sensor was working, the dash calibration was correct but just couldnt get a reading. Oh well, spoke to the tester and told him the issue and we began the test.
First up, it failed again on emissions, WTF, we had done a good bit of work at the dyno to ensure the correct readings at the tested RPMs, but then i realised we had the VVT issues at the dyno and i never took it back for another check. My fault again. The rest of the test goes fine, apart from right at the end he slipped in another fail point, he didnt like the toggle switches on the dash and found a very obscure rule.
The offending switches
So his point was that the guards were not strong enough or certified to meet the force requirements. My argument was the rule states "if contactable by a 165mm sphere" which they aren't as the guards prevent contact and the rule states it applies to switches and control knobs. He took my feedback on board but it still went on the fail sheet. It had already failed on the 2 other points anyway so wasn't any point in appealing it. I would have done if it had been the only fail point.
So all in all a bit of a disappointing day, 3rd IVA test and the first one I'd failed. DIdnt like it! and with the tester stating they were stopping testing imminently because of covid it could be a long wait for a retest.....
Sadly before i even left the street I knew Id failed, the speedo wasnt registering on the AIM dash
. Gutted, never mind crack on get to the other end and see if we can sort it befor the test starts. After an uneventful drive through to test still no joy, the speedo sensor was reading the target as the indicator light on the sensor was working, the dash calibration was correct but just couldnt get a reading. Oh well, spoke to the tester and told him the issue and we began the test.First up, it failed again on emissions, WTF, we had done a good bit of work at the dyno to ensure the correct readings at the tested RPMs, but then i realised we had the VVT issues at the dyno and i never took it back for another check. My fault again. The rest of the test goes fine, apart from right at the end he slipped in another fail point, he didnt like the toggle switches on the dash and found a very obscure rule.
The offending switches
So his point was that the guards were not strong enough or certified to meet the force requirements. My argument was the rule states "if contactable by a 165mm sphere" which they aren't as the guards prevent contact and the rule states it applies to switches and control knobs. He took my feedback on board but it still went on the fail sheet. It had already failed on the 2 other points anyway so wasn't any point in appealing it. I would have done if it had been the only fail point.
So all in all a bit of a disappointing day, 3rd IVA test and the first one I'd failed. DIdnt like it! and with the tester stating they were stopping testing imminently because of covid it could be a long wait for a retest.....
sdh2903 said:
The offending switches
So his point was that the guards were not strong enough or certified to meet the force requirements. My argument was the rule states "if contactable by a 165mm sphere" which they aren't as the guards prevent contact and the rule states it applies to switches and control knobs. He took my feedback on board but it still went on the fail sheet. It had already failed on the 2 other points anyway so wasn't any point in appealing it. I would have done if it had been the only fail point.
So all in all a bit of a disappointing day, 3rd IVA test and the first one I'd failed. DIdnt like it! and with the tester stating they were stopping testing imminently because of covid it could be a long wait for a retest.....
This kind of this is ridiculously annoying, they're clearly compliant but he's just got the hump...So his point was that the guards were not strong enough or certified to meet the force requirements. My argument was the rule states "if contactable by a 165mm sphere" which they aren't as the guards prevent contact and the rule states it applies to switches and control knobs. He took my feedback on board but it still went on the fail sheet. It had already failed on the 2 other points anyway so wasn't any point in appealing it. I would have done if it had been the only fail point.
So all in all a bit of a disappointing day, 3rd IVA test and the first one I'd failed. DIdnt like it! and with the tester stating they were stopping testing imminently because of covid it could be a long wait for a retest.....
So first up, speedo, confession time, some idiot had got 2 pins crossed for the load and the ground 
in my defense the load wire was black and the ground blue so easy done. Any way a nice quick easy fix.
Then onto the switch issue, I didn't want to redo the whole dash and fit different switches if possible. Very kindly one of the guys on the WSCC drew up a possible solution to try and shroud the switch toggles.
This would be able to use all existing dash holes. So I sent an email off to the DVSA to try and get clarification on whether this would satisfy the failure point.
Emissions next, needed to get the car back to the dyno to check the map, he's normally booked up well in advance but he managed to slot me in just a couple of days after the IVA fail. A quirk in the system means that as I'm driving to make repairs for an IVA fail I can legally drive it there this time (after confirming with the insurance) and it was a lovely crisp sunny spring day too, bonus!
So map was checked and all was ok, didnt have time to do full power runs as only had an hour or so, it seems its probably down to the magnaflow cats. They have to be seriously hot to work, not just up to temp, properly hot. It was failing on the figures again, but after holding the car at say 4000 revs for a few minutes you could see the cats starting to work and the figures come right down to the correct levels.
Also on the drive home managed to stretch the cars legs a little, was very happy. The power is just so linear, its rapid but doesnt feel as though it wants to chuck you through the nearest hedge like the ecoboost sport250 could. Plenty of torque and it really comes on song above 5k revs.
Had a reply back from the IVA man who confirmed the switch guard would pass the test so the guy who designed it was also kind enough to 3d print me one too. Thats all the failure points now addressed but sadly unable to make a retest appointment, no full shutdown in place but not taking any bookings.
Oh well nothing better than taking it apart again while I wait! The AIM dash unit had always looked a bit "stuck on" to the dash, so with the help of a very helpful chap called Paul (now runs mofast for alsorts of kit goodies https://mofast.co.uk/) whos an absolute whiz with CAD and another chap from the WSCC who did CNC machining, they put together a recessed dash mount, cleverly with built in plastic switch buttons to operate the buttons on the side of the dash.
As it arrived from machining
Almost a shame to paint it
During the IVA test, jokingly the tester had asked was i leaving the (obviously very second hand) padded IVA steering wheel on the car as its crap! I said well no, but the momo wheel wouldnt pass the test, he then told me as long as the spokes were radiused he would be happy to pass it. So cracked on with building up the freewheel button plate.
Also fitted the quick release boss as well from Go-race, they make a complet upper column for the westfield with the fitting already machined into it, so one pinch bolt, slide out the old column and fit the new. Quality is superb too.
You can see the now-painted up switch guard is fitted too.
And a new lower dash panel made up with just the heated seat switches (yes am soft) and a 12v accessory socket.
Positioned everything to maintain as clear a view as possible to the dash
Re-writing this now makes me realise i was probably pushing things a little in changing things before the retest, if the tester was being arsey i think he could have refused to retest and make me do another full test.
in my defense the load wire was black and the ground blue so easy done. Any way a nice quick easy fix.Then onto the switch issue, I didn't want to redo the whole dash and fit different switches if possible. Very kindly one of the guys on the WSCC drew up a possible solution to try and shroud the switch toggles.
This would be able to use all existing dash holes. So I sent an email off to the DVSA to try and get clarification on whether this would satisfy the failure point.
Emissions next, needed to get the car back to the dyno to check the map, he's normally booked up well in advance but he managed to slot me in just a couple of days after the IVA fail. A quirk in the system means that as I'm driving to make repairs for an IVA fail I can legally drive it there this time (after confirming with the insurance) and it was a lovely crisp sunny spring day too, bonus!
So map was checked and all was ok, didnt have time to do full power runs as only had an hour or so, it seems its probably down to the magnaflow cats. They have to be seriously hot to work, not just up to temp, properly hot. It was failing on the figures again, but after holding the car at say 4000 revs for a few minutes you could see the cats starting to work and the figures come right down to the correct levels.
Also on the drive home managed to stretch the cars legs a little, was very happy. The power is just so linear, its rapid but doesnt feel as though it wants to chuck you through the nearest hedge like the ecoboost sport250 could. Plenty of torque and it really comes on song above 5k revs.
Had a reply back from the IVA man who confirmed the switch guard would pass the test so the guy who designed it was also kind enough to 3d print me one too. Thats all the failure points now addressed but sadly unable to make a retest appointment, no full shutdown in place but not taking any bookings.
Oh well nothing better than taking it apart again while I wait! The AIM dash unit had always looked a bit "stuck on" to the dash, so with the help of a very helpful chap called Paul (now runs mofast for alsorts of kit goodies https://mofast.co.uk/) whos an absolute whiz with CAD and another chap from the WSCC who did CNC machining, they put together a recessed dash mount, cleverly with built in plastic switch buttons to operate the buttons on the side of the dash.
As it arrived from machining
Almost a shame to paint it
During the IVA test, jokingly the tester had asked was i leaving the (obviously very second hand) padded IVA steering wheel on the car as its crap! I said well no, but the momo wheel wouldnt pass the test, he then told me as long as the spokes were radiused he would be happy to pass it. So cracked on with building up the freewheel button plate.
Also fitted the quick release boss as well from Go-race, they make a complet upper column for the westfield with the fitting already machined into it, so one pinch bolt, slide out the old column and fit the new. Quality is superb too.
You can see the now-painted up switch guard is fitted too.
And a new lower dash panel made up with just the heated seat switches (yes am soft) and a 12v accessory socket.
Positioned everything to maintain as clear a view as possible to the dash
Re-writing this now makes me realise i was probably pushing things a little in changing things before the retest, if the tester was being arsey i think he could have refused to retest and make me do another full test.
Couple more mechanical tweaks done, swapped the clutch master cylinder from a 0.7" to a 0.625" as it was a touch on the heavy side. At the dyno when checking emissions we noticed that the fuel pump was getting a little more "vocal". In fact you could hear it whilst idling and weas gettting worse. Id used a Sytec 044 style pump which i'd not had issues with in the past, went for a walbro this time, now much much quieter.
Also noticed a tiny puddle under the dash coming from the heater box, not from the pipes but the matrix itself. Replacement classic mini matrix ordered.
The gelcoat did have a few marks and imperfections so went for it with p2500 and some 3m gelcoat polish. Came up well.
Had always thought that although i had no real reason to open up the bonnet scoop (it just lets muck in) it did look a little odd, do it got the same treatment as the gills.
And some custom gel badges.
At this point we're now into July/August 2020, my IVA retest application had been accepted onto the system at the DVSA and finally they gave me a retest date of the 1st September.
Also noticed a tiny puddle under the dash coming from the heater box, not from the pipes but the matrix itself. Replacement classic mini matrix ordered.
The gelcoat did have a few marks and imperfections so went for it with p2500 and some 3m gelcoat polish. Came up well.
Had always thought that although i had no real reason to open up the bonnet scoop (it just lets muck in) it did look a little odd, do it got the same treatment as the gills.
And some custom gel badges.
At this point we're now into July/August 2020, my IVA retest application had been accepted onto the system at the DVSA and finally they gave me a retest date of the 1st September.
So the day of the retest. Nothing really to report, everything went to plan and it passed!! I had an email as long as your arm regarding covid protocols which in reality meant wearing a mask.
I had all the registration docs ready to go already so along with the pass cert they were sent off the same day.
Whilst waiting for the v5 to come back i had managed to secure another slot on the dyno. For a few reasons, 1, i had a very small amount of lumpiness at low revs, 2. a brief hesitation between 2-3k and 3. with the stuck vvt solenoid and the potenially gubbed fuel pump it was probably the sensible thing to do.
All went very well and the car was transformed, the fuel pump must have been really struggling as we gained 20bhp and nother 10ftlb meaning headline figures were now 229bhp and 216lbft at the hubs. Figures aside the car was much smoother and pulled very well indeed. Well worth the additional session.
obligatory video
https://youtu.be/-RLexQA-es4
I had also managed to find a set of TD pro1.2s up for sale at a decent price, had always wanted to try 13's as everyone raves about them, the only issue being they came with r888r and theres little real choice from other brands without spending £££ on a set of zzs, dont get me wrong the 888r is a great tyre when its warmish or on a track, but as this is primarily a fast road car and i live in scotland they arent my first choice. Love the look of the 13's though. They filled the arches a treat with only a small spacer too due being a better offset.
Well despite all the goings on in the world the DVLA worked wonders, only 2 weeks from passing IVA the V5 landed, only 1 slight issue theyd registered it as a caterham, which would have gone down well in caterham circles
, well not as much as a caterham owner recieving a westfield logbook!. They confirmed the error would be sorted and the reg remain the same so I was free to get out and about!
I had all the registration docs ready to go already so along with the pass cert they were sent off the same day.
Whilst waiting for the v5 to come back i had managed to secure another slot on the dyno. For a few reasons, 1, i had a very small amount of lumpiness at low revs, 2. a brief hesitation between 2-3k and 3. with the stuck vvt solenoid and the potenially gubbed fuel pump it was probably the sensible thing to do.
All went very well and the car was transformed, the fuel pump must have been really struggling as we gained 20bhp and nother 10ftlb meaning headline figures were now 229bhp and 216lbft at the hubs. Figures aside the car was much smoother and pulled very well indeed. Well worth the additional session.
obligatory video
https://youtu.be/-RLexQA-es4
I had also managed to find a set of TD pro1.2s up for sale at a decent price, had always wanted to try 13's as everyone raves about them, the only issue being they came with r888r and theres little real choice from other brands without spending £££ on a set of zzs, dont get me wrong the 888r is a great tyre when its warmish or on a track, but as this is primarily a fast road car and i live in scotland they arent my first choice. Love the look of the 13's though. They filled the arches a treat with only a small spacer too due being a better offset.
Well despite all the goings on in the world the DVLA worked wonders, only 2 weeks from passing IVA the V5 landed, only 1 slight issue theyd registered it as a caterham, which would have gone down well in caterham circles
, well not as much as a caterham owner recieving a westfield logbook!. They confirmed the error would be sorted and the reg remain the same so I was free to get out and about!After a couple of evening runs and with the nights drawing in it was apparent the headlights were crap, thought about uprated bulbs but went LED instead.
This is 1 halogen headlight
Vs 1 Led headlight
Bit of a difference!
After a good few runs out I ended up switching back to the 15s. For late autumn runs they were just the wrong tyre, the michelin ps3 on the 15s are so much more confidence inspiring when the temp drops or theres plenty of moisture around. I think i managed to get around 1500 miles on the car before the roads started getting salted with no real issues to report, i had noticed the engine did need a top up of oil now and again, maybe after a 250 mile day it would take 250ml to bring it back up, nothing alarming but 1 to definitly keep an eye on.
This is 1 halogen headlight
Vs 1 Led headlight
Bit of a difference!
After a good few runs out I ended up switching back to the 15s. For late autumn runs they were just the wrong tyre, the michelin ps3 on the 15s are so much more confidence inspiring when the temp drops or theres plenty of moisture around. I think i managed to get around 1500 miles on the car before the roads started getting salted with no real issues to report, i had noticed the engine did need a top up of oil now and again, maybe after a 250 mile day it would take 250ml to bring it back up, nothing alarming but 1 to definitly keep an eye on.
Fantastic! Superb build thread, and a thing of great joy, I'm sure: real, usable, reliable shove, a nice soundtrack, and ...different.
Wonderful.
Wonderful.
J4CKO said:
Loving this, I like all the bike engined, highly strung, racetrack refugee type stuff but this is more appealing, nice big V6 with decent power, weather gear etc, so should be as pleasant as a seven can be to live with and put miles on.
I agree - and I say that at 13yrs into a' bike engined, highly strung, racetrack refugee' Fisher Fury with an R1 lump.Megaflow said:
Great build and a great looking car.
Can I ask why the V6? It’s an unusual choice, but then again that maybe answers the why question.
Thank you. Well I like doing things the hard way! Can I ask why the V6? It’s an unusual choice, but then again that maybe answers the why question.
In all seriousness I wanted 200bhp. I think it's a sweet spot for one of these in road trim. In the more traditional choices that left c20xe, zetec or duratec. As the cheap crate zetecs have all but vanished it would have meant a rebuild and fettling. And after seeing a guy over on locostbuilders successfully fit the same engine in an mk indy and rave about it I was sold. Especially with the availability of the rocketeer adapters to get a decent box for peanuts as all the 4 cylinder options would have needed 1500 ish for a decent ratio type 9 too.
I really like the aj30 engine. It's torquey right through the range likes to rev and just pulls. 250ish bhp as standard without being tuned to death. Although it's not been without problems, I'll get to that in the next couple of updates as the car is currently about to get it's 3rd engine. Some my fault, some external suppliers fault.
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