MEV Rocket Build

[Mabbx]

Hi all,

Thought I would share my MEV Rocket build progress. Having had a few performance cars in the past and being an Engineer, rather than just purchase my next week-end car - I decided to build my own. This is my first kit build and I wanted a car that was a non traditional looking seven style kit that had a good base but could also give me room to put my own 'stamp' on. After veiwing several kits and companies I decided the Rocket would be ideal for me. For those who are not aware, it is based on doner parts from a Ford Focus using a Zetec power plant (although the factory will mod the chassis to suit almost any engine). I wanted to build a car from all new parts, and new parts are plentyfull for the focus (aswell as doners). Also there is lots of infomation and performance enhancements available for the Zetec.

I now also work within the composites industry supplying most areas of motorsport, so for me I have a bit of a carbon fibre fetish and paneling will be re-tooled for carbon parts. I am now 8 months into the build and enjoying every moment

Edited by Mabbx on Thursday 18th August 17:54

Edited by Mabbx on Friday 19th August 09:36

[Mabbx]

A couple of starting pics:




I had the chassis, wishbones, uprights etc powder coated in 'chrome' coat. This is a patented process with the deepest chrome shine depth available on the market. Very pleased with results.

Edited by Mabbx on Friday 19th August 07:52

Edited by Mabbx on Friday 19th August 07:54

[Mabbx]

Floor fitted. This is a sandwich of kevlar and carbon fibre

[Mabbx]

Most of my pics are over 2mb - can anyone help ??

[Mabbx]

Many thnaks - my current photo editor would not allow me to resize over 800 x 600 ??

Steve_D said:

Open them in something like MS Picture manager.
Follow the menus and find 'Resize'.

Copy all the pics you want to resize into a new folder first so you still have the originals.

Steve

[Mabbx]

Front end panel work started, Steering column fitted:



Cycle wings, calipers etc fitted :

[Mabbx]

Have had some front wings made for the car and a rear wing is currently being made. The contour is from the Mosler GT car. Mainly asthetic look but should help in handeling. Time will tell when its completed:

]

Brake, clutch lines all fitted. Have gone for fully braided:



Rear Calipers with handbrake mechanism:

[url]|http://thumbsnap.com/fl2SKTA5[/url

[Mabbx]

Using the origional Ford Focus steering column cover, I have decided to re-model and extend. From this I will make a pre-preg tool for a carbon fibre part:

[Mabbx]

Gearbox. Fitted with a Quaife straight cut close ratio gear set and Quaife ATB LSD. All parts are new with exception to the casing which has been reconditioned. Should run to 55mph in 1st and 160mph in 5th at 8000 RPM with the wheels I have fitted:



I have gone for some performance engine mounts, as the OEM untis tend to let the engine move excesivly. These have been tested on the Rocket and work very well:

[Mabbx]

Rear LED Lights fitted:



Front Lights: Decided to use DRL's as the sidelights. Water jet some arms for the indicator stalks in Aluminum and polished:

[Mabbx]

Car finally grounded. I have had the wheels made to the correct PCD and offset to suit the car, and unfortunatly the process to get them took 6 months, but worth the wait. The fronts are 15 x 7 (5kg each) and rears are 15 x 8 (6.2kg each) fitted with Toyo R888. Car still needs to be lowered but will do this when it goes for setting up:

[Mabbx]

Column cover made and fitted:





Carbon centre tunnel made and fitted:

Edited by Mabbx on Friday 19th August 09:18

[Mabbx]

Was origionally going to fit some Carbon seats but after sitting in various designs I opted for a bit more comform. Obviously can be changed in the future should I want to reduce car weight etc:

[Mabbx]

Engine built and ready to fit. Obviously looking to supercharge. With the car being transverse, I wanted relative delivery of power and torque with hopefully no heavy spikes and for me supercharging was the route. Supercharger mounting bracket design is currently underway which will be a nice billet aluminium unit to support the power/torque. Engine is fully forged, balanced, lightned flywheel, Jenvey plenum with 70mm throttle body, cams to support supercharging, ceremetalic clutch and block has been decked with valve pockets also machined into the forged pistons. The engine was origionally a new unit which has obvioulsy been stripped and re-built:

Edited by Mabbx on Friday 19th August 09:42

Edited by Mabbx on Friday 19th August 11:26

[Mabbx]

That's pretty much up to date. Car is currently away having a bespoke stainless exhaust system made. Carbon Fibre bonnet is completed and ready to fit. Engine is in and Supercharger fitment is well under way and just sorting out the charge cooler system. Will update with further pics as and when. A more detailed build blog is on the MEV forum : http://www.mevowners.proboards.com/

[Mabbx]

Racing8 said:

Very nice work there, how much are you expecting it to cost you being built in new parts ?

I am relitivly close to the finishing line now and have a list of final parts and all receipts to date. This link should give you a guide: http://www.smartsrus.com/mev_rocket_kit_in_a_box.h...

[Mabbx]

Paul Drawmer said:

Really nice build - I do like to see nice work.

Just one thing,
You have twin master cylinders, but a common feed from one of them to both brake circuits. If you had a leak upstream of the Y joint, you would lose both brake circuits. You could have completely separate circuits by commoning one brake with the clutch master cylinder.

Hi Paul,

Yes I am aware of this. This is the standard way most of the builders have fitted them and have had no issues but the risk is always their. I have looked at a three chamber unit made by Tilton, which may be the way to go. It is quite a large unit and would need to mod the caps for the switch but is a neat alternative.

Edited by Mabbx on Saturday 20th August 08:12

[Mabbx]

eliot said:

Love that chrome paint.
You may be interested in my diy calibrated fuel gauge, as i understand the tank is a funny shape. Someone else with a mev made one.
http://www.mez.co.uk/ms13.html

Many thanks, may well be in contact.

[Mabbx]

chuntington101 said:

Can i ask who built that engine for you? Also how much power are you looking at making once its supercharged?

Cracking build there! Love the carbon.

The last engine built with this supercharger (i have only found 1 other) produced 310BHP and 250ft/lb torque on a rolling road. I have done a little more with mine and can go further with the head if needed but will be more than happy with 270+bhp with whats been done with a nice relaitve torque curve. The charge cooler being made should also be able to keep the power consistent throught the temperature also (hopefully).

[Mabbx]

More progress. Had some front splitter stays made from ST.ST and the carbon fibre bonnet arrived. Origional GRP unit weighing 6kg and this bonnet weighing 1.8kg. Still very strong.



Also had some vinal artwork made to follow contour of bonnet:



Bonnet complete with Aerocatch and hydraulic lifters.