Birkin S3 Kitcar Build....
Discussion
My Dad and I have started a build on a Lotus 7 style kit car. Its a "Birkin" which has been imported from South Africa. We've gone for one of these rather than a Caterham or any of the other options mainly due to the high quality engineering involved with these kits. Its the best we've seen......and we've looked at them all. 
The crate arrived with all the parts and the chassis is not in pic - waiting to be unwrapped
We have sourced a brand new 2L Ford Duratec engine which will run throttle bodies. Target figure is around 180-200bhp when finished so in a lightweight kit car it will be plenty.
Colour scheme to be metalic silver with a dark anthracite stripe down length of car and around tip of nose cone (same colour as the wheels)
I'll keep this updated....things should move pretty quick......my Dad doing most of the build, i'm very much a novice and learning as we go!! Also my Dad is retired so he's got plenty of time to crack on with it!!
So far..........
Chassis unpacked and on build stand ready to start...first job was putting together all the suspension. It will actually be ready for wheels quite early on in the build so Team Dynamics Pro Race 1.2's have been ordered with Yoko Paradas. Yeah..I know these are common wheels now but they look the part and the "Graphite" colour will suit our colour scheme.
Front Suspension etc starting to come together, also steering column/rack in place.
Wheels arrived from Demon Tweeks and diff and gearbox also arrived.
Wheel colour doesn't show up that well in pics but its called Graphite (its a new colour) but i'd say its an anthracite type colour.
Front and rear suspension complete and hubs/brakes on. Front brakes are all Wilwood stuff which comes standard in the kit. Not sure on the rears. Wheels go on pretty soon and then it comes off the build table.
My Dad has also altered the fuel and brake line runs through the cockpit. They came in place on the chassis but he's changed them to make it better and anchored it all better too. The rubber brake lines are also getting swapped for braided stuff.
Also, the low level sump, flywheel and clutch assembly have been ordered. Sump was pretty expensive but its aluminium etc. http://www.raceline.co.uk/products/part_section.as...
Flywheel is going to be a lightened version.
I'll keep this updated as and when progress is made!
The crate arrived with all the parts and the chassis is not in pic - waiting to be unwrapped
We have sourced a brand new 2L Ford Duratec engine which will run throttle bodies. Target figure is around 180-200bhp when finished so in a lightweight kit car it will be plenty.
Colour scheme to be metalic silver with a dark anthracite stripe down length of car and around tip of nose cone (same colour as the wheels)
I'll keep this updated....things should move pretty quick......my Dad doing most of the build, i'm very much a novice and learning as we go!! Also my Dad is retired so he's got plenty of time to crack on with it!!
So far..........
Chassis unpacked and on build stand ready to start...first job was putting together all the suspension. It will actually be ready for wheels quite early on in the build so Team Dynamics Pro Race 1.2's have been ordered with Yoko Paradas. Yeah..I know these are common wheels now but they look the part and the "Graphite" colour will suit our colour scheme.
Front Suspension etc starting to come together, also steering column/rack in place.
Wheels arrived from Demon Tweeks and diff and gearbox also arrived.
Wheel colour doesn't show up that well in pics but its called Graphite (its a new colour) but i'd say its an anthracite type colour.
Front and rear suspension complete and hubs/brakes on. Front brakes are all Wilwood stuff which comes standard in the kit. Not sure on the rears. Wheels go on pretty soon and then it comes off the build table.
My Dad has also altered the fuel and brake line runs through the cockpit. They came in place on the chassis but he's changed them to make it better and anchored it all better too. The rubber brake lines are also getting swapped for braided stuff.
Also, the low level sump, flywheel and clutch assembly have been ordered. Sump was pretty expensive but its aluminium etc. http://www.raceline.co.uk/products/part_section.as...
Flywheel is going to be a lightened version.
I'll keep this updated as and when progress is made!
Edited by Ben Jk on Monday 11th July 17:51
Tim.C said:
Dare I ask, but what are you expecting the build to cost?
It looks very nice by the way.
Caterham money to be honest.It looks very nice by the way.
Some people may be thinking why didn't we go for a Caterham then.....but dare I say it we believe these to be better engineered than Caterhams, and alot rarer. The Caterham was our second choice though.
Also we've had import costs and duties to include.
The plan is that this will stay in the family for many years to come, so no corners are being cut etc.
Paul Drawmer said:
Nice to see a new Birkin being assembled in the UK. I looked at them a few years ago (when there was last a UK agent) and agree with your comments on the quality. I liked the touches like the adjustable pedal box, but there's more that I don't remember.
You should have something really good there when done.
PS - like your wheels, but disagree about the Paradas !
I wasn't sure about the Paradas as I wanted some road legal track tyres like R888's but my dad wasn't so keen, so we went for the Yoko Paradas because they are quite soft so should be nice and sticky. Tbh if they aren't up to it we will change them.You should have something really good there when done.
PS - like your wheels, but disagree about the Paradas !
Wacky Racer said:
Paul Drawmer said:
Nice to see a new Birkin being assembled in the UK. I looked at them a few years ago (when there was last a UK agent) and agree with your comments on the quality. I liked the touches like the adjustable pedal box, but there's more that I don't remember.
You should have something really good there when done.
This.You should have something really good there when done.
Definitely a labour of love though.
Birkin's have an excellent reputation for quality, although I would be personally wary of dealing with a company based so far away.
Nice pics btw......
We also had a concern about dealing with a company based in SA and tbh it hasn't been stress free but now there is a new UK agent its made things a bit easier.
h4muf said:
My 888's are fine in the wet as long as you bear in mind their semi slicks 
Durabang with tb's will be around 175 bhp.
Keep up the good work!
Tbh 175bhp will probs be plenty to start with whilst learning to drive it properly!Durabang with tb's will be around 175 bhp.
Keep up the good work!
200bhp is the target figure I think so we may need to look at some internal work in future.
Nice Westfield you've got.....what's your Zetec putting out?
Right, got back today from Norfolk. Pretty successful weekend. Engine is in place. Few other bits and bobs done. We got the diff ready to go in, mounts put in etc then realised that it should have gone in before the fuel tank. This means that fuel tank needs to come back out (not a big issue) plus the rear suspension top arms need to be released again to remove a rear section in order to slide the diff in from the rear. We assumed it went in from the top. Annoying but s
t happens I suppose!
This is one of the problems of not having a proper build manual!!! Birkin's build manual is very much work in progress!! Their biggest market is in AUS/SA/US where they seem to prefer to buy ready built!
Anyway....some pics....
Engine/gearbox/transmission etc etc ready to go in.
Actually putting engine in was easy. We lined it up with the car, making sure it was sat at roughly the right height for mounts etc...then picked up the front of the car and wheeled/lifted it over the engine!! No need to mess about with a hoist etc. Simples!
Before...
After...
Petrol tank etc in place...(which has to come out again now to fit the diff!!)
Basically the tank needs to come out, the top suspension arms released and the silver plate you can see needs to come out to slide diff in from rear. If only we had known beforehand.
Seat runners in and seat belts. Leaving the standard issue inertia reel jobs in until after IVA is passed then swapping for harnesses.
Cheeky pic of Wilwood calipers peeping through....wheel nuts are going satin black once build is finished. No point until then as they will just get chipped with wheels going on and off.
Lastly...pic of the sump. Really tidy bit of kit imo. £500 worth tho! Could have got a cheaper steel one but didn't look as nice!!!
So...after the fuel tank etc has been removed diff has been put in with drive shafts/prop shaft, then its time to dress the engine and then onto electrics.....
t happens I suppose!This is one of the problems of not having a proper build manual!!! Birkin's build manual is very much work in progress!! Their biggest market is in AUS/SA/US where they seem to prefer to buy ready built!
Anyway....some pics....
Engine/gearbox/transmission etc etc ready to go in.
Actually putting engine in was easy. We lined it up with the car, making sure it was sat at roughly the right height for mounts etc...then picked up the front of the car and wheeled/lifted it over the engine!! No need to mess about with a hoist etc. Simples!
Before...
After...
Petrol tank etc in place...(which has to come out again now to fit the diff!!)
Basically the tank needs to come out, the top suspension arms released and the silver plate you can see needs to come out to slide diff in from rear. If only we had known beforehand.
Seat runners in and seat belts. Leaving the standard issue inertia reel jobs in until after IVA is passed then swapping for harnesses.
Cheeky pic of Wilwood calipers peeping through....wheel nuts are going satin black once build is finished. No point until then as they will just get chipped with wheels going on and off.
Lastly...pic of the sump. Really tidy bit of kit imo. £500 worth tho! Could have got a cheaper steel one but didn't look as nice!!!
So...after the fuel tank etc has been removed diff has been put in with drive shafts/prop shaft, then its time to dress the engine and then onto electrics.....
Edited by Ben Jk on Monday 26th July 20:52
No joke. Build manual is pretty much non existant. As I've now mentioned above most people go for a factory built car or a rolling chassis, not a kit. However Birkin are sorting this out now and producing a proper manual as they are hoping to really push the UK market and most UK buyers would want to build there own...in SA/US/AUS where Birkin are most popular it seems this isn't the case.
We are managing as such and have a good contact at Birkin who is now sending us a build order for us that will show the order they build the cars in the factory, which should eradicate any future issues.
We are managing as such and have a good contact at Birkin who is now sending us a build order for us that will show the order they build the cars in the factory, which should eradicate any future issues.
Edited by Ben Jk on Monday 26th July 20:50
Edited by Ben Jk on Monday 26th July 20:53
ezakimak said:
Hi Ben, You are making great progress.
any chance you can tell me what size the bolts are that are used to hold the pedal box in on the Birkin ?
You win the award for the most random question ever asked!!! I'm in Lake Como, Italy at the mo, but will ask my dad for the size if I speak to him whilst here, or when I get back. any chance you can tell me what size the bolts are that are used to hold the pedal box in on the Birkin ?
Edited by Ben Jk on Tuesday 10th August 07:12
mickrick said:
Great thread! I'm building a Caterham, and I would say, after looking at these pictures, it's as good as, if not better than.
I particularly like the IRS back end.
I bet you didn't have as much bother getting the diff bolts in, (or the top shock bolts) as most folks do with a caterham.
Diff had to be slightly modified in the end to enable it to sit low enough to line up with the mounts. The strengthening fins etc were preventing it from sitting in line for the mounts. A few fins etc had to be ground back a bit.I particularly like the IRS back end.
I bet you didn't have as much bother getting the diff bolts in, (or the top shock bolts) as most folks do with a caterham.
Do you mean the Birkin is as good as if not better than the Caterham?
If so....a Caterham owner admitting that another 7 kit is as good as or even maybe better than his Caterham...Hats off to you sir!!!
Tiny update.
Not much happened as i've been in Italy for 2 weeks and my Dad has been doing a few niggly jobs etc.
Dash sorted and dials/guages/switches in place.
Birkin's usually come with Birkin branded guages/dials but the speedo comes in kmph so we've sourced our own - They are VDO dials and guages.
Throttle bodies and ECU ordered now too. Should be here within a week. Ordered from a company based next to the Lotus factory - http://www.atpower.co.uk Once built the car will be going there to have the map tweeked etc.
Not much happened as i've been in Italy for 2 weeks and my Dad has been doing a few niggly jobs etc.
Dash sorted and dials/guages/switches in place.
Birkin's usually come with Birkin branded guages/dials but the speedo comes in kmph so we've sourced our own - They are VDO dials and guages.
Throttle bodies and ECU ordered now too. Should be here within a week. Ordered from a company based next to the Lotus factory - http://www.atpower.co.uk Once built the car will be going there to have the map tweeked etc.
Edited by Ben Jk on Sunday 22 August 13:01
Edited by Ben Jk on Sunday 22 August 13:03
Throttle bodies were collected today from AT Power. http://www.atpower.co.uk
Just resting in position on this pic. Manifold also on and a few other bits.
Just resting in position on this pic. Manifold also on and a few other bits.
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