Bits And Bobs

Getting your hands a bit dirty

We have chosen a slightly easier construction route for our MEV Rocket build, using more new components than other builders. Our choice entirely, and as a consequence our build cost will potentially be higher.

Why you might ask?

 

Well not only will my son Aaron (aged 14) be helping with the build of the Rocket, but we do hope that he may be able to drive it on a few occasions at Under 17 Car Club driving events. Therefore, the brakes in particular are ALL NEW, as his mother insisted they should be.

 

We have retained the 2nd used steering rack and front uprights supplied by MEV.

Our donor vehicle is a rear drum brake Ghia 1.6 version so our rear brake calipers came from a breakers yard as trade in items against the purchase of a new pair.

 

Rally Design must have made a fortune out of us so far, but their stuff is really good. They have provided the alloy hubs and bearings, vented, cross-drilled and grooved front discs, Wilwood calipers, master cylinders, and pedals.

 

The main bits that need engineering are the steering column, and the exhaust. With the latter representing a good chunk of cash, we are looking everywhere to source parts for the build rather than go down the bespoke exhaust route from MEV. We may not succeed but the savings might allow us some other bits we would like in the end product. Time will tell.

 

We are excited by the build even if some things have proved to not be quite so straightforward as anticipated. More elsewhere....

 

The gearlever

Mondeo gearlever assembly    Mondeo gearlever required for MEV build

 

Gearlever assembly before modification.    Gearlever modification

 

The gearlever from the donor Focus leaves you with a mirror image gear gating sequence. So to get everything back where it needs to be, the gearlever from a post 96 Mondeo is put to work. Price from breakers yard £5 - £10, depending if it is off the car already, or you take it off and save them some work.

 

As seen in the pictures above, removing the plastic moulding as marked in red make life easier later on.

 

The MEV supplied front uprights

Used Front Cortina Style Upright    Degreased Upright, partial rust removal stage

 

Cleaned Upright before painting. Orange colour is not rust but poor lighting.    My assistant at work with his paintbrush and a tin of Hammerite Smooth Blue paint.

 

After a full degrease of the uprights and the removal of several  years of surface rust, we are left with serviceable uprights.

 

My assistant decided that the car will have some feature colour components, and the colour of choice is blue. Several shades will be seen around the car as matching everything is pretty much impossible.

 

Harnesses and seats will also feature blue as will the steering wheel if we have sufficient funds at the end of the build. We will see!

Things We Never Thought About

WIRING

The donor Focus provides loads of wiring but are there sufficient wire lengths for front to back connections on the Rocket?

 

Brake pipes RUNS

The brake and clutch pipes run from front to back, needing to go over chassis rails. What is best and safest installation?

 

BRAKE PEDAL SWITCH

The donor provides the switch unit, but how easy is it to make up the bracketry around the Willwood pedals?