WINSTON '88 MK2 Scirocco RWD

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treefingers
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Re: WINSTON 1988 GT MK2

Post by treefingers » Sun Nov 14, 2021 8:35 pm

I have started work on the car once more, more things are being made... updates soon



treefingers
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Re: WINSTON 1988 GT MK2

Post by treefingers » Thu Nov 18, 2021 9:57 pm

So picked this build up again after 6 months of not even touching it, and got a little bit more momentum now.

Continued on the cabin, and made some removable seat bars, copying a motorsport design I saw.

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Made some 3mm captive nut plates and welded to chassis, then the seat bars bolt to this. This means the bars can be removed easily for painting/carpets/future mods

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Mounts for the CAE shifter, 5 different possible positions! 5mm plate.

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Filled in the gaps..

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Handbrake next. Find some way to re mount the handbrake 240mm away from the standard location, and to run the cables.

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Beginnings of the new handbrake bracket

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Folded up some profile..

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For a rear bulkhead to replace the rear seat backs and retain luggage space.

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Note handbrake bracket!
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Fabricated a mini engine/gearbox lift table from scraps. Will be useful when the time comes to lift heavy parts and can be modified later (possibly made bigger).
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treefingers
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Re: WINSTON 1988 GT MK2

Post by treefingers » Sat Nov 27, 2021 11:11 am

So after getting the seat rails and everything in that area basically done, I began to think about the crossmember in front of the seat rails.. it went like..

'hmm those crossmembers will be on show on front of the seats. probably should redo them'

'while I'm there, how about a bigger tunnel, in case I decide to go AWD later on'

'If AWD later on, why not now?'

'If AWD, why not RWD?'

Can you see where this is going now.. Thanks to Darren for paving the way!


A BMW 120D rear axle was purchased

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Some chopping required

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Fully committed now then!

Going RWD makes so much sense, to solve some of the engineering problems I had with this Rocco build...

- RWD means no FWD torque steer (no need for equal driveshafts)
- RWD means better weight balance (less weight all over front of the car)
- Allows fully independent rear suspension (I had been thinking of how to do this anyway)
- Should be much more challenging and rewarding to drive
- It's a bit more original and should be fun to build.

Some problems to solve though..

- Steering, where to put the rack and get it to work properly
- Retaining cabin space, I want the car to feel roomy, like a MK2 Escort, not like an MX5 or an E46 with offset pedals from the driver. Yuk to that.
- Getting rear wheels to fit inside the standard arches as I don't want to run big berg cup arches.

This is the vibe of how I want it to look..

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So back to the build..!

Much thinking and thinking needed of how to mount whilst allowing for clearances of everything, and how to join to the chassis. New chassis rails to begin with. Took some measurements off the subframe, drew up in autocad, then cut out in cardboard to check it was all ok.

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Chassis frame tacked up, 50x50x3 box.

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In rough place in the car..

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treefingers
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Re: WINSTON '88 MK2 Scirocco RWD

Post by treefingers » Mon Nov 29, 2021 11:09 am

Ploughing on then....


Next job: forming a plan of how to tie this new chassis frame into the body of the car.

Wheel arches. It seemed like a good idea to cut these out and do my own, as they are not the same each side where the cage will mount, and they will be getting new suspension turrets anyway. I plan to keep the outer arches the same, and just redo the inners to give clearance for suspension.

Inner arches cut out and a bit of X - bracing to keep chassis shape

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The first arch tacked into place. The plan is to have the suspension turret on the inside. The vertical part of the arch is 1.5mm steel, the curved part is 1.2mm. I followed the radius of the inner arch return flange, which is not a uniform arc at all!

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Lots of space for wheels, the subframe being the limiting factor now for wheel width.
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The piece of aluminium angle clamped on is the center line of the car and is what I used to take measurements from. I also used a Digipas spirit level, zero'd on the dash support.
The plan is that the new chassis frame will sit exactly in the gap between the arches. LHS arch is the right width, but the RHS one needs narrowing to match (just mocked in at the moment)
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Will keep playing with this design for arches and see what comes up. I'm feeling it will work for clearances and strength, but don't want to eat into the boot space too much, so may narrow them a bit to gain some space back.



big_wig_074
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Re: WINSTON '88 MK2 Scirocco RWD

Post by big_wig_074 » Wed Dec 01, 2021 12:07 pm

liking this, dont let the thread die! very cool



mk2daz
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Re: WINSTON '88 MK2 Scirocco RWD

Post by mk2daz » Wed Dec 01, 2021 2:13 pm

Awesome Andi!

Can't wait to see what you do with it and how you go about it too.

I can picture our RWD roccos at a drift event already ... 8-)



treefingers
Posts: 396
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Re: WINSTON '88 MK2 Scirocco RWD

Post by treefingers » Sun Dec 05, 2021 12:06 pm

big_wig_074 wrote:
Wed Dec 01, 2021 12:07 pm
liking this, dont let the thread die! very cool
I shall try not to :)
mk2daz wrote:
Wed Dec 01, 2021 2:13 pm
Awesome Andi!

Can't wait to see what you do with it and how you go about it too.

I can picture our RWD roccos at a drift event already ... 8-)
I can picture them going sideways around Glencoe.. Seems like I've got a lot of catching up to do, yours will be on the road next summer at this rate!



treefingers
Posts: 396
Joined: Wed Aug 14, 2013 1:04 pm
fill in the right answer: 15

Re: WINSTON '88 MK2 Scirocco RWD

Post by treefingers » Sun Dec 05, 2021 11:29 pm

Rear arches welded up and welded in

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The new chassis rails will be boxed in to the original ones here.
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Need to decide how to mount the rear axle to this frame, then it can be positioned and welded in.
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isaidthephil
Posts: 231
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Location: Northwich, Cheshire

Re: WINSTON '88 MK2 Scirocco RWD

Post by isaidthephil » Tue Dec 07, 2021 11:13 am

Looking crazy as ever :) looking forward to seeing this develop.

There are going to be some crazy Scirocco's in a couple of years time aren't there.



treefingers
Posts: 396
Joined: Wed Aug 14, 2013 1:04 pm
fill in the right answer: 15

Re: WINSTON '88 MK2 Scirocco RWD

Post by treefingers » Sat Dec 18, 2021 12:20 pm

isaidthephil wrote:
Tue Dec 07, 2021 11:13 am
Looking crazy as ever :) looking forward to seeing this develop.

There are going to be some crazy Scirocco's in a couple of years time aren't there.

Yours too Phil!

Roll cage time!

Goals for the cage:
- strong
- motorsport specification
- bolt in
- aesthetically pleasing
- keep the bars out of the way so it's not annoying as a daily driver
- be able to fit a headlining above it!
- 6 point and possibly run through to front turrets

Sold my £900 CAE shifter and used the funds to buy a tube bender. Bought 24 meters of 44.45mm x 2.65mm CDS tube, should be enough and I can use it to make the engine cradle too..

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Messed myself up by trying to draw up the main hoop in cad. Just made it more complicated, but eventually got the measurements right! The former tool is a 5.5" radius.
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Happy with the measurements..
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Main hoop feet
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Captivated M10 nuts welded in
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Feet for the rear stays. A 3mm plate with captive nuts was welded underneath too.
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Main hoop and bottom bar
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Rear stays
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I knew I really wanted this X-piece!
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I'm using my tube notcher and a grinder to get the tubes to fit
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One more bar..
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Tig welding all this up is a bit of a challenge and I will be a lot better at it when it's done! Strength is the first goal from the welding but would be nice if I can make a nice job of it too.

The front section will be joined using these approved clamps:
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