Kitcar Build

Kitcar Build

Kitcar Blog

This blog is to cover out progress through the stages of the strip down and rebuild of a robin hood kit car.
Started the blog a bit late as a fair bit of the stripdown has already been done, this is to follow our progress of the build.

Get your finger out Manley

Other bitsPosted by Christian French Sun, November 06, 2011 16:35:42
Its been a couple of months now since the car was moved, and as yet its been in neal's garage covered in junk!


Come on manley, get the clutch parts and lets get it sorted!

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Eventful Day

Other bitsPosted by Neal Manley Mon, June 27, 2011 14:15:06
picked car up from garage to return home after MOT pass, decided to give the car a quick blast to see how she runs, well got a few surprises.


on the run up the bypass at about 60ish lost the gearbox completely no drive and could not select any gear pulled over and still could not select a gear with the clutch in so thought clutch had stretched again and needed adjustment, put into second gear started car and limped to workshop, at workshop had a look and cable was fine so tried again and gears selected fine with car running and clutch depressed. Time for another run up the bypass again this time making sure all gears work discover no fifth gear at all cant even select, ok no big deal at the moment can look at that later so continue on all seems ok apart from the major pinking at about 2-3k just some timing issues to contend with there then.


so as im not overly happy but content decide to make the trip home, just about to get onto the duel carriageway when cough and splutter, my first thought was cant be fuel had put 10 litres in about 9 miles ago and had only had a small amount of time at idle, car dies and pull to side of road, get on the phone and ring for HELP! only person I think will be available is Mr Badcock, as Mr French was otherwise indisposed, so a jerry can of fuel later and we are back on the road. By my recollection this would mean im getting a great fuel economy of about 4-5 miles to the gallon not bad me does not think. lol


on the journey home Mr Badcock decides to follow if there are any other incidents and also can give me a lift back to pick up my car from the workshop which i feel is a great idea. Now what you need to know is that he has brought along his jelloppy, which is an old 1.8 petrol Freelander and does not have the best track record either. so we get back to home and drop off the car and have a nice cuppa tea to celebrate, on the way back just getting onto the main duel carriageway can you believe it engine slowly dies on the Freelander and we are now sitting on the side of the road again.


What a great day was had by all I must say. the sun was shining and eventually we all got home.


Thanks Mr Badcock and Mr French for all your help over the rebuild of this car.

Mr Badcock

Mr French

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MOT Day

Other bitsPosted by Neal Manley Sat, June 25, 2011 21:41:31
Passed MOT today.


While was waiting for a slot was able to get the car on the alignment ramp @PSR

took a few hours to get sorted but eventually got something that I hope will work, there is not allot you can find on the set up of these cars as I think most just get what they can and after doing this I can see why.


Have set up the car with negative camber to hopefully help with the understeer and set 0 toe


Also managed to get the steering directly aligned and centred.



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Awaiting MOT

Other bitsPosted by Neal Manley Fri, June 24, 2011 20:36:26
the car is now ready for its MOT. Have been waiting all day today to get it done so first thing tomorrow its down the garage and hope it goes through.


wish me luck!



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Finishing off

Other bitsPosted by Neal Manley Thu, June 23, 2011 20:33:44
So its getting close to finishing the car now, but as always things are sent to try us.

Have had a few problems with the brakes and had to purchase a new Master Cylinder, Starter motor is not engaging properly so have ordered a new one of those also, have discovered that the carbs are not jetted correctly so now will require new jets. This will explain the problems with the car not idling and running right.


Pedal box was to close to the driver and becomes uncomfortable after a while so have had to cut and and re shape the pedals for a nicer feel and fit.


re designed the clutch cable holder to stop the clutch from becoming lose when the pedal was knocked forward.


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Steering Pt3

Other bitsPosted by Neal Manley Thu, June 23, 2011 20:07:42
so have had the new column made by a local engineering company it was turned from a solid piece of mild steel, has a 28mm hole with clearance in the middle the machining for the bearings at 35mm to the specified depths to accommodate the shaft.


the column was then welded for the mountings to enable it to be bolted to the cross member under the scuttle.


the existing stalks were used and just held in place with threaded rod.


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Steering Pt2

Other bitsPosted by Neal Manley Thu, May 26, 2011 13:05:37
so as a continuation of the steering problem have attached a couple of pics. im sure Christian will update with his experiences.

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Interesting Day

Other bitsPosted by Neal Manley Sat, May 07, 2011 22:39:15
Was a nice day today so decided to get the kids down to the garage and get some more done to the car and let the kids play with he remote control cars. Continued work on the body mainly to the nose cone as this needs alot of work.

Chris came down later in the day to work on the dash Mk4 and completed the installation of the switches warning lights and digital dash display.


Pics will follow soon


whilst on one of our breaks Chris decided to take a VX220 for a test drive as Paul @PSR Automotive has one for sale


where we are located on a private estate there is a reasonably straight clear road at the back which Chris felt would be a good place to test the car to his astonishment whilst flooring the accelerator to the floor a mechanic from another garage jumps out into the road to which Chris took evasive action to avoid hitting him.

so when he comes back to the garage to drop the car back this guy shows up to have a pop and rant about the fact that its not a race track and he was breaking the law and could have killed someone OMG!! take a pill mate it an empty industrial estate.


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Day from hell!

Other bitsPosted by Christian French Wed, May 04, 2011 12:41:41
Definitely the worst day we have had so far on this build, nothing seems to have gone right


Started by rebuilding the dash, which is now on its mk4 connotation

The original one is at the top, which had original analogue instruments, which we decided to bin as they just were not bright enough in the dark, even if we fitted LED backlights... not good.


We then decided to fabricate it out of steel to stop flex, but then binned that idea.


I couldn't drill any holes in the dash because we had no drill or any bits, which meant a trip to screwfix to collect supplies. We also picked up new connectors for the switchgear and some new 2 amp equipment wire to link them all in. This turned into a 2hr trip. Also picked up some sparco pedal grips.


Then on to the MDF (third down) which was going well until the holes drilled in the bottom edge for the switches were too big, they should be 22mm not 25mm, not mentioning any names as to who's suggestion the size was...


This has lead on to dashboard mk4 (the plywood one) which has not progressed too far at present because we still need to locate the correct holesaws, which Neal must have somewhere as he used them on dash mk1. Hopefully he'll find them somewhere.


So for all yesterday, all I managed to do was get in the water temp sensor for the new digital dash:

Route the wires for it and the oil temp into the cabin and wire in some of the new harness into the old one.



I have now tested the new digital dash and it works in a preliminary sense, although we still have a way to go before proper testing can be carried out.


Forgot to mention the other disasters of yesterday:

I broke the wheelarch liner of a mini (we had to change the brake pads on Neal's girlfriends car)

Knelt on a brake pad (hurt more than I can describe)

Neal almost ran me over with the mini and drove over a pot of copperease in the process

One of the rear wings for the kitcar fell on to the floor, picking up a bit of damage

Still can't get the steering column back in as the engineering firm haven't turned the surround yet. If you're wondering why we have removed the column, keep checking back as we'll write up that odyssey when we have progressed further.


This just about sums up yesterday's progress...



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Roll bar painting

Other bitsPosted by Neal Manley Mon, March 28, 2011 22:40:27
Got round to painting the roll bar for fitting.


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