Wanganui, Mcsorely 442E / MX5

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Wanganui, Mcsorely 442E / MX5

Postby Wanganui7 » Tue Feb 06, 2018 5:01 pm

Hi all, I decided after squeezing into a Sylva Striker for many years, to sell up and build something a bit more comfortable for someone over 6'. Also a windscreen and top an added bonus for the wife. The Mcsorely 442 has bags of room compared to the Striker and chose MX5 componantry due to it's abundance and avaliable upgrades. Ordered steel through work at a good price and purchased a stripped out, part built mx5 race car from Mx5 Spares, New Plymouth. A borrowed trailer and short trip to NP saw my donor car back home in the drive giving me engine, gearbox, race seat and most of the components needed for my build for $1900. Built a construction table from 50x50 box with ply top (now for sale if anyone needs one) and cut all chassis steel at work on power bandsaw. Makes things easy :) A week later the basic chassis was tacked together and then the fun starts. Because the Mcsorely plans do not include any information for front or rear suspension, (They don't know what donor components you are using) you need to nut all this out for yourself. After I finished a lot of research and coming up with a design I then stumbled on one by Saturn sports cars UK. The end result is a combination of the two. I have used the rear mx5 lower arm with fabricated upper and front arms. The recommendation is to submit a design approval form to the LVVTA followed by the build approval before you start but being a naughty boy I basically built the whole thing before doing this. Reasoning that you change your mind so many times during the build process you would have to redo drawings again and again. As I'm building a bog standard design my paperwork was approved first time. The six suspension arms taken to work and Tig welded as per regs then sent to Stork Testing, New Plymouth for the non destructive testing. Passed no problems. I've spent years tig welding aluminum and stainless steel but I think mild steel is more difficult. Steel has to be scruplessly clean.Setting up the rear suspension was quite easy .I decided not to use the whole mx5 subframe as builders like Almac and Westfield do, rather build my own into the chassis to give a tidier look. I chose to use the lower mx5 arm with the brakes positioned at the rear. Gives a slightly longer wheelbase but makes the fitting of the standard hand brake cables easy also fitting the shock an easy task. All the arm mounting geometry is the same as a na mx5. People have listed all the dimensions on various mx5/ Miata forums. You just need to decide on a ride height before you start. I've set mine at a realistic 120mm having found my Striker would bottom out on our uneven roads at 80mm. My front suspension was a much harder job. The dimensions for the mx5 front uprights are totally different from the usual Ford cortina ones used. I tacked up a set of arms to Saturn Sports Cars design and found they worked on the Mcsorely chassis perfectly. Just required a bit of mucking around with the top arm mounting position to minimize excessive camber and bumpster change. At this point I made a bump steer guage along the lines of what is shown on the LVVTA site. I ended with a bumpsteer change of 3.5 degrees full bump to droop. The position of the steering rack seams to make the greatest effect on this. And you need to watch for the rack hitting the lower arm on full bump and lock. With the basic chassis assembled a dry run fitting the engine and gearbox is needed to finalize the transmission tunnel size. The mx5 gearbox requires a bigger tunnel than the original book design. I also offset the engine 30 mm to the left so as not to reduce the driver's footwell. Now is a good time to have your fiberglass nose on hand. I visited Almac cars in Wellington and picked up a second hand nose and wheel guards. Perfect height as they also use the Mazda engine but the Mcsorely chassis is narrower than the Almac at the front. Requiring 60 mm to be cut out then rejoined. Look at your seating position next.
Attachments
IMG_20180207_104926-1160x870-870x653.jpg
Chassis from side
IMG_20180207_104926-1160x870-870x653.jpg (157.71 KiB) Viewed 150 times
IMG_20180207_104508-1160x870-870x653.jpg
Front layout
IMG_20180207_104508-1160x870-870x653.jpg (141.23 KiB) Viewed 150 times
IMG_20180101_135358-1160x870-290x218.jpg
Front & top rear suspension arms
IMG_20180101_135358-1160x870-290x218.jpg (30.87 KiB) Viewed 196 times
Wanganui7
 
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Re: Wanganui, Mcsorely 442E / MX5

Postby bzrse7en » Sat Feb 10, 2018 9:07 am

Good work and welcome to the forum. Tell me, are the roll bar rear stays at more or less than 30 degrees? It is a bit hard to tell from the photos.
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Re: Wanganui, Mcsorely 442E / MX5

Postby DMC » Sun Feb 11, 2018 4:31 pm

Nice work, and a quick start, look forward to seeing things progress from here.
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Re: Wanganui, Mcsorely 442E / MX5

Postby Wanganui7 » Sun Feb 11, 2018 8:15 pm

Yes, stays are good. All built to MSNZ regs in case I want to use for competition in the future. Chassis passed first scutineering and bump steer test last week so is now off to get sandblasted and powder coated. Have spent the past few weeks cleaning up diff, gearbox and engine. Cleaning, painting, new oil seals,oil, boots, clutch eta. Can't wait to get painted bits back and start assembling :)
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Re: Wanganui, Mcsorely 442E / MX5

Postby Wanganui7 » Sun Feb 11, 2018 8:45 pm

Chassis was tacked together in my garage using a 170 amp single phase welder and co2 gas. Find the CO2 gives harsher weld and more splatter so took into work where I have a 250 amp three phase welder with argoshield gas. Still took 13 hours to weld over two days, then another 7 hours of cleaning up until I was happy to send to painters.
Attachments
IMG_20180210_130332-464x348.jpg
Stripping engine
IMG_20180210_130332-464x348.jpg (67.58 KiB) Viewed 110 times
IMG_20180121_192040-464x348.jpg
Gearbox reconded
IMG_20180121_192040-464x348.jpg (59.72 KiB) Viewed 110 times
IMG_20180106_164008-348x464.jpg
Diff reconded
IMG_20180106_164008-348x464.jpg (48.51 KiB) Viewed 110 times
Wanganui7
 
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Location: Wanganui NZ

Re: Wanganui, Mcsorely 442E / MX5

Postby Wanganui7 » Sun Feb 11, 2018 9:24 pm

Did a rough fit of the driver's seat (Bride bucket seats to be recovered in black vinyl later) Folded a channel steel sub frame, bolted to chassis, with runners on driver's side only. This allows you to sit in comfortable position and find best position for steering wheel, peddles scuttle design eta. Seats are an easy fit in the Mcsorely + 100mm chassis. Steering column is mx5, intermediate shaft mx5 to another custom made intermediate shaft supported by 16 mm rod end, and Ford escort steering rack. Quickrack brought from Palmside, later found you can import new from China for $100. My old Sylva Striker was a squeeze at best but I find the Mcsorely very comfortable for my 6' + frame with bags of room.
Attachments
IMG_20180207_105205-696x522.jpg
Seat sub frames
IMG_20180207_105205-696x522.jpg (106.14 KiB) Viewed 107 times
IMG_20180207_104443-696x522.jpg
Bump steer check
IMG_20180207_104443-696x522.jpg (111.67 KiB) Viewed 107 times
Wanganui7
 
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Re: Wanganui, Mcsorely 442E / MX5

Postby 7ish » Mon Feb 12, 2018 7:31 am

Nice work.

I wouldn't send it off to be painted till I had finished the entire assembly.
There is nothing worse than finding you need to weld on a bracket for something you forgot....
Ask me how I know ( I powdercoated mine).
7ish
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Re: Wanganui, Mcsorely 442E / MX5

Postby Wanganui7 » Mon Feb 12, 2018 2:13 pm

Everything has been assembled. Your right, on cleaning up chassis found I'd forgotten a bracket to attach end of muffler to. Famous last words, think I've thought of everything. I'm also getting the chassis blasted, powder primed then powder coated grey.
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