PAINTING AND POWDER COATING
With the chassis and components all completed, fitted for any tweaking all the bits and pieces were soon outside the workshop ready to be sent off to the powder coaters and painters respectively.
July has been a process of emails arriving with a simply instruction from the McGregor Team, “decision time – please call.” My latest high tech toy, the iPhone G3s being wireless compatible allows SKYPE to be my instant communicator. From paint colors, dash configurations, tire selection all requests were answered in numerous locations through out Japan.
Author: admin
A New Zealander living in Japan - a Professor at Faculty of Design
Diverse BLOGS from custom car building to Contemporary Modern Dance
Friday 26 June 2009
QUESTIONS
A rhetorical question is asked for its persuasive effect without the expectation of a reply. Two weeks ago Robert from McGregor MotorSport asked, “Would you mind a two week delay on the chassis as we would like to incorporate the latest updated design features?” Obviously I would not say no but this again shows the professionalism of the team at McGregor MotorSport to ensure the customer is fully informed during the build process.
The module descriptions that McGregor MotorSport is now using are really informative for first time kit car builders. The detail is well appreciated and certainly allows a clear picture of the entire build process. This has certainly changed the image of inviting a few mates over armed with beers and hammers to knock out a car before the rugby starts on the TV!
Driving in Japan is something that you may be interested in. I have a daily roundtrip commute of 100kms on local and paid highways. In the past five years I have lost count of the number of accidents I have seen and certainly could not count all those accidents in waiting I see daily. It is as if there is this intense desire to bend thin metal panels, explode glass and shatter plastic. Even in my most cynical moments there is an underlying belly of truth for the causes.
Japan has a driver’s license system that expects all people to attend authorized driving schools which meticulously instructs students. In fact I would say without hesitation that Japan has the most skilled parkers in the world. Reversing into a space the size of a matchbox using only mirrors is done effortlessly – well done all those white gloved diligent drivers and stoic instructors. Sadly the driving skills like awareness, following distances, driving conditions, car control, decision making, and high speed versus immovable objects are sadly lacking.
Now the above driving education program costs about $5,000 NZ dollars and for that investment serious questions need to be asked about the 2005 Japan 933,828 accidents, 6,871 deaths and 1,156,633 injuries. On that note I will now go out for a drive!
Saturday 9 May 2009
BRAKES
While the chassis is away being prepared for powder coating the build focus shifted towards brakes. My brother Grant was concerned about the braking capacity and my reply was from a comment on driving a Lotus 7 Kit Car during a club day event. One of the new members complained that he was experiencing brake fade after 4-5 laps. An experienced fellow Lotus & driver when consulted gave a succinct reply; “don’t use your brakes then”.
During my learning laps at Ruapuna I asked Mark for a braking point at the end of the main straight. Mark look puzzled and said you do not really need to brake…then smiled. Last week Mark emailed me with some pretty exciting news in regard to brakes. Currently McGregor MotorSport use the cast iron set up clearly detailed by Mark in the photo below.
I was asked if I would like to be the first customer for McGregor MotorSport’s Designed Hi Performance Brake Calipers. The design details further reinforce McGregor MotorSport’s continued quest for improvements;
Aluminum Calipers
Aluminum Uprights
Aluminum Hubs
Rotors – slotted and drilled
Fully Certified
The expectations are that the new design will be 60% lighter and 70% more efficient! Of course I have accepted the offer and look forward to seeing the finished Anodized Aluminum Units with the McGregor MotorSport name and logo machined into them.
Well done team!
Tuesday 5 May 2009
MAY IN JAPAN
Japan is now settling down after the euphoric cherry blossom season which after 12 years I have accepted as;
A time to lay out a large blue tarpaulin under a flowering cherry tree
Encourage friends, families and even strangers to sit with you
Drink copious amounts of intoxicating beverages and pretend to BBQ
Try and make your face match the color of the falling red blossoms
See who can full up a 4GB SD card first of cherry blossom moments
Engage in any form of intoxicated behavior knowing all will be forgiven
But…I love it too!
So as this very merry cherry season fades away I am focusing on the Mach 7 build. The distance from New Zealand has been further bridged by the Lotus Forums in New Zealand which can be seen at http://www.lotus7.co.nz/forum
This has been fantastic and allowed for such positive sharing and discussions within and about the world of Lotus 7 folks. I applaud the organizers and of course all those who contribute.
Wednesday 29 April 2009
APRIL UPDATE
It is important to keep everyone on the same page during a project. In my Mach 7 build it is even more critical given that I am in Japan and the car is in Christchurch. Mark and Robert quickly established themselves as excellent communicators from day one and this has been a vital part of this initial build.
Today was a recap of progress and the next steps that will be taken. I was very fortunate to work within the MRP [Manufacturing Resource Planning] world initially in Marketing and Management then Seminar Training. Learning about the BOM [bill of material] alongside the theories of assembly to manufacturing has been so valuable in this Mach 7 Kit Car project to date.
The update today from the factory was;
The Chassis is ready to be cleaned, prepared for powder coating after a final install check of all the components for a basic rolling chassis.
The engine is pristine and attached to the transmission awaiting a standard or aftermarket complete air intake. I am going to source that here in Japan given I am in the land of Mazda!
I again confirmed that I want this as a rolling chassis build. This means that the car can start and drive onto a transport vehicle. Now I am using the term car very liberally as it will have no body parts, they may need to sit on a milk crate but it will go forward, backwards and turn. The temptation for Mark and Robert to take the milk crate mounted chassis around the block may be hard to resist! I am sure that sanity will prevail!
Another very valuable conversation – SKYPE is going to be such a valuable part of the build in Auckland with live viewing of any, which there will be many, puzzling moments.
Tuesday 28 April 2009
MOTOR AND TRANSMISSION
After the test drive I was convinced that the MX5 1800 motor and transmission would be more than adequate. It has an excellent power to weight ratio and the fit was as if it was made for a 7 chassis! Once seated your hand fell naturally to the gear lever allowing for effortless changing.
The standard motor produces about 140-150 HP at the flywheel so it was decided with the motor easily accessible it would be the right time to;
Install a set of performance camshafts.
Port and polish
Powder Coat Custom Parts
New Intake plenum.
These two procedures should produce more low end power and a zippier response overall. The standard ECU will be replaced by entire LINK G4 ECU package. This is by no means a race motor but will keep me more than happy.
Monday 27 April 2009
CHASSIS AND SUSPENSION
McGregor Motorsports uses a space frame chassis. The heritage descends from the Colin Chapman 1957 Lotus 7 Design but with considerable improvements. A slightly longer cockpit, larger foot-well area increases comfort. The McGregor Design results in improved safety, strength and production simplicity. NZS4711 certified trades people maintain the high quality.
I am following McGregor Motorsports Suspension recommendations;
Independent rear suspension
Fully adjustable front and rear suspension
Fully adjustable GAZ shocks
Ford Sierra differential and axles (need shortening)
Ford Cortina front uprights and brakes
Ford Escort steering rack (std) and Mazda 323 steering column and an adjustable binnacle.
Monday 13 April 2009
APRIL IN JAPAN
Back in Japan, a large amount of time passes searching endlessly via Google for all facets of Lotus Super 7 information. A seemingly endless search uncovers incredible information, some shared, discussed and saved. More importantly in New Zealand, progress is happening so I have decided to blog the build in the following categories;
Which Lotus 7 Kit set?
Chassis and Suspension
Motor and Transmission
Fabrication and Paint
Body and Paint
Great Drives
McGregor Motorsports
New Modifications
Monday 23 March 2009
McGREGOR BUILD BEGINS
The build is now a reality with a very comprehensive cost outline from Robert and Mark with flexibility to alter as the build progresses. I was more than happy and with a flick of the mouse funds were sent south that would begin the McGregor Kit Car Project.
The motor selection was still very much in our hands and the 1.6 MX5 that Grant had found was not looking to be that promising. So it was a call to Mark to begin a search for a 1.8 MX5 motor and box. This again saved money as if we found it in Auckland Mark still wanted it shipped to Christchurch to fit the motor to meet the design needs and McGregor’s high standard of manufacturing. I was now beginning to feel very excited at not just the car but the entire way the build was sequentially coming together.
My spare time was now being devoted to internet searches on Lotus 7 builds, wheel and tire options and carbon fiber after market products. This was incredible as the devoted Lotus 7 owners all have common thread of passion for this Colin Chapman little sports car rocket.
Tuesday 17 March 2009
RUAPUNA RACEWAY TEST DRIVE
Not being a travel agent or gaining monetary gain from saying that Hotel So and their bar What is truly a hidden gem in Christchurch and gains my absolute approval. To add a touch of decadence to this was having Mark parked outside in the McGregor M7 at 9:30am ready to head out to the local racetrack for a test drive.
Zipping effortlessly through the streets of Christchurch I quickly settled into the wind though the hair, well what is left; driving that is synonymous with sports cars. The torque of the MX5 unit proved well suited as you could keep the law enforcement happy trundling along in 5th gear or check the rear vision, the road ahead, grab another gear and the car snaps into life. Even with a sunny sky I was chilly but the smile on my face kept me warm…however, the side windows would have been nice!
The mandatory gasoline and tire pressure stop opened comments and stares from others at the gas stand….”nice car mate”….”have a nice drive” yes we were gaining attention. The Ruapuna Race Track is a significant part of New Zealand motor racing history, which is sadly at risk for noise violations. Years of watching Ruapuna on television and scouring through magazine articles, I felt very much at home gazing at the track and soaking up the live feeling.
The local race car coaching school was in process so I was lucky to see the track plan, the three cones for cornering and some sensible tips written largely on the white board. Mark proved to be an equally excellent instructor and with a pair of McGregor Overalls and a borrowed lid we strapped ourselves in for a few warm up laps. I was comforted by Marks last comment that was simply if things do go horribly wrong “fold you arms tightly in front of you”…um! The McGregor snaps into life then proceeds to devour corners with a cheekiness that is difficult to ignore so, so addictive. The first laps were a blur…so much for studying breaking points, turn in lines and locating the apex! Now Mark took the car into the pits with a procedure that ensured the brakes cooled to avoid a possible heat-to-heat attachment! This gave a few minutes to take in those first exhilarating laps while Mark re-set the suspension…another very clever McGregor innovative design component. Helmet back on, belts pulled tight we set off on a few more laps where the McGregor attacked corners with savage precision reveling in the minor arm wrestles thrown at the driver. Back to the pits, same slow down break routine and it was now to be my turn!
I did not want to be like Morgan Freeman in “driving aunt daisy” but equally I did not want to be known as the bloke from Japan that dented the McGregor test car…um! Approaching all brake points, I went in slow and attempted to exit fast while remaining smooth and in control. Honestly, it is such a forgiving design I felt things beginning to go all wrong in the hairpin so I simply eased into the throttle and trusted the car more than my ability. Mark commented later he was ready for the car to spin but was pleasantly surprised how it all smoothed out.
I have no allusions of setting lap records but even after a handful of laps the lines became easier and the car allowed me to really feel like I was racing…not fast but racing. I cannot imagine anyone not enjoying this and my hand was already reaching for my PC, login to my bank to send a deposit for the car…I was, am totally hooked!
The flight to Auckland was a time to shape the entire build project and upon being picked up by Brother Grant, we of course headed off to the coldest beer in the world for a Mach 7 meeting. Grant was quickly up to speed and we both agreed that some of the pre-assembly, while interesting, is really just time consuming. This was a quick decision to have a rolling chassis come out of the McGregor workshop. The reasons being are;
Why take the motor and transmission out for shipping?
Minimal involved in suspension/brakes/wheels installation
Cost effective for shipping
I have limited time due to living in Japan
This was a certainly a two beer worth while meeting in fact we were enjoying it so much we changed venues and had wine and pizza to seal this first step in our heads.