Robin Hood Lightweight

The Build Pt1

First stage is to build the chipboard jig. Robinhood in there wisdom supplies two 8' x 4' sheets and after a lot of head scratching you then go out and buy a third. The most important dimension is the centre line from which all the other measurements are taken

The jig

First bit, diff and rear wishbone support

First Bit

Chassis sides and floor rivited to diff support

Floor and Diff

Another view of the tunnel sides & rear diff support

Another diff view

The Build Pt2

The picture below shows the diff in place before the "15" panels are rivetted in place and form a rigid compartment. Be aware that this seals the diff into the chassis and you will only be able to remove the internals and not the casing after this stage.

Diff in Place

Panels "15" rivetted in place. I'm using a hand riveter with extensions made from the Sierra's roof bars. Robin Hood Engineering do sugest the use of an air riveter

Diff in Chassis

Another view of the sealed in diff

Another view of the Diff

The Build Pt3

Next stage fixing the front panel

Front view

The Build Pt4

Engine fitting time

The old Sierra had an 1800 CVH engine which I shall be using untill an upgrade. This will involve a little extra work compared to Pinto engines as the main difference is the inlet and exhaust are on opposite sides.

As I don't want to make a hole in the side for the exhaust only to fill it in and reposition it on the other side. I'm going to snake the exhaust under the car!

Engine Mounts

Engine Mounts

Painted Engine

Painted Stock Engine

Tight Squeeze

Tight fit at the rear Tight fit at the front

The Build Pt5

Due to a problem with a Lightweight failing a SVA test on the grounds that the chassis did not seem to be strong enough around the suspension tubes and a worry about seat belt mounting fixing points.

A group of us met at Graham's to discus ways of improving the design, eat bacon rolls and drink tea. Thanks again Graham.

Re-enforcing template

Here is my attempt at reinforcing the drivers floor starting with cutting ovals so I'm able to bolt the panel in

Cut outs

The edges of the holes were rolled over to add strength and remove the sharp edges

Smoothed cuts

Then the sides are bent to make a triangle box section

Box Section

Next stage fitting into car

Fitted Another fitted view