2 SECONDS TO 60 WORKSHOP

COMPLETE KIT CAR MAY 2020 – ISSUE 166

SYLVA PHOENIX  TECH TALK: ENGINE TYPES

BUILT FOR THE DRAGSTRIP  RUNNING REPORTS
BUT STILL ROAD LEGAL  OUR CARS UPDATES
 READER’S MEV EXOCET BUILD

#BuildDriveEnjoy

FORD v FERRARI: THE REPLICAS

Ford versus Ferrari replicas  Sylva Phoenix Pt2  Lotus Seven group test  Retro Round-Up  MEV Exocet build  Tech Talk: engine types

S TA R S O F L E M A N S A N D T H E S I LV E R S C R E E N R E C R E AT E D F O R T H E R OA D

On sale 24 April
£4.95
www.completekitcar.co.uk

LOTUS 7s HEAD TO HEAD PLY BODIED TRIUMPH

BASED CENTURION
TALKING SHOP WITH
MK SPORTSCARS
MAY 2020

All four generations of a legend head to head And more kits and specials Behind the scenes at the
PLUS: New Caterham Super Seven 1600 revealed
Issue 166

that time has forgotten busy Essex manufacturer

2 May 2020 www.completekitcar.co.uk
 COMMENT | W ELCOME

WELCOME
THE CKC TEAM /CKCMagazine

Editor Adam Wilkins @CKCMagazine

[email protected]
@CKCMagazine

W
Editorial Assistant Jack Wood
[email protected]
hat a different office – two weeks before you’ll read still able to dispatch parts to keep
Roving Reporter Ian Stent place the it and things could have changed for your projects on the go.
[email protected] world became better or worse in that time. The priority right now, of course,
in the two As it stands at the time of writing, is staying safe and healthy, but that
Technical Editor John Dickens
[email protected] weeks between we don’t know when shows and doesn’t prevent me daydreaming
our last issue going to print and it events will start happening – all that about the many things we usually take
Columnists Gary Axon, reaching newsagent shelves and lays ahead is a sea of cancellations for granted. Let’s hope for a return
Richard Heseltine subscribers’ doormats. There are and postponements. In the meantime, to normality as soon as possible,
Contributors Jeroen Booij, many more important things going all we can do is carry on the best followed by a mass deSORNing
James Horsley, Chris Pickering, on right now than building cars and we can in the circumstances presented of kit cars and maybe the best ever
Peter Rosenthal, Martin Scott writing about them, but we hope the to us. Perhaps that means more time Stoneleigh gathering we’ve ever seen
fact that we’ve got this issue out to in the garage preparing your car for some time later in 2020. I don’t know
Running Reporters John Clements,
Trevor Crout, Rob Davenhall, you on time in very strange prevailing the delayed season of shows, touring, about you, but I’m ready for it.
Mark Davenport, Pete Dawson, conditions offers some escape from trackdays or whatever else floats Stay safe.
Ross Maynard, Simon Skelding, the outside reality. your boat.
Claire Spindloe, Andy Westgate Quite what this year will have in To help pass the time, we’ve Adam Wilkins
Race Diarists Ollie Batten,
store for us is anybody’s guess. I’m knocked some money off our books Editor
Ian Chapman, John Pick, Alisdair Suttie writing this – from my makeshift (see the advert on page 18) and we’re
office in the dining room at home sending email updates to subscribers @AdamWilkins_
Graphic Designer Sarah Scrimshaw rather than the Complete Kit Car to let you know which companies are [email protected]
[email protected]

Proof Reader Andy Bliss

Advertising Manager
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MEET THE TEAM
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Complete Kit Car is published

every four weeks by
Performance Publishing
Ltd. Sorry, but lack of time
prevents us answering
technical queries over the
phone. We would much prefer
you contact us by email or
write, enclosing an SAE for a reply.
ADAM JACK JOHN RICHARD
While every effort is made in compiling
the editorial and accepting only bona fide
WILKINS WOOD DICKENS HESELETINE
advertisements in Complete Kit Car, the publisher Editor Editorial Assistant Technical Editor Columnist
cannot be held responsible for any effects arising
therefrom. Freelance features and photographs “What makes the Lotus “It’s fully road legal “Karl Benz produced the first “The Triumph Spitfire
are submitted at the owner’s risk and, whilst Seven so special that it has and capable of 0-60mph motor vehicle adapted to based Burlington Centurion
every care is taken, no responsibility for loss or
damage can be taken by the publisher or their inspired imitators?” in under 2sec” run on petrol in 1885” was a distinctive coupé”
agents. Copyright Performance Publishing Ltd. Lotus Seven group, p42 Sylva Phoenix, p32 Tech Talk, p74 Retro Round-Up, p56
All rights reserved. ISSN 1754-1271

www.completekitcar.co.uk May 2020 3

 32

42
FEATURES REGULARS
24 FORD VERSUS FERRARI REPLICAS 8 NEWS
Total Headturners has built a GT40 to Abridged compared to our usual news round-
replicate the one from the film. up, but there are still things happening.

32 READER’S SYLVA PHOENIX 11 NEW PRODUCTS

Meet the Sylva that’s built to excel If you’re spending more time than usual in the
on the quarter-mile dragstrip. garage, here’s some kit to keep you entertained.

42 LOTUS SEVEN GROUP TEST 12 SHED

Pitting four generations of Lotus Seven against
each other – the car that inspired a genre.
In place of our usual club pages, here’s what
you’ve been getting up to in your sheds! EVENTS
56 RETRO ROUND-UP 15 LETTERS 17 ANTWERP
Heseltine takes one of his regular dives into the We love hearing your views on all things Gary took a pre-lockdown trip to
archives to find forgotten kits and specials. kit car related. Keep them coming! Antwerp to capture this show review.

24 20 TALKING SHOP
Before social distancing, we spent the day with
Sean Smith and Neil Barker at MK Sportscars.

80 CARS FOR SALE

Here’s something to inspire you for
when we can take to the roads again.

82 FINISH
Rounding off the issue with the loose ends
that didn’t fit anywhere else. 17

56 20 12
4 May 2020 www.completekitcar.co.uk
 M AY 2020 | C O N T E N T S

SUBSCRIBE & SAVE

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WORKSHOP
64 READER’S MEV EXOCET BUILD
Kuljeet Ubhi’s MEV Exocet takes the
Mazda MX-5 based kit to the extreme.

70 OUR CARS
James sent the Nova away to the paintshop
pre-lockdown, and has been busy ever since.

74 TECH TALK: ENGINE BASICS

John Dickens discusses the different kind
of internal combustion engine types.

76 RUNNING REPORTS

64 Our team of real world builders have been

keeping themselves busy in the garage.

70 76

74
www.completekitcar.co.uk May 2020 5
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Siltech Racing is a family run business Welcome to the Tifosi Family, Rana, SS and JEM
that specialise in Wide Track Front Rana being the “Frogeye” Sprite that we all can associate with, the SS “Sebring
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Aim FP Stoneleigh 2020.indd 1 13/03/2020 11:33 am

NEWS
ROUND-UP OF THE
LATEST KIT CAR
INDUSTRY NEWS

SONIC7 HARDTOP RETURNS

T
here is still some MEV previously offered a hardtop to get in and out of the car. There finished car are available. Equilibrium
development going on for the car, and it’s that which forms will be a polycarbonate rear window was able to send this photo from
by kit car engineers the basis of this new iteration. The to allow light into the cabin, while a earlier in the year, when the styling
isolating themselves in main change is to the engine cover, louvred panel is being considered as was mocked up with tape. The finished
their workshops. Angus which is being restyled to better an option. version will be ready in time for when
Weijers of Equilibrium Kit Cars sent suit the hard top. The coupé-like The moulds are made and the the show season gets going later in
us these images of the hardtop he is styling will have a T-bar roof with panels are in production, but it may the year.
currently working on for the Sonic7. hinging outer panels to make it easier be some time before photos of the W: www.equilibrium-kitcars.co.uk

MOT EXTENSION
The DVSA announced on 25 March that it will be however, you are still required to ensure that if you
extending any MoT with an expiry date on or after take any car onto the public highways that it is
30 March for a total of six months. safe to drive (roadworthy) and it is within your rights
As a car owner you aren’t required to do anything to have it repaired at a local garage should
with your paperwork, as the changes will be made you need to – it’s likely they’ll appreciate your
automatically by the DVSA and all updated dates support too, due to the sudden loss of steady
will be added to the MoT check website below – testing income.
although at the time of publication our own MoT W: www.gov.uk/coronavirus
data had not been updated. As a driver, W: www.check-mot.service.gov.uk

IN BRIEF
Keep up to date online between
NEC RESTORATION SHOW RESCHEDULED FOR AUGUST
With so many events postponed or
cancelled, here’s one that has been
7-9 August. We’ve taken the events
page out of this issue as it’s likely to
issues at www.completekitcar.co.uk rebooked for later in the year. The change frequently over the coming
or on our social media channels Classic Car and Restoration Show – weeks. We’ll be keeping the events
known affectionally in the Complete page on our website up to date every
Kit Car office as the rust show – is time we hear of any changes.
/CKCMagazine @CKCMagazine @CKCMagazine rescheduled from its date in May to W: www.completekitcar.co.uk/events

8 May 2020 www.completekitcar.co.uk

 JACK WOOD
THE SOCIAL
SIDE OF CARS
With the coronavirus lockdown in
place at the time of writing, I’ve
had plenty of time to contemplate
GLICKENHAUS TEASE KIT CAR
the things I’ve taken for granted New York boutique car constructor of Ferrari – and his latest hypercar, the shock is that the proposed kit
recently. With both my cars currently Scuderia Cameron Glickenhaus is best 007, is set to take on the establishment is set to be an off-road buggy, which
registering gallons per month – as known for producing ultra-rare, race at the Le Mans 24 Hours when it takes will be engineered to take part in
opposed to miles per gallon – not ready hypercars under the direction place in September this year. the gruelling Mexican Baja 1000
getting out enough is a big one. of American movie mogul, and So it was a bit of a shock to find race when complete – no small
With so many events set in renowned supercar collector, James that the American manufacturer task. This is a project we will be
the calendar for spring, I became Glickenhaus. In the past, Glickenhaus announced via social media in March keeping a close eye on in the
complacent and pushed back all has been a customer of Carrozzeria that is was looking for, ‘an optimum coming months.
attempts to get the Midas back out Pininfarina – much to the annoyance way to launch a kit car’. More of a W: www.glickenhausracing.com
each weekend by choosing to sit
around instead – an activity that I’ve
become particularly bored with in
our current situation.
DEHAVILLAND F48 PROJECT FOR SALE
While I do miss the quiet early
morning runs on a Sunday, it’s the
shows and classic car community
that I miss the most. Car chatter in
my household is particularly thin on
the ground, and seeing the same
grey motors out the window each
day has made me determined to
get out to as many car shows as I
can when it’s possible.
I know that the events industry
has been hit particularly hard by
these lockdown measures, and I
do hope this collective cabin fever
effect will result in record breaking
ticket sales when we’re all allowed
out again later this year. Ever since DeHavilland announced it was to develop its and is looking for a new owner to take over the project as
I’m also hoping that the first clean sheet design three years ago, Complete Kit Car has a going concern. To ease the transition, in addition to the
extra time at home will see a kept tabs on the quick-build, single donor, track-focused tooling, production rights and demonstrator, DeHavilland
few more interesting kit cars sports car from concept to creation. boss Terry Groves is offering the new owner six months
attending the rescheduled shows. But following the kits release at Stoneleigh last year, of back-up as well as the opportunity to build an F48 at
I’m hopeful that my little Midas DeHavilland has decided the F48 should be seen as a DeHavilland to learn more about the process.
will be one of them! separate entity to the marque’s established Dino replica W: www.dehavillandmotorcompany.com

COMPLETE KIT CAR SALE

If you’re finding you have too much research what’s currently out there, a buy-three-get-one-free deal on all our
free time on your hands at the minute, we have lowered the price of the back issues – of which there are over
you may want to check out our new UK Kit Car Guide by £2. There’s also a 100 editions in stock – should you wish
deals on kit car related books and £2 discount on the popular Modify, to fill any gaps in your collection, or
back issues via our website. Improve & Upgrade Your Kit Car book, research a bygone kit. Get saving today!
If you’re looking to take the plunge should you wish to renovate your W: www.performance
with a new kit car build and want to existing kit instead. We’re also offering publishing.co.uk

www.completekitcar.co.uk May 2020 9

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10 May 2020 www.completekitcar.co.uk
GEAR
THE LATEST USEFUL
AND COOL STUFF
KEEP THE POWER FLOWING
Following recent events it’s highly likely
FOR YOUR KIT CAR that many of your kits have had their
winter hibernation period extended
into spring, and possibly beyond, which
means it’s also likely that many batteries

ESSENTIALS are beginning to feel the strain.

If it’s been a while since your car
has had a good blast, you may wish to
invest in one of Clarke’s new Intelligent
Battery Chargers that are able to
charge, maintain and restore dormant
batteries with the minimum of fuss –
ensuring you don’t miss out on any of
the motoring events later this year!

Price: £131.98
W: www.machinemart.co.uk

COLOURISE YOUR
CALIPERS
Designed to refresh both brake
calipers and drums, Autotek’s
brush-on paint kits are ideal for
adding a little sportiness to any
set of dull or ageing brakes, with a
high gloss finish that’s available in
four different colours. What’s
more, being heat, oil and brake
fluid resistant means that, if you
CARBONATE YOUR KIT
follow the instructions carefully,
they’ll stay looking better for longer.

Price: £9.60
W: www.carbuilder.com

INSPECT AND PROTECT

Want to check the condition of your
kit car’s internals without taking
FLYWEIGHT FLYWHEEL These carbonfibre mudguards from Kit Car Direct are
designed to fit any Lotus Seven inspired kit car, and are
everything apart? If so, you might With its one-piece forged steel construction, this Competition just the ticket for updating the look of your roadster.
be interested in this new endoscope Clutch lightweight flywheel from Freaky Parts is a welcome Each pair is made using pre-impregnated carbonfibre
available from Rally Design. With addition to any naturally aspirated Mazda MX-5 based kit car and oven baked to prevent any distortion in the weave,
it’s LCD screen, waterproof camera – especially those used on the track. and when fitted with a set of rear carbon stone guards –
and 1m of flexible tube, there’s very Not only should its fitment make rev matching a breeze sold separately – should leave your sevenesque roadster
little that can hide from this handy and improve throttle response, it should also prove longer looking clean and modern.
inspection tool. lasting than a standard Mazda flywheel.
Price: £189.98
Price: £44.90 Price: £283.92 W: www.kitcardirect.co.uk
W: www.rallydesign.co.uk W: www.freakyparts.co.uk

www.completekitcar.co.uk May 2020 11

SHED
SHOW US YOUR CAR
TO SEE IT HERE!
With social distancing now in place, it’s the perfect time to take a
closer look at what you’ve been getting up to in your garages. Send
[email protected]
your pics and information to [email protected]
FINISHING TOUCHES
Andrew Semon has used his time
away from work to perform the little
finishing touches to his Sylva Leader
400. These have included bleeding
the brakes, mounting the seats and
getting its Fiat twin-cam engine to run
sweetly. It looks like rewarding work
but, as Andrew explains, “For every job
I tick off the list, I find three more to
do on this historic kit!”

Sylva’s seats in place.

Fiat twin-cam is running sweetly. This leader should be a lot of fun when it hits the road again this year.

HACKED-OFF HENSEN

The Hensen’s bodywork will need many repairs... ...here’s how it looked when it was collected.

Tom Hextall has been hard at work 3D printed plugs as a mould, and is
rebuilding his Hensen M30, a task awaiting a new mould to rebuild the
that’s been made more difficult due rear of the car.
to the dubious modifications made by Tom is also currently considering
a previous owner, who attempted to what new engine should power his
redesign the rear end of the muscular Hensen when it’s complete, and is
coupé. During his time in the garage undecided over whether he should fit
Tom has been hard at work creating a lightweight V8, straight six or even a
a new tail light assembly using four-cylinder turbo. New tail light holes... ...for the new tail lights.

12 May 2020 www.completekitcar.co.uk

COOL COBRA REPLICA TRIPLE EDGE

Steve Smith’s Brightwheel Cobra is awaiting its IVA test.

Steve Smith purchased his One of Tim Russell’s earlier Devils lives in the Netherlands.
Brightwheel Cobra replica as an
unfinished project, and has spent Tim Russell has been hard at work
the best part of two years fabricating building his Edge Devil, which will
many components to complete the be his third Edge build in total. His
build. This includes a whole new rear first Devil was powered by a naturally
suspension system, which he has aspirated 2.3-litre Audi five-cylinder
designed around Ford Sierra Cosworth engine, his second a turbocharged
componetry. Unfortunately the Cobra unit from the ever rare S2 and his
replica was due to be tested in March, third build, when complete, will make
just after the DVSA postponed all IVA use of a 4.2-litre Audi V8 – which
examinations for private vehicles, but should provide the single-seater with
it’s hoped the Cobra replica will be appropriate performance when it hits
hitting the road in the near future. Steve built the car in two years. the road in the near future. The single-seater should prove fun.

Audi V8 is torquey. Tim’s Audi 100 graveyard.

Early rolling chassis. New rear wishbones.

NEW BUILD
Dave Glozier took delivery of his new
MK Indy RX-5 kit on 21 March,
two days before the UK went into
lockdown, so he has had plenty of time
to work through its assembly book.
As it stands at the time of publication,
Dave was almost ready to fit the
Mazda MX-5 engine and gearbox to
the spaceframe, and looks on track to
beat the MK build record of 16 weeks.

The MX-5 donor’s body being removed from the powerplant frame. Engine and gearbox pre-paint. Dave Glozier is making good progress.

www.completekitcar.co.uk May 2020 13

14 May 2020 www.completekitcar.co.uk
MAIL
SHARE YOUR KIT LETTER OF THE MONTH
CAR OPINIONS
[email protected]
ITALIAN ESCAPE

HAWKE MEMORIES
In the late ’90s, I saw an advert in a
British magazine for an unstarted
GCS Hawke kit. I was astonished
to see that the phone number was
a Belgian one from a zone next to
where we live. As my wife always liked
Morgans, I called the seller who was
only 30km from home. I met the seller
in the street where he lived and where
he was working on a classic Mini in
front of his home. He took me to a
big storage place where he had at least
a dozen classic Minis, some of them
hanging on the walls on big hooks!
In the middle of all those slightly
damaged Minis, mostly from the
South of France origins, he had the
complete GCS Hawke kit, a Ford
Cortina and a 2.0-litre Pinto engine
for sale. I could see that the chassis
and the body were rather complete and
in near new condition, but I couldn’t
be sure that all the parts where there. In August of 2018 I bought a Spartan from eBay, went to time to make our way back home without using a toll road
The Ford Cortina (1300 or 1600) was Scotland to bring it back to the Isle of Man and, after a or motorway. From Lucca it was up to Switzerland through
supposed to be the main donor along rebuild, we took it on a small road trip to Yorkshire during St Bernard Tunnel and back into France to Mulhouse
with the Pinto engine on the floor. Easter 2018. I did a few more jobs on her and then, at the where we spend some time at the fabulous car museum,
The asking price was very high end of August, it was time to go on a proper road trip to then up to Belgium before going back into France to get
and I still wasn’t sure if all the parts Lucca in Italy. the ferry back to England.
where there or if the Pinto engine was First it was on the Steam Packet to sail to Liverpool Then we had a long drive from Dover to Heysham
working and what I would find while followed by a drive to Dover to get the ferry to France, a without using any motorways to get the ferry back to the
dismantling the Cortina. The seller drive through France and through the Mont Blanc tunnel Isle of Man. This was a 3200-mile road trip.
wasn’t very co-operative and claimed into Italy to Lucca. After spending a week in Italy it was Graham Turner, Isle of Man
I would have a rolling chassis in just
a week after quickly dismantling the
Cortina, which I knew it wasn’t true.
EVERY ISSUE, LETTER OF THE MONTH
I made an honest bid but I never WINS A COMPLETE KIT CAR MUG
heard from him again. I don’t know if Send us your thoughts and opinions on all things kit car related
that kit was ever sold in Belgium or if and if your letter makes it to this spot we’ll send you one of our range
it went to a more kit friendly country. of Complete Kit Car mugs – perfect for a brew in the garage.
The biggest problem with that kit was
that it was nearly impossible to register
it in Belgium (it still is!) once finished.
You had to transport it to the factory
METALWORKING TIP
(or to another one in Britain) in the I have just been reading Martin
UK, have it registered in Britain and Scott’s article including making a
then import into Belgium as a second new lamp bracket (Stoneleigh – Issue
hand British car. 165). Some time ago, following an
Ian McHattie had more luck than unfortunate incident I had to make
me with his unfinished GCS Hawke some new wishbones. I came across
(April 2020 – issue 164). He made the a website called Metalgeek. This
right changes and used the right new allows you to print coping patterns
parts to build up his very, very nice for any tube size, any tube thickness
traditional tourer. The only thing that and any angle. It calculates it all and
astonished me is that he doesn’t have you print the paper pattern to stick
a hood or some other kind of weather on your tube before cutting. It made
protection yet… Scotland is not such a life so easy.
sunny, dry country as far as I know! Gordon Hick, via email
Antoine Ryckman, Belgium

www.completekitcar.co.uk May 2020 15

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16 May 2020 www.completekitcar.co.uk
OUT &
ABOUT

ANTWERP ANTIDOTE
One of the last events to take place before the lockdown
was the Antwerp Classic Salon. We were there.
Words and pictures: Gary Axon

The Citroën Mehari is an evergreen at continental We’d buy a 99 from this Mini pick-up based ice cream Jaguar’s own E-Type Lightweight recreation has
classic car shows, but its popularity isn’t as van. It wasn’t the only commercial classic on display inspired replica makers – and it’s no surprise, given
obvious in the UK. at the show, some of them earning their keep. the official car’s lofty pricetag.

Why should I be there? The impact and concerns

over the worldwide spread of the coronavirus has
inevitably lead to the postponement and cancellation
of a number of public events – motoring and
otherwise. The 43rd edition of March’s Antwerp
Classic Salon was held before it took hold.
Visitors were rewarded with a varied palette of
classic cars, with special displays of Abarth and
Alvis models being staged (the latter including an
interesting one-off post-war Gordon racing special).
This Abarth Scorpione SS 1300 formed part of Other machinery of note to Complete Kit Car readers A display to celebrate a centenary of Alvis
the Antwerp show’s special homage to the was a tad thinner on the ground than in previous included this stunning one-off post-war
Italian performance marque. years, although there was still plenty to appeal. Gordon racing special.
Jaguar E-Types, original and recreations,
seemed to be particularly prolific this year, with
‘fake’ examples including a recent Lightweight
competition recreation, plus an older RHD Triple
C Challenger that had most visitors fooled. Porsche
Speedster replicas were also out in force, with an
unusual and misshapen racing interpretation of the
1950s classic causing considerable head scratching.
The local Antwerp Caterham agent staged a
tempting display of new Sevens, and an earlier model
on a club stand also commanded attention, as did a
At first glance, it looks like a Porsche 356... but brace of used Cobras being sold by Belgian dealers, Excalibur SSK looked huge parked with more usual
you soon realise that it’s not. It caused no end of including a rare German-built Weineck 427. A classics offered by this local classic car dealer. Cobra
head-scratching among showgoers... 1980s Excalibur SSK two-seater roadster appeared replicas were out in large numbers.
enormous near the Cobras.
It was amusing to see an older British Asquith kit
van employed to sell tasty Belgian waffles, as well as
one of the autojumblers actually using his Citroën
Relay van fitted with a Caselani HY body panel kit
to transport his wares.

THE DETAILS
What: Antwerp Classic Salon
Where: Antwerp Expo, Belgium
...particularly as the rear end styling bore very little When: March Jaguar E-Types, in both real and replica form, were
resemblance to the 356 at all. Information on what it W: www.antwerpclassicsalon.be/en out in force at Antwerp. It was good to see a Triple
was or its background were not available. C Challenger among the originals.

www.completekitcar.co.uk May 2020 17

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 KITOLOGY | COMMENT

NON-BUYER’S REMORSE
After a quarter of a century of enthusing and writing about kit cars,
is Richard finally going to take the plunge and own one?

P
lease forgive yet another self-indulgent column,
but while you’re here… By the time this issue goes
“I’M AWARE I SHOULD
to press, I will be celebrating a minor milestone. PRACTICE WHAT I
And by ‘minor’, I mean it will be celebrated by me
and me alone. And by ‘celebrated’, there won’t be PREACH AND BUY A KIT
much uncorking of champagne bottles, marching bands or even
a quick spin around a city centre aboard an open-top bus. I CAR. BUT WHAT?”
may treat myself to a cake, but that’s about it. It’s just that 25
years ago, almost to the week, the first article I ever wrote
RICHARD
was committed to print. I was a student at the time, and not a however, feel a bit of a fraud because I have never owned one, let
particularly good one. I was one year into a four-year business HESELTINE alone built something. I have, at various times, owned cars that
administration course, surrounded by future captains of industry, Respected classic come under the ‘specialist’ banner, and am currently running a
but all I cared about was cars. car journalist Richard 1966 Moretti (pictured) which is essentially a Fiat 850 in lingerie.
I knew to my core that I wanted to do something with cars, but Heseltine has been Nevertheless, I am acutely aware that I should practice what I
what? And then something rather magical happened: I became a major player at preach and buy a kit car. But what?
friends with a motoring writer who suggested I had a go. He gave Classic & Sports Car and When I started scribbling, the kit car industry was considerably
me plenty of encouragement, and my first attempt at scribbling Motor Sport magazine bigger than it is now, and there was infinitely more choice. The
concerned the Liege sports/trials car. It was later translated into before becoming a difference now, however, is that the products on sale are infinitely
something vaguely approximate to English and appeared in the sought after freelance better in terms of quality. I am trying to overrule my default setting
March 1995 edition of Kit Cars International. I clearly recall journalist. But he also and buy something ‘classic’ and opt for something made in the
meeting the editor Ian Hyne for the first time at that year’s kit car happens to be one of here and now. I have whittled it down to a couple of options, the
show in Stafford and then seeing my by-line in the mag. From that the most knowledgeable surprising thing (to me, at least) being that they’re both replicas.
moment on, I spent as much time as humanely possible annoying kit car boffins you’ll ever Normally, I am not a huge fan of this sort of thing because most
editors by pitching stories at them. That, in turn, led to a job on come across. are nothing of the sort; they merely resemble their inspiration.
Which Kit? before I headed off to pastures new. Basically, 25 years I do, however, have a soft spot for clones where the resemblance
of penury beckoned. is more than skin deep, and where the real thing is way beyond
The funny thing is, my interest in kit cars has never slackened. reach. The winner will be revealed in a future issue of Complete Kit
I keep returning to them and I doubt that will ever change. I do, Car. Cue drumroll…

www.completekitcar.co.uk May 2020 19

Q&A
TIME FOR TEA WITH
FIGURES IN THE KIT
CAR INDUSTRY

Neil Barker (left)

and Sean Smith( right) are
in charge of MK Sportscars
and Kit Car Direct.

Indy chassis ready for delivery. The RX-5 launched last year.

20 May 2020 www.completekitcar.co.uk

 TALKING SHOP WITH…
MK SPORTSCARS
We take a look behind the scenes of Kit Car Direct and MK Sportscars
and talked about both companies’ interesting past, present and future.
Words and pictures: Jack Wood

E
ver since Neil Barker and Sean Smith NB: It was probably 2012. That MK was my first
acquired MK Sportscars four years ago kit car, which I bought as an unfinished project
the sevenesque roadster manufacturer on eBay. I realised quite quickly why it was never
has grown exponentially, and just finished, you just couldn’t source any of the
over one year on from moving into its bloody parts! That’s when I thought, “Hang on,
larger premises near Braintree, Essex, the team is if I’m having this problem then so must everyone
once again looking for more space. But MK isn’t all else.” So I spent a bit of time scouring everywhere
of what Neil and Sean do here and, through sister for parts and then set up Kit Car Direct.
company Kit Car Direct, the team supplies for, and
restores, models from other manufacturers too. How did Kit Car Direct evolve to include
As I walk through the workshop today there are MK Sportscars?
myriad different Lotus Seven inspired roadsters NB: Before all this I was a computer engineer,
in mid-build, with powerplants that range from in fact I was a trained electronics engineer who Branded simulator lives in the showroom.
recognisable car engines all the way to 550bhp moved into computing. I’m an ex-Microsoft
turbocharged motorcycle units. There’s a lot here to employee, I was a senior engineer there way back NB: It was a great product, but the support wasn’t
take in, but who better to fill us in on what makes when. My background was in e-commerce, which there. We had to stick our heads above the parapet
both companies tick than the pair in charge. is why I was drawn to setting up Kit Car Direct. and say, “We are here and we will support you.” Roll
SS: I was a civil engineer by trade, I worked on the clock forward four years and the business has
How did you both get involved with kit cars? several big projects that included the monorail at turned a full 180 degrees.
SS: My first kit car build was a JC Locust that I Stanstead Airport. I later moved into the retail
purchased as a part-built project in 1997, it had a sector and worked as a retail manager for brands How did you rebuild MK Sportscars’ reputation?
very simple aluminium-over-wood frame body and like Ikea. I did that for about nine years before NB: We have been consumers of the product in
a ladder chassis. I had some good friends who were deciding I needed to do something different. I the past and we only do what we, as customers,
into kit cars at the time and I was later convinced always wanted to work with kit cars, I knew there would want. We didn’t sit down with a pad and pen
to move onto more substantial kits. It all sort of was an opportunity to make money there and Kit brainstorming ideas, we just put ourselves in the
spiralled from there really. Car Direct fitted with that. customer’s shoes. One of the biggest changes is we
I began building cars to sell on. I’ve built them all The business quickly evolved from supplying answer the phone – we pride ourselves on always
really, Daxes, Westfields, loads of MKs – obviously – parts, to restorations, to upgrades and basically getting back to people.
Locosts, Spires and MNRs. Some of them I kept for everything else. I’d known of MK Sportscars
about five minutes and others that…Well, actually I myself since 2003, I’d built some of the kits and How have the models changed under
sold most of them pretty quick [laughs]. my cars were often found on MK’s show stands. your direction?
NB: What was the record, the Westfield? NB: We supplied them with parts as well. SS: The Indy has changed quite a bit in the four
SS: I did about 40 miles in that! I’ve always been SS: When I caught wind that things weren’t years, as I always modified my own MKs anyway.
more into the build than the drive; I enjoy taking going so well with the old management, I asked Every kit car out there, it doesn’t matter which
on new challenges and developing new designs. them if they wanted out. We got a price and me brand, has a weakness somewhere along the line that
I like driving, but often I’ll get bored with a car and Neil seriously discussed it. needs ironing out. It may be inherently in there and
and want to build something new. That’s how it NB: We were doing a lot of restorations at the there may be a cost implication, as everything needs
went, I kept building cars and through that I met time and, to do that, you need the right car in the to hit a price point and, while the MK platform was
Neil, who needed parts for his MK project, via the first place to make it worthwhile. Back then it very safe and strong, there were a few engineering
LocostBuilders forum. I can’t even remember what was becoming increasingly difficult to find good aspects that needed addressing. Dave Flavell, who
year that would have been. sevenesque roadsters to work on, so when the designed the original Indy R platform, worked
opportunity arose to buy the jigs, moulds and IP with us closely on the redesign, before we added in
to make our own we jumped on it. alterations like differential bracing and a few other
It was a bolt-on to what we were already doing things to make the build easier.
and we had the infrastructure in place to do it NB: We added brackets, bosses and all the bits you
properly. We discussed it for about a nanosecond used to have to fabricate yourself. The new RX-5
before we made a move for the business. especially has been designed to remove all the niggly
SS: That was in November 2016. The transition jobs that used to infuriate us. For instance, the
period was a little painful, we had unfulfilled exhaust manifold’s exit hole in the bodywork works
orders to sort and a stigma to fight. Any failing with both NA and turbocharged Mazda engined
business is going to be a challenge to take on, but cars, no modification is required. The rollcage is now
everybody liked the product, they just didn’t like a bolt-in option too, which means it can be fitted
Honda S2000 VTEC engine revs to 9000rpm. everything else to do with the business. either straight away or later as a retrofit.

www.completekitcar.co.uk May 2020 21

Q&A

What are the ultimate ingredients for a My old 330bhp Kawasaki ZX-10 engined MK
sevenesque roadster? was mental too but, coming back to the previous
SS: I’m a bike engine fan and have been for years. As question, a lot of these cars border on the undrivable
a track car they just work with their low weight, high for most drivers.
performance, sequential shift and that noise that NB: We once had a Dax in that had a turbo the size
makes you feel like you’re going really fast. But on of a dustbin [laughs], which is coming back to us.
the road it has to be a car engine, as you don’t need But yeah the 550bhp Hayabusa car will take some
masses of power. A lesson I’ve learned over the many beating, the craziest thing about that car isn’t
builds we’ve done is that you can always build a the number, however, it’s the engineering that
faster car, but with 140bhp you can learn more about underpins it.
driving. You don’t need 250bhp on the road in one of
these, it’ll just be wasted most of the time. What do you think the lasting appeal of the
NB: For me it’s the roadster that doesn’t rattle, clang sevenesque roadster is?
and can handle the bumps. It doesn’t have to go SS: It’s such an iconic shape and, when built Mazda MX-5 engines are a common fitment.
super quick. It’s nice to have something that you can correctly, they drive like nothing else on the road.
also cruise in, a car that doesn’t let you down and can NB: You could be driving behind a £200,000 is the customer. They tell us what they want and we
be left outside a hotel without a worry. I want a road Ferrari and people will still look and wave at you want to build those products, we’re very approachable
car that’s fun, starts on the button and doesn’t require in one. They’re also so personal and bespoke to and always willing to do bespoke work.
constant fettling to make it work. the builder, very few are the same and there’s lots NB: A worldwide dealer franchise would be my aim.
SS: Thinking about it, I’d much rather have really of changes you can make to them. I think the We have dealers in France and other territories, and
good brakes than high power figures. I like a car that individuality is a big draw. I’m eyeing up more. There’s some big opportunities
fills you with the confidence to push it, and good SS: I don’t think the aesthetics will ever date, the to get the cars out there and we do get a lot of
brakes are a huge part of that. Watch this space, there underpinnings will change, but the design will enquiries from abroad.
may be a little development coming on [laughs]. always remain recognisable. SS: Me and Neil are very different in the way we
approach things here, I’m very engineering minded
What would you say is the craziest sevenesque What does the future hold for MK Sportscars? and Neil is very business minded, but that’s what
build you have worked on? NB: Bigger premises for a start, we’ve outgrown this makes it work.
SS: We’re building a 550bhp Suzuki Hayabusa place in a year. NB: It’s very much a collaboration. It’s not just the
turbo car for a customer at the moment, which is SS: We have to keep going forward and new one guy making decisions, but it isn’t a committee
going to be pretty wild when it’s done [laughs]. launches are a part of that, and the impetus to do it either, we bounce ideas off each other and it works.

22 May 2020 www.completekitcar.co.uk

25TH & 26TH JULY 2020
SAT & SUN 9.30 – 4.30
Newark Showground | Lincoln Road
Winthorpe | Newark | NG24 2NY

ADMISSION
Adults £12.00 | Children 8 to 16 £4.00
FREE ENTRY FOR KIT CARS
Overnight Camping available
Live entertainment Saturday evening
Organised by Grosvenor Shows
Orgainers of the Stoneleigh Show

All enquiries contact:

Telephone 01406 372600 or 372601 | Email: [email protected]
www.completekitcar.co.uk May 2020 23
SPOTLIGHT | LE MANS REPLICAS

1966 AND ALL THAT

The recent release of the Le Mans ’66 film has inspired Total Headturners
to recreate the Ford versus Ferrari grudge match in replica form.
Words and pictures: Adam Wilkins

24 May 2020 www.completekitcar.co.uk

 I
t’s the archetypal blue collar hero story – Ford taking on
sports car racing royalty Ferrari and claiming victory in
the world’s most prestigious endurance motor race, Le
Mans. The fact that it was a very personal battle between
Enzo Ferrari and Henry Ford II only adds to the intrigue.
It’s a story that captures the imagination to the extent that
Hollywood deemed it worthy of retelling with Le Mans ’66
(called Ford v Ferrari in some territories).
The Ford Motor Company was on the cusp of buying Ferrari
when, after 22 days of negotiations, Enzo walked away from
the deal. Henry Ford II took it as a personal sleight, and sought
revenge by vowing to end Ferrari’s dominance of endurance sports
car racing in Europe. It’s often told as a story of the underdog
beating the establishment, but let’s not forget that Ford was a
huge corporation in comparison to Ferrari. It had the dollars to
do as it pleased, and it spent millions of them to get to the finish
line ahead of the Italians.

www.completekitcar.co.uk May 2020 25

SPOTLIGHT | LE MANS REPLICAS

Not that it was plain sailing for the wonder that it has turned out to be one of
American giant. It took three years before the most replicated cars, and the release of
the GT40 claimed 24-hour victory, by which Le Mans ’66 will surely perpetuate its already
time the Lola designed car was strong following.
being prepared by US outfits Shelby Over the years, a number of companies
American and Holmes and Moody, and have offered GT40 replicas. One that
Alan Mann Racing in the UK. Competition was built in only very small numbers was
between the Ford factions was often even designed by John Tojeiro. His name may
fiercer than it was against their common be forever associated in kit car circles with
adversary Ferrari. the Dax Cobra replica that bore his name,
For its victorious visit to La Sarthe in but he built the first of many racing cars
1966, Ford went prepared with 20 tonnes after World War Two and his machines
of spares – this was the full clout of the can still be seen competing at events like
The Ford V8 in the Tojeiro GT40 replica has been fully rebuilt. corporation. The win itself was shrouded the Goodwood Revival. He also designed
in controversy after team orders requested the car that became the AC Ace, itself
Ken Miles to squander his four-lap lead paving the way for the Cobra. There’s some
for a photo finish with the other GT40s. disagreement over how many GT40 replicas
Race organisers, the ACO, vetoed such he built, but the consensus is fewer than five.
orchestration and subsequently a botched Mark Harrison of Total Headturners,
pitstop, which saw Miles’ car fitted with where both the cars seen here are currently
brake discs that hadn’t been bedded in, in stock, discovered one of these rare replicas
caused him to have to pit again, losing some in the garage of Tojeiro’s neighbour. It was
of that lead. By the time the chequered in a sorry state, having been dismantled for
flag dropped, the photo finish Ford wanted a restoration that was never completed. But
had come to pass. Both Miles and the its history was enough for Mark to see its
race commentator believed he’d won the value, and it was a project he could task his
race, only for officials to declare the Chris full-time mechanics with.
Amon/Bruce McLaren car the winner as Total Headturners is used to carrying
Ford Cosworth engine the cuckoo in the nest of the Ferrari P4 replica. it had started further back on the grid and out all manner of work on the cars that
consequently driven further in 24 hours. pass through its showroom. Whether it’s
It soured a hard-fought win, and robbed mechanical refurbishment, a visual change
Miles – who had been instrumental in the to make it more appealing to the market or
GT40’s development – of being the only a response to a buyer’s request for a change
man to have won Daytona, Sebring and they’re used to working on all aspects of cars.
Le Mans. He died testing another car two What they don’t usually do, though, is apply
months later. it all to one car. “We got a bit carried away
Those were the details. The part that cast with this one,” says Alex Parkinson, manager
the longest shadow was that the Ford had at Total Headturners.
achieved its goal and the GT40’s legendary While the car was already disassembled,
status was set in stone. Iconic is an over-used Total Headturners stripped it back
word, but if it’s reserved for any car then to a bare chassis and started right from
it must be for cars like this. Over half a the beginning. The chassis was repainted,
century later, it has the traffic-stopping and the suspension fully overhauled with
Additional frame under rear bodywork replicates the original car. looks and a legendary reputation. It’s little new dampers and reconditioned

To make the car a replica of Ken Miles’s GT40, the bodywork had to be changed to a Mk2. The panels were sourced from Tornado Sports Cars.

26 May 2020 www.completekitcar.co.uk

 “STYLING IS A SUBJECTIVE
MATTER, BUT ON KERBSIDE
APPEAL ALONE I RECKON THE
P4 HAS THE GT40 BEATEN”
wishbones. The Ford V8 engine had During that mission, new panels were
stood for a couple of decades, so Thurston sourced from Tornado Sports Cars and
Engineering was tasked with rebuilding it, modified to fit the Tojeiro. Additional chassis
complete with new carburettors, water members were added to the rear, where it’s
pump and other ancillaries. visible under the rear bodywork, and Avon P4’s interior is cosy for two. Modern stereo a nod to convenience.
It was when the mechanical work was tyres with big sidewalls also add to the
nearing completion that the team had an authentic ’60s racer vibe.
outing to watch Le Mans ’66. “We came They also dropped the floor and added
out of the cinema and we all said ‘we know a Gurney bubble to ensure that those of
what colour we’re painting that car,’” says 6ft and over would be able to fit in the car.
Alex. The decision to make it a replica of Other upgrades included a removeable
Ken Miles’s car brought with it further steering wheel and the addition of air
complications: the car had Mk1 replica conditioning. While a lot of the car had been
panels, where they’d need Mk2 bodywork renewed, the team was careful to retain the
to replicate the 1966 car. The direction on patina it had build up over the decades. “We
the car’s look was taken in the middle of wanted it to still look like a car that’s had a
December and they wanted it on show at life,” says Alex.
the Autosport International show in January. After working around the clock, the team
They worked through the Christmas break, got the car to a visually complete state in
only taking one day’s holiday. time for the Autosport show, and by the GT40 replica features dropped floors to improve headroom.

www.completekitcar.co.uk May 2020 27

SPOTLIGHT | LE MANS REPLICAS

THE REBUILD OF THE GT40 REPLICA

Chassis was repainted and suspension refreshed. Air conditioning has been fitted. The team worked through the night a few times.

Front and rear clams replaced with replica Mk2 items. New metalwork added to more closely ape original. New front bodywork coming together.

Rebuilt Ford V8 engine installed. Bodywork now all one colour. It was a team effort to get the car finished on time.

Lee Noble was first to offer a Ferrari P4 replica, and it has been replicated by several other companies since.

28 May 2020 www.completekitcar.co.uk

 “THE DECISION TO MAKE IT ABOVE: This is one
of a small number of
A REPLICA OF KEN MILES’ CAR GT40 replicas built
by John Tojeiro.
BROUGHT WITH IT FURTHER
COMPLICATIONS”
Period looking wheels essential to the look. following month it was a runner in order to later be heavily involved in Cosworth
drive into the London Classic Car Show. development and tuning, so it makes sense
There’s no doubting the car’s visual clout, and that his own Ferrari replica would be
even on Total Headturners’ packed stand it powered by what he knew best.
stood out... especially when it was presented While the car may lack a V12 soundtrack,
alongside its nemesis (also in replica form). Alex has been impressed by the way the car
The Ferrari 330 P4 is a later development performs. “We’ve used it for a couple of track
of the car the GT40 scored its victory over days at Brands Hatch,” he says. “It’s so well
in 1966. In the mid-1990s, Lee Noble’s balanced with that engine, the handling is
Kitdeal developed a replica of the curvy superb.” It’s to be expected: the Noble P4
racer and it has been offered on the market borrowed it suspension geometry from Lee’s
Avon tyres with high sidewalls look the part. on and off by various manufacturers ever earlier design, the Ultima, and was originally
since. The car you see here has been through designed around the Renault V6 engine
Total Headturners’ showroom a few times, rather than a bigger, heavier V12 engine.
and has been owned by at least one famous The fact that this P4 replica doesn’t tread
name in between. as authentic a path as the GT40 replica is an
Styling is a subjective matter, but on illustration of how kit-form recreations can
kerbside appeal alone I reckon the P4 has be whatever you want them to be. Where the
the GT40 beaten. Where the Ford is utterly Tojeiro offers the V8 thunder of the original,
purposeful, the P4 combines its competitive wrapped in a body that apes the Le Mans
edge with an undeniable Italian flair that contender as closely as possible, the P4 offers
makes it all the more alluring. But there’s a more contemporary dynamic package in
False rivets disguise the GRP bodywork. a secret lurking beneath the Scarlet red a jaw-dropping shape that would captivate
bodywork. Where the original race car wherever it goes.
would have had a screaming V12 engine,
this replica has an engine from its arch
enemy – Ford. USEFUL CONTACTS
It was built by former Ford development Total Headturners, Unit 1 Weald Place Farm,
engineer Terry Drury. He’s not without Duck Lane, Thornwood, Essex CM16 6NE.
hands-on GT40 experience, having built the T: 01992 573564.
original Ford Supervan in the ’70s, which E: [email protected]
used the endurance racer’s mechanical W: www.totalheadturners.com
Most of the GT40 has been renewed. package in the familiar panel van. He would

www.completekitcar.co.uk May 2020 29

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107INC.VAT
.98

110E 30-100 £229.98 £275.98 STOCK 8/260

135TE Turbo
151TE Turbo
30-130
30-150
£249.98
£289.00
£299.98
£346.80 £
FROM ONLY
194EX.VAT .99 WHERE QUALITY MODEL
8/260
MOTOR CFM TANK
2HP 7.5 24ltr
EXC.VAT
£89.98
INC.VAT
£107.98
175TECM Turbo 30-170
205TE Turbo 30-185
£449.00
£489.00
£538.80
£586.80
£
233INC.VAT
.99 COSTS LESS 7/250
11/260
2 HP 7 24ltr
2.5HP 9.5 24ltr
£94.99
£109.98
£113.99
£131.98
8/550 2HP 7.5 50ltr £119.98 £143.98
NO GAS/GAS NO GAS/GAS AC80
7/510# 2HP 7 50ltr £119.98 £143.98
MIG WELDERS MIG WELDERS 11/550 2.5HP 9.5 50ltr £139.98 £167.98
Professional type torch with INTELLIGENT 12V BATTERY 16/550* NEW 3HP 14.5 50ltr £199.98 £239.98
Uses flux cored steel 16/1050* NEW 3HP 14.5 100ltr £249.98 £299.98
on/off control Thermal overload
wire, which creates own BATTERY CHARGERS
protection Turbo fan cooled CHARGER/ For lead acid batteries *’V’ Twin Pump #Oil free
Easy conversion to gas gas shroud as it burns
with optional accessories 151EN MAINTAINERS *Automatic
FROM ONLY MIG102NG FROM ONLY FROM ONLY
charger INDUSTRIAL AIR
£
124EX.VAT
.99 £
219EX.VAT
.98 £
49EXC.VAT
.98
COMPRESSORS
BEST *no £
263INC.VAT
.98 IBC40
- maintains FROM ONLY
£
149INC.VAT
.99
SELLER gas only £
59INC.VAT
.98 optimal charging £
condition 17EXC.VAT
.99 Top quality belt driven air compressors for industrial &
commercial users inc; garages, factories, workshops
MODEL VOLTS MAX EXC.VAT INC.VAT
MODELMIN/MAX AMPS
MIG 102NG* 35/90
EXC.VAT
£124.99
INC.VAT
£149.99
MODEL AMPS EXC.VAT INC.VAT CHARGE AMPS
£
21INC.VAT
.59
and farms. 10 bar/150psi max working pressure
151EN 30-150 £219.98 £263.98 IBC7 12/24V 7A £49.98 £59.98 MODEL MAX EXC.VAT INC.VAT
MIG 106
MIG 145
40/100
35/135
£159.00
£179.98
£190.80
£215.98
130EN 30-130 £239.98 £287.98 IBC15 12V 15A £46.99 £56.39 CHARGE AMPS BEST
160EN 30-150 £279.98 £335.98 IBC20 12/24V 20A £59.98 £71.98 LA4 4 £17.99 £21.59 SELLER
MIG 196 40/180 £219.00 £262.80
MIG 240 50/240 £399.00 £478.80 FROM ONLY
HEADER IBC25 12/24V 25A £89.98 £107.98 LA6 6 £19.98 £23.98
GWH4
FROM ONLY
HEADER
£
37EXC.VAT
.99 IBC40 12/24V 40A £109.98 £131.98 AC80* 8 £33.99 £40.79
£
59EXC.VAT
.98 £
45 .59
FOOTER
INC.VAT
ARC
ACTIVATED BC210C INTELLIGENT
ARC
£
71 .98
FOOTER
INC.VAT
HEADSHIELDS BATTERY CHARGERS/ AUTOMATIC
WELDERS Activates instantly when FROM ONLY
HEADER CHARGER /
For home user, Arc is struck Protects to ENGINE STARTERS
Ammeter FROM ONLY
£
24EXC.VAT
.99
MAINTAINERS
automotive EN379 Suitable for arc,
MIG, TIG & gas welding Multi-position £
64EX.VAT
.99
£
29 .99
FOOTER
INC.VAT CB09-12 Keep
and charge regulator £ batteries
Overload protection 77INC.VAT
.99
industrial SEE FULL RANGE in top
applications. MODEL AMPS EXC.VAT INC.VAT IN-STORE/ONLINE on charging cycle condition
SEE THE EA110 40-100 £59.98 £71.98 over a FROM ONLY
MODEL MAX AMPS
FULL
RANGE
115N 30-110 £71.99 £86.39
SOCKET SETS CHARGE/BOOST EXC.VAT INC.VAT long £
425EXC.VAT
.00 XEV16/100
EA165 65-160 £72.99 £87.59 period
ONLINE & 160N 40-150 £79.98 £95.98 BC130C 15/120 £64.99 £77.99
£
510INC.VAT
.00
†V-Twin *230V
IN-STORE EA200 Top quality chrome BC190 38/180 £94.99 £113.99 AIR
60-200 £99.98 £119.98 PRO360 MODEL STAGES BATTERY EXC.VAT INC.VAT
#Turbo fan 190N 50-185 £104.99 £125.99
vanadium steel. BC210C 25/200 £119.98 £143.98 CB03-12 3 6Ah-40Ah DISP. MOTOR AIR EXC. INC
cooled 235TEN# 40-210 £159.98 £191.98 18 Sockets 8-32mm BC410E 35/400 £139.98 £167.98 12V lead acid £24.99 £29.99 MODEL cfm (HP) RECEIVER VAT .VAT
Reversible ratchet WBC180 35/180 £139.98 £167.98 CB09-6/12 9 Up to 80Ah 6V / XEV16/100†* 14 3 100ltr £425.00 £510.00
MMA & ARC/TIG Comfort grip handle WBC240 45/240 £154.98 £185.98 12V lead acid £39.98 £47.98 XEV16/150†* 14 3 150ltr £459.00 £550.80
INVERTER WELDERS ONLY BC205N 30/200 £179.98 £215.98 CB09-12 9 Up to 160Ah £59.98 £71.98 XEV16/200(OL)†* 14 3 200ltr £525.00 £630.00
£
26EX.VAT
.99 LIFETIME
GUARANTEE
WBC400
BC520P
60/350
50/510
£199.00
£219.00
£238.80
£262.80
12V lead acid & calcium XEV16/150(400V)†14 3 150ltr £535.00 £642.00
XE18/200 (OL)* 18 4 200ltr £579.00 £694.80
PRICE CUT
NOW FROM
£
32INC.VAT
.39
XET19/200 (OL)* 18 4 200ltr £619.00 £742.80
£
79EXC.VAT.98 HUGE RANGE OF PRO 7" SANDER/ XEV26/200† 23 5.5 200ltr £739.00 £886.80
RATCHETS, SPANNERS POLISHER £ XE37/270 (OL)* 36 2x 4 270ltr £1169.00 £1402.80
£
95
WAS FOOTER
.98
INC.VAT AND SOCKET SETS .98
69EX.VAT HYDRAULIC
£117.60 inc.VAT
BOTTLE JACKS 26EXC.VAT
£ HEADER
.99
MODEL MIN/MAX ELECTRODE 1 /2 "
TORQUE
£
83INC.VAT
.98

OUTPUT DIA. WRENCH - CHT141 CP185 HEADER

FROM ONLY WORKSHOP
£
32 .39
FOOTER
INC.VAT

CURRENT
MMA80* 20A-80A
(MM) EXC.VAT INC.VAT
1.6-2.5 £79.98 £95.98
5" Extension
bar 1/2" -
Includes hook &
loop backing pad and 9EXC.VAT
£.98 AIR TOOLS PGF14

11
MMA140#20A-140A 1.6-3.2 £99.00 £118.80 3/8" adaptor hook & loop wool £ .98
AT133 10A-130A 2.5/3.2 £129.98 £155.98 28-210 Nm
polishing bonnet. FOOTER
INC.VAT
AT162 10A-160A 2.5/3.2/4.0 £149.98 £179.98 1200W motor
MMA200‡20A-200A 1.6-4 £139.00 £166.80 ONLY
JACK
AT135 10A-130A 2.5/3.2 £169.98 £203.98
£
26EX.VAT
.99
HEIGHT EXC. INC. 64EXC.VAT
£ HEADER
.99
AT165 10A-160A 2.5/3.2/4.0 £199.98 £239.98
*was £117.60 inc. VAT #was £142.80 inc. VAT
£
32INC.VAT
.39
BLAST CABINETS MODEL CAP. (mm) VAT VAT £
77 .99
FOOTER
‡was £190.80 inc. VAT Blast away paint, CBJ2B
CBJ3B
2
3
148-276
180-350
£9.98
£14.99
£11.98
£17.99
INC.VAT
BEST
TAP & DIE SETS surface rust, scale, SELLER
CBJ5B 5 185-355 £17.99 £21.59
CAR CREEPERS High quality tungsten steel burrs, carbon & dirt &
CBJ8B 8 190-365 £19.98 £23.98 CAT131
Supplied in metal revitalise aluminium
• Oil resistant vinyl covered padded storage case (except Min. air flow 10cfm CBJ10B 10 195-375 £24.99 £29.99 HUGE CHOICE IN-STORE/ONLINE
backs & headrests • Swivel castors 16pce) Bench & floor CBJ12B 12 200-380 £27.99 £33.59
for easy manoeuvrability FROM ONLY standing models CBJ15B 15 205-390 £29.98 £35.98
FROM ONLY £
16EX.VAT
.99
ALUMINIUM OXIDE FROM ONLY
CBJ20B 20 217-407 £38.99 £46.79
£
24EX.VAT
.99
£
20INC.VAT
.39 POWDER FROM ONLY £
109EXC.VAT
.98 CBJ30B 30 230-370 £59.99 £71.99
DIAGNOSTICS
£
29INC.VAT
.99
TYPE EXC.VAT INC.VAT
£10.99 EX.VAT
£13.19 INC.VAT
£
131INC.VAT
.98
CSB20B FROM ONLY EOBD
MODEL DESCRIPTION EXC.VAT INC.VAT
CHT203 16pce Metric £16.99 £20.39
MODEL DESC. TYPE EXC.VAT INC.VAT
£
39EX.VAT
.98
FAULT
CHT302 24pce UNC/UNF/NPT £21.99 £26.39 .98 CODE
CMC36 Car creeper £24.99 £29.99 CHT303 28pce Metric £26.99 £32.39 CSB20B Compact Cabinet Bench £109.98 £131.98 2 & 3 TONNE £
47INC.VAT READER
CMC40 With tool storage £39.98 £47.98 CHT304 33pce Metric/UNF/BSP £32.99 £39.59 SB30 Large Cabinet Floor £279.00 £334.80 TROLLEY JACKS MODEL EXC.VAT INC.VAT
CMC45 With adjustable headrest£29.98 £35.98 CHT774 37pce Metric £39.98 £47.98 FROM ONLY
PRESSURISED EOBD Fault Code Reader £39.98 £47.98
CMC50 Folding car creeper £49.98 £59.98 CHT527 32pce Metric £48.99 £58.79
SANDBLASTERS
£
29EX.VAT
.98
Engine EOBD/OBD2 £49.98 £59.98
CHT775 52pce Metric/UNF/BSP £56.99 £68.39
SSC1000G CHT776 76pce Metric £66.99 £80.39 Heavy duty steel construction
£
35INC.VAT
.98 Fault code reader
Engine Diagnostic & £99.98 £119.98
sandblasters for the quick
STRUT SPRING removal of surface rust, paint, JACKS EOBD/OBD 2 Fault Code Reader
CORDED IMPACT dirt/grease etc. ALSO IN
COMPRESSOR WRENCHES CPSB100B
CAR RAMPS
Foot operated STOCK
CEW1100 INCLUDES UP TO 5 CTJ3000G Lift cars
hydraulic powered safely and
Adjustable for SANDBLASTING GUN, TONNE quickly
FROM ONLY
springs up to 400mm
dia. & 520mm in
DELIVERY HOSE, 4
CERAMIC NOZZLES MODEL TYPE TONNE EXC.VAT INC.VAT Tough
£
29EX.VAT
.98

length Adjustable Ideal for AND SAFETY HOOD CTJ2L Long 2 £29.98 £35.98 angled steel
£
35INC.VAT
.98

garage mechanics FROM ONLY CTJ2000LPB DIY Low Profile 2 £33.99 £40.79 construction PER PAIR
spring retainers
Inc. spring
£
54EXC.VAT
.99 FROM ONLY
139EX.VAT
CTJ2250Q Quick Lift 2.25 £34.99 £41.99 MODEL CAPACITY EXC.VAT INC.VAT
710
INC 17, 19, £ .99
CTJ2250LP* Low Profile 2.25 £39.98 £47.98 CR2 2000kg £29.98 £35.98
retaining guard 21, 22MM £
65INC.VAT
.99
167INC.VAT CTJ3000GB Pro Garage 3 £79.98 £95.98
£
129EXC.VAT
.99 SOCKETS Nm £ .99
CTJ3000QLB Quick Lift 3 £86.99 £104.39
CRW25 2500kg £37.99 £45.59
& CASE
CTJ3QLG Pro Instant Lift 3 £99.95 £119.94
£
155INC.VAT
.99
MODEL POWER TORQUE EXC.VAT INC.VAT CTJ3000G Pro Garage 3 £99.98 £119.98
CEW520 1/2" 520W 320Nm £54.99 £65.99 MODEL TANK FLOW RATE EX. VAT INC.VAT CTJ2QLP Low Quick Lift 2 £114.99 £137.99
CEW1000 1/2" 1000W 450Nm £59.98 £71.98 VOLUME REQ. CTJ1500QULP Ultra Low BOLTLESS
ALUMINIUM CEW1100 3/4" 1100W 710Nm £89.98 £107.98 CPSB100B 32 litre 6-25 cfm £139.99 £167.99 Quick Lift 1.5 £156.99 £188.39 QUICK ASSEMBLY
RACING JACKS CPSB200B 63 litre 6-25 cfm £169.99 £203.99 STEEL SHELVING
Quick lift Non-marking * CTJ2250LP has a 2.25 tonne capacity, has a
low entry of only 80mm and includes 2 sockets Simple fast assembly
nylon wheels Rubber in minutes using only
contact pad - helps CRANES a hammer
protect vehicle 18V ½"
HEAVY FROM ONLY
HEADER
150
FROM ONLY
undersides *steel BRUSHLESS
chassis BEST £
164EXC.VAT
.99
DUTY
£
29EXC.VAT
.98
CTJ1250AB IMPACT 450NM SELLER £
35 .98
WRENCHES
£
197INC.VAT
.99
LONG REACH FOOTER
INC.VAT KG

3 forward and JACKS CTJ2GLS

SAVE
FROM ONLY MODEL DESC. EXC.VAT INC.VAT
reverse gears £
114EXC.VAT
.99
CFC100 1 ton fold £164.99 £197.99
197.99
ASSEMBLES
FROM ONLY
HEADER
137INC.VAT CFC1000LR 1 ton £219.00 £262.80
262.80

10%
1
£ .99
94EXC.VAT
£ .99
long reach
RA
AS BENCH OR
LOW
£
113 .99
FOOTERINC.VAT EXT CORNER UNIT
CIR18LIC
ENTRY LIFTING MODEL TONNES EXC.VAT INC. VAT WHEN YOU BUY CHOICE OF 5 COLOURS
Folding and fixed FROM ONLY
ONLY MODEL CAP. EXC.VAT INC.VAT 4 SHELVING UNITS
85MM CTJ1250AB 1.25T £94.99 £113.99 MODEL DESC. EXC.VAT INC.VAT Fully tested
frames available
Robust, rugged construction
£
179EXC.VAT
.98 CTJ2GLS 2 £179.98
CTJ3GLS 3 £249.00
£215.98
£298.80 AND
RED, BLUE, GREY,
30 May 2020
CTJ1800A 1.8T £159.98 £191.98 CIR18LIC 2x 2.0Ah Li-Ion £114.99 £137.99 to proof load CFC100 Overload safety valve
£
215INC.VAT
.98
CTJ5GLS 5 £339.00 £406.80
SAVE AT LEAST
www.completekitcar.co.uk
£23.99 INC.VAT SILVER OR
CTJ2500QLG* 2.5T £149.98 £179.98 CIR18LI 2x 4.0Ah Li-Ion £169.98 £203.98 CTJ10GLS 10 £439.00 £526.80 GALVANISED STEEL
29793LH

MM1 Complete Kit Car 297x230 pg1.indd 1 06/03/2020 13:57 MM

 EASY TO USE WEBSITE GET
PAY Monthly
NO DEPOSIT
NOW O
VER

PRODUCTS ONLINE!
21,000 NEW
CATALOGUE
508
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YOUR
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For hard-to-find,
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T JUMP STARTS
Provides essential home, 1 TOOL CHESTS
£
FROM ONLY
64EX.VAT light
.99
garage and roadside
assistance Integral work
DIESEL HOT JETSTAR £FROM ONLY
59EX.VAT
.98 & CABINETS
910 includes air
145 Bar WASHER PRESSURE £71INC.VAT
£
77INC.VAT compressor
.99
Long life battery
2103 psi
HARRY HOTWASH
.98
PRO TOOL CHESTS
STARTING PEAK EXC. INC. Ideal for effective WASHERS & CABINETS
MODEL BOOST AMPS VAT VAT cleaning of vehicles Makes easy work for
900 400 900 £64.99 £77.99 with a hot jet of washing vehicles, patios,
JS1100 500 1100 £69.98 £83.98 up to 80°C stonework, etc. JET7500, FROM ONLY
910 400 900 £72.99 £87.59 8500 & 9500 include
hose reel
£
72EXC.VAT
.99

BEST
SELLER EXTRA LONG
JS1100C
4000
500
700
1100 £79.98 £95.98
1500 £139.98 £167.98 PRICE CUT
HEADER 210 Bar
JET9500 £
87INC.VAT
.59

1m LEADS JS12/24
JS12/24Li
1000
600
2000 £159.98 £191.98
1200 £179.98 £215.98 AMAZING
479EXC.VAT
£ .00 3045 psi
* was £149.99 inc.VAT RUBBER
GRIP SIDE
INC. CONTAINER
FOR DETERGENT LOW PRICE!
574
£
WAS FOOTER
.80
INC.VAT MODEL MOTOR MAX. PRESSURE EXC.VAT INC.VAT 1 HANDLES
£598.80 inc.VAT JS1850 1400W 1523psi £59.98 £71.98
GARAGES/WORKSHOPS JS1950 1600W 2030psi £89.98 £107.98
2
FROM ONLY
HEADER IDEAL ALL-WEATHER MICRO HEAVY DUTY Jet 7500* 1600W 2030psi £119.98 £143.98
£
229EXC.VAT
.00
PROTECTION Jet8500 2100W 2610psi £149.98 £179.98
£
274 .80
FOOTERINC.VAT
JUMP Ideal
Honda NEW PETROL
POWER
Jet9500 2400W 3045psi £179.98 £215.98
STARTS for
& Diesel
FROM ONLY starting WASHERS
£
49EX.VAT
.98 cars, engine AXLE STANDS EXTRA
charging models 2 LARGE
£
59INC.VAT
.98
JSM200 phones, etc. in stock Ratchet action FROM ONLY DRAWER
MODEL START
BOOST
PEAK
BOOST EXC.VAT INC.VAT
for quick height
adjustment
13EX.VAT
£ .99 PULLS

JSM200 200A 400A £49.98 £59.98 PLS195A Sold in pairs 16INC.VAT

£ .79

JSM300 300A 500A £64.99 £77.99 #per single CHROME

FROM ONLY
JSM350 350A 500A £84.99 £101.99 SPOKED
BRIGHT WHITE
INTERIOR
LENGTH
UP TO 24'
£
229EXC.VAT
.00
CAN DRAW
stand
*Aluminium WHEELS
Ideal for use as a AUTOMOTIVE £
274INC.VAT
.80
OWN WATER
garage/workshop WHEEL DOLLY SET PRESSURE ENGINE EXC. INC. MAX MIN/MAX
Extra tough triple layer AWD1 MODEL BAR/PSI HP VAT VAT MODEL TONS HEIGHT EXC.VAT INC.VAT
weatherproof cover Heavy Tiger1800 110/1595 2.6 £229.00 £274.80 CAX2TF 2 235-360mm £13.99 £16.79 EXTRA WIDE 56"
duty powder coated steel tubing Tiger2600 170/2465 4 £289.00 £346.80 CAX3TP 3 325-490mm £21.99 £26.39 CHESTS/CABINETS
Ratchet tight tensioning Tiger3000 200/2900 6.5 £349.00 £418.80 CAX-3TBC 3 300-430mm £23.99 £28.79 IN STOCK
ZIP CLOSE DOOR
PLS195A NEW 182/2640 5.5 £439.00 £526.80 CAX6TP 6 333-500mm £29.98 £35.98
£
47EXC.VAT
.99
CAX-6TBC 6 400-615mm £34.99 £41.99 The ultimate
MODEL
CIG81015
SIZE (LxWxH)
4.5 x 3 x 2.4M
EXC.VAT
£229.00
INC.VAT
£274.80 BIG £
57INC.VAT
.59
PLS265A NEW 225/3263 13 £669.00 £802.80
CAX3TA* 3 295-395mm £49.98 £59.98 in tool storage
CIG81020 6.1 x 3 x 2.4M £279.00 £334.80 3" CASTORS PER PAIR BODY CAX10TP# 10 450-750mm £86.99 £104.39
CIG81216 4.8 x 3.7 x 2.5M £279.00 £334.80 Four non-marking castors for easy MODEL DESCRIPTION EXC. VAT INC. VAT
CIG81220 6.1 x 3.7 x 2.5M £349.00 £418.80 movement in confined spaces Heavy duty steel FROM ONLY
REPAIR CBB203B 3 Dr step up £72.99 £87.59
CIG81224 7.3 x 3.7 x 2.5M £419.00 £502.80 construction - load rating 500kg per dolly 89EX.VAT
£ .98 KITS CS10BRK
1 CBB209B 9 Dr Chest £129.98 £155.98
DRILL PRESSES CBB210B 10 Dr Chest £139.98 £167.98
£
107INC.VAT
.98
Range of precision bench CBB213B 3 Dr Cabinet £199.98 £239.98
& floor presses for enthusiast, CBB215B 5 Dr Cabinet £199.98 £239.98
PRICE CUT 2 CBB217B 7 Dr Cabinet £249.98 £299.98
NOW FROM ENGINE PARTS engineering & industrial
£
42EXC.VAT
.99 STANDS WASHERS applications MECHANICS’ TOOL
FROM ONLY B = Bench CHEST & CABINETS
£
51 .59
INC.VAT
Rotates
WASFOOTER
PARTS WASHER £
69EXC.VAT
.98 mounted
£59.98 inc.VAT
through 360˚
FLUID FROM Fast .98 F = Floor
Fully tested to
£5.99 INC.VAT snap connector attachments for quick & easy as-
£
83INC.VAT standing
CES680F FROM ONLY sembly Hydraulic pump, ram & hose with various
proof load MOTOR (W) EXC. INC.
£
42EX.VAT
.99 tubes, pieces & connectors Includes metal case
MODEL SPEEDS VAT VAT REAR LOCKING
EXC. INC. ‡ was
MODEL CAPACITY VAT VAT £59.98
£
51INC.VAT
.59 * Fast action pump CDP5EB 350 / 5 £69.98 £83.98 SECURITY BARS
MODEL CAPACITY EXC.VAT INC.VAT CDP102B 350 / 5 £79.98 £95.98
CES340 ‡ 340kg £42.99 £51.59 inc.VAT CS4BRK 4 tonne £89.98 £107.98 CDP152B 450 / 12 £149.98 £179.98 CTC1300B
CES450 450kg £64.99 £77.99 MODEL TANK CAP. TYPE EXC.VAT INC.VAT
CW2D 10Ltrs Bench £42.99 £51.59 CS10SBRK *10 tonne £155.99 £187.19 CDP202B 450 / 16 £189.00 £226.80
CES560 560kg £79.98 £95.98 *Folds for CS10BRK 10 tonne £149.98 £179.98 CDP10B 370 / 12 £199.98 £239.98 LARGE
CES680F* 680kg £99.98 £119.98 storage CW1D 45Ltrs Floor £99.98 £119.98 CAPACITY
CWM20 22.5Ltrs Floor £144.99 £173.99 CDP352F 550 / 16 £229.00 £274.80 LOWER
CW40 75Ltrs Floor £159.98 £191.98 GRINDERS CDP452B 550 / 16 £239.00 £286.80 CDP152B STORAGE
PETROL & STANDS CDP502F 1100 / 12 £569.00 £682.80 WITH
FROM ONLY
GENERATORS INVERTER Stands come 6" & 8" LOCKABLE
99EX.VAT
£ .98 GENERATORS complete with AVAILABLE HYDRAULIC DOORS
Produces sine wave & bolt mountings WITH LIGHT
£
119INC.VAT
.98
stable power, essential and feet PRESSES FROM ONLY
for computers & anchor holes STANDS FROM ONLY
£47.98 INC.VAT PROFESSIONAL QUALITY
£
69EXC.VAT
.98
sensitive equipment
Low noise Fuel £
FROM ONLY
35EX.VAT
.99
Built for tough daily use in
automotive/industrial workshops
£
83INC.VAT
.98

Efficient Eco Throttle

Honda 12V battery charging
£
43INC.VAT
.19 * Available with/without 7
pce pin, bracket & pressing
engine facility Up # With *Was £83.98 inc.VAT
FROM ONLY sanding belt plate kit
models to 7 hours run ‡ Adjustable polycarbonate #Was £101.99 inc.VAT
available
£
179EXC.VAT
.98
time on 3/4 *8" whetstone
& 6" drystone safety screen # Economy ^Was £143.98 inc.VAT
IG1200B £
215INC.VAT engine
.98 load 4 stroke model MODEL DESCRIPTION EXC. VAT INC. VAT
CHECK FRAME TYPE MODEL DUTY WHEEL
WHEN ORDERING PG3800 DIA. EXC.VAT INC.VAT CSA10BB CTC600B* 6 Dr Chest £66.99 £80.39
MAX WEIGHT EXC. INC.
MODEL OUTPUT KG VAT VAT CBG6RP DIY 150mm £35.99 £43.19 MODEL EXC.VAT INC.VAT CTC900B# 9 Dr Chest £79.98 £95.98
MODEL KVA HP EXC.VAT INC.VAT
G720 0.7 - £99.98 £119.98 IG950B 800W 9.3 £179.98 £215.98 CBG6250 HD 150mm £37.99 £45.59 4 tonne bench# £144.99 £173.99 BEST CTC500B^ 5 Dr Cabinet £109.98 £131.98
CTC800B 8 Dr Combination
G1200 1.1 - £159.98 £191.98 IG1700F 1700W 22 £199.00 £238.80 CBG6RZ PRO 150mm £42.99 £51.59 10 tonne bench* £209.00 £250.80 SELLER
1100W 12.4 £249.98 £299.98 CBG6RSC HD 150mm £56.99 £68.39 12 tonne floor*# £269.00 £322.80 Chest/Cabinet £119.98 £143.98
PG2500 2.2 6.5 £179.98 £215.98 IG1200B FROM ONLY CTC700B 7 Dr Cabinet £129.98 £155.98
CBG6SB# PRO 150mm £58.99 £70.79 20 tonne floor £359.00 £430.80 £
HD 150mm £59.98 £71.98 30 tonne floor‡ £769.00 £922.80 £144EX.VAT
PG3800 3 7 £239.98 £287.98 IG3500F 3400W 35 £329.00 £394.80 .99
1800W 19.4 £329.00 £394.80 CBG6RWC CTC1300B 13 Dr Combination
PG3800DV 3 7 £269.00 £322.80 IG2000B
CBG8W* (wet) HD 150/200mm £59.98 £71.98 50 tonne floor‡ £1498.00 £1797.60 173INC.VAT Chest/Cabinet £159.98 £191.98
.99
PG6500DVES 5.5 13 £499.00 £598.80 IG2200 2200W 26.6 £379.00 £454.80
V
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www.completekitcar.co.uk 0131 659 5919 MIDDLESBROUGH Mandale Triangle, Thornaby 01642 677881 May 2020 31
29793RH Calls to the catalogue request number above (0844 880 1265) cost 7p per minute plus your telephone company’s network access charge. For security reasons, calls may be monitored. All prices correct
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3:57 MM2 Complete Kit Car 297x230 pg2.indd 1 06/03/2020 13:57

R E A DE R ’ S B U I L D | S Y LVA P H O E N I X

SUPER SYLVA
We take a look at a 28-year-old Sylva Phoenix that will out-accelerate almost anything
on the road, and learn a little about the unusual drag cars that led to its creation.
Words and pictures: Jack Wood

32 May 2020 www.completekitcar.co.uk

 W
hen most people think of isn’t your typical trackday Phoenix after all. But
drag racers they tend to as David points out this car could be just as
picture impossibly heavy, ferocious when it returns to the circuit in the
nitrous fed, American V8 near future – more on that later.
muscle cars that are all Like many honed race cars, this Phoenix is the
about going fast in a straight line, and little else. It’s culmination of several builds – most of which are
a motorsport that many deride as being a little bit equally unusual – and its development story began
crude and simple. Scratch the surface, however, and with, of all cars, a lowly Mk1 Ford Fiesta XR2.
you’ll find there’s a real science to building a car Despite starting small, the Fiesta would make
to take on the toughest opponent of all, the clock. David’s name in the amateur drag racing scene
It’s this science of incremental gains that David as, through trial and error, he managed to build it
Edmands finds particularly interesting, and readers into the fastest road legal front-wheel-drive car in
of his build story in the previous issue will already the country at the time. At its heart was a heavily
know the lengths he and fabricator Ray Addis have modified Ford Crossflow powerplant producing
gone to create this near 8sec Sylva Phoenix. 208bhp at the wheels, as such it was famed for its
A car which, with its aero addenda, bespoke giant killing abilities. And it wasn’t too long before
aluminium Cosworth derived powerplant and race his fast Fiesta became the darling of the modified
honed sequential 6-speed shifter, appears far more car magazines of the ’90s, where it would embarrass
Silverstone than Santa Pod at first glance. It’s only the likes of Ferraris on the strip. But the novelty of
when you dig a little deeper to find clues such his supercar killing supermini eventually wore off,
as the terrifically wide Hoosier rubber and huge as David moved his focus away from brute force
turbocharger intake that you begin to realise this and towards weight reduction – and kit cars.

www.completekitcar.co.uk May 2020 33

032 Sylva Phoenix.indd 33 15/04/2020 11:27

 R E A DE R ’ S B U I L D | S Y LVA P H O E N I X

Cosworth derived engine produces around 700bhp.

Siltech Racing transformed the front suspension.

His first kit car drag build was a prior “I was thinking I wouldn’t mind going
Phoenix, which took on the Fiesta’s down the turbo route for the first time,”
Crossflow to reduce David’s quarter-mile explains David. The move to forced induction
time by almost a second. A subsequent wasn’t without its hitches, as the tuned
Phoenix followed with a Cosworth BDX Cosworth’s peaky torque curve and masses of
unit fitted, but it would be a new approach turbo-lag proved ill-suited to the strip at first.
with a ground-up Caterham build that As he goes on to say, “It only felt fast and it
really moved the game on. “The best wasn’t nearly progressive enough through
way of getting weight out of a car is to the rev-range, which is what you want in a
build lightness into it in the first place, as drag car.” It would take many modifications
opposed to subtracting it from an existing to make it competitive, and as it stands today
car,” explains David. His live axle Seven the Phoenix is far removed from the car
remains his lightest build to date, weighing David purchased seven years ago.
in at just 428kg, and would go on to feature “The first eureka moment for me was
a Hart 420r racing engine, which was to when BorgWarner introduced the EFR
Lots of information to take in here. make way for an incredibly sought after turbocharger range, with that new turbo
Hart 415t monobloc unit. But it was while fitted it felt like I was running nitrous,” he
rebuilding this state-of-the-art powerplant, explains. It’s at this point I should mention
which was originally engineered for the that none of David’s cars have ever run on
900bhp-plus Formula One cars of the nitrous oxide, and he isn’t one to simply
infamous ’80s turbo era, when David’s turn up the turbo boost either; as such
interest in the sport began to waver. As he the Phoenix is relatively low stressed for
explains, “The kids were growing up, and it a drag build. Its current Smith and Jones
was getting harder to rationalise the effort Engineering alloy 2.2-litre powerplant, built
and money I was putting into the car.” by Allon Tucker at HT Racing, is a work of
A brief sabbatical from drag racing soon art. It weighs 25kg less than the Cosworth
followed, but the allure of an extremely rare YBD unit from which it derives and is much
Caterham Blackbird proved far too great to more powerful, producing nearly 700bhp at
ignore. But it was the subsequent purchase 1.4bar of boost – pushing the Sylva beyond
of this Phoenix in 2013, with its modified the magical 1000bhp per ton threshold.
Cosworth turbocharged powerplant, It’s mated to an Elite IL300 sequential
that would see his times at Santa Pod transmission, which keeps the engine at the
Second speedometer and gear indicator are a must. significantly drop. top of the rev-range on the strip – low down

34 May 2020 www.completekitcar.co.uk

032 Sylva Phoenix.indd 34 15/04/2020 11:27

ABOVE: David’s torque is the enemy of a lightweight drag car Much of that year was spent reading and
Phoenix produces – and is a component that David is rightfully researching instantaneous centres, anti-squat I BUILT THIS
over 1000bhp fond of. It’s an evolution of Elite’s earlier set-ups and suspension theory, which gave
per ton. IL200 gearbox, which was in part David’s him the knowledge to reconfigure the angles
idea and a component that was developed of the bars in his 4-link suspension system.
and tested around his earlier Caterham build. He also fitted a large diameter, hollow tube
The final piece of the powertrain package anti-roll bar at the back to reduce the torque
is the car’s heavy duty Ford Atlas live axle reaction on the live axle, and he regularly
at the rear, which is a common fitment on uses corner scales before a weekend to ensure
both Ford based drag and rally builds. It’s much of the Sylva’s mass is centralised.
a formidable set-up, but there’s more to These seemingly small rear suspension
this Sylva than its brutal powertrain and revisions make all the difference to the car,
featherweight build. and together keep the car stable off the line
The next key part of the its mechanical without the need for pre-load. Name: David Edmands
make-up is its specially set up suspension, The rear is only half of the equation, Age: 51
which plays a bigger role in David’s success however, and the front suspension plays Occupation: Finance Director
at Santa Pod than you might imagine. In the an equally vital role in keeping the Sylva First car: Ford Fiesta
past he used to dial in masses of preload at on the straight and narrow at over 150mph. Lottery win car: Porsche 911 GT2 RS
the rear, to keep the car straight off the line, With the front clamshell removed you Best tool in your garage: Corner weight
but as the tension unloaded over the run can see the impeccably clean, and carefully scales
the Sylva had a tendency to snap violently set-up, Siltech Racing rosejointed double Best bargain in the build: Lithium battery
sideways at speeds over 130mph. “I didn’t wishbones and billet uprights, which again
crash it, but I had a couple of big moments,” would look at home underpinning a top
he explains. Thankfully, an opportunity to spec circuit car.
take a year away from work in 2015 gave So does the Sylva’s uncompromising aero
David the time to troubleshoot the issue. package. It’s impossible to talk about David’s
Phoenix without mentioning its huge rear
wing, which is modelled on a BAR Honda
“I DIDN’T CRASH IT, F1 design and plays an important role in
pushing the power onto the tarmac and
BUT I HAD A COUPLE keeps the car stable at speed. Fitting a drag
inducing spoiler may seem counter intuitive
OF BIG MOMENTS” but, working with the rear diffuser, it makes Sequential shifter helps keep revs high.

www.completekitcar.co.uk May 2020 35

R E A DE R ’ S B U I L D | S Y LVA P H O E N I X

Hoosier is synonymous with drag racing.

USEFUL CONTACTS
Gearbox: Elite Racing Transmissions,
Stoke-on-Trent, Staffordshire.
T: 01782 280136.
E: [email protected]
The difference in width between the front and rear tyres is significant! W: www.eliteracingtransmissions.com

SYLVA all the difference for David. As he explains, simple due to the choices he’s made. As he Engine: Smith and Jones Engineering,
PHOENIX “My initial run with the aero package was explains, “The rear suspension would need Bridgnorth, Shropshire. T: 01746 764066.
the first time I truly fell in love with this stiffening, it’d need new tyres and the wing E: [email protected]
ENGINE: 2.2-litre all- Phoenix, it made it a completely different is adjustable, but the engine and gearing is W: www.smithandjonesengineering.com
alloy Smith and Jones animal and I thought I can actually drive perfectly suited to the track.”
Engineering Cosworth it now.” It paid to go against conventional David’s Sylva further cements the Suspension and brakes: Siltech Racing,
YB derived engine.
GEARBOX: 6-speed
thinking, as not only does the car feel more point that a kit car is never truly finished, Norwich, Norfolk. T: 01362 820456.
sequential transmission. composed with its wing and diffuser it’s and that classic kit cars make the perfect E: [email protected]
SUSPENSION: Front – faster too, due to the fact it’s no longer basis for insane restomod builds like his. W: www.siltechracing.com
Independent double
wasting energy through wheelspin. Everything about this Phoenix is satisfyingly
wishbones. Rear – Coil
sprung live-axle. The Phoenix’s new sleeker front end is extreme, and it’s amazing that a car with Intercooler: Airtec Motorsport,
BRAKES: Discs all- the latest addition, which was based on Rob such a tiny footprint is able to look, and Canvey Island, Essex. T: 01375 371449.
round. Johnson Racing’s Cyana front clam, and sound, so imposing. What’s most amazing, E: [email protected]
WHEELS: MBR Racing
magnesium split rims – looks the business with its gigantic turbo however, is the fact that it’s fully road legal W: www.airtecmotorsport.com
13in front, 15in rear. intake hole and steeply raked engine bulge. and capable of going from 0-160mph is
INTERIOR: Stripped While the new front hasn’t been tested on around 9secs, and to 60 in less than two! Rear wing: MVS Racing, Lampeter, Wales.
Sylva Phoenix interior
with custom seat the strip yet, David expects it will bring It’s hard to comprehend how that level of T: 01570 471550.
cushions. him ever closer to his goal of achieving an performance will translate onto the track in E: [email protected]
EXTERIOR: Cyana 8sec run at Santa Pod, and once he achieves the near future, but if David takes the same W: www.mvsracing.co.uk
derived front clam, rear
MVS Racing wing and
that the Phoenix will be repurposed into a methodical approach to the set-up as he has
custom rear diffuser. trackday monster – bringing the Sylva full with his drag builds it could potentially be Bodywork: Chris Isaacs Race Cars,
circle. It’s a task that should prove relatively just as competitive. Wickford, Essex. T: 01268 571077.
E: [email protected]
W: www.chris-isaacs.com

Performance parts: Julian Godfrey

Engineering, Heathfield, East Sussex.
T: 01435 865999.
W: www.racetuners.com

Wheels: MB Racing Wheels,

Rochester, Kent. T: 01634 711801.
Rear diffuser helps the car stay stable off the line. Large turbo intake for this Sylva. E: [email protected]
W: www.mb-racingwheels.com

Front clamshell: Rob Johnson Racing,

Stoke-on-Trent, Staffordshire.
T: 07918 638546.
F: www.facebook.com/cyanasportscars

Turbo: Turbosport, Bedford, Bedfordshire.

T: 01480 406886.
W: www.turbosport.net
The rear wing is based on a BAR Honda design. Heat dissipation is a struggle.

36 May 2020 www.completekitcar.co.uk

 +44 (0)1264 772811
www.moto-lita.co.uk

“A Fine Example of British Craftsmanship”

Sir Stirling Moss OBE

www.completekitcar.co.uk May 2020 37

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40 May 2020 www.completekitcar.co.uk

www.completekitcar.co.uk May 2020 41
GROUP TEST | LOTUS SEVENS

ORIGINS OF A GENRE

Where would the kit car scene be

without the Lotus Seven? We brought
together all four generations of a car
that inspired an entire genre.
Words: Adam Wilkins Pictures: Ian Stent

T
he Lotus Seven occupies an unusual place in the kit
car firmament. Most cars that spawn replicas are, to
some extent, relatively unobtainable. Whether it’s a new
Ferrari or a classic Cobra, most cars that are replicated
are in some way financially out of reach. There aren’t that
many kit cars that are replicated, but one stands out: the Lotus Seven.
So what makes this self-build so special that it has inspired imitators?
There’s not another Lotus that more aptly illustrates Colin
Chapman’s ‘simplify and then add lightness’ philosophy. The barely-
there bodywork, the lack of luxury and the unfiltered focus on
performance make it one of the most single-minded Lotus road cars of
all time. If you need proof, dwell on this: indicators remained an option
for over a decade. Simple. Light.
Of course, there was a reason the Seven was paired back like a racing
car – because that’s what it was. It was designed to fit in with 750
Motor Club rules, and most early buyers raced their cars. The car’s road
legality simply meant that it could be driven to and from venues.
For many owners, though, the Seven became more than that. It’s a
car for touring as well as competition, and the Seven recipe remains –
somewhat astonishingly – popular and relevant today. The fact that over
60 years after the first Series 1 hit the road the Seven remains available
as a supercar-baiting Caterham tells you something about the rightness
of the model. Just like the 28bhp Sidevalve powered original, a modern
Seven remains one of the fastest ways of travelling from point A to B.
By the 1970s, Lotus outgrew the Seven. Chapman famously said
it’s the kind of thing he could “dash off in a weekend” as he took his
marque upmarket with cars like the Europa and Esprit. That’s as may
be, but decades on the Seven still delivers levels of performance and
entertainment that its peers cannot. It punches way above its weight,
just as it always has. From Series 1 to 4, here is the Lotus Seven.

42 May 2020 www.completekitcar.co.uk

www.completekitcar.co.uk May 2020 43
GROUP TEST | LOTUS SEVENS

Interior was basic even by later Seven standards.

Would have had drums all-round in the ’50s. Steering wheel at a reclined angle in the S1.

Only the top spec Sevens had a Coventry Climax engine... Seven S1 arrived in 1957, two years after the Six was discontinued.

I OWN THIS
Thomas Woolley has owned a number of Lotus
models over the years (Elans, Europa, Elite, Eleven)
and regrets selling them all, but it’s unlikely he’ll
ever part with the Seven. He co-owned this car with
QED founder Ken Snailham, and it became his when
Ken sadly passed away. He loves it for its handling, simplicity and
looks, even if he jokes that’s not ideal “for someone of my age who
suffers with a bad back.”
...you’d usually see a Ford Sidevalve in an S1. It’s the only car here on wire wheels.

44 May 2020 www.completekitcar.co.uk

LOTUS SEVEN S1 The chassis borrowed heavily from the a steering column that routes itself between LOTUS
By the time the Lotus Seven made its existing Eleven (the centre tunnel and the clutch and brake pedals, so you have SEVEN S1
public debut in October 1957, its direct scuttle were carried over), while the front one foot on either side of it. It competes for
forebear, the Six, had been out of production and rear portions were all new. At launch, it space in a narrow footwell that sometimes ENGINE: Coventry
for two years. Pent-up demand for the new had a Nash Metropolitan live axle, Triumph has you catching your right shoe on the Climax four-cylinder.
Lotus clubman racer, which took its Seven Mayflower front brake drums and a Burman chassis. I asked Thomas if that happens to SUSPENSION: Front
– Double wishbones,
type number from a stillborn Formula 2 steering box. That was soon changed for a him, and he said no. I guess it’s something coil-over dampers.
car, meant it was an instant hit and served Morris Minor rack mounted upside down, you get used to. Rear – Live axle,
as Lotus’s primary road-going model while before being replaced again in 1959 with a This car has the Coventry Climax engine. coil-over dampers.
BRAKES: Discs all-round
production of the much more complex rack from the then-new Triumph Herald. Its in-period figures of 75bhp with a
INTERIOR: Aluminium
Elite, which had been launched The prototype Seven had a Coventry 0-60mph in 9.2sec and a top speed in dashboard, bench seat,
simultaneously, got under way. The 243 Climax engine, but its expense meant that excess of 100mph being in a different league four-point harnesses.
examples were built before and after the it became a very rare fitment. In fact, it to its Ford powered contemporaries. Even EXTERIOR: All
aluminium body,
move from Hornsey to Cheshunt. wasn’t offered as a production model until so, it needs plenty of revs and encouragement eggcrate grille, wire
Most Seven owners bought their cars in December 1958, dubbed Super Seven. A to get motivated. wheels, aeroscreen.
kit form. While the £526 pricetag (£12,056 much more common fitment was the 28bhp The period crossply tyres offer little
in today’s money) represented a huge saving Ford 100E Sidevalve engine. You could opt in the way of grip and fidget over the
over the £1036 (£23,764 today) of the ready- for twin SU carbs and Lotus’s own exhaust mildest imperfections in the road surface,
built car, it was a lot more expensive than manifold to up power to 40bhp. but you can still feel the inherent balance
contemporary kit cars of the time. The Lotus Thomas Woolley has brought his S1 that made the Seven such a force to be
buyer, however, received a complete package to our group, and even compared to the reckoned with on track. It’s there at the
of everything required to build the car with back-to-basics S2 and S3, it feels like a core, wrapped up in a package that feels
no second-hand parts whatsoever. This was a step back in time. It’s the only car here that distinctly vintage in a way the later cars do
premium product, even in DIY form. lacks seatbelts and it has the peculiarity of not. It’s utterly charming.

www.completekitcar.co.uk May 2020 45

GROUP TEST | LOTUS SEVENS

LOTUS SEVEN S2 the MG was proving popular, and therefore Despite the car still being fitted with LOTUS
Despite its pared-back nature, the Seven had become ubiquitous, in the States. its competition engine and gearbox, these SEVEN S2
proved expensive to manufacture thanks to From 1961, the Ford 105E became a days it’s used solely as a road car. The
its intricate spaceframe chassis and hand- factory option, superseding the 100E unit, forgiving Uniroyal tyres have distinctly ENGINE: Lotus
formed aluminium body panels. That was having been offered in the aftermarket by noticeable sidewall movement, which Twin-Cam.
assuaged to some extent, but not entirely, Caterham Cars for a year. The Super Seven emphasises the car’s inherently supple SUSPENSION: Front
– Double wishbones,
by the introduction of the S2 in June 1960. moniker was re-introduced in 1961 for the ride. They give plenty of warning before coil-over dampers.
The complex aluminium wheelarches and version fitted with the 1340cc Cosworth you reach anywhere near the limit of grip. Rear – Live axle,
nose were replaced by simpler John Frayling tuned 109E Consul engine. The large-rimmed steering wheel comes coil-over dampers.
BRAKES: Discs all-
designed GRP items and some chassis Today, there are few S2s on the road, many from an Eleven and is the perfect match
round.
members were removed. being used in competition because their age for the light yet precise turn-with-your- INTERIOR: Aluminium
Under the skin, the rear axle was now renders them eligible for historic motorsport. fingertips steering. dashboard, bench seat,
from a Standard 10. By now, windscreen The car that John Vaughan brought along to While it undoubtedly still feels like a four-point harnesses.
EXTERIOR: Aluminium
wipers became standard fitment, but the group test was raced in period, and in the classic – bench seat, an absence of any body with GRP nose and
indicators and a rev-counter stayed on the 1970s the 1172cc Ford engine was replaced roll-over protection – it does feel like a wings, Minilite wheels.
options list. with the Lotus Twin-Cam engine it still has step on in modernity compared to the S1.
Something that was no longer an option today. It drives through a 4-speed gearbox You could step from a modern Caterham
was the Coventry Climax engine because it that is straight-cut on first, second and third into an S2 and not feel as though you’d
was incompatible with the new chassis. The gears. It’ll do almost 70mph in third, with time-travelled too far.
Sidevalve engine remained popular among fourth acting like an overdrive. The S2 was the longest-lived of the
750 Motor Club racers, but the BMC Other areas where it deviates from Lotus Sevens, so it comes as no surprise
A-series, complete with an MG Midget standard are the later, larger headlights, the that it’s the most numerous. It total, just
sourced 4-speed gearbox, also became an S3 rear wheelarches (the S2’s were narrower) over 1300 were built, securing its place in
option. This made sense internationally, as and the later clamshell front wings. the classic car landscape.

46 May 2020 www.completekitcar.co.uk

 S2’s interior still small, but improved on S1’s.

Wheel borrowed from a Lotus Eleven. Running gear courtesy of Triumph.

GRP wings and nose helped reduce the S2’s manufacturing cost. Lotus Twin-Cam fitted early in this S2’s life.

I OWN THIS
John Vaughan had originally intended to build a
new Caterham, but a friend persuaded him to
restore this classic Lotus instead. He’s delighted he
did and, 22 years later, still loves owning the car.
“I should have had it when I was 20,” he says. John is
a Lotus fan through and through, and his Seven shares garage space
with an Excel and an Elan Plus 2, and he has previously owned an
Esprit S3 and an Elise 111R.
Sidedraught carburettors: period tuning. Minilite style wheels a typical upgrade.

www.completekitcar.co.uk May 2020 47

GROUP TEST | LOTUS SEVENS

Driver and passenger still share bench seatback.

Fuel cap moved to exterior for the S3. Chunky steering wheel suits purposeful S3.

Ford Crossflow engine introduced for the S3. This S3 is used for sprints, just as many would have been in the ’60s.

I OWN THIS
John Muirhead currently owns no fewer than five
Lotus Sevens, some as road cars others strictly set
up solely as competition cars. He has owned this
one since 1993 and is succinct on the subject of
what he likes most about it: “Handling, braking,
acceleration – it’s pure wind in the hair driving, the perfect sports
car.” Those are precisely the reasons the Seven has remained so
enduringly popular.
S3’s engine bay is still a picture of simplicity. Super-sticky Yokohama A050 tyres.

48 May 2020 www.completekitcar.co.uk

LOTUS SEVEN S3 red, while the fuel filler moved to the smaller, thicker-rimmed steering wheel LOTUS
For many, the S3 is the archetypal Seven. outside of the bodywork and the dashboard gives this car a more purposeful feel, too. SEVEN S3
It’s the foundation for the car Caterham grew a fuel gauge. As well as the additional Before you get that far, though, the heavy
continues to manufacture today, and indeed instrument, the dials were also now clustered competition clutch requires some ENGINE: Holbay Ford
it was the Surrey-based firm that was around the steering wheel, making them re-acclimatising. Crossflow.
instrumental in its conception. By 1967, easier to see. It feels a much more serious car than SUSPENSION: Front
– Double wishbones,
Graham Nearn’s company was the sole In plenty of other respects, though, the others we’ve driven so far – faster, and coil-over dampers.
outlet for the Seven and he proposed a it retains many classic Lotus cues. The more willing in every aspect of its dynamic Rear – Live axle,
series of updates to Colin Chapman. They unpainted aluminium bodywork, clamshell performance, it’s probably the car that coil-over dampers.
BRAKES: Discs all-round
were approved and it became the S3. The wings and bench seat all contribute to its feels most at home in the 21st century.
INTERIOR: Aluminium
rest is history. old-school charm. The classic character remains, but it has a dashboard, bench seat,
One of the main driving forces behind John Muirhead brought along the S3 level of performance that doesn’t feel out four-point harnesses.
the S3’s introduction was that Ford Sidevalve to this group. It’s an original ‘black badge’ of place today. Where the S1 feels almost EXTERIOR: Aluminium
body with GRP nose and
engines were becoming increasingly difficult model, with all the myth that surrounds pre-war, the S3 shows how the Seven began wings, MSA rollover bar.
to source new. The logical move was to the that, and today is used for mixed road-going to galvanise itself to remain a credible
more up to date Ford Crossflow in its and sprint use. It’s for the latter purpose performance car for several decades to come.
1297cc (72bhp) and 1598cc (84bhp) that it has some of the equipment you see The Lotus Seven S3 only had a 15-month
guises – in fact, these engines had already in the photos, such as the substantial (but life but, in that time, around 340 were built.
been fitted to the last of the S2s. Increased removeable) roll-over bar and the modern Maybe a small total number, but it was a
power and improving tyre technology were Yokohama A050 ‘semi-slick’ tyres. fast seller. More than that, though, there’s
putting a strain on the drivetrain, so the Stepping straight from the S2, the no doubting the S3’s significance in the
S3 also received the live axle from the Ford starkest contrast is in the S3’s willingness Seven’s story.
Escort. Other changes included a move to to turn in, but a lot of that must be down But the Seven was about to take a
black interior trim in place of the traditional to those stiff-walled and grippy tyres. The different course with the S4 that replaced it...

www.completekitcar.co.uk May 2020 49

GROUP TEST | LOTUS SEVENS

S4 has a stylised dashboard and centre console.

All GRP body was made in-house by Lotus. Generous array of instruments and switches.

1600cc GT Ford Crossflow engine. The S4 was a Seven for the ’70s, aimed at Midget and Spitfire buyers.

I OWN THIS
“I’d always wanted a Seven since childhood,” says
Paul Wedge. And while it wasn’t an S4 that he was
particularly looking for, after giving his one-
previous-owner car a nine-year restoration he’s
convinced it’s one of the best examples of its
kind in existence. We’d be inclined to agree. His advice to anyone
looking to buy an S4 is to “be prepared to tinker with it to keep it
in tip top condition.”
The S4 is inescapably 1970s in its detailing. Flip forward bonnet was new for the S4.

50 May 2020 www.completekitcar.co.uk

LOTUS SEVEN S4 boot delivered on the promise of greater produced (some way short of the 2000 LOTUS
And now for something completely practicality. There was even an optional per year target) and the rights were sold SEVEN S4
different. By 1969, there was a will within hardtop, but not many buyers took it up. to Caterham Cars. Caterham built a small
Lotus to modernise the Seven. Mike Under the skin, the Ford axle was now number of S4s to use up remaining stock ENGINE: Ford Crossflow
Warner, the chief executive of Lotus located by a Watts linkage and single before re-introducing the S3. 1600cc.
Components, was charged with developing triangulated arm, while up front it has All of which leaves the S4 freezeframed SUSPENSION: Front
– Double wishbones,
a Seven for the ’70s. It would have a new suspension based on the Europa’s. Engine in a short period of the early 1970s. Paul coil-over dampers.
dealer network, greater sales ambition and options included Ford’s 1600cc Crossflow Wedge has just spent nine years restoring Rear – Live axle,
even a new type number: 60. The plan was and the Lotus Twin-Cam in both stock and this one to original condition, and it’s coil-over dampers.
BRAKES: Discs all-round
to rival more practical sports cars like the Holbay forms. the perfect embodiment of Lotus’s more
INTERIOR: Moulded
MG Midget and Triumph Spitfire; a tall Lotus intended to make the S4 cheaper habitable Seven. We have proper seats for dashboard, three-spoke
order for a Seven. It made its debut in to produce than its predecessors, but the list the first time and the dashboard looks as if steering wheel, ashtray.
March 1970. prices were higher than the S3’s. In kit form, it has been styled rather than just being a EXTERIOR: All GRP
bodywork, sidescreens,
Peter Lucas designed a new chassis it was £895 (£13,161 in today’s money) with convenient panel on which some instruments weather gear.
that featured spot-welded cockpit sides a £100 premium for the GT model. can be mounted.
and engine bay and a folded steel front The cars were built by Lotus Components, It is undoubtedly more comfortable than
crossmember. More to the point, it was which turned into Lotus Racing before the earlier cars, yet the Seven’s handling
almost a foot longer, with the increased being closed in 1971. At that point, magic is still there. Eroded slightly, perhaps,
interior space that came with. Alan Barrett production of the S4 was transferred to but the trade-off seems favourable. Maybe
was responsible for the new all-GRP Lotus Cars where the Elan was being built. comparisons to other Sevens are unfair and
bodywork. Derided in period for losing the The two models didn’t make comfortable the S4 should be seen as a standalone model;
purity of the original Seven shape, today it bedfellows and that, combined with Lotus’s it served a different purpose for a different
looks so of its time that you can’t help but desire to move upmarket, spelled the end. era. An appeal shorter-lived at the time, but
see the appeal. A proper soft-top and larger By October, just over 620 cars had been one that grows with age.

www.completekitcar.co.uk May 2020 51

GROUP TEST | LOTUS SEVENS

ABOVE: The S3 is
probably the closest
THE FINAL RECKONING
How do you choose between these four
“MAYBE LETTING YOUR HEAD
in spirit to most cars when you’d be more than happy to RULE YOUR HEART WHEN IT
cars that have been open your garage door to any of them? S4
inspired by the aside, the Seven has remained steadfastly COMES TO A SEVEN IS THE
single-minded in its intention and execution,
WRONG THING TO DO”
Lotus Seven, and is
the direct ancestor utterly unswayed by prevailing fashions for
of today’s Caterham over six decades. There’s not another car that
range. has achieved that for so long and, for that
alone, you have to give it credit. Seven is the wrong thing to do, but it’s for significance when picking an outright
The fact that the Seven has been able to that reason it takes fourth place here. winner. If that’s the criterion, second place
remain true to its core while staying at the Next up is the S4. Again, this is another must go to the S2 with outright victory
sharp end of performance is evidence of how car that could so easily be the winner if you for the S3. Had Caterham not taken such
correct that initial design was. The Seven asked me the same question tomorrow. Like a keen interest in the Seven, it wouldn’t be
hasn’t become an irrelevant anachronism – the S1, it has an utterly distinct character. the car it is today. And the car it is today is a
far from it; in its Caterham guise, it’s still at Overlooked for so many years, I reckon significant part of its story.
the cutting edge of performance today. So its time will come – if it hasn’t already. Of But whichever generation of Seven you’re
let’s, somehow, try to rank them in order. all the cars here, it was the one that had talking about – right up to the current day –
The first to go is a car that, on the day, me scouring the classified adverts. It’s so the Seven has made motorsport accessible to
was my winner: the S1. I completely fell in wonderfully 1970s – in the best possible way. the masses and has a uniquely affordable way
love with how different it felt to the later It’s as much a product of its time as the S1 of offering high performance. There is no
cars. Its vintage charm totally won me over is of its era. other car like it.
and I’d love to spend more time with one. And that leaves us with the two most
It’s a car that demands your undivided conventional Sevens (‘conventional’ being
attention. So why the change of heart? a relative term) battling for the win. It THANKS TO:
Blame it on my head. You know that one only seems right: the S2 and S3 are the The owners for letting us drive their cars,
of the later cars will be easier to live with core Seven models; together, they set the Ann-Marie at Club Lotus, Rod Thonger at
and encourage you to take it out more often legend in stone. Development from S2 to the Lotus 7 Club and Paul Townsend at the
and for longer trips. Maybe letting your S3 is the most incremental in the Seven’s North Yorkshire Lotus Owners’ Club for
head rule your heart when it comes to a history, so really it comes down to historical helping us find the cars.

52 May 2020 www.completekitcar.co.uk

N E W C A R | C AT E R H A M S U P E R S E V E N 16 0 0

CATERHAM BUILDS A LOTUS

Following its two previous heritage models, Caterham has
just taken the wraps off its new Super Seven 1600, a car that
channels the spirit of the Lotus that spawned the company.
Words: Adam Wilkins Pictures: Caterham Cars

Y
ou only need to witness throttle bodies designed to look like a pair
the popularity of retro of DCOE carburettors.
mainstream models like Caterham CEO, Graham Macdonald,
the Mini or Fiat 500, or said: “Caterham has always been about
the stratospheric values of individuality and the quality engineering
‘backdated’ classics like Singer Porsches, to that makes the Seven peerless when it
understand that mixing modern mechanicals comes to the driving experience.
with old-school looks is a recipe for success. “Ownership of any specification of
So it’s little wonder that Caterham has Caterham Seven is a mark of distinction
developed a habit of creating retro themed and a ticket to driving adventure, but our
versions of the Seven. heritage line of models holds a special place
The limited edition Sprint of 2017 sold in the hearts of the true brand enthusiasts.
out in just a week, and the Super Sprint that Both of our most recent retro-inspired
followed a year later took a day before they Sevens – the Sprint and Super Sprint –
ABOVE: Traditional were all gone. There are some key differences sold out in record time so we know the
interior. between Caterham’s previous heritage cars appeal for these cars is strong.
and the new Super Seven 1600. For one “We’re excited to introduce the most
RIGHT: Throttle thing, this is not a limited edition model powerful Super Seven ever built, a
bodies disguised as but a permanent part of the range. Secondly, re-imagining of a true modern icon,
twin DCOE carbs. it doesn’t use the three-cylinder Suzuki delivering exactly what the original was
engine, but instead a 135bhp 1.6-litre designed to offer – a focus on driving feel
BELOW: Clamshells Ford four-cylinder. And thirdly, it will and race-inspired upgrades but with some
come back again. be available with the option of the wider touches of luxury to the finishes.”
SV chassis. People often forget that Caterhams
The car harks back to the Super Seven remain available for self assembly, the
of the ’70s, Caterham claiming it’s marque’s widespread recognition somehow
designed to “reflect the joy and glamour not sitting with the fact that the Seven
of motoring in the 1970s – minus the remains a kit car. If you’re willing to build it
drawbacks.” Styling cues include the yourself, the price for a comprehensive kit
clamshell wings, retro 14in wheels and a is £33,495, or you can spread it out using
spare wheel carrier. There is a choice of Caterham’s finance option.
seven paint finishes, each epitomising the Press drives are not available until the
Super Seven’s ’70s inspiration. lockdown is over, but we’ll get behind the
Inside, you’ll find a wood-rimmed wheel of the Super Seven as soon as we can.
steering wheel and interior fully In the meantime, more details are available
upholstered in leather. Lift the bonnet, on the model’s microsite.
and the retro theme continues thanks to W: www.thenew-oldschool.com

www.completekitcar.co.uk May 2020 53

 MORE
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• Hawk 289 • Auto Mirage 250 GT • NG TF V8 • Coutach real v replica • SSV Bug:R driven • Dave Jones GTE
• Euro sprinting tour • GKD Legend • Desert Scorpion Pt2 • Westfield Pt2 • Kozmo and Finnluxury • Nubodi Koupé
• Fisher Fury Pt2 • RTR Rocket 3-cylinder • Stimson Minibug • Buckland B3 • Mini Marcos Pt2 • 60 years of the Seven
• MK Indy build • Desert Scorpion build • Westfield build • Mini Marcos restomod • Stoneleigh 2017 • Lister Bell STR build
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R ETRO ROU ND-UP | FROM THE ARCHIVE

RETRO ROUND-UP
In our latest instalment of retro goodness, we look at a once lauded kit cabriolet,
a plan-form coupé, a pre-war-style roadster and a trio of one-off specials.
Words: Richard Heseltine Pictures: Archive

Jan Quick with the Triumph Herald-based Stanbury TT. It was sold in kit or plan form.

QUICK STEPPED INTO PIONEERING ROLE WITH STANBURY TT

The 1980s witnessed the emergence of the plans- it, I suppose, but if it takes off as a commercial project, hydraulics are retained. The original rear seat covers
form kit car, the vast majority being based on the I will probably eventually run it on a full-time basis.’ may be adapted to form “bench back/separate squab”
Triumph Herald. The Stanbury TT was among their The preferred donor car was the Herald 13/60, the seats for the conversion. The original fuel tank, turned
number. This skimpy device broke cover publicly in chassis being retained (minus outriggers), a body from 90deg is incorporated. The Herald wheels are
1983, which is remarkable given that its instigator, assembly being offered for £250 which comprised a retained, but may, with advantage, be replaced by the
Jan Quick, had little interest in cars prior to bringing plywood floor and bulkheads, aluminium-over-wood equivalent spoke variety [from a Morris 8 on the first
it to market. What’s more, she passed her driving body and aluminium cycle wings. Alternatively, plans car made].’
test that same year. The draughtswoman from Worle, were offered for builders to go their own way. The The intention had been to offer variations on the
Weston-super-Mare was arguably the first woman to brochure trumpeted: ‘The essence of the Stanbury TT theme, including a more ‘complete’ edition with
run a kit car enterprise in the UK. is its simplicity, and the car has been designed from doors plus a 2+2 model, but none came to market.
She told Kit Car in February 1984: ‘Although [my the outset for ease of assembly and fitting by anyone Stanbury Design Services was quietly shuttered in
husband] Dave designed the car and got the ball with basic mechanical and DIY abilities and facilities, 1986. As to how many cars were made, your guess is
rolling, I gradually got involved and found the work whether contemplating starting from scratch or as good as ours. Some sources claim 12 kits were
surprisingly easy. The more I did myself, the more I buying one of the kit options.’ sold, others estimating it was closer to seven. And
understood car building, and soon I really got the It went on to add: ‘The chassis alterations are that doesn’t include TTs built from plans alone. The
bug. Dave showed me how to do lots of jobs, but simple and basically consist of softening the rear original prototype, latterly known as the Raneleigh
now I do just about all the work except the heavy spring and lengthening the steering column. The Flyer, was sold via an internet auction site for £13,000
stuff. It was all a self-imposed test to see if I could do original instruments, controls, loom, lights and a while back...

56 May 2020 www.completekitcar.co.uk

The one-off Avante began life as a project to teach students about working in glassfibre.

THE CURIOUS CASE OF THE AVANTE (NO, NOT THAT ONE)

It’s a yarn that stretches the imagination. The Avante
was built by Lyndon Kitchen, but the bodyshell
began life as a project instigated by a youth club in
Huddersfield. The aim was to teach teenagers how
to work with glassfibre. It was created in 1973, the
intention being to mate it to a Volkswagen Beetle
floorpan. Instead, it was sold to Kitchen in September
1974 for £100. He then managed to get hold of an
unfinished spaceframe chassis in Bolton and then set
about extending it by two feet for its new application.
He then added Triumph GT6 front suspension and a
complete rear end from a Vitesse. Kitchen wasn’t keen
on using VW power in the rear and instead opted The car was originally intended for Beetle power, but was completed with a 1725cc Sunbeam ‘four’.
for a front-mounted 1725cc four-cylinder unit from
a Sunbeam Rapier which gained a Piper cam and
Holbay head.
There were, however, significant problems when
it came time to mate the body to the chassis. So
much so, he ended up throwing the ’shell onto a
bonfire on Guy Fawkes Night... Kitchen then produced
a new body from the moulds that came with it which
was then chopped and changed, and reconfigured,
this part of the build accounting for two years’ work.
Three months were spent simply trying to obtain a
smooth finish around the Rover P6 2000 windscreen,
other proprietary parts including Rapier rear glass,
Hillman Hunter rear lights and Mini door hinges.
The interior, meanwhile, was equipped with Billover
Highrider seats, Rapier instruments and lashings
of dark brown velour. The car was registered on
1 September 1977, three years to the day since
Kitchen acquired the project. He advertised it for
sale shortly thereafter. The Avante featured a narrowed Rapier rear bumper and Ford Mustang-derived faux vents in the C-pillars.

www.completekitcar.co.uk May 2020 57

R ETRO ROU ND-UP | FROM THE ARCHIVE

Devised by America’s Quincy-Lynn Enterprises, the Centurion was offered in the UK by Burlington.

BEST LAID PLANS – THE BOLD BURLINGTON CENTURION

Distinct from most other plans-form, Triumph-based shaped very similar in concept to the manner in of guy who’s going to take the trouble of building a
kit cars, the Burlington Centurion was rather more which boats are constructed. The whole thing is then car in this rather labour intensive fashion is hardly
contemporary in terms of its styling. Revealed in clad in sheets of one inch thick polyurethane foam – going to let these obstacles stand in his way. Oh
1984, it was derived from a US design by the ever available at most GRP stockists – and cut as per the no. Such is the flexibility of the manufacturing
inventive Quincy-Lynn Enterprises. Based on a brilliantly projected views.’ concept that apertures and mounting flanges for
Triumph Spitfire platform, it was a distinctive coupé, There were, however, a few ‘issues’ which glass, lights, etc can be modified to accept suitable
but the build wasn’t for the faint of heart. Component blunted its appeal. Key among these was sourcing British counterparts.’
Car detailed its construction in December 1985. non-Triumph components needed during the Plans cost £14.95. As to whether any cars were
It wrote: ‘...perhaps the most interesting facet is build. These extended from a 1981 Buick Riviera ever completed in the UK, we have yet to see one.
its bodywork. This is fabricated from sheet ply windscreen to Oldsmobile Vista tail lights. If you know of any, do please shout. You know
employed in an eggbox fashion that results in a car Nevertheless, Component Car concluded: ‘...the sort where we are.

58 May 2020 www.completekitcar.co.uk

Colin Robertson with his brainchild, the well-received Estivo, outside his factory in Leeds.

OPPORTUNITY LOST – THE SADLY STILLBORN CAVALLO

It was a car that, for a brief period, seemed to be spoiler combo, plus a change of headlight operation
omnipresent in the media. And then it was gone. The from mechanical to electrical. Robertson then
Cavallo Estivo was an intriguing prospect, a practical changed tack again, and reverted back to offering the
and attractive kit-form sports car that unfortunately car in kit form from late 1984 as the Chaval, still using
never quite took flight. The car was conceived by Colin BMC 1100/1300 widgetry. This was the entry level
Robertson, a man well-versed in specialist cars. The package which cost £1399 (around £4750 adjusted
sometime quantity surveyor had previously built and for inflation) before VAT. A comprehensive kit – the
modified assorted Lotus Elans, including a fixed-head Estivo – included everything from the Alfasud Sprint
coupé variant for which he devised his own Targa- windscreen and bespoke side glass to a set of 100+
style roof arrangement. He then set about building a Quasar alloy wheels. Not only that, a Metro-based
four-seater sports car/buggy crossover vehicle. Work variant using all new parts and largely factory-built
commenced in 1979, but Robertson then changed was also promised. The Aventura was to have been
tack early on and decided to make something that bit equipped with a fixed roof and a plusher interior.
more grown up. It was to be revealed at the 1985 London Motorfair
Scroll forward to 1983 and the prototype Estivo was and priced at around £6000 (around £15k in new
completed. Based upon BMC 1100/1300 running gear money). Sadly, that never happened, while plans to
(but with coil spring dampers in place of a Hydrogas ultimately develop a car based upon FWD Ford Escort
set-up), it didn’t quite live up to Robertson’s exacting components remained precisely that.
standards to the point that the second test hack was Kit Car judged the Chaval/Estivo to be: ‘...in our
made. It incorporated more than 150 detail revisions, opinion, the most important new kit to hit the
though, but it was at this juncture that the first cracks market since Dutton’s all-conquering Sierra.’
began to appear in the scheme. Robertson decided Component Car, meanwhile, labelled it: ‘...an excellent
to chase Type Approval in order to sell complete cars design concept. It is comfortable, fun to drive, well
comprising more up to date componentry. In a bid produced and should have an excellent future as a
to chase backing for the project, a stand was booked top notch concept car.’ Sadly, the Cavallo marque
at the 1983 Motorfair at Earls Court. Unfortunately, (later renamed Equus) never quite escaped the
there was a slight problem-ette in that the display car prototyping stage. Leeds-based Cavallo Cars
was damaged en route when the doors of a passing had all but fizzled out by the mid-1980s, more’s the
van flew upon, the contents therein spilling out and pity. As for how many cars were made, our best
landing on the car’s bonnet. guess is fewer than ten. If anyone knows of any
After the show, the Cavallo underwent further survivors, do please get in touch as we would love Shades of TVR: The Estivo was a practical kit sports
changes, not least the addition of a new front bumper/ to hear from you. car but it was sadly undone by fate.

www.completekitcar.co.uk May 2020 59

R ETRO ROU ND-UP | FROM THE ARCHIVE

A BUG’S LIFE – STUART MCDOUGAL’S MINI SPECIAL

Edinburgh blacksmith Stuart McDougal aboard his homebrewed Dougal Bug special.

While perhaps not the prettiest of specials, or even The blacksmith created his own chassis which the sides were hand-painted by a friend of Stuart’s.’
close, the Dougal Bug was unquestionably different. accommodated Mini subframes, the angular Powered by an 848cc A-series, it was not particularly
That was the point of the exercise, Edinburgh’s Stuart coachwork being fabricated from sheet steel and powerful, but it was quick enough to ‘…give a good
McDougal’s handiwork appearing in the December pop-riveted together. Hot Car went on to add: ‘The account of itself in the Frances St Grand Prix’. Quite.
1971 edition of Hot Car which reported: ‘Stuart wanted Mini engine, transmission, “dry” suspension, brakes As to what happened to the car subsequently, we
something a little different – the sort of car that would and what-have-you sits up front where Alec Issigonis would love to know. McDougal wasn’t altogether
make even a Scotsman turn and stare. He started with intended, and at the rear swinging arms are used finished with specials-building, though, as he later
an old Mini and a pile of square steel tubing and the along with Armstrong shockers. The wheels are made the chassis for the vaguely Moke-esque,
Bug was born.’ widened steels up to 61/2in. The “Dougal Bug” signs on Mini-based CLL Minamow.

THE MYSTERIOUS MANDER

A degree of intrigue surrounds the origins of this
car, not least when the car was completed (the
pics date back to 1978). What is known is that this
distinctive coupé was designed by Warwickshire
man Clive Mander whose previous experience
was limited to fettling tractors. It was originally
powered by a 1172cc Ford E93A four-banger allied
to a 100E gearbox with manual overdrive. It had
Standard 8-derived front suspension which was
later changed to a modified Ford Cortina Mk3
set-up, the rear end comprising a shortened
Cortina MK1 rear axle and home-brewed trailing
arms and a Panhard rod. The Standard engine
later made way for a 1.5-litre Ford Crossflow
‘four’, the top speed being in excess of 100mph
according to a hand-scribbled caption we found
attached to one of the images… The Mander, seen here towing a Jago Geep, racked up more than 150,000 miles during the 1970s.

60 May 2020 www.completekitcar.co.uk

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62 May 2020 www.completekitcar.co.uk
 WORKSHOP
IN THIS MONTH’S COMPLETE KIT CAR MAGAZINE WORKSHOP...

64 70

64 READER’S BUILD
Kuljeet Ubhi’s MEV Exocet takes the popular
exoskeletal sports car to the extreme.

70 OUR CARS
James has sent the Nova off for paint,
but not before working to get it ready.

74 TECH TALK
John Dickens talks through the various
kinds of internal combustion engine.

76 RUNNING REPORTS
Here’s the latest updates from our team
of real-world kit car builders.

74 76

www.completekitcar.co.uk May 2020 63

READER’S BUILD

EXTREME EXOCET
There’s been no shortage of classic restomod builds in Complete Kit Car lately, but this
month we take a look at what’s possible when you use a modern kit car as a basis instead.
Words and pictures: Jack Wood

MEV
EXOCET

ENGINE: Turbocharged
1.8-litre Mazda DOHC.
GEARBOX: 6-speed manual.
SUSPENSION: Mazda MX-5
derived fully independent
double wishbones front
and rear.
BRAKES: Discs all-round,
Wilwood 4-pot calipers at
the front.
WHEELS: 17in Work M8R
wheels.
INTERIOR: GRP seat shells,
digital dashboard.
EXTERIOR: Wrapped GRP
bodywork, quad headlights,
sidepods, wing.

The best bit about modifying an existing kit is that you can drive it from day one.

W
e are firm believers that Honda VTEC powerplant that got him thinking
there is more than one way about building his own high powered exoskeletal
to build a car and, while the kit. As he explains, “The Atom has always been the
traditional method may be dream for me, as I’ve been a VTEC fanboy for a
to assemble one from start good few years, but it was a little outside my price
to finish, there’s no shame in taking on a prebuilt range and the thought of binning a £40,000-plus toy
kit and putting your own spin on it. The booming on the track was a little too daunting.”
restomod trend of recent years can attest to that, There’s no hiding the fact that Ariel’s
with cars like Dave Edmands’ 26-year-old Sylva breakthrough track car has inspired many kit car
Phoenix drag build – full feature on page 32 – models over the years, which meant Kuljeet – or
showing just what can be done to breathe new life Kully as he’s known in MEV circles – had no
into a pre-registered kit. All it takes is a little time shortage of alternatives to choose from. One model
and vision. that caught his eye early on was MEV’s ever popular
For JDM and karting enthusiast Kuljeet Ubhi, it Exocet which, despite its unusual – for the sector
was the allure of the Ariel Atom and its modified – front-engine rear-wheel-drive layout, had lots of

“THE ARIEL ATOM WAS THE DREAM,

Kully purchased this supercharged car in 2018. BUT IT WAS A LITTLE OUT OF RANGE”
64 May 2020 www.completekitcar.co.uk
 MEV EXOCET

The original supercharged engine... ...produced a healthy 208bhp at the wheels... ...but a swap to turbocharging would bring more.

A new Turbo Dynamics kit... ...was purchased... ...via BOFI Racing.

Borg Warner Turbo is good for 400bhp-plus! Lightened flywheel. Lots of toys to play with here.

1000cc injectors didn’t work with the unit... ...so were replaced with Mazda RX-8 items. New turbo in place and plumbed in.

Work wheels were shipped from Japan. Michelin Cup Tyres fitted to increase grip. Kully used the car in this state for around a year.

www.completekitcar.co.uk May 2020 65

READER’S BUILD

JDM credibility and tuning potential, thanks to its

Mazda MX-5 basis.
“WITH THE SUPERCHARGER IT HAD
Kully was keen to purchase the best car he could ENOUGH PERFORMANCE FOR ME
as the basis for his modified build, a smart move
considering the many temping eBay ‘unfinished TO SEE WHAT IT WAS CAPABLE OF”
projects’ are often more difficult to complete than
scratch-built kits. And when he spotted a well
maintained supercharged model for sale in Kent, power would soon develop from a cheap and cheerful team had to revert to the original Mazda RX-8
he wasted no time in travelling down from his conversion to a more comprehensive set-up, which items fitted to the car. Despite this hitch, the turbo
West Midlands base to purchase it. One of the joys would include forged internals and state of the art conversion managed to raise the power from 208bhp
of rebuilding a road ready kit car is the fact that componentry. at the wheels to 320bhp at 1 bar of boost pressure –
you can find its strengths and weaknesses on the Following a conversation with Mazda MX-5 an increase of nearly 55 percent!
road before you begin to buy parts. As Kully puts specialist BOFI Racing, Kully ended up with a long With the power increased, Kully was in need of
it, “With the supercharger fitted, it had enough shopping list, which included an EFR turbocharger, more grip and ordered a set of Work M8R flow
performance for me to learn the capabilities of the new manifold, oil and water lines, a lightened formed wheels from Japan, which were fitted with
car, which already had a decent power to weight flywheel, 1000cc injectors, 3.6:1 ratio differential Michelin Cup 2 tyres all-round. Keen to get as much
ratio, but very little weight over the driven wheels!” and a 6-speed gearbox. On delivery the Exocet was grip at the rear driven wheels as possible, Kully opted
Originally Kully intended to simply replace the sent along with the new parts to Dyno Torque in for wider 255-section tyres for the rear and kept the
Eaton M45 supercharger with a larger unit, but Tyseley, Birmingham, for assembly and later to standard 205-section tyres at the front. With the
he soon discovered his options were very limited Powers Performance in Longworth, Coventry, for a car suitably upgraded for now, Kully spent the best
and usually expensive. It was during a fact-finding remap. While Kully had been careful to select only part of a year enjoying the Exocet and exploring its
mission at the MEV Action Day at Curborough the best parts for the engine’s rebuild, swapping new limits on the road. As he puts it, “Whenever
in 2018 that he discovered the more cost effective from supercharged to turbocharged induction wasn’t the weather was anywhere near dry I was out trying
solution to the issue would be to switch to a more without its teething problems. The 1000cc injectors to get some heat into the tyres, before finding out
common turbo conversion. But his quest for turbo in particular proved difficult to set up and so the where my fear limits were.”

New exhaust being fitted. Big brake upgrade kit came from Freaky Parts. Wheel alignment made a huge difference to the car.

MEV Action day at Curborough... ...where Kully’s car won top prize. Hoonigan sticker is appropriate for this build.

Heat wrapped exhaust. With the engine seeing further upgrades... ...Kully prepared the ancillaries for a respray.

66 May 2020 www.completekitcar.co.uk

 MEV EXOCET

The exhaust manifold was primed... ...as was the cam covers... ...before the new crackle black finish was applied.

The new intake manifold ready for fitment. New parts fitted and ready to go. An initial rolling road set-up gained 10bhp...

As well as finding the time to enjoy his car, the

year gave him ample opportunity to properly set up USEFUL CONTACTS
its suspension to handle the extra horsepower, which Kit: MEV, Unit 32, Staunton Court
was now well over double what the donor MX-5 Business Park, Staunton,
would have had when it left the factory. “I bought Gloucestershire GL19 3QS.
myself a set of corner scales to balance the car and T: 07977 503430.
played with the geometry in my garage. If you take E: [email protected]
your time with it, you’ll surprise yourself with what W: www.mevltd.co.uk
a difference you can make to the handling of a car
with just some string and a spirit level,” he explains. Performance parts: BOFI Racing,
He also used the time to make small additions to the ...but the car should achieve 380bhp when it’s ‘done’. Huntingdon, Cambridgeshire.
MEV, such as heat wrapping the exhaust system. T: 020 3795 0515.
While the Exocet wasn’t yet fully to his vision, for Kully to play with, and also eight different launch E: [email protected]
Kully wasn’t averse to tagging along to events, and control modes. But sadly, it was just as the car was W: www.bofiracing.co.uk
even at this early stage, the 320bhp Exocet was beginning to make real gains that the coronavirus
attracting attention within the MEV crowd. Most outbreak put the brakes on the project, for the time Assembly: Dyno Torque, 8 Tyseley Industrial
notable of all was the reaction the car got at its being at least. But it’s believed that when work Estate, Tyseley, Birmingham B11 2LF.
second MEV Action Day at Curborough last year, can recommence on the Exocet, its power will be T: 0121 772 2453.
where it won the top prize – and where it first caught around 380bhp at the wheels. If he achieves this, W: www.dynotorque.co.uk
our eye. It was also during this event that Kully Kully’s will have a 60bhp advantage over the current
got to fully test the car on track, where he found it VTEC Ariel Atom on the track. And while it may Engine mapping: Powers Performance,
performed impeccably despite a brief lapse in driving be tempting to go even further in the future, Kully 339 Bedworth Road, Longford, Coventry CV6 6BN.
talent that saw the car on the grass – no damage was believes 380bhp is the sweet spot for his car. “The T: 024 7636 6177.
done, thankfully! plan was always to end at 380bhp as the Mazda E: [email protected]
While the Exocet was good enough to win gearbox wants to turn to glass at anything beyond W: www.powersperformance.co.uk
awards, it wasn’t quite good enough for Kully and the 400bhp mark,” he explains.
with the winter months approaching he began to That doesn’t mean there aren’t any more big Wheels: Work Wheels, Osaka, Japan.
order more deliveries. A four-pot Wilwood brake upgrades to come, as the mechanical package of the W: www.work-wheels.co.jp
kit was ordered from MEV’s sister company Freaky car is only part of Kully’s vision. In the near future,
Parts, a harmonic engine balancer was ordered from when the lockdown measures are reduced, he intends Brakes: Freaky Parts, Unit 32, Staunton Court Business
Fluidampr in the States, a set of 750cc injectors and to fit the car with customised active aero additions Park, Staunton, Gloucestershire GL19 3QS.
a new inlet manifold came from Skunk 2 Racing that will likely include a front splitter, perfectly flat T: 07977 503430.
and, finally, a new wastegate was ordered from floor and a functional rear diffuser. “Those upgrades E: [email protected]
Turbosmart. With so many new parts going onto should see it at a point where I’m happy with it, W: www.freakyparts.co.uk
the Mazda powerplant, Kully took the opportunity although the process of refining all the little bits will
to respray the wrinkle red covers in wrinkle black continue for as long as I manage to keep it on the Harmonic engine damper: Fluidampr, 180 Zoar Valley
before handing the car back to Dyno Torque for black stuff,” he explains. Road, Springville, New York 141441, USA.
assembly, and to Powers Performance for mapping. We’ll take a closer look at the developments of T: (00) 716 592 1000.
As well as mapping around the new modifications, Kully’s Extreme Exocet when we’re able to in the – E: [email protected]
which brought power up by 10bhp – with more rises hopefully – not too distant future. But having seen it W: www.fluidampr.com
to come – the team added in three switchable maps before completion, we know it’ll be worth the wait.

www.completekitcar.co.uk May 2020 67

 DO YOU HAVE WHAT IT TAKES TO
BE A KIT CAR MANUFACTURER?
Design and Build a Sports Car by Stuart Mills
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operation to show you what’s involved in taking a kit car from the drawing board to the
market. As well the technical side of designing and building a kit car, it gives insight into
budgeting, marketing and intellectual property. Whether you’re planning on becoming a
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68 May 2020 www.completekitcar.co.uk
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OUR CARS

The Complete Kit Car team doesn’t just write about cars – we own
them, too! Here are the latest updates from inside the team’s own
garages and, occasionally, on the road.

OFF TO THE PAINTSHOP

James was able to get the Nova into the paintshop before the coronavirus
lock-down, leaving him time to prepare other parts while it’s away.

Canopy off car again for adjustments.

I
’m going to stop writing about the canopy repairs! paintshop stating ‘Business as usual’. I read into this correctly,
Hooray, you say! He’s finished! Alas no, but I have to when I visited the bodyshop the next morning they confirmed
accept it is as far as I can take it for now. After my last that demand had dropped hugely. I asked what the lead time
report when I had found the new seal to be stopping the would be to paint the car again and just 90 minutes later it
roof closing enough I spent many hours using markers, was loaded up and in the paintshop. As to how much could be
Blu Tack and other methods to find the point of interference. achieved pre lockdown is another question, but at least it is in the
The side sections of rubber seal were unstuck and pinned in right place now, and the end is in sight.
alternative positions and then refitted. When then tested again In the meantime, I am focussing on tidying the workshop and
JAMES (after a lot of making good on paintwork) similar problems completing my ‘to do’ list. I am going to repaint the rear louvres
ensued. In short, the thickness of the mounting edge and myself – they have blistered in a couple of places, and some paint
HORSLEY adhesive is too much for my canopy and side sections and had was damaged fitting the Aerocatches. As the louvre panel has
Projects: to be removed to help the roof pull down sufficiently. I am still always been satin black, it is easy for me to repaint separately to
Nova not 100 percent happy with the fit, but I hope in use the new the car. The car is staying a shade of grey, but I am refining the
This month: seal sections remaining will compress more and allow a tighter scheme to have all other items black, and eliminating chrome or
Some more canopy shutline. I have reached the point now that I feel I cannot spend silver parts. A new black fuel filler has been sourced. I am also
adjustments before the more time on this. repainting the radiator cover, and rear air intake grilles are being
Nova went for paint. With that project parked, I focussed on some final bodywork changed from chrome to black. As these are plastic they have
blemishes I spotted – on the canopy edge and some paint been sanded and prepped with etch primer ahead of final paint.
cracking below the louvre hinges. As the coronavirus crisis started Hopefully I can use the garage space to get all of my bits prepped
to escalate I happened to spot a post on Facebook from my local ahead of the jigsaw returning.

70 May 2020 www.completekitcar.co.uk

 IN OUR GARAGES

Line of canopy seal had to be changed to improve The stress cracks that have appeared around louvre Scraping off expensive sealant and removing seal
shutline and then areas repaired and repainted. hinges have now been repaired. was soul destroying.

Some final repairs to canopy. Nova setting off for paint.

Etch primer used on plastic parts. High build primer applied to louvres ahead of paint. Louvres repaired ahead of paint.

Suddenly plenty of space in the garage! While the Nova is away other parts can be painted. Nova battery remains in workshop on trickle charge.

www.completekitcar.co.uk May 2020 71

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 A DV ERTOR I A L | AIM TECHN O LO G IES POWER DISTR IBUTI O N MO DULES

A POWER DISTRIBUTION
MODULE – AND MUCH MORE!
The old method of distributing and controlling vehicle electronics – fuses and
relays – is cumbersome, heavy and it can be difficult to diagnose problems.
This can now be a thing of the past when you an Advanced PDM Modules
(Power Distribution Modules) from Aim Technologies.

IVA – Road legal

I
nstalling the electrics in a kit car can be a The PDMs receive, use and record data from: An internal datalogger is included, capable of
time-consuming job and, even when it’s  ECU – more than 1000 protocols available recording all the analogue inputs, digital inputs,
complete, it can be difficult to troubleshoot  Digital/analogue inputs ECU channels, GPS values, currents, status of all the
any problems that may arise. The idea of  Internal 9-axis EMU power outputs, up to 1000htz.
simplifying a car’s electrics is, therefore, very  GPS – position and lap time A choice of 6in or 10in dashboard displays are
appealing – whether you’re installing the wiring from  Expansions available. What’s more, there are additional safety
new or looking to replace what you already have.  Switch signals into the PDM or remote features available with the PDM. They allow you to
That’s where the range of Advanced PDM expansion to preconfigure aspects of the vehicle power supply
Modules from Aim Technologies come in. Not only  Push buttons, from RIO02 Module or to ‘switch off ’ in given conditions, for example, in an
do they save time during installation, but they also from any commercial CAN keypad, accident or impact. This is a positive safety feature,
save weight and improve reliability. thanks to the simple plug and play particularly in motorsport or on track, as it protects
Both Aim Advanced PDM08 and PDM32 configurability of the CAN protocols the driver from potential spilt fuel ignition. PDM32
models are engineered using lightweight anodised  All the currents and status of all the features two analogue camera inputs that allow you
billet aluminium cases, specifically designed to stand power outputs to swap your display into a mirror camera either at
the rigours of the motorsport environment and  Other user defined math channels the press of a button, or most commonly, through
therefore well up to road and trackday use. Sleek configurable event logic-reverse gear.
and stylish, they are easy to fit into most vehicles, The PDM08 is priced from £1560 and the
allowing you to simplify your wiring harness and PDM32 is priced from £1980. In one go, you can
electronics installation, while providing much simplify your car’s wiring, save weight and add
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whole vehicle power distribution network.

www.completekitcar.co.uk May 2020 73

TECH TALK

ENGINE BASICS
In the first of a new series, John Dickens takes a look at what makes your engine tick
– starting with the different types of internal combustion engines.
Words: John Dickens Diagrams: John Dickens and Sarah Scrimshaw

The four-stroke engine, like

this Ford Duratec, is the
most dominant engine type.

T
he first self propelled road vehicles it is possible to buy model Stirling engines or kits 1 Intake. With the piston (D) at the top of the
were, predictably, steam powered. which will operate using the heat of a cup of tea, but cylinder the inlet valve (A) opens. As the piston
Steam engines are classified as developing the engine into a useable power source moves down a mixture of petrol and air is drawn
external combustion engines as the proved difficult and practical examples are rare. into the cylinder through the inlet manifold.
fuel is burned outside the working 2 Compression. When the piston reaches the
cylinder of the engine. The French inventor Nicolas FOUR-STROKE bottom of the cylinder the inlet valve closes. The
Cugnot developed a steam powered artillery carriage The four-stroke engine, patented by Nicholas Otto, rotating crankshaft (F) and the connecting rod
in 1769 and Richard Trevithick demonstrated his began its life as a gas powered stationary engine. (E) cause the piston to rise again compressing the
steam powered road locomotive in 1801. By the turn The fixed plumbing needed to supply the gaseous petrol/air mixture.
of the 19th century, almost half the cars on the road fuel obviously restricted the usefulness of this fuel 3 Power. As the piston reaches the top of
in America were steam powered but the weight of as a power source for transport. American George the cylinder the spark plug (C) ignites the
the steam engine would always limit its practicality Brayton invented the first commercial liquid-fuelled compressed gases and the rapid expansion of
for road use. There was a brief experimentation internal combustion engine and Karl Benz, generally the burning gas forces the piston back down
with electric power around this time too. Ferdinand regarded as the inventor of the modern automobile, the cylinder producing the power to turn the
Porsche’s first car, in 1898, was driven by electric produced the first motor vehicle adapted to run on crankshaft, the drive train and finally the wheels.
motors but, at the time, the high weight and petrol in 1885. The four-stroke or Otto Cycle engine 4 Exhaust. When the piston reaches the bottom of
low capacity of the lead/acid batteries made this has been the predominant power source for motor the cylinder and begins to rise again the exhaust
impractical too. In 1816 Robert Stirling, a Scottish vehicles ever since. valve (B) opens and the waste gases exit through
minister, patented an alternative form of external The engine is designated as a four-stroke as the exhaust system. As the piston reaches the top
combustion engine which bears his name. Like there are 4 individual piston movements needed to of the cylinder the exhaust valve closes and the
many inventions the basic principle was sound, and complete the whole combustion cycle. whole cycle begins again.

74 May 2020 www.completekitcar.co.uk

 ENGINE TYPES

Inlet A C B

1
Inlet
D
Exhaust A
B Exhaust 2
D
F

E C
E Inlet A

G B

Exhaust 3
F

The basic four-stroke engine. For clarity, The basic two-stroke engine. Lack of valves and A single-rotor Wankel engine. It is possible to use
details of the valve gear are not shown. associated valve gear make this cheap to produce. two, three or even four rotors coupled end to end.

Power is only produced every second revolution Since the engine fires every revolution (twice (A). When the apex seal passes the port this
of the crank so a single cylinder four-stroke engine as often as the four-stroke) this engine has the chamber will be sealed.
needs a substantial flywheel to store enough kinetic potential to produce twice as much power as a four- 2 Compression. The volume in chamber two is
energy to drive the engine through the exhaust, stroke engine for a given capacity. In practice this decreasing, compressing the mixture within.
intake and compression cycles to the next power was never realised until Walter Kaaden, a German 3 Power. When the gas reaches maximum
stroke. Multi-cylinder engines have more frequent scientist who had worked on the V rockets under compression the spark plugs fire and ignite the
power pulses and produce a smoother running Werner Von Braun, became head of the racing mixture forcing the rotor round. Twin spark
engine with less reliance on flywheel inertia. department at the DKW (later to become MZ) plugs are usually used as the long thin shape of
This basic engine design has been powering motor motorcycle factory. His breakthrough was to harness the combustion chamber does not encourage
vehicles for the last 125 years and has been the intake and exhaust gas resonances within the engine efficient combustion.
subject of constant intensive development resulting to enable it to breathe efficiently. In 1961, his 125cc 4 Exhaust. Chamber three contains the hot
in continuous improvements in power output, fuel engine was producing 25 bhp, a specific output of expanding gases. When the apex seal opens the
consumption, exhaust emissions and reliability. It is 200bhp per litre. The Achilles’ heel of the two-stroke exhaust port (B) these gases escape into the
not the only design which has been used however. engine is its lubrication system. To lubricate the exhaust system.
There have been other engine designs which have crankshaft and connecting rod bearings oil is either Each face of the rotor has one power stroke per
found limited use. mixed with the petrol or injected directly into the revolution. There are three rotor faces so there are
bearings. Either way the oil is then mixed with the three firing strokes per revolution. The crankshaft
TWO-STROKE inlet charge and burnt in the combustion chamber or eccentric shaft (E) is driven by the rotor through
The two-stroke engine has no valves so it is simple producing a very dirty exhaust compared to a lobes (F) and revolves three times for every
and cheap to produce. It has been extensively used four-stroke. The inability of the two-stroke engine revolution of the rotor. The engine therefore fires
to power motorcycles but has also been used in the to meet modern emission standards has led to its once for every revolution of the crankshaft, just like a
Saab 93 and 96, Wartburg Knight, Trabant, Bond virtual demise as a vehicle power source, although single-cylinder two-stroke engine. It also shares one
Minicar three-wheeler and a number of other bubble research is still continuing with the use of direct fuel of the major disadvantages of a two-stroke in that a
and microcars. injection offering the possibility of a cleaner exhaust small amount of oil is injected into the combustion
This engine is designated as a two-stroke as only for these engines. chambers to lubricate the rotor seals. This has made
two movements of the piston are needed to complete it difficult to clean up the exhaust emissions.
the full combustion cycle. It achieves this by utilising WANKEL ROTARY NSU used the engine in the Ro80 then licensed
the space below the piston and by using the piston The piston engine, whether two-stroke or four- the engine design to many other companies.
itself to open and close ports in the cylinder barrel. stroke, is a reciprocating engine. The piston moves Unfortunately, the fuel crisis caused most of these
1 Power/exhaust. Every time the piston back and forth with a linear motion and this has to companies to abandon their research and only
reaches the top of the cylinder the spark plug be converted to a rotary motion by the crankshaft. Mazda, which had already invested huge amounts
ignites the mixture forcing the piston down The Wankel rotary engine, as its name suggests, has of money in this engine, continued development.
the bore. As the top of the piston passes the no reciprocating parts. This results in a very smooth It went on to produce a range of very successful
exhaust port (B) the waste gases exit through running engine. Wankel powered sports cars including turbocharged
the exhaust system. This engine was developed by the German versions and also won the 1991 Le Mans 24-Hour
2 Intake/compression. As it continues downwards engineer Felix Wankel while working at the NSU with the highly developed 26B four-rotor unit. I was
the piston compresses the petrol/air mixture motorcycle company. His first prototype was fortunate enough to be there and I will never forget
in the crankcase below it. When the top of the running in 1957. the unbelievable sound of that engine.
piston opens the transfer port (D) fresh mixture Like a two-stroke the engine has no valves. Gas Some motorcycle companies, such as Norton,
is forced into the cylinder. As the piston rises flow is controlled by opening and closing ports. Sachs/DKW/Hercules, and Suzuki also produced
again it closes the transfer and exhaust ports Instead of a piston there is a three-lobed rotor (D) a small number of rotary powered bikes but, in
and compresses the fresh mixture. As the rising rotating in an epitrochoid chamber. Sprung seals at the face of conservatism and a reluctance to invest
piston skirt passes the inlet port (A) fresh the apex and sides of each lobe separate and seal the money the Wankel engine, like the 2 stroke has all
mixture is drawn in to the crankcase below the chambers. but disappeared as an automotive power source.
piston. When the piston reaches the top of the 1 Intake. The volume in chamber one is increasing Once again, though, research is still continuing
cylinder the spark plug ignites the mixture and as the rotor turns, drawing in the petrol/air using the latest developments in electronic fuel and
the whole cycle begins again. mixture from the inlet system through the port ignition control.

www.completekitcar.co.uk May 2020 75

RUNNING REPORTS

Want to know what it’s really like to build a kit car? Our team of Running Reporters
tell all about building their cars at home in their garages. Follow their progress every
other issue... and maybe even be inspired to get in the garage yourself this weekend...

BEETLE BEARINGS
With new bearings fitted to the Beetle platform,
Clare is getting close to completing her Chesil’s rolling chassis.

Gentle persuasion was the order of the day... ...as Clare had plenty of bearings to replace. Some were harder than others to remove.

New driveshafts and CV joints... ...were attached to the Beetle donor’s transaxle. New brake shoes and springs for the rear drums.

W
ork has continued on the brakes; we thread and finding a Nyloc nut to fit it is proving tricky. We’ll
wanted to replace the wheel bearings find one eventually or use a different bolt.
while we had access to the hubs. We’d The front brakes are discs rather than drums. Once again,
already bought new bearings for both there are two wheel bearings on both sides at the front, which
the front and rear axles, and we removed actually sit in the discs themselves, and the whole arrangement
the old bearings fairly easily with a hammer and socket. The slides on to the stub axle on the adjustable suspension. These
IRS axles have two bearings in each hub, outer and inner. The were a much tighter fit than the rear bearings, so we were
outer one slotted in fairly easily with a bit of grease. There is a worried about damaging both bearings and discs trying to force
CLARE spacer inside the hub that sits in a well of grease which makes them in. However, we have a friendly garage around the corner
the job pretty messy, but the grease was quite clean and showed who took this job on, and fitted them for next-day pick-up.
SPINDLOE no signs of water ingress. We left the existing grease inside the The discs now slide on neatly and the calipers fit well. We need
Project: hub and topped it up with some new stuff. The outer bearing to get the hub nuts and washers to secure them, then bolt the
Chesil Speedster needed some gentle persuasion with a little hammer action and calipers to the axles.
Age: 37 a piece of wood to seat it fully, but it’s in solidly now. The stub We had ordered new driveshafts with CV joints already
Occupation: axles from the donor car were a little grubby on the exterior but fitted to link the gearbox to the rear axles. These are of course
Business analyst in good condition so we’ve cleaned these up and pushed them aftermarket parts, but very good quality. They come with six
Project Start Date: through the bearings. They are a solid fit which is reassuring. bolts for each CV joint to join them to the gearbox drive plates
July 2017 We have new parts for the rear brake drums including shoes, and stub axles in the hubs, and two tubes of grease to fill the
springs and clips. We assembled these and they are now ready end of the CV joints. Attaching these look simple but there
to put on. There is a single bolt on each arrangement that holds does seem to be a technique to it, especially if you don’t want
the shoes to the handbrake actuator lever, a new one of which to get covered in more grease. Now attached on both sides, we
did not come with the refurbishment kit. The bolt is OK but the can turn the spindle in the gearbox and see the axles in the hubs
Nyloc nut needs replacing. The bolt appears to be an imperial turning, a small thing but one step closer to a rolling chassis.

76 May 2020 www.completekitcar.co.uk

 REAL-WORLD BUILDS

THE FINISH LINE

After four years of hard work, Andy is ready
to reveal his modified Merlin to the world.

Andy made up a set of ‘door cards’ himself. Interior is looking good. The new paint scheme is a work of art...

...but that’s not going to stop Andy from... ...using the Merlin as it was intended.

T
his is my 24th Running Report, which means I
have been rambling to you about my build for the
“A CAR IS MEANT TO BE
past four years! How time flies when you’re having USED AND ENJOYED”
fun, but sadly for me this will be my last report as
I have now passed the chequered flag, crossed the
finishing line and I’m coasting along on my lap of honour. paint job. All my other builds over the years have had a gelcoat
Work at the ‘dust factory’ has been very quiet over the past few finish, but this paint job is amazing and I’m almost too scared to
months, which has enabled me to crack on with the fiddly finishing take it down the brambly country lanes around my workshop.
ANDY jobs like tidying the wiring ad trim inside. Trimming an interior For me much of the fun with this build was creating a design
can be a very costly business but, as my standard of trim is very on paper then making it a reality, and that’s exactly what I’ve
WESTGATE basic, it didn’t take long to do the couple of door cards needed – done. So when I mentioned to the partner that I’d thought about
Project: for where the doors would be, if it had doors! selling the car, she made it very clear to me that it’s going to
Merlin 2+2 A trick I learned while working on a boatyard a couple of be a good few years before I’m allowed to build another – and
Age: 64 years ago made templating the panels a breeze. First you cut something about needing to decorate the house. So I should
Occupation: some lengths of plywood about 50mm wide, offer them to the enjoy this one in the meantime, and I think she is right. Yes, it
Fibreglass Repair area where you want your panel, hot glue them in place and take will get stonechips and the odd scratch, but so what! It’s a car and
and Design the ply formers out and lay them onto the board you’re going to a car is meant to be used and enjoyed – and I’ve bought his and
Project Start Date: use. Once the panels are cut around, stretch the vinyl across and hers matching helmets so it will be. So there you have it, I have
August 2015 glue it in place. my orders to use it and when we eventually get to Stoneleigh we
Since I had the front section back from the paintshop and fitted, shall see you there. Thank you, and good night... you’ve been a
it occurred to me that I have to take great care around its £4000 wonderful audience!

RUNNING REPORTS IS SUPPORTED BY

Car Builder Solutions ETB Instruments Dampertech Woolies Midland Wheels SiliconHoses.com
T: 01580 891309 T: 01702 601055 T: 01709 703992 T: 01778 347347 T: 01926 817444 T: 0845 8385364
E: [email protected] E: [email protected] E: [email protected] E: [email protected] E: [email protected] E: [email protected]
W: www.cbsonline.co.uk W: www.etbinstruments.com W: www.dampertech.co.uk W: www.woolies-trim.co.uk W: www.midlandwheels.com W: www.siliconhoses.com

www.completekitcar.co.uk May 2020 77

RUNNING REPORTS

TRACKING THE TIGER

John has been working on the tracking of his Tiger
and found the time to upgrade his garage space.

Home-made wheel centring device. Steel bar was used as a parallel marker... ...and a depth gauge was used to set up the wheels.

John’s camber gauge. Time consuming, but rewarding work. John’s old kitchen units add needed storage.

O
n a sunny day, I opened the garage doors and With both sides somewhere near correct, I was ready to play
used a couple of wooden blocks to jack the car with the alignment tool. However at this time a couple of – now
up one side at a time before lowering it onto infamous – storms rolled in and my timber garage just did not
a ramp. It wasn’t without incident, with the seem to be a good place to be as it creaked and groaned in concert
handbrake off – to stop it seizing – the car did with the wind and driving rain.
roll backwards slightly before the chocks held. With both sides In order to maintain some form of matrimonial harmony,
raised up slightly, I slipped a couple of turntables I made up we were about to refurbish the kitchen – now on hold due to
under the front wheels, and I was pleasantly surprised by how coronavirus. To ease the inconvenience, previous experience
JOHN easily the steering turned. suggests that some form of stand-in kitchen is essential, especially
I put a piece of wood across the centre of the car with a couple as it looks as though the kitchen fitter will be me and not some
CLEMENTS of angled packing pieces to protect the aluminium, and cable ties speedy band of professionals. About 18 months ago, I partly
Project: were used to keep the steering wheel central. I then used my 3m refurbished the utility room and now there was a further rethink to
Tiger Cat long steel tube to help get my offside wheels parallel. I used my add a necessary sink and more storage.
Age: 65 digital depth gauge to check the distances between the front and Bad news was that in the interval a certain well known DIY
Occupation: rear of the rear wheel rim with the tube. It was all slow, boring chain had not only discontinued the cabinet doors and handles,
Heating engineer and repetitive but simple. but that the new wall cabinets are deeper. Good news, the old units
Project Start Date: Beginner’s luck, I thought, as it was almost exactly right, then I now look great in the garage!
July 2001 realised that I had knocked the axle stand during the measurements Afterwards, I finally got to check the alignment with the
and moved the tube. So I moved the stands to aid stability and Trackace. It relies solely upon friction to hold the mirror assembly
started again. in the right position against the front wheel. Being new the friction
I decided that instead of setting the front wheels completely was a bit high and trying to tilt the mirror would turn the support
parallel to the rear, I’d be better to put in about 2mm toe-in per bars, taking you back to square one. After some impolite words and
side as specified by Tiger. When I bought the alignment tool a bit more practice I finally got the hang of it. Small movements of
it came as a package with a camber gauge. This is basically an either laser or mirror are amplified. Initially these are difficult and
adjustable spirit level with a large magnet which attaches to the fiddly, but it makes for great accuracy, but if you have a short fuse,
brake disc. Without the front mudguards in place, it was easy to it might be best avoided.
put the tool onto the inside of the disc. To my great surprise and It is a test tool showing the total angle, so once you get the first
relief both registered the same at zero camber, which is what result adjust both track rod ends the same small amount and test
Tiger specified. again. Repeat until happy with the result. Again slow, but simple.

78 May 2020 www.completekitcar.co.uk

 REAL-WORLD BUILDS

SHORT CIRCUIT
The Avante’s electrics may have taken time,
but they were worth the wait.

Dynamat insulation is all over the car. The electrics are all mounted to the bodyshell. A bypass plug on the chassis can run the ignition.

Triumph TR7 light motors proved a pain to set up. Simon is getting close to... ...marrying the body to the chassis.

T
he past month has been taken up with the wiring!
Darren, my electrician, has created the whole loom
“THE TIME TAKEN TO
from scratch, using the Car Builder Solutions’ fuse THINK EACH SECTION
board as the basis. Following on from the ignition
circuit last month, he has worked switch by switch THROUGH HAS PAID
to get everything working. The steering wheel has wireless switches
too, which has challenged his thinking! But now they are working DIVIDENDS. IT ALL
LOOKS PROFESSIONAL”
and the indicators, lights, wiper and horn can all be controlled via
SIMON switches mounted in the centre of the steering wheel. The wiring
has been run and covered in sheathing with it all mounted in the
SKELDING body, so it can be removed from the chassis easily in the future. A
Project: new-style 15-pin trailer plug was mounted underneath the dash, so signal from the light switch, which needed a couple of extra relays
Avante Mk1 when it’s unplugged the rolling chassis can run the ignition using to get it under control.
Age: 53 a bypass plug. Darren is very meticulous in his work, and the time While this was being done, I fitted Dynamat to the roof and
Occupation: taken to think each section through has paid dividends. It all looks installed the rear seatbelt rings into the body crossbrace. My
Suspension like a factory job! exhaust parts came back from the tig welder fully welded up and
manufacturer The biggest struggle this month has to be the pop-up headlights. I popped these into place to ensure they still fit, which they did.
Project Start Date: The flaps are lifted using Triumph TR7 motors, which work on Bonus! I’m now ready to join the body to the floorpan, but my
May 2018 a continuous rotary motion that required some extra circuits to progress has been halted by the current world health situation.
get them to stop in the right place. They are controlled by the Keep safe, and we will get the Avante finished as soon as we can.

RUNNING REPORTS IS SUPPORTED BY

Car Builder Solutions ETB Instruments Dampertech Woolies Midland Wheels SiliconHoses.com
T: 01580 891309 T: 01702 601055 T: 01709 703992 T: 01778 347347 T: 01926 817444 T: 0845 8385364
E: [email protected] E: [email protected] E: [email protected] E: [email protected] E: [email protected] E: [email protected]
W: www.cbsonline.co.uk W: www.etbinstruments.com W: www.dampertech.co.uk W: www.woolies-trim.co.uk W: www.midlandwheels.com W: www.siliconhoses.com

www.completekitcar.co.uk May 2020 79

CARS FOR SALE
Book your ad now! £25 for two months (private advertisers)
W: www.completekitcar.co.uk T: 01476 978843 E: [email protected]
1985 FIERO FINALE I purchased the 1985 Fiero Finale in 2002, it now SOLD
has 59,000 miles on the clock and has an MoT
until September 2020.The car is now right-hand-
drive, with a manual 5-speed gearbox, updated
bodywork, interior, suspension. New paintwork,
new tyres etc. For all further details see April issue
of Complete Kit Car or www.piperracingcars.co.uk.
MEV EXOCET 2014.Correctly registered.1.8 Mazda As the original designer of the Finale body style, I AVANTE MK 1 1985 one owner. Porsche 914 2.0 engine.
Eunos engine.Very good condition, hardly used, can confirm that this is the only Fiero Grand Finale Overhaul 2007, new discs, shocks, tyres, exhaust,
£5000 or sensible offers.T: 01305 753538. M: 07787 ever produced! £12,950 ovno. T: – Tony Claydon – clutch, lights, seats and carpets.
560133. E: [email protected] (Dorchester). 01621 851589 (Essex).

GBS ZERO 2017, 67 plate, built by GBS, 2.0 Zetec, 3500 THREE-WHEELER Kawasaki powered. Single seat, FT BONITO 1975 Beetle floorpan. Mid-mounted Golf ARISTOCAT SPORTS 140 XJ6 based, IVA March 2018,
miles, weather gear, carbonfibre parts, quick release KLR 650, Spitfire uprights disc brakes, in board front 1.8 16v engine, 5-speed Audi transaxle. Road legal, 4.2 engine, Weber twin carbs, Getrag 5 speed gearbox,
wheel, LED rear lights, £13,500. T: Barrie – 07976 suspension, adjustable dampers, £4500. T: Dick – competition log book, £9750. T: 07792 154077. wire wheel, Moto-Lita steering wheel, CD/radio/iPod,
928951. E: [email protected] (Chesterfield). 01249 750433. E: [email protected] (Wiltshire). E: [email protected] (Dorset). £15,750 l: 07540 993690 (Croydon).

POWDER COATING MACHINE Never used, complete

SOLDMagic.
with a bag of black powder. Make is Electrostatic
In excellent order. Cost new is now £149. Will accept £95
ono. (Kent).

GUNSON CARB BALANCER Never used, looking for SYLVA FURY Rebuild and respray, new instruments and LAMBORGHINI COUNTACH BODY Fibreglass FERRARI REPLICA MR2 based, with new coilovers,
£25. T: 07828 174883 (Kent). interior during rebuild, then unused since 2011. Paint body, finished in white. Has previously been fitted Woodsport Lexus 3.0-litre V6 conversion, refurbished
and brakes need attention, can be heard running. OIRO to a car. No doors. Offers invited. Tel: 01704 894006 gearbox, new clutch, custom exhaust , new P-Zeros,
£4500 for car and trailer. Tel: 07730 431363 (Kent). (Ormskirk). 2-pack paint, £17,495. Tel 01765 600558 (Yorkshire).

ADVERTISE
JC MIDGE Stalled project. 1968 Triumph Herald SYLVA STRIKER 1997, Kawasaki ZX9R installed. MoT ONLINE AND
IN PRINT
based. Wind screen and other parts included. Sleaford June 2020. Toyo R888 tyres. 6-speed, reverse box.
Lincs £350 ono. 07473 975965 Speedo doesn’t work, wobble from propshaft at 30mph
to 40mph. £8000 ono. Tel: 07860 937 283 (Fife).

JUST £25 FOR TWO MONTHS

Place your advert today
When you place a classified advert with Complete Kit Car magazine, it
appears on our website for two months and in two editions of the magazine.
To place your ad…

1) Got to www.completekitcar.co.uk to book and pay for your advert, filling

KLX5 Cars and project for sale. MX-5 Mk1 based demo, TRIBUTE 250 GTO MX-5 based, Gaz dampers, larger
out the wording in the ‘comments’ box when you place the order (or call us on
year MoT, 97,000 miles. leather seats. Momo wheel, front discs. Pro paint, no problems, outstanding car, 01476 978843 with your wording and payment details)
adjustable coilovers. Moulds included, and part built MX-5 needs viewing. SORN. Eye problems, must sell, £10,950. 2) Email a photo to [email protected]
Mk2 build, £8000. T: 07746 449445 (Macclesfield). T: 01276 23078 E: [email protected] (Surrey).
80 May 2020 www.completekitcar.co.uk
 www.aero-master.com
facebook.com/aeromastersportscars
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The Only Full Size LMP Kitcar On The Market
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For full details please visit our website at:
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Owner: Valentino Fry, Switzerland

BAFFLED BY YOUR CAR’S WIRING?

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In Automotive Electrics, technical writer John Dickens
takes a subject that many car builders and restorers
find mystifying and covers it in a simple, easy to
follow way that will help you solve your wiring woes.

It covers…
 Basic theory
 Component choice
 Wiring diagrams
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www.completekitcar.co.uk May 2020 81
FINISH
EVERYTHING THAT
DIDN’T FIT INTO THE
REST OF THE MAG

IN BRIEF

NOT THE MEV WE KNOW...

I
t’s not unheard of for car
companies to use pre-existing
WHERE DO YOU READ model names from other
YOURS? PART 26 manufacturers, for instance
It’s a lockdown special of Where Dutton, Ford and GMC have
Do You Read Yours this month, all used the Sierra nameplate in the
which means we’ve scoured our past, as did Maserati and Volkswagen
archives for pre-coronavirus travel with its respective Boras. But it’s far
pics – we‘re not resorting to in the less common for manufacturers to
garage/kitchen pics just yet – to share brand names, even in acronym
act as inspiration for when social form, which is why we were surprised
distancing ends. Here we can see to find that there’s a new company
Complete Kit Car subscriber John using the familiar MEV name.
Ball enjoying his October 2018 issue One of course being Gloucestershire
during simpler times, beneath the based Mills Extreme Vehicles, and
Statue of Liberty in New York. the other being the lesser known –
If you have any pictures of you in our circles at least – Manchester
with the magazine in an interesting Electric Vehicles. For the uninitiated,
place, please send them to Manchester Electric Vehicles produces
[email protected] the Bee, a recyclable electric ‘people’s
car’ with a composite body – see it’s
relevant – that hopes to offer a cheap
and cheerful entry point for those
looking to go electric. So if you’re
in the market for a practical Exocet
stablemate that almost stays on brand,
then you should look no further than
the MEV Bee!
W: www.beeanywhere.com
BAD ROADS
SAVE LIVES SOCIAL DISTANCING, EMBLEM STYLE
When Indian MP Tezpur Assam was
recently asked by constituents of the With social distancing being the topic
Karnataka state whether he would of the month, we’ve seen several
improve the quality of local roads, clever marketing campaigns stress
he claimed he wouldn’t due to the to us its importance in reducing
safety advantages of keeping them transmission of the dangerous
in a “dilapidated condition.” coronavirus disease.
It’s an interesting angle for a But one idea that may have
politician to take, but he explains passed you by was the trend of
that the heavily potholed roads of manufacturers in April changing their
his jurisdiction do promote slower emblems temporarily to promote the
speeds from motorists and therefore new measures.
fewer fatalities. And he worries that Here’s four of our favourite
by repairing the roads, he would see alterations from Audi, Hyundai,
both an increase in collisions and Mercedes-Benz and Volkswagen. Until
the speeds at which they happen. next time, stay safe and see you soon.
Food for thought.

82 May 2020 www.completekitcar.co.uk

2020 Avon + Brochure - Hi.Spec_Layout 1 15/01/2020 09:53 Page 1

NEW for 2020 - 68 page colour brochure now available - FREE Just phone or email

Build a TOP CLASS - Hi Spec Avon for far

less than you would imagine!
Starter Kit - just £1,845 inc.vat
Comprising:- Powder coated chassis, alloy panel set, rivet
set, brake pipe set (ended), brake master cylinder, pedal
set, fuel lines x 2, wiring loom. Add body and parts as you
need them on our daily courier service.

The brochure contains full details of our entire

model line up of Sports and Race Cars plus our
extensive engineering services and facilities.
It also contains details of our outstanding
Tiger Avon restoration facilities which are applicable for
(road spec.) both Classic Cars and Kit Cars.

...and remember, the

For FULL details of any of our 6 model Tiger you drive on the road,
is the Tiger you
line up, contact: Paul, Jim or Laura on can use on
01945 466200 or 01945 461423 the Track !

or alternatively, phone or email for our Powered by

new FREE 68 page full colour brochure.

[email protected]
Tiger Sportscars www.tigerracing.com Tiger Avon
(full race)

Unit 10, Anglia Way, Wisbech, Cambridgeshire PE13 2TY Tel: 01945 466200 /461423 [email protected]

Why not pick up

the dog and bone
and give us a call?

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Call our Specialist Vehicles Team

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www.aplanspecialist.co.uk
AP2003/07

A-Plan Insurance is a trading style of A-Plan Holdings who are authorised and Regulated by the Financial Conduct Authority. Registered office: 2 Des Roches Square, Witney, OX28 4LE. Registration number 750484.

AP2003-07_KitCar_131mmx200mm_HalfPage - FINAL.indd 1
www.completekitcar.co.uk 06/04/2020
May10:14:24
2020 83
 01892 750341 Oakdene,
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All parts available for original 289 & 427 cars

Supplier of coffin spoke and

HF 3000 Giro d’Italia Workshop FIA Mk2 & Mk3 427 wheels
www.completekitcar.co.uk May 2020 84

Hawk Ad FP September 2018.indd 1 26/03/2019 4:20 pm