Simon's Clubman Site

The 2nd Coming

Having once said that my second build would not be a repeat of the first, it's funny how things change !!

For my second ICV (Individually Constructed Vehicle) I was always thinking of something mid-engined, a la a FWD power plant in the rear. Along the lines of the Sylva MoJo2 http://www.stingraymotorsport.com/sylva.htm. At one stage I did quite a bit of research and planning but got stalled on the Engineering requirements (read costs) in Australia and lack of general information for a novice.

You know what it's like - as time goes by you never have enough and want more. The same applies to the Clubbie, particularly in the power department. Whist the MX5 (Miata to the American folk) is a great engine with a superb gearbox, it is still only a 1.6L 86kW motor. Any new car had to up the ante to make it worth the effort and avoid disappointment.

Fast forward a couple of years. In discussion with others who had previously built a clubbie (ICV, Locost or Seven), plans were laid for #2.

Having sat in just about every Clubbie around, together with a mate, we determined what we think is the ideal chassis dimensions. Also having access the an Elfin, Birkin, Westfield, Kestrel and a number of Locosts, we also have plans to mod the chassis design and simplify construction.

The choice of motor was a harder decision, with limited options in Australia due to tough emission compliance rules. The final selection came down to:

  • Toyota 4AGE 20v Blacktop 1.6 (123kW)
  • Toyota 3SGE Gen3 2.0 (132kW)
  • Toyota 2ZZGE 1.8 (140kW)
  • Ford/Mazda Duratec 2.0 (122kW)
  • Honda S2000 F20C 2.0 (176kW)

My line of thinking was if I'm building a new car, I want to use a current bread engine, with all aluminium design. This effectively eliminated the 4AGE & 3SGE. Whilst the Honda is considered the ultimate, availability and cost would usually put it out of most peoples reach. Realistically I was tossing up between the 2ZZGE and Duratec 2.0. The current model MX5 comes with the 2.0 Duratec and 6 sp R/W gearbox, so there would be no gearbox / adaptor plate / clutch matching issues or expense. It also comes with VVT which the Focus version doesn't.

All this went out the window when a local Honda S2000 write off was advertised and purchased for a price I couldn't refuse. It all happened quickly, and the rest, as they say, is history. The Honda F20C 2L motor develops 250hp / 176kW / 208nM in standard form. Put this into a 650kg Clubman, and we should have a rocket ship. The only down side is the height of the F20C motor, which will be addressed in the chassis design.

So the key components will be Honda F20C 2 litre, moly 5.5kg flywheel, H/D clutch & 6sp gearbox, Nissan GTiR IRS LSD diff and rear uprights, Gemini (Isuzu) front uprights.

The chassis will be losely modeled on the Gibbs chassis, +50mm in width.

May the good times in the shed roll on again.

S2000 lump on the table to design one peice centre tubes around

 

Bottom tubes sketched out on build table

 

Complete bottom tubes

Basic chassis complete

 

Front suspension setup

 

Steering column (Honda Civic) with S2000 steering lock grafted on

 

String computer to test suspension setup

 

Cutting wishbones to fit jig

 

Completed front wishbones

 

Jig it fit front suspension brackets

 

Shortened Escort quick rack next to a standard rack

 

Painted chassis

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Rear Suspension

 

Front Suspension

 

 

 

Full S2000 loom being stipped and shortened

 

 

Building the headers

 

Complete legal exhaust

 

 

 

Forward side panel is on with side cooling fin - panel is removable for future access

 

On goes the side panel

 

Rollbar shaping

 

Rear brake setup using Nissan Pulsar GTiR doner

 

Shaping air scoop mould

 

It's getting close

 

Rear end setup

 

 

 

Folding bonnet

 

Competed Car