Mev Rocket (The Build) Page 3


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Right here we go!
Provided in the kit is a piece of 2mm aluminum sheet, the chassis is turned upside down and the profile of the chassis is marked on to the aluminium. Then as the tube is about 50mm diameter, I marked an internal parallel line of 15mm, giving me a cutting line just over the center line of the tube once in place.

Here is the sheet cut out, de burred and ready to be riveted. As I mentioned, the edge overhangs the tube center line by about 10mm.
I started on one side and drilled holes every 100mm, I used 4.8mm large head rivets for this job, the holes were drilled 10mm from the edge. The rivets were temporarily put in place to make sure the sheet did not move.

Once all the holes were drilled, I removed the rivets and de burred all the rivet holes, on both the chassis and the aluminium sheet.
Putting 100 plus rivets in gives you cramp, it would have been nice to have a pneumatic rivet gun, maybe a present to my self this christmas.

All riveted. Jobs a goodun.
A quick flip back the right way up and now time to get on with the suspension.

These used hubs are supplied by MEV as part of the kit. For a smallish fee I popped them down to my local engineers and they sandblasted them giving a nice key'd finish, I then primed and painted them with satin black enamel paint and cooked them in the oven for about an hour at 120 deg C. I think the finish is pretty good considering.

The stub axles are provided in the kit and have also been sandblasted and then a coat of enamel paint applied, any one making a kit with used parts, I would suggest its well worth the extra effort and cost.

The bush's for the wishbones are supplied but not fitted and this was actually a fairly time consuming task. For each corner there were 2 bush's to press in, then a coat of teflon grease around the inner holes and then the crush tube finally being pressed in place through the two. Satisfying once completed though. Here you can see the semi completed hub assembly.

As part of the SVA test, there cannot be and radius less than 2.5mm protruding, to help matters some plastic wheel nut covers are placed over the bolts and nuts to help comply with the regs.

The original wheel studs have been removed as they need to be upgraded to longer ones. Wilwood 4 pot calipers added as an upgrade, they look better and are a lot lighter than the original focus steel calipers.

Rear wishbone assembly assembled and wheels fitted to complete a rolling chassis. Fender stays are yet to be fitted, I will leave this task to last.

Drive shaft fitted to temporarily help keep the rear bearing together.
Top view of the rear wishbone assembly.
The donor focus steering wheel assembly attached to the mounting brackets. M6 holes were already in place, but I opened these out to M8.

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