Hank's MEGABUSA Project

[Hank]

It has begun!

http://www.henry-bell.com/megabusa/images/111408/crate01.jpg

http://www.henry-bell.com/megabusa/images/111508/01.jpg

[11Budlite]

Congrats Hank, you must be thrilled! :hurray: Keep us updated on your progress.

Bruce :7drive:

[Ian7]

I remember that point in the build...

... you'll be done in a matter of days ;)

[powderbrake]

You are truly at the fun part of seven ownership. Congratulations !!

[Hank]

I think my Megabusa was built on a Monday. Lot of missing parts. :( Either that or a pretty large box o' bits fell off in the Atlantic.

It's a helluva good time building it though!

[Hank]

Very good day. I actually have a pretty good system going to find bolts for the specific task at hand. A lot of empty boxes to throw away now, but I'll hold them until I'm done in case something is lost in one of them. :ack:

Things I completed today:
Front Suspension
Rear Suspension
Rear Differential
Rear driveshaft
Reverse Box
Steering Rack

I am still constructing my build website. It has not been released yet because I'm having too much fun building the car! =)

[Kitcat]

Is yours the only Westfield Megabusa in the states?

What are you doing for reverse?

Should be an awesome car when done!

[JohnCh]

Congratulations Hank! Sounds like you are off to a great start. If you are looking for inspiration, this site (http://westfield-world.com/homebuilds.html) lists about 50 Westfield-related sites, many of which have detailed build logs. Very good resource.

Kitcat, there is at least one other Magabusa in the States. Dennis Palatov, of dp1 fame, built one several years ago (build blog here (http://www.dpcars.net/westfld/index.htm)). Last I heard it was in the San Diego area, but not sure where it is now.

-John

[Hank]

I'm going to use the Westfield reverse box, and WHEN it starts leaking (I give it five minutes *laugh*) I will replace the drive shaft/reverse box assembly with two driveshafts and a CV joint. I will attach a ring gear to the crankshaft hub and fabricate a bracket for a starter motor sliding assembly. Louisiana doesn't have strict laws for "stratch built" vehicles. I could have a slide plate and move the car ala Fred Flintstone if I wanted to. :D

Click here for my inspiration on the electric reverse. (http://www.westicles.net/orange/build/240402/)

Bailey Morris is a UK source to fab the new driveshaft assemblies, but a local fab shop offered to do it in exchange for website work. I can't argue with that!

I really can't wait for the Pro Shift paddle setup. That and the turbo kit next summer. 300whp and 875lb total weight. WOO WHOOO! I'm ordering "POWR 2 W8" or "POWR2W8" as a license plate.

[Hank]

Ton of work over the past few days.

I put together a quick website:

http://www.hanksmegabusa.com

[Hank]

I've been updating the website in lieu of posting here.

Comments are always welcome.

:ack:

[11Budlite]

Looks good Hank! The quality of the suspension, uprights, etc, looks pretty impressive! :cool: When do you hope to have it finished?

Bruce :7drive:

[Ian7]

In your photo titled "front shocks inverted..." the angularity of the steering links relative to the AArms looks odd. Arms are almost parallel to the ground, yet steering link points downwards quite alarmingly. Maybe its a photo optical illusion, but suggests potential for wicked roll and/or bump steer. At first thought, the outer tie-rods might be inverted, but these usually have tapered fits so they can't be put on 'upside down'.
Just curious...

[JohnCh]

I think it is an optical illusion. The links look parallel to the arms in this photo (http://www.hanksmegabusa.com/images/112608/08.jpg).

-John

[Hank]

I hope to have her done by Christmas.

Thanks for the comments. Please keep in mind NOTHING has been torqued other than the driveshaft, differential, and engine mounts. :d

[Ian7]

I think it is an optical illusion. The links look parallel to the arms in this photo (http://www.hanksmegabusa.com/images/112608/08.jpg).

-John

yup, sure do, quite a difference that perspective makes ;)

[Hank]

I can now say I own a racecar. I fit the rollcage today.

http://www.hanksmegabusa.com "The Build" for pics.

WOO WHOOO!

[WestTexasS2K]

Hank that thing is flyin together. You shouldnt belong before you are terrorizing someone.

[Kitcat]

He doesn't seem to be following the build instructions (I don't see any empty Guiness bottles in the garage:)).

[Hank]

Unfortunately my wife and I have been on a diet for 2 months. I haven't had any alcohol since. The good news is the longer I'm on this diet the lighter my race weight will be.

I used to be 6'1" 201 lb, but I'm down to 185 lb now.

I bet it's going to be expensive to get the MEGABUSA down to 899 lb. I think I set an unrealistic goal. We'll see...

[Ian7]

from Hank's blog...

" and I found it after cussing and trial fitting for 5 minutes or so. "

if there's cussin' goin' on after only 5 minutes, be thankfull it's not a Caterham kit ... :ack:

[Hank]

if there's cussin' goin' on after only 5 minutes, be thankfull it's not a Caterham kit ... :ack:

Well, I realize it's a kit car and the instruction manual will eventually run out. This darn front anti-rollbar (swaybar) is so odd-shaped and the area it fits in is so cramped that it can only go in one way. And the manual ran out of directions a LONG time ago. :D Pretty much everything else is self explanatory for a gearhead like me. It helps that I'm a mechanical engineer by trade.

[Ian7]

And the manual ran out of directions a LONG time ago. :D

you got a manual... ?! :confused:

[Hank]

Getting closer to cranking the beast! The dry sump oil lines are almost complete. The fuel lines are complete. Tomorrow is wiring the engine!

:shocked:

[Monte Busa]

I looked at your website build log - don't be too distraught about your header cut-out job on the bonnet - use this opportunity to put a stainless steel sheet surround around the opening - now that you know where the headers will exist, you can spend time making a nice paper template and cut out a very nice and classy looking and durable piece - stainless insulates from heat quite well, and your paint will thank you later as well.

Cheers,

Aric



Getting closer to cranking the beast! The dry sump oil lines are almost complete. The fuel lines are complete. Tomorrow is wiring the engine!

:shocked:

[Ian7]

- don't be too distraught about your header cut-out job on the bonnet - use this opportunity to put a stainless steel sheet surround around the opening -


Seconded !! how about a pair of SS panels that butt together in the middle to form two small openings, one for the front pair and another for the rear pair?

[Hank]

Thanks for the suggestions on the exhaust cutout. I may just try it.

I really wish I could figure out what the oil tank threads are (multiple bungs) so that I could plug them and prime the oiling system. :mad:

[RDROCKT]

Oil tank bungs are usually NPT (pipe thread). Do not try to force a straight thread bolt or plug into them.

[Hank]

Well, by God's grace I was blessed in finding the proper hardware to plug 2 of the 3 dry sump oil tank holes.

The very bottom bung takes a M14x1.5 bolt. This serves as an oil drain plug, so I added a copper washer and teflon tape for safe measure.

The bottom bung on the SIDE of the tank takes a 1/8" NPT thread. With that settled I ordered an Autometer oil temperature gauge with 1/8" NPT sender.

The top bung on the SIDE of the tank is still a mystery. I was told it was 3/8" BSP (British Standard Pipe) thread. I purchased a 3/8" BSP cap from McMaster-Carr and it didn't fit.

Any guesses? :ack:

[11Budlite]

Hank - Do you have a thread pitch gauge you could measure it with? I usually check out the Pegasus website for all the available fittings: http://www.pegasusautoracing.com/advcat.asp?CategoryID=PLUMADAPT

Bruce :7drive:

[Ian7]

Here's a less-than-complete answer, but I found out the hard way that NPT and BSP aren't the same... :ack:

wish I could remember the details though. :confused:

For what its worth, don't force anything that won't spin in with light finger torque

[11Budlite]

Check out the thread fitting guide from Pegasus for the difference between NPT and BSP. Close, but not quite the same: https://www.pegasusautoracing.com/threaded-fitting-guide.asp

Bruce :7drive:

[Hank]

Woo who! 3/8" NPT it turned out to be. I put Teflon tape on the bung, screwed the cap on hand tight, and I finished it off with my channelock pliers.

I'm so happy right now. I only wish the parts I ordered this week would be arriving tomorrow:
Oil Temp Gauge
Oil Press Gauge
Coolant Temp Gauge
Odyssey PC625 battery
205/50/15 Falken Azenis RT-615's
Atm press sensor
starter relay
fuel pump relay
dry sump/tranny vent tank
fiberglass resin

I still need to order a piece of carbon fiber big enough for the Westfield dash. A UK company sells it pre-made, but I'm not having the best of luck in getting parts in a timely manner from Britain.

My 15" wheels are currently in transit (3rd time). No tracking number (3rd time). D'OH! :crazy:

[Monte Busa]

... but I'm not having the best of luck in getting parts in a timely manner from Britain.



Story of my life, I've waited over 6 months for certain things....can't be in a hurry with the Brits

[Monte Busa]

...Odyssey PC625 battery


A Odyessey 545 will probably be enough for you - keep in mind you really only need it for starting capacity - the 545 is plenty big enough to turn over a Hayabusa...

I have a 545 on my Yamaha R1 and it doesn't break a sweat....ever.

[Hank]

Well, as far as the battery goes, I chose the PC625 to fit the Westfield supplied battery tray. Of course, I could build my own battery tray for the smaller PC545. If I run out of options to lighten the car the battery change nets me an additional 1.5 lb reduction. :jester:

[Monte Busa]

every ounce counts ! ;)

Well, as far as the battery goes, I chose the PC625 to fit the Westfield supplied battery tray. Of course, I could build my own battery tray for the smaller PC545. If I run out of options to lighten the car the battery change nets me an additional 1.5 lb reduction. :jester: ;) ;) ;)

[Hank]

D'oh!

I have to wait until 5 am when SummitRacing opens again to order my Flaming River battery/alternator kill switch, push button starter, and split wiring loom tubing.

[ayseven]

Looks very nice! Again, don't be impatient waiting for parts. They are notoriously slow sometimes from the UK, but I've never had anything not arrive eventually, either from an individual on FleeceBay, or company site.

It always surprises me, however, that after thousands of these 7 cars have been built over the years, people still don't get proper instructions with them. How does Factory Five do it, and why hasn't anybody copied their format? ie. things arrive in numbered containers.

My so-called kit (Deman originally) had instructions that were written by a 3 year old. And although it's not highly recommended, I have spent 3 years obsessing over something that isn't work related, that may or may not be finished by summer. That's just how these things go.

[Hank]

Wheels finally made it from Britain (2.5 month journey). I mounted them in 205/50/15 Falken Azenis RT-615's. A little bit of electrical work is all that remains. Should be cranking the engine soon. I spent most of today tightening all of the bolts and marking their current location to a reference on the frame.

SO CLOSE!

http://www.hanksmegabusa.com/thebuild.htm

[shiva]

Wow Hank, it's coming along quite fast!

I was wondering if you could take a few shots of the cage mounting points. I'm gonna have a custom 2-piece cage made. And was trying to figure out what westfield uses as mounts. Seams to be 2 bolts on the side. Where do those bolts too? directly to the frame?

Thanks, and keep up the good work! :)

Jean-Philippe

[Hank]

Wiring sucks. That is all...

[Sean]

Wiring sucks. That is all...
Amen to that!

[Hank]

I pity you poor guys that take forever to register your 7.

I called the DPS (State Trooper kind-of) and they told me to trailer the car to their location for a physical inspection (when I finish it). They will look the car over in 5 minutes or so, they will send me to DMV for my registration, and I will be road bound the same day! Sweetness.

Oh the horror of the SVA over in Britain. Most fail their first time I hear.

[Hank]

The MEGABUSA has been at a friend's shop getting the engine harness finished.

I updated my website with pictures of the car on the trailer. It looks gorgeous outside in the sun!

I like this one:
http://www.hanksmegabusa.com/images/020509/06.jpg

[Hank]

My god this wiring guy is taking forever.

:mad: :mad: :mad: :mad: :mad: :mad:

[Hank]

I got bored last night and decided to build a spec sheet like the famous Road/Track magazine test layout.

Man this took a long time! The Photoshop PSD file is over 20MB.

I will fill in the missing data when I finish the project and she hits the track.

CLICK THE SPEC SHEET TO ENLARGE!

http://www.hanksmegabusa.com/images/Megabusa-Specs-tn.jpg (http://www.hanksmegabusa.com/images/Megabusa-Specs.jpg)

[manik]

Very, very cool!

tm

I got bored last night and decided to build a spec sheet like the famous Road/Track magazine test layout.

Man this took a long time! The Photoshop PSD file is over 20MB.

I will fill in the missing data when I finish the project and she hits the track.

CLICK THE SPEC SHEET TO ENLARGE!

http://www.hanksmegabusa.com/images/Megabusa-Specs-tn.jpg (http://www.hanksmegabusa.com/images/Megabusa-Specs.jpg)

[Hank]

Instrument engineer returned from his cruise. He worked with me half a day today, but he had to leave because of a sinus infection. By God's grace and four (4) wiring diagrams I figured out the dash harness. I connected the entire dash, and I have 50% of the dash harness marked for removal (heater, wipers, tach, speedo, wiper pump, useless switches, etc).

Completed so far:
Engine bay harness
ECU
Test plugs (2)
Dash harness

Things left to do:
Complete wiring for factory Hayabusa fuse box/relays
Remove unnecessary dash plugs/wiring

Must... be... patient...

[Hank]

Car runs great.

I took the header off and sent it to Jet Hot to get recoated. Westfield put a ceramic coating on the header but fingerprints and weld slag made it look really crappy when the engine warmed up. I cleaned the header with rubbing alcohol before I cranked the engine. The damage must have been done in the coating process.

I ordered a Bailey Morris driveshaft kit to eliminate the reverse box. That should be in next week.

I ordered $600 in carbon fiber from Carbon Mods in the UK. Pictures will follow when the bits come in. Woo whoo!

I can't wait to weigh her, corner scale her, alignment, certification, then drive on the street!

Damn all of these final details...

[Hank]

I added over 3 entries to the build diary. Quite a few pictures and progress over the last few weeks. I get my speedometer calibrated on a local chassis dyno probably tomorrow. After that is inspection by the State Police. I bought insurance from American Collectors last week.

Almost there!

After inspection: remove reverse box and replace with drive shaft kit w/ carrier bearing, install FlatShifter paddle shift kit, install Carbon Mods dash.

[Spaz]

This is awesome news!!!

I love the rear arch (fender) protectors.

This car is going to be too nice to drive.

[Hank]

This is awesome news!!!
I love the rear arch (fender) protectors.
This car is going to be too nice to drive.

Thanks! I think I'm going to cry when I get my first rock chip. Even with all of the preparation to prevent the inevitable (8 mil clear shield paint protectant film, sacrificial carbon fiber protective pieces, etc) damage will still occur. I guess I'm just second guessing the gelcoat fiberglass to be able to take the abuse of track days and some street duty. It's so much easier to repair a metal bodied Se7en after years of abuse, but I may have gained a weight advantage by using the fiberglass body. I still love her though! :D

[yellowss7]

Hank, forget the first stone chip. Wait until you rip your first fender off!!!!!

Good thing is that they are easily repaired or replaced. I used 3-5 nylon bolts to hold mine on with. If you hit a cone they just rip out without tearing out the rivenuts or damaging the side skin.

Tom

[Hank]

Whoa! Cool photo. Maybe that's why I didn't build her to autox. I'm more of a lapping day guy. No cones. :D

[JohnCh]

It's not just cones that can get you. I hit a tire carcass in the dark on the freeway when returning from USA2005.

http://john15.web.officelive.com/Documents/rearwing.jpg

-John

[MHKflyer52]

Hank, forget the first stone chip. Wait until you rip your first fender off!!!!!

Good thing is that they are easily repaired or replaced. I used 3-5 nylon bolts to hold mine on with. If you hit a cone they just rip out without tearing out the rivenuts or damaging the side skin.

Tom

Tom you know you were just trying to make your car weigh less so you could go faster.....

[Hank]

WOOO WHOOOOO! STREET LEGAL AT LAST!

Trooper looked at the car for 5 minutes. I didn't have to make anything work. He didn't even check the VIN on the chassis. I opened the hood, he spit some skoal on the ground, and he wrote down a few things onto a report. He talked a bit about a Hayabusa that he owned, and that was it. She stayed on the trailer and never moved. No appointment. I showed up at 4:15pm and they close at 4:30pm. After he gave me the document to take to DMV for my plate they were closed already. I will go pay TTL tomorrow morning at DMV.

First street drive tomorrow. First car show this Saturday. First race? Who knows...

:D :D :D

[Croc]

Congratulations Hank - it has to be a happy moment for you to pass the inspection without a hassle.

[Spaz]

http://www.usa7s.com/vb/attachment.php?attachmentid=248&stc=1&thumb=1&d=1241558484
http://john15.web.officelive.com/Documents/rearwing.jpg

Ouch. I had problems with both my front fenders, but the back, Noooo.
This really got me thinking, next Sat 4/16 is my first auto-x in the 7.



Moving on to happier things. Hank is street legal this weekend!

Watch out Baton Rouge, LA, a 7 is on the street!

[TheDingo8MyBaby]

Why not just make up something that will protect the rear wings from cones?

http://img.photobucket.com/albums/v121/TheDingo8MyBaby/SANY0354.jpg

The exhaust on the other side does a pretty good job of protecting the rear wing.

[t walgamuth]

I'm contemplaing a bike engined seven....is the extra starter motor for reverse actually lighter than using an automotive tranny?

[ottocycle]

Think about how much you will need a reverse. I have been running mine on the street for over 2 years without reverse and I have not missed it. You have to think about how you park but considering I only go for fun blats with it, the PITA factor is not worth it in my opinion.
The option of using a car trans is intriguing but the weight and parasitic drag would dull the edge of the bike engine, which is part of the joy of having a BEC to begin with. On the other hand 36 forward gears and 6 reverse speeds....
Just my 2c worth.

Dermot.
Hayabusa Heritic.

[Hank]

I like the weight savings of not having reverse. Besides, who would turn down a beautiful woman that offers to push me backwards out of a parking spot? :D

[andrew7]

First check if your state requires it. Pa. requires "powered reverse" for inspections although mine has never been checked. 3 bolts could completely remove it from the car which is about 15#'s. I think my electric reverse might be a little heavier than a Quaife box, but a few days before the 50th anniversary rally my reverse went out. I still drove 325 miles those two days, a box would have side lined me. It might be possible to take a light manual and just run fifth and reverse gears and remove the rest of the gears. I heard a T5 is around 70# plus you have hp losses from 2 transmissions. A BEC is not much of a tourer and like others here parking is planned, usually away from other vehicles. A bike engine will work the best when a cars weight is kept low.

[Hank]

Soooo... A dirt track guy is bringing his scales over to my house tomorrow. :)

[andrew7]

So Hank......... your setting up the car to turn only left.

[Hank]

Well, I figured the dirt track guy would want to go adjusting my car and what not, so I locked all of my tools up in the back bedroom. My goal is to roll the car on the scales and see where I'm at. If he brings some tools and can adjust the car while I'm in it then I might go for it. Might make it interesting and leave the engine running and give him 2 minutes to do it. :D *air impact noises*