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Author Topic: Morgan F build  (Read 442 times)

Chris Brown

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Morgan F build
« on: 08 March 2019, 04:24:47 pm »
At long last I've made a start, doing the front suspension frame first, all tacked together. I need a bit more practice before I weld it up fully, it's been too long since I did any amount of welding. It's a new welder so I need to play with the settings, the wire feed died on my old one. Couldn't resist the (slightly blurry) view from the workshop, it is Wales after all, twice as many sheep as people.  :D

Should have mentioned the end uprights will be cut, and the piece of tube used for the suspension sliders to run on, just welded in to keep everything in alignment.
« Last Edit: 08 March 2019, 04:27:47 pm by Chris Brown »

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RhysN

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Re: Morgan F build
« Reply #1 on: 08 March 2019, 04:58:41 pm »
First step is the hardest. Great news.

Chris Brown

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Re: Morgan F build
« Reply #2 on: 08 March 2019, 05:15:46 pm »
I'll be back at it Monday, other things taking up the next two days, walking tomorrow morning, then RUGBY, Car Boot sale, autojumble, and rugby Sunday. Hopefully I'll get a "mould" for the radiator Sunday, and I can finalize the width of the front end of the chassis. Need to weld up a bench top before I start on the chassis though.

StefanN

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Re: Morgan F build
« Reply #3 on: 10 March 2019, 09:24:48 pm »
Well done Chris.  Its great that there’s lots of CKs being built.  Looking forward to following you progress.
S

Chris Brown

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Re: Morgan F build
« Reply #4 on: 18 March 2019, 05:24:33 pm »
A bit more progress, bench top built, and design finalized. I'm going to hinge it to the wall with two alternative mounting points, to match the two heights of my ancient Workmate. I'll lift the end with a high lift jack, and slide the Workmate under to support the end. Easier to make than the original idea, and it won't take up as much space since I can easily demount it and store it against the side wall of the shed.

The jack will also come for raising the top deck on the trailer, again simplifying the design, and making it lighter.

Yes you do see 4 wheels hanging on the end wall, I spotted them on ebay, they'll be ideal for the second kart. I'll be going a bit "off piste" with that one too, a brainstorming session with Rhys established that a car I'd discounted as impossible, isn't, just needed some lateral thinking (literally going sideways). Details will emerge eventually, keeping it under wraps until I start it.

Should be able to make a start on the Morgan chassis tomorrow, doing the bench top has just about got my welding back up to scratch. I've decided to taper from the scuttle forward, as per the original, a bit more work, but worth it I think.

Chris

Chris Brown

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Re: Morgan F build
« Reply #5 on: 19 March 2019, 04:39:30 pm »
More progress today, though as I started to type this I realised I intended to drill the front crossmember for the U bolts before welding it in place. Never mind that's easily sorted, still got some welding to do on it before I'm ready to clear the decks and start stripping the scooter. The rearmost crossmember won't be welded in place until I'm ready to attach the back end of the scooter, it's just lying in place to keep the rear of the frame parallel.

I've attached the photo from yesterday again, as well as today's, didn't realise that they were rotated. 

Steve Cole

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Re: Morgan F build
« Reply #6 on: 19 March 2019, 10:25:24 pm »
Brilliant Chris, you’ve made a good start. Bring your chassis to builders day please. I brought mine to Rhys when we met in November and now it’s just about finished and I’m not retired 😳

Chris Brown

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Re: Morgan F build
« Reply #7 on: 19 March 2019, 10:42:43 pm »
Won't be at the builders day Steve, too much to do otherwise, apart from the kart, I've got a pond yacht refurbishment to finish off, and I need to get on with fitting out my enamelling studio. I'm still four years off retirement, it's just a quiet time of year for me.
« Last Edit: 02 April 2019, 03:31:27 pm by Chris Brown »

Chris Brown

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Re: Morgan F build
« Reply #8 on: 02 April 2019, 03:45:14 pm »
Finally made a bit more progress, too many "things" getting in the way. I've got the suspension frame fitted, though I've discovered the U bolts are about 10mm too short to fit the lock nuts. Also done a test fit on the handbrake and cable, looks like it'll work OK. If necessary I can take the cable further forward through the suspension frame, as the grille fits forward of the suspension. Just waiting for the tube for the spacers to go inside the box section where the U bolts are, then I can fit the anti crush box section to stop the front crossmember getting squashed when I pull the U bolts down tight.

Graham Hill

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Re: Morgan F build
« Reply #9 on: 02 April 2019, 06:12:23 pm »
Chris, it's going to be so interesting to follow this build ! Definitely worth waiting for!
Hope to see you again at Stretton (Morgan or no Morgan).

Chris Brown

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Re: Morgan F build
« Reply #10 on: 02 April 2019, 07:24:09 pm »
I'll definitely be at Stretton, the target is to have it running, may not have a body though. As soon as I've got the front suspension done I'll clear the decks, strip off all the extraneous bits of the scooter, and get it running, before I cut the frame.

I wasted most of a day last week fiddling with it, because it's decided not to start.

Chris Brown

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Re: Morgan F build
« Reply #11 on: 08 April 2019, 05:09:00 pm »
 Right, done various bits and pieces over the last few days, none of which are visible, welded sleeves bracing and the like inside the chassis. So today I continued with the front suspension, made a jig for the sliders cleaned them up and welded them. I test fitted the wheels before making the jig, and got 5 degrees, checked against the photo of the original, and got the same, so I've got something right.

Photo shows the rear of the offside (UK, so right hand side facing forward), with the assembly in place, with the spring I'm going to start with, it'll be cut down to 2 x 4", and 2 x 1" springs, so will do both sides. The bearings will go inside the sliders, not fitting them yet, I'm waiting on some weld nuts and grease nipples, before I fit them.

The bolts used for the spindles will be retained by grub screws, 2 each side, to clamp them in place and prevent rotation.

Still struggling with the degree of accuracy required, I'm used to building 1/12 scale or smaller with fractions of a millimetre accuracy, working to 3/4 scale and within 1/6" or thereabouts takes some adjusting to.

« Last Edit: 08 April 2019, 05:14:41 pm by Chris Brown »
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Steve Cole

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Re: Morgan F build
« Reply #12 on: 08 April 2019, 10:36:23 pm »
Looking good progress Chris, keep it up, 5 weeks to go till Stretton

Chris Brown

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Re: Morgan F build
« Reply #13 on: 17 April 2019, 04:24:47 pm »
Latest update, just to prove I haven't been sitting on my backside doing nothing.

Steering wheel adaptor plates and spacers made, just waiting on bolts to fit the back plate, and a 20mm holesaw so I can line up the shaft adaptor with the back plate before drilling the holes to mount it.

Sliders finished with bearings fitted, just ordered a reamer as they're a bit tight on the uprights.

Front suspension frame finished, reinforcing pieces fitted to the pivot tubes, stops to prevent sideways movement, caster adjuster bracket, and headlamp brackets.

Next job is clearing the decks so I can get the scooter in and start stripping the bodywork off. Then I need to get it running before I cut the back end off, and weld it to the front chassis.
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Chris Brown

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Re: Morgan F build
« Reply #14 on: 17 April 2019, 10:25:04 pm »
The scooter strip down, and cure for non starting proved to be easier than expected. It seems that at some point the side stand switch became dislodged, hence no sparks, and no start. Setting it back to it's correct position cured the problem, it's now disconnected and the wiring will be used for the kill switch.

The petrol tank will be moved forward to above the engine, and the surplus frame cut off, to lower the rear bodywork.

I can't manage to post portrait  photos in the correct orientation, I'll take the same ones tomorrow in landscape and post them.
« Last Edit: 17 April 2019, 10:34:25 pm by Chris Brown »