Spent last 10 days finalizing brake and suspension design. Will be making new front and rear uprights instead of trying to modify the donor pieces. That will save weight and improve looks. I will essentially copy the Brammo design as seen on the Leno car build photos. That version is improved from earlier photos I have seen (maybe Ar-i-el version).
Will use donor front rotors. Donor had rear drums, so will use 91 CRX rotors and in lieu of buying new Honda calipers with integral emerg brake for $160 ea, will buy Wilwood 2-piston Dynalite calipers and mechanical spot brakes for e brakes. I could use the donor front calipers, but they are 12 lbs ea and don't match the Wilwood rears, so will use Wilwood forged, 4 piston Dynalite fronts. That will make the donor brake pedal look out-of-place, so, you guessed it, I will need to use Wilwood pedal system with dual master cylinders and balance bar with remote adjuster. Thanks, Santa. (All included in $6000 build budget)
Ordered 16+ 1/2" diameter, high strength rod ends for all upper wishbones and rear, lower outers. Will use bushings for all lower wishbone frame pickups, and Moog ball joints for front, lower, outers.
Regarding recent comments:
Yes, all panels will be unpainted aluminum, including seat pan and what little body panels are used on the car.
There was, luckily, no evidence of either a passenger or driver left behind in the donor car. Dismantling would have been a greater challenge if I had to remove feet before I could remove pedals.
I found the donor by chance when I went to salvage yard looking for a tail light for my van. $800 dollars for car with 29,000 miles, good air bags, undamaged power steering pump, ABS unit, AC compressor, steering rack, brake MC and booster. Coolant and oil still in engine. I had to buy a shifter base on Ebay.
The motor mounts have plastic (of unknown species) bushings. The original mounts would probably not fit the frame and they are heavy. I will save 12 to 15 pounds by tossing them and making custom pieces. I don't need no stinking isolation, harmonic-cancelling mounts. I have other cars that are quiet and vibration free. This will be designed with maximizing NVH as design criteria.
I'll use the donor gauge panel mounted in center of dash. Will put ignition switch in dash and may mount Honda light and turn indicator controls near dash, removed from wheel.
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