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SC38's Zetec Midlana Clone
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Author:  ShadowCat38 [ January 10, 2016, 4:08 pm ]
Post subject:  SC38's Zetec Midlana Clone

Hello everyone,

My project is reaching a point where I actually have something worthwhile to post instead of picture-less dreams; therefore, I shall lurk no more.

I've been very inspired with Kurt Bilinski's Midlana for about a year now, and I am building my own version of this potent little car. My donor is a 2001 Ford Escort ZX2 with the 2.0L Zetec DOHC engine. Ost of the build will follow Kurt's build, adapted to fit my drivetrain. Unlike Kurt's build, however, I'm going to try my hand at composites for the body paneling. I had several opportunities to work with the stuff before in high school solar car projects and college SAE and Mini-Baja teams, so I have a solid idea of what I'd be getting myself into with that approach. In any case, I'm more excited about this project now than ever before because it is about to start taking shape and is getting very real.

Thanks for looking!

--I'll have to add the pictures from a PC later. Apparently, my phone is being uncooperative.--

EDIT: Photos are now here:

Attachment:
File comment: The little red car that, after a year of driving around, will actually be hard to take apart for the build. It is pretty fun to drive, so I can only imagine how much more fun a car that I'VE built will be.
donor.jpg
donor.jpg [ 112.48 KiB | Viewed 5292 times ]

Attachment:
File comment: Build table frame. Yes, this is probably over-engineered. I am an engineer, so it is my prerogative. I also intend on having the car nearly self-powered before taking it off the table, so it needs to be able to handle most of the car's weight, preferably with little deflection. I liked Kurt's design for his table, so I followed it pretty closely.
table1 - Copy.jpg
table1 - Copy.jpg [ 570.64 KiB | Viewed 5292 times ]

Attachment:
File comment: Framing continued...
table2 - Copy.jpg
table2 - Copy.jpg [ 600.53 KiB | Viewed 5292 times ]

Attachment:
File comment: Tabletop is ready!
table3-2 - Copy.jpg
table3-2 - Copy.jpg [ 573.1 KiB | Viewed 5292 times ]

Attachment:
File comment: The frame is sketched and jig blocks are added. All that is left is to cut the metal and start welding.

Yes, that is snow under my garage door. It is not well sealed. My 23,000 BTU heater struggles to keep it comfortable (i.e. around 55) even when it is barely above freezing. With the temperatures dropping to below zero even at midday here lately, it may be a few more days before I actually do some welding. At least it is hot work.

jigblocks1 - Copy.jpg
jigblocks1 - Copy.jpg [ 277.68 KiB | Viewed 5292 times ]

Attachment:
File comment: A close-up of the jig blocks. The red phantom line is the centerline for the rear axle.
jigblocks2 - Copy.jpg
jigblocks2 - Copy.jpg [ 262.31 KiB | Viewed 5292 times ]

Author:  wicky [ January 10, 2016, 8:18 pm ]
Post subject:  Re: SC38's Zetec Midlana Clone

First to say Welcome! and Good Luck!

Author:  1055 [ January 10, 2016, 8:25 pm ]
Post subject:  Re: SC38's Zetec Midlana Clone

welcome! I have never had luck getting pictures to upload from my phone.

Author:  ngpmike [ January 10, 2016, 8:33 pm ]
Post subject:  Re: SC38's Zetec Midlana Clone

I only recently learned how to do it from my PC, and I've been here 5 years! :ack:

Author:  trialsmangasgas [ January 10, 2016, 8:57 pm ]
Post subject:  Re: SC38's Zetec Midlana Clone

Welcome ShadowCat38 to the mad house. You might want to come up to the Midwest Se7ens gathering in LaCross, WI in early June. You can look at our cars and get some ideas on how to build yours. Russ

Author:  ShadowCat38 [ January 10, 2016, 9:53 pm ]
Post subject:  Re: SC38's Zetec Midlana Clone

Thanks for the welcome. I got the pictures up.

Author:  ngpmike [ January 10, 2016, 10:12 pm ]
Post subject:  Re: SC38's Zetec Midlana Clone

What are the dimensions of your table? Looks a little bigger that 4x8!

Author:  ShadowCat38 [ January 10, 2016, 10:18 pm ]
Post subject:  Re: SC38's Zetec Midlana Clone

Yeah, it is 5 x 10. 3 sheets of 5/8" CDX did a pretty good job of covering it (top and bottom for stability, and per Kurt's design), but sketching is a bit of a challenge. It would have been easier if it was MDF or some other engineered panel, but this was less than half the cost of MDF. As long as my framing was level and consistent, laying out the CDX was no problem to get flat.

Author:  1055 [ January 11, 2016, 12:15 am ]
Post subject:  Re: SC38's Zetec Midlana Clone

keep an extinguisher, or tall glass of water handy for when you start melting some metal on it!

Author:  Trochu [ January 11, 2016, 5:04 pm ]
Post subject:  Re: SC38's Zetec Midlana Clone

A couple hundred bucks of insulation goes a long way, keeps it warmer in the winter and cooler in the summer, just saying....

Good luck.

Author:  ShadowCat38 [ January 11, 2016, 11:57 pm ]
Post subject:  Re: SC38's Zetec Midlana Clone

Oh, I know. But being a homeowner, I have a newfound respect for the rampant plague known as everythingisconnecteditis. I can't insulate the garage because i have too many lawn tools hanging on (and in... you know what I mean) the walls. I need to find a new home for them, which would be a lawn shed ideally. There is another $500. It build and builds until you realize you've spent $2,000 when all you wanted to do was a 2-hour weld session. It is almost paralyzing for getting anything done that I actually want to, unless I ignore it altogether, which means I'll probably end up welding in the frigid night... but I'd really like to hang better lighting. :BH:

Author:  oldejack [ January 12, 2016, 12:12 am ]
Post subject:  Re: SC38's Zetec Midlana Clone

ShadowCat38 wrote:
... but I'd really like to hang better lighting


There's your answer, several 300 watt halogens pointed in the area that you're working.

Author:  Leggman [ January 12, 2016, 1:26 am ]
Post subject:  Re: SC38's Zetec Midlana Clone

I am also starting a mid engine build with a 05 focus as the donor.
Are you using the midlana book or just using your own designs?

Author:  1055 [ January 12, 2016, 9:46 am ]
Post subject:  Re: SC38's Zetec Midlana Clone

ShadowCat38 wrote:
Oh, I know. But being a homeowner, I have a newfound respect for the rampant plague known as everythingisconnecteditis. I can't insulate the garage because i have too many lawn tools hanging on (and in... you know what I mean) the walls. I need to find a new home for them, which would be a lawn shed ideally. There is another $500. It build and builds until you realize you've spent $2,000 when all you wanted to do was a 2-hour weld session. It is almost paralyzing for getting anything done that I actually want to, unless I ignore it altogether, which means I'll probably end up welding in the frigid night... but I'd really like to hang better lighting. :BH:


I'm sure you have a lowes nearby. They have 48" T11 two bulb fluorescent fixtures for something like $11/piece. I bought three for my garage. Combine it with a single 500watt work light and there isn't much I can't see in there now.

Author:  ShadowCat38 [ January 12, 2016, 3:39 pm ]
Post subject:  Re: SC38's Zetec Midlana Clone

@Leggman - I am following the book as closely as I can, but since I'm using ZX2 parts instead of Miata parts, I'm going to need to change some things up to make it work, unless Wickyc finds me a Miata steering assembly at the Pick-n-pull he frequents. Such places are nearly non-existent in a state where they salt the roads more than their meats. The bodywork will be significantly different. I still am fleshing out exactly how I want it to look when I'm done.

@1055 - I will have to visit my "local" Lowe's sometime soon, then, if the lighting is that reasonable. Dark, unpainted wood walls soak up what little light I do have. Thanks for the tip.

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