Motor mounts:
I used the same mounts that Caterham used, which are of course from British parts big pieces. ÜRO PARTS: C18556 from '61-71 Jaguar XKE.... a whooping $5.50 from RockAuto. Feeling generous, I splurged and picked up 4.
Design:
Again, I'm pulling design cues from Caterham and some members on the board here. I started with 2"x3"x.083" square and cut it diagonally such that I have 2x 2" wedges, tapering from about 2.5" to .5" over 10" length. I wish I took pictures of the process...
The arms are welded to .250" plate, bolted to the block in 4x places. I tried the use as much of the plate footprint as I could for the arm so as to minimize the bending load on the plate. I'll snap a picture of the Caterham mount I used as inspriation and you'll see where it bent. At the outboard end, I'm using .875" OD, .5" ID tube as the sleeve for the 1/2-20" motor mount bolt.
The open face of the arm got welded closed with 2"x.083" strip.
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On the chassis side, I'm using .75" OD, .375" ID tube as a sleeve. I'm planning on using washers under the bolt head (bolt feeds up from the bottom) to held distribute the load.
Transmission mount:
Stole this idea from a member on the forum here. It's pretty simple - I had some 1" aluminum plate lying around, so I used that to make the adapter. The only tricky part due to the nose down position of the engine (I matched the driveshaft angles) to help the engine sneak under the hood line, I needed to drill the holes on an angle so the trans mount isn't always loaded in bending.
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With the drivetrain mounted, I spent a week triangulating the outer portion of the chassis and building the rough transmission tunnel.
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Next installment: FIELD TRIP to England
-Andy