Haynes Haynes may refer to:
People
*Haynes (surname)
Places
In Australia:
* Haynes, Western Australia
In Canada:
* Haynes, Alberta
In the United Kingdom:
*Haynes, Bedfordshire
** Haynes Church End
In the United States:
*Haynes, Arkansas
* Haynes, Nort ...
Roadster is a replica of
Lotus Seven
The Lotus Seven is a small, simple, lightweight, two-seater, open-top, open-wheel, sports car produced by the British manufacturer Lotus Cars (initially called Lotus Engineering) between 1957 and 1972.
It was designed by Lotus founder Colin Cha ...
home-built according to a book ''Build Your Own Sports Car: On a Budget'' by Chris Gibbs ().
Ford Sierra
The Ford Sierra is a mid-size car or large family car manufactured and marketed by Ford Europe from 1982-1993, designed by Uwe Bahnsen, Robert Lutz and Patrick le Quément — and noted for its aerodynamic styling producing a drag coefficien ...
is used in the car as a donor for drivetrain and suspension components.
Haynes Roadster is a follow-up to the
Locost
A Locost is a home-built car inspired by the Lotus Seven. The car features a space frame chassis usually welded together from mild steel square tubing. Front suspension is usually double wishbone with coil spring struts. The rear is tradition ...
design described in a book by
Ron Champion
A Locost is a home-built car inspired by the Lotus Seven. The car features a space frame chassis usually welded together from mild steel square tubing. Front suspension is usually double wishbone with coil spring struts. The rear is tradition ...
. Locost uses
Ford Escort Mark II as a donor, but as these have become increasingly rare, a design based on a more affordable
Ford Sierra
The Ford Sierra is a mid-size car or large family car manufactured and marketed by Ford Europe from 1982-1993, designed by Uwe Bahnsen, Robert Lutz and Patrick le Quément — and noted for its aerodynamic styling producing a drag coefficien ...
has been proposed. In contrast to Locost, which used Escort's
solid axle
Solid is one of the four fundamental states of matter (the others being liquid, gas, and plasma). The molecules in a solid are closely packed together and contain the least amount of kinetic energy. A solid is characterized by structural ri ...
at the rear, Haynes Roadster has independent,
double wishbone
A double wishbone suspension is an independent suspension design for automobiles using two (occasionally parallel) wishbone-shaped arms to locate the wheel. Each wishbone or arm has two mounting points to the chassis and one joint at the knuckle ...
, front and rear suspension.
Technical details
The main part of the car is a
space frame
In architecture and structural engineering, a space frame or space structure ( 3D truss) is a rigid, lightweight, truss-like structure constructed from interlocking struts in a geometric pattern. Space frames can be used to span large areas with ...
chassis
A chassis (, ; plural ''chassis'' from French châssis ) is the load-bearing framework of an artificial object, which structurally supports the object in its construction and function. An example of a chassis is a vehicle frame, the underpart ...
, which can be home-built according to the drawings and instructions in the book from rectangular 25x25 mm and 19x19 mm mild steel tubes. Several suppliers offer pre-built chassis. Flat pack kits, or sets of tubes cut to size and ready for assembly, are also available. Since the cars are hand built, and often the book design is modified to some extent, each chassis is unique, but as a rough guide, it weighs around 700 kg.
The suspension wishbones are fabricated out of
cold drawn seamless mild steel tubes. Sierra front uprights are used with some modification. At the rear fabricated uprights support Sierra rear hubs.
Coilover
A coilover is an automobile suspension device. The name coilover is an abbreviation of "coil-over shock absorber".
Description
Coilovers are found on many vehicles, from RC cars to normal passenger cars, race cars and 4x4 vehicles. They are som ...
dampers used for the design are available at specialist suppliers.
The drivetrain usually consists of a
Ford Pinto
The Ford Pinto is a subcompact car that was manufactured and marketed by Ford Motor Company in North America from 1971 until 1980 model years. The Pinto was the first subcompact vehicle produced by Ford in North America.
The Pinto was marketed ...
,
CVH, or
Zetec
Ford Motor Company used the Zetec name on a variety of inline 4-cylinder automobile engines. It was coined to replace "Zeta" on a range of 1.6 L to 2.0 L multi-valve engines introduced in 1991 because Ford was threatened with legal acti ...
engine mated to a Sierra gearbox, a shortened or custom made
propeller shaft
A drive shaft, driveshaft, driving shaft, tailshaft (Australian English), propeller shaft (prop shaft), or Cardan shaft (after Girolamo Cardano) is a component for transmitting mechanical power and torque and rotation, usually used to connect ...
, Sierra
differential and
driveshaft
A drive shaft, driveshaft, driving shaft, tailshaft (Australian English), propeller shaft (prop shaft), or Cardan shaft (after Girolamo Cardano) is a component for transmitting mechanical power and torque and rotation, usually used to connect ...
s.
The book design is based for the
Type 9
Type 9 (also, Type N, T9, or T-9) is a gearbox from Ford that was used in Ford Capri 1.6, 2.0 1984 onwards, Capri 2.8 1983 onwards, Ford Sierra 1.6, 1.8, 2.0, Sierra XR4i, Sierra XR4x4 2.8 and the Scorpio 4x4 as well as the US market Merkur XR4Ti a ...
gearbox, but the list of chassis modifications in order to fit the bigger
MT75 transmission is provided on the Haynes forum.
The braking system is taken directly from Ford Sierra, with the exception of
vacuum servo
A vacuum servo is a component used on motor vehicles in their braking system, to provide assistance to the driver by decreasing the braking effort. In the US it is commonly called a brake booster.
A vacuum servo also known as a power booster or ...
, which is not required for the lightweight car.
The steering system is usually composed out of a lengthened Ford Sierra steering column and a Ford Escort MkII steering rack.
The bodywork is a combination of
GRP parts and
sheet aluminium panels.
Alternate donors can be used by adapting the design of the front and rear suspension, a common alternative is the BMW
E30/
E36(an increasingly utilised kitcar donor as in the
GKD Legend) and the
Mazda MX5
The Mazda MX-5 is a lightweight two-passenger roadster sports car manufactured and marketed by Mazda with a front mid-engine, rear-wheel-drive layout. The convertible is marketed as the or in Japan, and as the Mazda Miata () in the United Sta ...
. Other manufacturers engine and gearbox's are also popular such as the
Vauxhall XE. The modern prevalence of
Front-wheel drive
Front-wheel drive (FWD) is a form of engine and transmission layout used in motor vehicles, where the engine drives the front wheels only. Most modern front-wheel drive vehicles feature a transverse engine, rather than the conventional longit ...
layout makes the choice of suitable engine/gearbox donors quite limited.
As the supply of Ford Sierra donors in the UK is waning, the use of Mazda MX-5 is becoming more widespread, with the modifications to the chassis and suspension necessary in order to accept MX-5 components being independently published by the members of the community.
Community
There is a community of builders, as well as parts and services suppliers, based around a forum focused on the Roadster. The forum is set up and operated by Haynes, the publishers of the book describing the design. The community is mostly UK-based, but there are builders all around the world.
There are 27 completed cars known to the forum members as of aug 2013.
Haynes Forums -- Completed cars
/ref>
Legal Rules
UK
In the UK, Self builds are subject to a stringent test. The now defunct SVA (Single Vehicle Approval) was replaced in April 2009 with the IVA (Individual Vehicle Assessment) which costs £450 and is carried out by one of a number of VOSA
Vehicle and Operator Services Agency (VOSA) was an executive agency granted trading fund status in the United Kingdom sponsored by the Department for Transport of the Departments of the United Kingdom Government, United Kingdom Government.
It w ...
testing stations throughout the UK. It is legal to drive to and from the IVA so long as the car is insured. Once the car has passed the IVA it must be inspected by the DVLA
The Driver and Vehicle Licensing Agency (DVLA; cy, Asiantaeth Trwyddedu Gyrwyr a Cherbydau) is the organisation of the UK government responsible for maintaining a database of drivers in Great Britain and a database of vehicles for the entire ...
(once DVLC) local office for the purpose of registration. The car is categorised as new built which by law a MOT test
The MOT test (or simply MOT) is an annual test of vehicle safety, roadworthiness aspects and exhaust emissions required in the United Kingdom for most vehicles over three years old. In Northern Ireland the equivalent requirement applies after ...
is not required until it has aged to three years, the same standard as are all new built retail cars).
The DVLA will issue an age related number plate if a substantial portion of components were from the same donor car (proof needed).
The DVLA will issue a NEW car plate if the car is built from all new (1 part can be re-manufactured) components.
The DVLA will issue a Q Plate if the parts are from many cars or an undetermined donor car.
Sweden
Technically, kit cars are not allowed in Sweden, but provided that most of the components and material are sourced by the builder personally it is possible to register them as amateur
An amateur () is generally considered a person who pursues an avocation independent from their source of income. Amateurs and their pursuits are also described as popular, informal, autodidacticism, self-taught, user-generated, do it yourself, DI ...
built vehicles. The inspection (SVA equivalent) in Sweden is handled by the car builder's association SFRO who makes two inspections; one when the car has reached the rolling chassis
A chassis (, ; plural ''chassis'' from French châssis ) is the load-bearing framework of an artificial object, which structurally supports the object in its construction and function. An example of a chassis is a vehicle frame, the underpart ...
stage and the second when the car is finished. Converting the MacPherson strut
The MacPherson strut is a type of automotive suspension system that uses the top of a telescopic damper as the upper steering pivot. It is widely used in the front suspension of modern vehicles, and is named for American automotive engineer Ear ...
of the Ford Sierra to a double wishbone
A double wishbone suspension is an independent suspension design for automobiles using two (occasionally parallel) wishbone-shaped arms to locate the wheel. Each wishbone or arm has two mounting points to the chassis and one joint at the knuckle ...
is not allowed as it is not designed for it.
Motorsport
By 2014 2 completed road-legal Haynes Roadsters have been used in the UK in amateur Motorsport Events run by the MSA at clubman level at tarmac sprints and hillclimbs. Just like the Locost car the Haynes Roadster fits in the MSA's "specialist production car class" as identical chassis are or have been commercially available to the public in quantities over 20 made in a 12-month period (only if an engine made in over 1000 units is used from a land vehicle).
Notes
References
* Adam Wilkins. ''Shed Seven''. Complete Kit Car magazine, May 2010.
External links
''Build Your Own Sports Car: On a Budget'' on Amazon.com
Haynes Roadster Forums
Roadster Builders Forum
{{Lotus Seven
Lotus Seven replicas