MEV Sonic7 Build guide

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1

MEV SONIC7

BUILD GALLERY CD

ENJOY YOUR BUILD.

TAKE YOUR TIME.

MOST IMPORTANT OF ALL – KEEP SAFE.

ANYONE CARRYING OUT THE OPERATIONS SHOWN IN THE

FOLLOWING PICTURES SHOULD HAVE DUE REGARD TO NORMAL

SAFE WORKING PROCEDURES.

MEV LTD WILL NOT BE HELD RESPONSIBLE FOR ANY MISHAP,

INJURY OR LOSSES RESULTING FROM BUILDING A VEHICLE. YOU

THE BUILDER, MUST TAKE ALL NECESSARY AND APPROPRIATE

STEPS TO ENSURE A SAFE WORKING ENVIRONMENT.

IT IS RECOMMENDED THAT A RISK ASSESSMENT BE CARRIED OUT

PRIOR TO PROCEEDING,WHICH COVERS EVERY ASPECT OF YOUR

BUILD INCLUDING TOPICS SUCH AS FLYING OBJECTS, FLAMMABLE

LIQUIDS, PERSONAL PROTECTIVE EQUIPMENT, ELECTRIC HAND

TOOLS ETC.

PDF created with pdfFactory trial version www.pdffactory.com

ITEM

FLOOR

RADIATOR IN

RADIATOR OPTIONS

GEAR LEVER & HANDBRAKE

SIDE PANELS

FIT DASH

FRONT GRILLE

SIDE PANELS

REAR PANEL

BRAKE PIPES REAR

CUTTING DASH HOLE

DASH INSTALLED

BUSHES

FRONT SUSPENSION

DRIVE SHAFTS

REAR SUSPENSION

AIR INTAKE HOLES (2)

AIR VENT HOLES

AIR INTAKE HOLES (1)

MEV SONIC7 BUILD GALLERY CD

INDEX

PICTURE

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

THROTTLE CABLE/ACC/PEDALS/MASTER CYLINDERS

FRONT DUCT/MASTER CYLINDERS

ZETEC WATER PIPE DIAGRAM

STEERING COLUMN BUSH

REAR UPRIGHT

20

21

PAGE

3

3

4

4

5

5

6

13

14

22 14

23

24

15

15

8

8

9

6

7

7

9

10

10

11

11

12

REAR DISC & WHEEL SPACER

SPEED SENSOR

BELT

BELT BRACKET

ENGINE IN (A)

ENGINE IN (B)

ENGINE IN (C)

ENGINE IN (D)

FUEL PUMP

FUEL TANK

EXHAUST

FRONT WING BRACKET

REAR WING BRACKET

WING (A)

WING (B)

FRONT INDICATOR

REAR LIGHTS

FRONT BONNET CATCHES

ENGINE OVER CATCHES & ROLL BAR

BUILT SONIC7

WIRING SECTION INDEX

USEFUL INFORMATION

IVA REQUIREMENTS

COMPLETED SONIC7 PICTURE

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

23

23

24

24

25

25

26

47-50

51

52

16

16

17

17

18

18

19

19

20

20

21

21

22

22

2


1.FLOOR. Turn chassis upside down and rivet floor on using large head 5mm diameter alloy rivets at approximately 100mm centres. You may leave the outer edge ones until you rivet the sides on as the rivets run along the same lines.

2. RADIATOR, RADIATOR PIPES & BRAKE PIPES. The aluminium pipes are installed before the engine is in place. Two standard Focus radiator pipes will be required at each end of the alloy tubes. They will need cutting and twisting to get a good route without kinking the pipes. Note the

route the brake pipes take along the chassis rails. Space p-clips no more than 150mm apart.

3


3. 1.6 radiator to the left and a very tight fit for the 1.8 twin fan rad to the right

4. GEAR LEVER & HANDBRAKE. Here the Focus handbrake assembly is bolted together with a

Mondeo gear lever (96-2000). If you use the Focus gear lever the linkage will be reversed.

Fit brackets shown loose to suite cable lengths. These are standard Focus 1.8 cables.

5. SIDE PANELS. Hook over the top and bottom chassis rails then drill and rivet using large

head rivets at 100mm centres to the top and bottom chassis rails. The required holes

should be cut out prior to fitting. (See picture No. 8)

4


6. FIT DASH. From top front corner of grille to top front corner of dash measures 1390mm.

7. FRONT GRILLE. The front grille is fixed to the side panels with four bolts (two each side). These may need loosening to get the front top wishbone bolts in place.

5


8. SIDE PANELS. These are supplied pre-marked for hole cutting. Cut before or after fitting.

9. REAR PANEL. Here you can see the rear panel clamped to the side panel to drill holes for the

6


fixing bolts. Careful alignment will ensure good shut lines from the outside.

10. BRAKE PIPES REAR. Here you can see the brake pipes routed along the chassis rail at the

rear. P clips should be spaced at a maximum of 150mm centres.

11. CUTTING DASH HOLE. Ensure the area to be cut is covered with masking tape to avoid cracks.

Mark out your hole then put a drill hole in each of the four corners. Use a hacksaw to cut out the

7


required hole. Then file the edge to 2.5mm radius for IVA purposes.

12. DASH INSTALLED. Here you can see a switch panel installed with the digital speed, rpm, temp

supplied by Trail Tech.

8


13. AIR INTAKE HOLES (1) Mask the area to be drilled. Mark equidistant drill holes.

14. AIR INTAKE HOLES (2). Having drilled the holes, here you can see the finished shapes being

made using a sanding drill attachment. Choose your own shape or just have round holes.

15. AIR VENT HOLES. Here you can see the finished air intake holes, and you will also need two

vent holes in the engine cover. The exhaust vent holes can be one oval with mesh behind.

9


Heat proof felt should also be applied to the engine cover underside as the cat gets hot.

16. BUSHES. Remove paint before inserting bushes. File corners off to ease fitting. Use Teflon

grease on steel crush tube. If the centre tube is too tight the suspension will creak and may require

reaming out. A 19mm flat bit for wood can be used in a slow drill to clean a little out, carefully!

17. FRONT SUSPENSION. Fully assembled. Note steering track rod end inserted from underside.

10


Also note top ball joint screwed in with locking nut far enough for preliminary camber setting

of ‘0’ when checked with a spirit level on brake disc. (Disc 90 degrees to road). The shortest

arm on the top wishbone is towards the front of the car. On the front bottom wishbones the

straight arm is nearest the front of the car.

18. DRIVE SHAFT SPACERS. With engine in slide the drive shaft gaiters back to ensure that the tri bearing is not near the edge of its socket when the suspension travels from bump to droop.

Use washers as shown if necessary provided there is enough thread on the hub nut.

11


19. REAR SUSPENSION. Viewed from the rear of the driver’s side, the bottom wishbones are handed, the brake calliper should be in front of the drive shaft. The shock absorber is therefore to the rear of the drive shaft. The top rear wishbones are fitted with the longer piece to the rear

of the car. They have a square boss to screw the top camber adjuster to. Preliminary setting for

camber should be with the wheel at 90 degrees to the floor.

12


20. THROTTLE CABLE / ACCELERATOR / PEDALS / MASTER CYLINDERS. Here you can see the

master cylinders and pedal assembly bolted to the bracket on the chassis. The throttle cable can

be seen to the right. Use an outer with nylon insert. Cable will need to be around 3.3m long.

The balance bar needs to be fixed with lock wire for the IVA test to prevent adjustment. This can be done by drilling a small hole in the shaft or one of the nuts to thread the wire through.

13


21. FRONT DUCT/MASTER CYLINDERS. This is part of the dash mould and can be packed up and bolted to the front bulkhead chassis rail to ensure a perfect fit to the bonnet. Pipes from reservoir also shown, you will need proof that these are suitable for brake fluid for the IVA inspection.

22. You can see from the diagram that we have blocked off the rear facing pipe from the thermostat housing. Also shown is a 10mm pipe from the top of the radiator to help reduce air locks.

14


23. STEERING COLUMN BUSH. You will need to fit a bush to the front bulkhead for support.

24. REAR UPRIGHT. Rear upright with the calliper attached, the half shaft inserted and the hand

brake lever plates, which have been swapped from the opposite calliper so that the cable pulls

upwards. Remove nut and screw next to spring to change the levers over.

15


25. REAR DISC & WHEEL SPACER. Use 205/40/17 tyres with a 40mm (FORD) offset wheel to the front and 15mm (PEUGEOT)offset to the rear, 25mm wheel spacers are used on the rear with longer studs. Or you will need 50mm rear spacers if using 40mm offset (ET) wheels all round.

Picture taken from nearside showing calliper in front of drive shaft. Car rear to the right.

26. SPEED SENSOR. Drill and tap or weld or glue a nut onto a moving part of the drive shaft for

the magnet, then make a bracket to mount the sensor switch.

16


27. BELT. For the 1.8 engine you will need to re-route the belt as shown.

28. BELT BRACKET. Here you can see a bracket made from 6mm x 60mm x 60mm angle to

support the relocated belt tensioner.

17


29. ENGINE IN (A). It is advisable to protect the sides of the car when installing the engine.

It can be fitted prior to fitting the sides if preferred.

30. ENGINE IN (B). Here you can see the ECU mounted on a bracket at the rear. A new battery

has been used (Type 54). This is smaller than the donor battery. It is strapped in using the

donor strap. We also use the donor battery cables. The 1.8 engine air inlet pipe is shortened

to clear the engine cover. The airflow meter is fitted as shown.

18


31. ENGINE IN (C). The diagnostic connector can be seen here mounted on a bracket. The

relays for start, fan, pump and main can be seen in the foreground of the picture.

32. ENGINE IN. (D) Water temp sensor fitted in pipe from the header tank to the former heater

hose. The second water hose is blanked off with a stud.

19


33. FUEL PUMP. Fuel pump extended using 3 lengths of 6mm bar to reach the bottom of the tank.

We suggest you remove the ¼ turn fitting from the bottom of the Focus tank and fit this back on the end of your pump housing. Adjust the 3 threaded bars to position the pump on the tank bottom.

34. FUEL TANK. Observe the arrows on the plastic moulding for outlet and inlet. The pump outlet is connected to the throttle body end of the fuel rail. Note that for BIVA the fuel tank must be separated from the passenger compartment by a bulkhead.

20


35. EXHAUST. The donor cat can be retained from the 1.8 engine. The new exhaust will then

bolt to the cat flange under the engine.

36. FRONT WING BRACKET. The front wing bracket is bolted to the upright with two bolts and the

top ball joint.

21


37. REAR WING BRACKET. Here masking tape is used for marking the holes to be drilled. Their

exact location is not critical as holes will need to be drilled in the wings themselves. The stay

shown will need to be around 80 degrees to the side of the upright so that it clears the body during

suspension travel.

38. WING (A). The wing is bonded to the wing stay using PU adhesive.

22


39. WING (B). For IVA purposes, the wing must be attached in a manner so that if a vertical line were drawn from the leading or trailing edge down to the floor, the edge of the wheel rim would be inside that line. Check the forward stay of the rear pair is clear the body during suspension travel.

40. FRONT INDICATOR. For IVA purposes, indicators must be positioned at a minimum height of

350mm (floor to edge of light emitting surface), & a maximum of 400mm from edge of car. 200mm from the front for visibility regs. The headlights need to be a maximum of 500mm above the ground.

23


41. REAR LIGHTS. For IVA purposes the stop lamp must be a minimum height of 350mm (floor

to edge of light emitting surface). The fog light must be a minimum height of 250mm. The

minimum separation distance between the fog light and the stop light is 100mm.

42. FRONT BONNET CATCHES. Here we chose quarter turn flush fit bonnet locks. These are

mounted on an L shaped bracket bolted to the chassis as shown.

24


43. ENGINE COVER CATCHES & ROLL BAR. The roll bar can be seen here, drilled and bolted

through the rear bulkhead. Also shown is the engine cover over centre catch.

44. FINISHED SONIC7.

25


WIRING SECTION

INDEX

ITEM PAGE

NO.

.

C80 PLUG WIRING DIAGRAM (Focus Fuse Box Plug)

ENGINE BAY WIRING DIAGRAM

LIGHTING SYSTEM

LIGHTING WIRING

C80 CONNECTOR LOCATION DRAWING

ENGINE FUSE BOX

C390 CONNECTOR IMMOBILISER SYSTEM

C80 PLUG WIRING DIAGRAM

IMMOBILISER SYSTEM WIRING TABLE

FORD LOOM CONNECTIONS

FOCUS ENGINE LOOM PICTURE

LAMBDA SENSOR TABLE

FRONT FUSE BOX DRAWING AND TABLE

27

28

29

30

31

32

33

34

IGNITION SWITCH CONNECTOR

INDICATOR SWITCH CONNECTOR

35

36

37

38

39

HAZARD & LIGHTING SWITCH WIRING 40

41

42

43 CONNECTOR LOCATIONS FOR:

C390 IMMOBILISER PLUG

C459 INDICATOR/LIGHTING STALK

C456 IGNITION SWITCH PLUG

DASHBOARD COMPUTER 44

OPTIONAL FOCUS INSTRUMENT HOUSING 45

MEV WIRING LOOM – QUICK REFERENCE



SONIC7 picture complete and ready to go!

46

47-50

51

52

26


WIRING DIAGRAM

Issue 1 (7/5/2007)

Ford Focus

DONOR ENGINE BAY FUSE BOX PLUG TO BE CUT OFF

AND CONNECTED AS PER WIRING DIAGRAM ON PAGE 33

27


Pin Number Colour

1 GN/BU

8

9

6

7

10

4

5

2

3

11

12

13

14

15

16

GY

BK/BU

RD

GN/YE

RD

BK/BU

GN/OG

GN/WH

GN/BU

GN/YE

Connection

Ignition Coil Supply

ENGINE BAY WIRING TABLE

Fuel Pump Relay Earth “86”

Alternator Battery Feed

Lambda Heater Supply

ECU Battery Supply

Low Speed Cooling Fan Relay “86”

Fuel Pump Relay Feedback / Fuel Pump Supply

Reverse Lamp Switch IN FROM FUSE

Component Supply

Reverse Lamp Switch OUT TO LAMP

Engine Run Relay NOT CONNECTED

Starter Solenoid Feed “87”

A.C Pressure Switch NOT CONNECTED

A.C Pressure Switch NOT CONNECTED

High Speed Cooling Fan Relay “85”

NOT CONNECTED

Source

Ignition Switch (Ignition

Supply)

ECU

ECU

Battery

Main Relay “87”

Battery

ECU

ECU

MEV Loom WH/BU

Main Relay

MEV Loom WH/BU

ECU

ECU Connection

52

53

13

8

Inc 37 & 57

31

28



Fuse

1

2

3

4

30


Engine Fuse Box

Fuse Value

20A

15A

20A

10A

Immobiliser System

Transponder Module (Fitted Around Ignition Barrel) Fitted with C390 Connector

31


32


Connection

Transponder Module Pin 1



Component

Connection

Colour

GN/BK

BK/GN

GY/OR

Immobiliser System

MEV Loom

Connection

ECU

Connection

BK/GN

Chassis Earth

Connection

OR/GY

NA

NA

38


Immobiliser Warning *

LED

Immobiliser Warning*

LED

WH/GN

RD

WH/BK

WH/GN

WH/BK

5

39*

33


Main Relay “87”

Connect to Focus Loom

Drivers Foot well


Drivers Foot well

Battery Connection


Drivers Foot well BL/OR

Colour

BK/OR

WH/BU

OR/BK

GY/OR

BK/RD

WH/PU

WH

WH/GN

GR/OR

All BK wires

BU/BK

GY/OR

BK/OR

BK

WH/BU

GR/OR

BK/GR

GR/BK

Ford Loom Connections

(There are several wires as listed below that need cutting and re-joining to MEV loom)

The diagnostic connector is located just above the brake pedal in the corner of the storage tray.

This needs removing and cutting off with 3” of wire to connect as described.

Connection ECU Notes

Immobiliser LED

N.C

Diagnostic Connecter

Pin 39

Immobiliser Module Pin 38

Starter Motor Relay “86” Pin 32

Connect to MEV loom WH/BK

Pin 17 Extend to Diagnostic Connecter Pin 13

Connect to MEV loom OR/GY

Connect to Starter Relay “86”

N.C

N.C

Immobiliser Module

Fuel Pump Supply

Connect to Earth



Pin 5

Pin 8

Connect to MEV loom WH/GN

Connect to in Tank Pump

Connect to Chassis Earth



N.C

Connect to Earth

N.C

N.C

N.C

N.C

Connect to Earth Pin 43

Connect to Chassis Earth

Clutch Position Indicator

(or Pin 64 on ECU with 104 Pins)

34


FOCUS ENGINE LOOM

NOTE ALL PLUGS RETAINED APART FROM THE ONE FROM THE FUSE BOX. THE WIRES RUNNING TOWARDS THE BACK OF THE

FOCUS BEYOND THE ECU ARE CUT AND RE-CONNECTED AS PER PAGES 33 AND 34 OF WIRING DIAGRAMS.

35


Colour

WH/RD

BK/BU

JOINED BR & BR/RD

GR/BU

Models with 2 Lambda Sensors

(pre and post cat)

Connection

Lambda Sensor

ECU

Pin 48

Lambda Sensor

Lambda Sensor

Lambda Sensor

Pin 51

Notes

Extend Ford loom to connect to post cat

Lambda Sensor


Lambda Sensor


Lambda Sensor


Lambda Sensor

36


Front Fuse Box

Fuse Number

4

5

6

1

2

3

37


Component

Side Lamps / Dash

Brake Lamps

Low Beam

High Beam

Reverse / Fog Lamp

Dash / Indicators

Fuse Value

20A

15A

20A

20A

15A

15A

Component

Left Indicator

Right Indicator

Side Lamps

Low Beam

High Beam

Lighting System

FRONT

Colour

OR/BU

BK/OR

BU/RD

PU

RD

BACK

Component

Left Indicator

Right Indicator

Brake Lamps

Tail Lamps

Reverse Lamp

Fog Lamp

Colour

OR/BU

BK/OR

WH/RD

BU/RD

WH/BU

BK/YE

38


39


40


Ignition Switch Connector

Pin Number

1

4

Connection

Ignition

Battery

7 Starter Switch

OTHER CONNECTIONS NOT REQUIRED FOR MEV LOOM

41


Colour

GN/YE to mev loom PU

RD to mev loom RD

GY/OR to mev loomOR/BK

Indicator Switch Connector

42


Connector Locations

43


Description

RPM

Road Speed Sensor

Road Speed Sensor

Ground

Clock Power Acewell

N.A. Vapor Trail Tech

Ignition Supply

Water Temp

Dash Board Computer

Acewell Colour

N.A. Vapor Trail

YE

MEV Loom

Colour

YE/GN

GN

WH

BK

BN

RD

BU

BK/BU

WH

OR/YE

Other Info

Connect to BK/OR

Wire on Ignition

Coil Connector

Connected to Road

Speed Sensor

Connected to Road

Speed Sensor

Earth Connection

Fused at board

From key switch

Connect To Water

Temp Sensor

44


Above you can see the optional Focus instrument housing, this enables you to use the instruments from the Focus.

Connections for the Focus dash are as follows. Normal wire colours below,

Dash pin number 13 connect to ECU pin 19 grey/orange or grey violet.

26 to 18 blue/black or blue white.

10 to ignition switch pin 6 (7.5amp fused) yellow/blue or yellow.

16 to ignition switch pin 1 (7.5amp fused) green/red or green/yellow.

14 battery constant positive (10amp fused) red.

2 earth. Black wire

45


MEV WIRING LOOM – QUICK REFERENCE

COLOUR DESCRIPTION COLOUR DESCRIPTION

PU 1MM

RD 1MM

BU/RD

BK/OR

PU 1MM

RD 1MM

BU/RD

OR/BU

PU/BK

PU/BU

GN/BK

PU/BK

DIP

MAIN

SIDE

RIGHT INDICATOR FRONT

DIP

MAIN

SIDE

LEFT INDICATOR FRONT

BRAKE RESERVOIR

DASH FUEL TANK LEVEL

PETROL PUMP

BRAKE RESERVOIR

WH/BK

WH/GN

OR/BK

BK 1MM

OR/BU

WH/BU

BK/OR

BU/RD

WH/RD

BK/YE

RED 2MM

IMMOB LED ECU 39

IMMOB MODULE ECU 5

STARTER RELAY

GROUND

LEFT INDIC REAR

REVERSE LAMP

RIGHT INDIC REAR

TAIL LAMPS LEFT/RIGHT

STOP LAMPS

FOG LAMP

FAN

YE/GN

OR/YE

WH

BK/BU

PU 2MM

RD 4MM

BK/GN

OR/GY

DASH REV COUNTER

DASH COOLANT TEMPERATURE

DASH ROAD SPEED SENSOR

DASH ROAD SPEED SENSOR

IGNITION FEED

BATTERY FEED

POWER TO IMMOBILISER

IMMOB MODULE ECU 38

46



STEERING SET UP

You will note from Fig 1 that the line intersecting the top and bottom front ball joints (when viewed from the front) is referred to as the King Pin

Inclination. By winding in the top ball joint this angle is increased and will cause the tyre to lean in at the top. This is the Camber Angle of the wheels whereas the KPI refers to the geometry of the steering.

CAMBER ADJUSTMENT

For initial set up adjust the ride height by adjusting the shock absorber spring seat, so that the bottom wishbones are somewhere near parallel to the ground. Then place a spirit level vertically onto the side of the front tyre, when the spirit level bubble is centred there should be a gap between the spirit level and the side of the tyre at the top of around

10mm, whereas the bottom of the spirit level will be contacting the side of the tyre. This is referred to as Negative Camber. The camber setting for the rear is adjusted in the same manner but initial settings would have the wheels set for zero camber i.e. perpendicular to the road.

CASTOR ADJUSTMENT

You will note from Fig 2 that the line intersecting the front top and bottom ball joints (when viewed from the side) is angled so that the line hits the ground slightly in front of the tyre contact patch. This is the castor angle and can be increased or decreased using washers as spacers to move the top wishbones forwards or backwards. Personal preference plays a big part here, but if castor is minimised then so is the self centring effect of the steering which could result in an SVA failure.

STEERING COLUMN SUPPORT

It is recommended that some form of bush is used at the point the column passes through the bulkhead. A piece of plastic 50mm x

50mm x 6mm with a hole in the middle the same size as the shaft could be used. This could be cut in half and then the two halves offered up and bolted on.

.

47


SPRING RATES

Please ensure you use the springs marked 325 on the rear. Fronts are 175. This relates to the amount of effort in lbs required to compress the springs per inch

DAMPER SETTINGS

It is recommended that initially the dampers be set to minimum i.e. adjuster knob fully anti-clockwise and that the ride height is set by adjusting the spring seat up or down. You should adjust the ride height so that the bottom wishbones are almost parallel to the ground. Provided the suspension bushes are greased then after a few hundred miles the suspension will become less stiff, and you may then wish to experiment with increasing the damping setting.

TRACKING

Four wheel alignment is not necessary as the rear tracking is fixed. Initial setting of the front tracking should tend to lead towards a small amount of toe in. This can be done using two straight edges of say 2 metres in length, if one is clamped to each front disc protruding exactly 1 metre forward and 1 metre back from the axle centre line, then it is possible to take accurate measurements. The measurement taken between the ends of the two straight edges at the front of the car should be 5mm less than the measurement taken between the ends of the two straight edges under the middle of the car.

BUMP STEER

Bump steer is when the tracking varies as the wheels go through their suspension travel. In order to assess this it is best to remove the front springs and put the shock absorbers back on, and then using the two straight edges as mentioned above, you can push the front hubs upwards until the shock absorbers reach the bump stops. Then take measurements between the two straight edges. Then lower the hubs so they are at full droop, and compare the measurements between the straight edges to those taken at full bump. By adjusting the height of the rack you will be able to achieve a balance so that if say, at full bump the measurement is 5mm less than at normal ride height, you will be looking to achieve the same measurement at full droop. If it is found the rack needs to be lowered slightly, then you can shave a small amount off the alloy around the bolt holes on the rack. To raise it, pack a washer under the rack each side. In carrying out either of these exercises you will note that a 1mm alteration in the rack height by can make a huge difference to bump steer.

LIGHTING POSITIONS

In order to comply with the IVA regulations, the light emitting surface of the amber and red areas of the stop and tail lights must be within 400mm of the outside edge of the cycle wing. The 400mm rule also applies to the directional indicators.

48


CYCLE WING POSITIONING

In order to comply with IVA regulations, it is necessary for the front and rear corners of the cycle wings to be proud of the wheel rim when viewed from the side, if a vertical line is taken from the external front nose the rim should not protrude forward of this line. When bolting the rear stays to the uprights the forward one will need to be around 80 degrees to the side of the upright so it clears the body during suspension travel.

TYRES/WHEELS

You will need 7”wide wheels for the front with a 40mm offset and 4 x 108 pcd stud holes. For the rear 4 x 108 with 15mm offset, and 25mm thick rear spacers. It is important to ensure maximum tyre contact patch with the road surface, and with a lightweight car running on wide tyres, it may be necessary to run front tyre pressures at around 18 psi and the rears at 22 psi. Our demo car is fitted with 205/40/17 tyres.

MIRRORS

We have found the most suitable mirrors are from a Yamaha R1, the later ones however have an unsuitable shorter stem. There is an IVA requirement for a rear view mirror. We suggest that a sucker type mirror be attached to the fly screen in order to comply even though there will be no rear visibility from it. The required visibility will be provided by the two wing mirrors.

BRAKE BRACKETS

It is possible to use the brake fluid reservoir from the donor by mounting it to the front bulkhead just above the top tube. Take care when making brackets to mount the flexible brake hoses as the positions are critical depending on the length of hoses. It is possible to use the donor hoses however, before riveting on your mounting brackets ensure that they do not pull tight when on full lock and do not allow the pipe to contact any moving parts when on the opposite lock

ENGINE MOUNTING

The top engine mount on the belt side may need the top part removing to clear the body work, but it is also possible to remove part of the bodywork in this area without a gap showing. If you do choose to modify the mount be warned that it is filled with oil and will spray when cutting into it.

RADIATOR

The Sonic7 uses the radiator from a 1.6 non air con Focus. If you have a radiator with two fans then this is too big. If you cannot easily source the correct one, then a Renault Megane 1.4 or 1.6 will go in with slight modification to the lower brackets. Top mounts are usually made from 3mm alloy which can be riveted onto the chassis or drilled and tapped.

49


THROTTLE CABLE

A 3.3 metre cable will be required. These are available from bike shops. It is best to use an outer cable with a nylon insert. By using a screw on nipple you will be able to pass the cable through, form a loop and then go back through the same hole before clamping at each end. It may be prudent to fit a stop on the pedal so the cable is not under strain at full throttle.

BOLT SIZES

You will need:

22 No. button head bolts (button head allen key) 12mm x 65mm, and a further 10 No. at 12mm x 80mm.

These are for the suspension and steering rack.

18 No. at 8mm x 30mm for the front bottom ball joints, handbrake, gear lever, gear box mount and steering column.

80 No. large head 5mm x 12mm rivets for the floor.

50 No. at 3mm x 12mm rivets for the bulkheads.

8 No. at 6mm x 25mm bolts for the rear cycle wing stays.

4 No. at 8mm x 100mm bolts for the front cycle wing stays.

4 No. at 8mm x 50mm with 12 nuts to mount the pedal assembly (extra nuts are spacers).

There will be numerous other 6mm bolts required of various lengths for mounting items such as brake fluid reservoir, header tank, radiator, etc. and you will also require bolts for fixing your seats.

Please note the above list of bolts will also require nylocks, nuts and washers.

You will also need at least one tube of polyurethane adhesive. It is recommended gloves are worn when using this.

UNDERSTEER

OVERSTEER when you lose control of the front end when you lose control of the back end

HORSEPOWER how fast you get there

TORQUE how much weight you can take there

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ALWAYS DOUBLE CHECK TO ENSURE YOU ARE AWARE OF UP TO DATE AMENDMENTS TO IVA RULES. Different Inspectors may have their own interpretation of the rules. Some are pedantic over minor issues, some are more realistic and apply common sense. However the following points will always be picked up on.

Virtually any point on the car that can be contacted with a 100mm diameter sphere needs to have radius edges of least 2.5mm. They should only check the suspension however from the front. Capping may therefore be required on some edges, various rubber u sections are available and it is advisable to use trims from the donor such as the boot seal. Make sure you can prove by way of a receipt or some other proof from the place of purchase that you have used proper brake pipe. Make sure you buy fuel pipe which has “fuel pipe” written on it.

If you fit the fly screen prior to IVA it will need a radius edge, and the bolts should be button head. Even the nuts on the underside of the bonnet should be capped, the cheapest way to do this is to cut a short length of petrol or heater hose, to push over the nuts. Bias adjustable brakes are not permissible for IVA.

In addition to the two wing mirrors (Yamaha R1 type) you will need a stick on internal mirror, even though it will be useless.

You do not need a spare tyre.

Airbags are not permitted, but a rubber steering wheel centre (shore 50 hardness maybe required).

Headlights can generally be adjusted during the test.

Be prepared to re-calibrate your speedo during the test.

Ensure all bolts protrude sufficiently into the nylon of the nylock nuts.

All lights except fog and reverse must have the edge of the illuminated surface within 400mm of the edge of the wing.

Defects such as tyres that would fail an MOT are not IVA failure points,

You do not need an MOT in addition to the Ministry’s Approval Certificate issued at the IVA station.

When registering your Rocket at the DVLA, request that the original MAC is returned, or at least a copy.

THINGS TO TAKE TO THE TEST FOR MINOR MODIFICATIONS – V5 to prove the donor age

Insulating Tape

Duck Tape

Rubber Pipe

Battery Drill

Self Tappers

Socket Set

Rivets

Spanners

Cable Ties

Cutters

Rubber Capping

P Clips

Pliers

Screwdrivers

51


WE HOPE YOU ENJOY BUILDING & DRIVING YOUR SONIC7.

ANY QUESTIONS PLEASE DO NOT HESTITATE TO CONTACT US.

MILLS EXTREME VEHICLES LTD. RATCHER HILL QUARRY. SOUTHWELL ROAD. MANSFIELD. NOTTS. NG18 4GE.

01623-655522 / www.mevltd.co.uk / [email protected]

52


MEV Sonic7 Build guide

Assistant Bot

MEV SONIC7

BUILD GALLERY CD

WIRING SECTION

INDEX

WIRING DIAGRAM

Ford Focus

Engine Fuse Box

Connection

Component

Connection

Colour

Immobiliser System

MEV Loom

Connection

ECU

Connection

Colour

Ford Loom Connections

Connection ECU Notes

FOCUS ENGINE LOOM

Colour

Models with 2 Lambda Sensors

(pre and post cat)

Connection

ECU

Notes

Front Fuse Box

Fuse Number

Component

Fuse Value

Component

Left Indicator

Right Indicator

Side Lamps

Low Beam

High Beam

Lighting System

FRONT

Colour

OR/BU

BK/OR

BU/RD

PU

RD

BACK

Component

Left Indicator

Right Indicator

Brake Lamps

Tail Lamps

Reverse Lamp

Fog Lamp

Colour

OR/BU

BK/OR

WH/RD

BU/RD

WH/BU

BK/YE

Ignition Switch Connector

Pin Number

1

4

Connection

Ignition

Battery

7 Starter Switch

Colour

GN/YE to mev loom PU

RD to mev loom RD

GY/OR to mev loomOR/BK

Indicator Switch Connector

Connector Locations

Description

RPM

Road Speed Sensor

Road Speed Sensor

Ground