In the June 2008 issue of Kit Car magazine you can read how I sourced and prepared all the donor components required for my RUSH CW460, a must-have for anyone building a kit car using Ford hardware. In addition, I cover the collection of my kit from D J Sportscars and the first few hours in the garage forming the passenger safety cell. If you have yet to read the feature, I suggest you get a copy of the magazine and share in my excitement as the build truly gets under way.

To complement the entertaining and informative magazine features, this page contains a large selection of additional images following my progress to date.

Remember, if you have any questions or comments just use the 'Contact Us' button above. I always endeavour to reply to all mails within 48 hours, but back to the RUSH CW460 build ...

 

The first stage was to source and prepare the numerous donor components, including driveshafts, differential, front uprights, rear stub axles, bearing carriers and hubs.

Brand new 100mm diameter Ford Cosworth driveshafts. Read the magazine if you want to know my source - there are only a limited number left in the country.

 

These pristine driveshafts could have been bolted straight on to my RUSH, but you know me ...

 

Removal of circlips at either end of driveshaft allows disassembly.

 

Lobro joint removed.

 

Once components cleaned, Innotec OEM high specification paint applied.

 

Lobro joints repacked with high temperature OEM grease.

 

Just waiting for new clips.

 

Brand new Ford Cosworth front uprights from Rally Design. Note application of OEM paint.

 

Brand-new Ford Cosworth Group 'A' rally specification rear stub axles and flanges. Very rare and expensive!

 

Even more expensive. Fully reconditioned 3.36 ratio rear differential from Rally Design. Larger 7.5 inch crown wheel selected for optimum strength. Both a 'must' to accomodate the CW460's power.

 

One of the first jobs on the RUSH CW460 chassis - bush insertion.

 

One differential bush in situ. Care must be taken not to damage the rubber outer during insertion. Read my article in Kit Car to tell you how.

 

Aluminium panels offered up to chassis ready for trimming.

 

Trimming tools are available from many suppliers. This nibbler was supplied by Car Builder Solutions.

 

Next stage is to drill the dozens of rivet holes.

 

Attention to detail. All the aluminium panels were sprayed with OEM paint prior to fitting.

 

Powdercoating removed from chassis rails to provide a 'key' for the sealant.

 

High quality sealant from Innotec.

 

Panels riveted into place.

 

Some panels require forming around chassis tubes. Note use of skin pins to clamp panel.

 

Fibreglass rear quarter sections require a fair amount of trimming.

 

The results of my efforts to date... don't miss next month's update and remember to get Kit Car magazine for an in-depth account of the work so far.