The Beginning

I haven't seen any other South African Blogs about this so this may be a first. This is my first stab at it so please be patient!

Ok so I better begin. I've always been keen to build a kit car, ever since I saw the Top Gear crew build the Caterham in that race with the Stig, I thought, well if they can do it....

I looked at the Cobra, but that needs some specialist bits in terms of suspension and I was NOT keen to hunt around scrapyards looking for a Jag suspension, so it fell to a Lotus 7 variant. The Birkin is just about the best replica going, apart from the Caterham, and it is local, so I guess it really was a one horse race.

So I rang them up, and placed an order for a CKD Birkin S3, with Independent Rear Suspension (IRS). I was told 4-5 weeks it would be ready for collection or freighting. When I heard the cost of freighting I opted to collect it FOB Pinetown.

During the intervening month from Order to Collection, I started looking for the bits and pieces that I would have to source to complete the project - the engine, gearbox and differential.

For the engine I had 3 choices - Toyota 20V AGE, Ford Zetec and Ford Duratec. I had heard a lot about the Duratec and it certainly looked like this engine was the "next best thing" being light, good horsepower delivery, parts readily available etc etc. So the Duratec 2.0 was my choice. There is a multitude of "go faster" bits available for this engine, mostly available from the UK. Some phoning around and I found one at Forma motor spares in Pretoria - it was an import made in Mexico and I think it came off a 2002 Mondeo because it came with an aircon and power steering units bolted on.

The next thing was the gearbox and really there is only one choice and that is the venerable Ford 5-speed Type 9 from the 80's that was fitted to millions of Sierras and Sapphires. I don't know what happened to all these vehicles but there are a few of them knocking around in Mokopane and every time I see one I silently wish the driver would wrap it round a tree so I can get the bits. Having said that the box would probably be knackered so I am thinking I will have to get a reconditioned unit.

Lastly the differential also comes from a Sierra or Sapphire. These boxes are built like a brick s**t-house so I am not expecting problems there.