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Planning
If a site like this is to be of any value to future Rush
builders, it should tell you what sort of cost you are letting yourself in for.
Budget
My build budget was £15,000. Rushes can be built for about half
this, but not a V8 IRS version with most parts bought from DAX!
I worked out all known costs in advance, using a spreadsheet and
included a healthy contingency of £500 to cover the unknowns. Amazingly, the actual build
costs come out to almost exactly £15,000, plus some extras for tools and garage
improvements.
Admittedly, my build was not a real budget job, but I
believe these numbers are typical of what you might spend to achieve a similar result.
I've tried to include every nut and bolt that I had to pay for.
It's the little items that mount up and contribute significantly to the build costs.
My build costs to date are recorded below under the headings:
Time Scale
During the build I kept a note of the number of hours spent in
the garage each day. The total comes to 400 hours for the build itself,
from kit delivery to SVA. This figure represents the total elapsed time, not the amount of
effort. For a good proportion of this time I had help in the garage. I would estimate that
roughly one-quarter of the time I had double the man-power.
The total build effort in man-hours therefore comes to 500
hours, plus approximately another 150 hours of
preparation time before the kit arrived.
Of course, some of these man-hours are actually woman-hours :-)
Thanks girls!
Extra Tools Bought
When I started this build, I already had a decent set of DIY and
automotive tools. However, I still had to buy some extra stuff to help progress along.
This section also includes replacements for the things we bust
during the build!
| Allen keys sets (2) |
£7.98 |
| File set |
£11.69 |
| Engine stand (750lbs), extra bolts |
£36.51 |
| Haynes manual - Rover 3500 |
£10.39 |
| Haynes manual - Sierra V6 |
£10.39 |
| Tin snips |
£2.00 |
| Wire brushes |
£25.99 |
| Socket breaker bar (1/2") |
£19.99 |
| Engine degreasant |
£9.99 |
| Torx socket set |
£24.95 |
| Leather gauntlets |
£3.23 |
| 41mm socket (Sierra hub nut) |
£16.85 |
| Socket breaker bar (3/4") |
£22.95 |
| T40 Allen key |
£0.92 |
| Another socket set |
£21.95 |
| Plus Gas (dismantling fluid) |
£3.29 |
| Methylated spirits |
£2.50 |
| 13mm socket |
£2.88 |
| Hub puller |
£19.99 |
| Deb Altrans (derusting fluid) |
£15.30 |
| Polishing wheel, arbour, polish |
£14.04 |
| Paraffin |
£3.99 |
| Latex gloves |
£7.05 |
| Angle grinder |
£19.25 |
| Grindstones |
£5.39 |
| Centre punch |
£1.00 |
| Steel rule |
£2.99 |
| 6mm cobalt drill bit |
£5.52 |
| Rivet gun |
£9.95 |
| Reamer bit |
£8.75 |
| Fume-resistant face mask |
£24.99 |
| Emery cloth |
£1.69 |
| 3/8" spanner |
£3.20 |
| Hole punch |
£1.50 |
| 3mm drill bit |
£1.19 |
| Wet & dry paper (1000 grit) |
£1.99 |
| 2" masking tape |
£2.19 |
| 4mm cobalt drill bit |
£3.29 |
| Rover 3500 Workshop Manual |
£2.00 |
| Ball-joint splitter |
£18.35 |
| String |
£3.17 |
| |
|
| TOTAL |
£ 411.23 |
Garage Conversion Costs
My garage was a plain, single garage with concrete floor and
brick & block walls. Luckily, the main house fusebox is in there. To transform it into
a palace of delight where I would be happy to spend many hours, I smartened it up a bit
and added extra light and power.
| Floor paint |
£32.49 |
| Trestle dogs and wood |
£26.41 |
| Gap filler |
£5.99 |
| Draught excluder |
£10.49 |
| Ceiling paint |
£8.49 |
| Fan heater |
£9.99 |
| Garage door bolt |
£8.24 |
| 2 Tool racks |
£3.98 |
| Fuse box, fluorescent lights, double sockets, wire |
£120.45 |
| Rope (for hoisting engine) |
£4.10 |
| Metal shelving |
£7.99 |
| Halogen light for inspection lamp, wire |
£7.78 |
| |
|
| TOTAL |
£ 246.40 |
Build Costs
These are the parts that make up the Rush itself. Since there are
so many of these items, I've categorised them:
Dax Items:
| Build Manual & Dax SVA guide |
£21.50 |
| Build Pack 1 deposit |
£200.00 |
Main delivery:
 | Build Pack 1 - chassis / body panels |
| Build Pack 2 - suspension 'A' |
| Build Pack 3 - suspension 'B' |
| Build Pack 4 - brakes 'A' |
| Build Pack 5 - brakes 'B' |
| Build Pack 6 - electrical |
| Build Pack 7 - brightwork |
| Powder coating of chassis |
| Stinless steel rear hoop |
| Aluminium bonnet and side panels |
| Rover V8 / IRS propshaft |
| Handbrake and harness gaiters |
| Explosafe-filled fuel tank |
| Fine matrix radiator |
| Wurth adhesive |
| Steering column modification |
| Clutch master cylinder |
| Rover V8 exhaust system / heatshields |
| Instrument set |
| Speedo cable |
| Wiper arms and blades |
| Battery |
| Filler pipe and cap |
| Alloy wheels |
| GRP dashboard |
| Vinyl squab seats |
| SVA grill bar |
| 4-point harnesses |
| Bonnet catch protectors |
| Delivery charge |
| Including discount |
|
£9978.52 |
| Heater vents, reversing lamp |
£25.79 |
| Carpet set |
£251.69 |
| Main and rear tonneau covers |
£211.50 |
| |
|
| TOTAL |
£ 10689.50 |
Donor Parts:
Donor engine & gearbox (see Specification):
| Rebuilt & uprated Rover V8 engine |
| Clutch & gearbox |
| Spare gasket set |
| Viper Typhoon camshaft |
| Rhoads lifters |
| Shortened pushrods & rocker shims |
| Spare standard camshaft |
| Remote oil filter kit |
| Kenlowe cooling fan |
| Spare electronic distributor |
| Service parts for Mallory distributor |
| Carter fuel pump |
|
£2000.00 |
| Ford Sierra XR4x4 rear subframe complete |
£175.00 |
Hollis parts #1:
| Ford Sierra steering column, wheel, stalks, key, cowlings |
| Mini heater & ducting pipes |
| Mini wiper motor, clamp, rack, wheelboxes |
| Cortina front subframe complete |
| Cortina Haynes manual |
|
£129.25 |
Hollis parts #2:
| V8 engine mounts |
| Rover expansion tank (not used in the end) |
| Mini heater fishtails (not used in the end) |
| SD1 reversing light switch |
| VW (Polo?) heater control valve |
|
£18.00 |
Hollis parts #3:
| Vauxhall Cavalier expansion tank |
| Coil mounting clip |
|
£5.88 |
| |
|
| TOTAL |
£ 2328.13 |
Donor Reconditioning Parts:
| Oil filter |
£7.99 |
| Rear brake pads (XR4x4) |
£30.23 |
| Front brake pads (Cortina) |
£17.58 |
| Front brake discs (Cortina) |
£38.49 |
| Front wheel bearings (Cortina) |
£14.97 |
| Front caliper seals (Cortina) |
£21.22 |
| Differential seals (XR4x4) (not used in the end) |
£18.88 |
| Diff. filler plug (XR4x4) |
£4.59 |
| Rear wheel bearings (XR4x4) |
£108.10 |
| Inlet manifold gasket & seals (Rover V8) |
£20.68 |
| Thermostat gaskets (Rover V8) |
£1.69 |
| Brake caliper bleed nipples (Ford) |
£4.00 |
| Front brake pad fitting kit (Cortina) |
£2.99 |
| Wiper motor rubber pad |
£3.06 |
| Spark plugs (Rover V8) |
£20.98 |
| Rear calipers (reconditioned XR4x4) |
£60.00 |
| Expansion tank cap (Cavalier) |
£4.00 |
| Lucas alternator & fan (exchange) |
£37.11 |
| Kenlowe thermostat unit |
£35.25 |
| Throttle return spring |
£0.30 |
| Spare ignition keys |
£0.00! |
| 125 degree wiper motor gear wheel |
£19.95 |
| Long wheel studs |
£6.77 |
| High-pressure oil relief valve & spring |
£3.52 |
| |
|
| TOTAL |
£ 482.35 |
Paint, glue etc.
| Red & black engine paint |
£17.10 |
| High-temp silver paint |
£4.50 |
| Anti-rust primer |
£3.99 |
| Gasket compound |
£9.27 |
| Gold caliper lacquer |
£19.95 |
| Spray glue |
£3.00 |
| Touch-up paint |
£4.98 |
| Gold spray paint |
£3.49 |
| Thread-lock glue |
£3.00 |
| Silicone sealer |
£7.98 |
| Polyurethane mastic |
£14.38 |
| Undersealing paint |
£8.99 |
| Contact adhesive |
£18.69 |
| Satin black spray paint |
£4.99 |
| Putty |
£1.70 |
| Meths |
£1.79 |
| Body filler |
£8.46 |
| Waxoyl |
£3.50 |
| |
|
| TOTAL |
£ 139.76 |
Fluids, hoses:
| Fuel filter & clip |
£2.00 |
| Fuel pipe |
£2.70 |
| Engine oil |
£29.98 |
| Differential oil |
£4.00 |
| Brake fluid |
£9.00 |
| Radiator hose |
£7.20 |
| Clutch hose unions |
£7.31 |
| Antifreeze |
£9.99 |
| Water hose |
£7.30 |
| Hose clips |
£19.64 |
| Brake grease |
£0.99 |
| 15mm - 8mm fuel hose reducer |
£1.75 |
|
|
| TOTAL |
£ 101.86 |
Fixings, bracketry:
| Cable ties |
£8.14 |
| Nuts, bolts, washers |
£46.18 |
| Aluminium sheet & tube |
£46.58 |
| Rivets |
£15.28 |
| Rubber mounting bobbins |
£2.00 |
| Assorted grommets |
£2.89 |
| Velcro |
£0.75 |
| |
|
| TOTAL |
£ 121.82 |
Electrical:
| Electrical cut-off switch |
£7.50 |
| Bullet & spade connectors |
£12.15 |
| Heater fans & finger guards |
£16.51 |
| Front indicator stalks |
£30.00 |
| Battery lead terminals |
£1.00 |
| Rear fog & reversing lights |
£7.90 |
| Bulbs |
£9.04 |
| Fuses |
£2.97 |
| Flasher unit |
£4.49 |
| |
|
| TOTAL |
£ 91.56 |
Miscellaneous Other Parts:
| Gearknob |
£22.95 |
| Throttle cable, guide & return spring |
£6.43 |
| Black vinyl sheet |
£5.00 |
| Locking wheel nuts |
£19.99 |
| Rubber edge trim |
£2.50 |
| Bridgestone S-02 tyres (4) & fitting |
£418.46 |
| Water temp. sender adaptor |
£5.62 |
| Foam sheet |
£10.00 |
| Speedo recalibration |
£40.53 |
| Mudflaps |
£3.99 |
| Choke cable |
£4.00 |
| Tax disc holder |
£4.30 |
| |
|
| TOTAL |
£ 543.77 |
Total of All Build Costs:
Other Costs
Stuff that doesn't fall into any other category!
| Van hire (to collect the engine &
gearbox) |
£60.00 |
| Diesel for hire van |
£28.40 |
| SVA manual (inc. P&P) |
£25.00 |
| SVA test fee |
£165.00 |
| Registration fee & road tax |
£180.00 |
|
|
| TOTAL |
£458.40 |
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