Rotrax to Fourtrax 'Safari' conversion.
Completed April 2005.

Base vehicle for this project is a Peach coloured 2wd Rotrax running on Ford Cortina running gear. The customers specification is to have this converted to a 4wd vehicle with ample seating for a family of four. Rear seats are to feature full seat belts and the rear body work altered to provide better access and create a more practical vehicle.

The first stage of the conversion is to source a Suzuki donor vehicle and strip away all it's upper bodywork and seating. The dash and all associated electrics remain in situ allowing the donor to remain driveable for ease of movement.

After a full days work the Suzuki is little more than a rolling chassis and ready to accept the roll cage. 

We have now got the roll cage fabricated and mounted onto the Suzuki's rolling chassis. The Rotrax bodywork has been cut to fit and made good, that is all the holes and marks from it's life on the Ford Cortina donor have been filled and fixed, together with the addition of several inches to it's length (a service we can only offer to kit cars I'm afraid folks). The bulkhead section of the body has been extended and strengthened to take the Suzuki's windscreen washer mechanism and we are now at the design stage for the nudge bars.

Unlike our last Suzuki/Rotrax conversion, this vehicle is being built as a 'Safari' style. The Safari was a second generation Rotrax that featured cut down rear bodywork granting greater rearward visibility amongst other changes. As you can see in the picture on the left compared to the one at the top, we have made significant changes to the rear bodywork in this 'safari' style. When not used for rear seating the cut down rear section will allow much easier access for storage with a tool box and Jerry can fuel holder planned for fitting. The roll cage design is also new and again has been designed to provide greater rear access, without compromising protection.

The Rotrax is again stripped back down so the roll cage and lower bodywork can be primed and painted in gloss black. The rather tired alloy wheels have been cleaned, etched and painted in Silver to match the bodyworks final colour scheme.

The bodywork is now fitted to the cage for the final time, it has been fully flatted and primed ready for an appointment with our spray booth.

   Fresh from the paint booth the stunning metallic silver finish contrasts well with the black painted roll cage and nudge bars.
 

Finished in perfect time to be proudly displayed on the club stand at the Stoneleigh Kit Car show in Warwickshire. The custom doors and hard top panels keeping the interior snug and dry through the odd rain shower that was encountered.