The idea of constructing a car with your own hands can seem like a pipedream, but whilst it may seem unattainable, there are ways of making this dream a reality.
Kit cars are popular because they offer enthusiasts the chance to own a rare or classic car without the exorbitant price tag.
Building a kit car is an unbelievably appealing idea for most petrolheads. In this guide, we explore everything you need to know about creating one yourself, from the costs involved to common challenges you may encounter along the way.
What is a kit car?
A kit car is a vehicle that is sold in parts and is then assembled by the buyer at home. As the name suggests they are sold in ‘kits’.
Once the kit arrives, you will then be able to start building your car. Different kits will be configured in different ways, requiring different levels of assembly.
There are a number of companies that supply top-quality kits to buy, including Caterham, who sell both kit cars to build yourself or factory-built ones ready to drive.
Kits are typically sold with the car’s body and chassis pre-assembled, leaving you to fit the engine, suspension, axles, body panels, cooling system, gearbox, wheel arches and other components.
Luckily we have a guide on the top ten kit cars for you to peruse for inspiration.
How to build a kit car
It may seem silly, but kit cars will come with instructions to follow, much like your IKEA furniture or LEGO, though a lot more complicated.
Crucially, though, you will need to ensure that nuts, bolts and fixings are tightened to the correct torque, and that the assembly takes place in the correct order, with the right greases, adhesives, silicones and threadlockers all applied in the correct specifications, amounts and locations.
It’s a common myth that people ‘build’ kit cars; instead the correct term is that they’re assembled. You will not be creating a gearbox or engine from scratch, nor will you need to tinker with it. Both will arrive as a complete unit, you will just need to follow the instructions on how to attach these parts before installing them in your vehicle.
Tips on building a kit car
Here are some tips to help with the planning and building stages.
Question what you’re going to use the kit car for
Before you get started, it’s important to choose the right kit car for you. Firstly, assess what you are looking for in a car before buying the kit, asking yourself when you will drive it, whether it’ll be used for short or long trips, and how confident you are in your abilities.
Kit cars come in a variety of different ability levels, so if it’s the first time you’re assembling one, ensure you are picking an entry-level kit car. If you’re unsure, speak to kit manufacturers who can point you in the right direction.
Create a step-by-step plan
Once you’ve assessed what level you are and what the kit car will be used for, you should then create a plan of action.
Decide a timeline for how long it will take to assemble, and be realistic in this planning. Don’t try to rush through the build and ruin the fun of this process. You will encounter setbacks, everyone does, so be generous with time planning.
It may also be handy to join a kit car club, where you’ll be able to speak to other kit car enthusiasts and ask for any tips.
Set up a dedicated area to assemble the car
Think about where you will assemble the kit car. You will need a clean and organised space – ideally a garage or a workshop.
Think about your budget
And lastly, consider how much you wish to spend on the project in total. Note that it will not just be the price of the kit itself, but the cost of the tools, additional parts and professional services that may be needed along the way, including welding and painting.
Where will you source components?
Whilst kits will include the essential parts of your vehicle, it’s inevitable that you’ll need to source additional components. For this reason, it’s important to think about where you might source these parts from.
Common components needed for sourcing include interior additions such as dashboards, seats and upholstery. Remember: the beauty of a kit car is that you can customise it to your heart’s content.
You may also need to source suspension and brake parts, along with bits for your engine and transmission, where you will need to consider how it will affect your fuel efficiency and power output.
Time to assemble
As aforementioned, you will need to follow the instructions of your kit meticulously to ensure it’s safe to drive.
It’s also advisable to break this up into sections to make the build seem more achievable:
- Chassis and frame assembly: Start with the foundation, ensuring everything is level and secure.
- Suspension and brakes: Install these components early to establish a rolling chassis.
- Engine and drivetrain: Carefully mount the engine and connect it to the transmission.
- Body panels and exterior: Fit the body panels, making adjustments as needed for a perfect fit.
- Interior and electronics: Install seats, wiring, gauges, and other interior elements.
- Final adjustments: Once everything is in place, perform a thorough inspection and make any necessary adjustments.
How long does it take to build a kit car?
This will entirely depend on your skill level, the time you have available to work on the car and whether you encounter any issues with the build.
If you have a few hours per week to spend on assembling your kit car, it could take up to a year to complete. On average, it takes between 120-150 hours to finish a kit car.
You will need specialist tools for your kit car build, no matter the complexity of the kit you opt for, as well as access to an electrical point.
Common tools include:
- Axle stands
- Screwdrivers
- Pliers
- An engine hoist
- Torx drivers
- Spanners
- Torque wrench
- Rivet gun
- Saws
- Knives
Is building a kit car difficult?
Building a kit car is not for the faint-hearted; it’s for those who have a working knowledge of mechanics or engineering, or have a deep enough passion to learn as they go.
However, kit car instructions are very detailed so if this is the first time you have undertaken a build project like this, you should still be able to do it. Kit car companies also have helplines that you can call to ask for any tips should you need them.
Building a kit car is a thoroughly enjoyable pastime and is an extremely rewarding project for those who have committed themselves to completing the task.
Do kit cars need to be approved before they’re driven?
Before you can drive your kit car you will need to have it checked by an expert once you have completed its assembly. Some companies such as Caterham provide this service.
It will also need to pass the Individual Vehicle Approval (IVA) assessment set by the Driver and Vehicle Standards Agency (DVLA). It can take up to 20 working days to get an IVA inspection appointment once you have completed the application process, and then transport the car, without driving it, to a DVSA IVA centre.
Once it has passed the test, it will need to be issued with a Q number plate and will need to be road taxed and insured to be legally driven on the road.
Adrian Flux – experts in providing kit car insurance
Talk to one of our experts today to find out how you can save money on your car insurance.
We’ve formed relationships with insurers over the decades to ensure you get the best value deal for your individual needs, including kit car insurance.
We also offer a discount to those who are part of an owner’s club of up to 15%, saving you hundreds of pounds each year.
Call us on 0800 369 8590 or book a callback at a time that suits you.
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