- Marlin 5EXi
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The build The Marlin 5EXi is one of the simplest kitcars to build and we estimate a total construction time, once the donor parts are prepared, of less than 100 hours. This ease of build has been a major consideration throughout the development of the 5EXi and a number of design features have been incorporated specifically to help the builder. These include: Aluminium chassis and body panels laser-cut, pre-formed and pre-drilled to save you work and ensure accuracy; The simple front/rear/side body section construction means minimal panel alignment - traditionally a tricky and time-consuming job; The front and rear body sections - where alignment is crucial - are bolted into place BEFORE hinge units are located and fitted - again ensuring a good panel fit; Stage one of the kit includes a photographic step-by-step CD build manual, featuring hundreds of photographs taken during several actual builds. Choice of donor When choosing a donor car for a kit car build, buy the best you can afford. MOT failures or even accident-damaged cars are fine, providing none of the required parts (see below) are damaged or missing, but a low-mileage car is obviously favourable. We find it for you And if you don't want to source the donor parts yourself, we will provide them on a pallet for you to prepare (with all details required to register later) or we can supply the parts reconditioned or brand new. Marlin build stands For extra ease of build Marlin’s specially designed build stands not only allow the car to be moved in, out and around your garage during the build, they also keep the chassis at the correct height to avoid un-necessary back strain. 5EXi donor options Option 1) – Honda Civic B1.6, 1.8 Vtec (K20 Civic engines are also available) Option 2) – Rover 200/25 1.6, 1.8, 2ltr TurboThese cars will (most times*) give you the entire donor parts needed to build a 5EXi. Any specialist parts come with the kit and further parts required are either available from us or on general sale. The Honda donor Using a Honda civic for your donor is a more recent option offered by Marlin. This Honda was chosen for the engine ability to kick out 160bhp from only a small capacity engine. It is totally awesome..... and not only that they are virtually bullet proof. Most models that have been fitted with the B-series Vtec engine are 3 & 4dr, Del Sol, CRX etc. *Using the Civic will mean that you have to source your heater assembly else where as it does not fit i.e from a Rover or after market. *Occasionally a 5EXi will require front axle/rear brake parts in exchange for those fitted to your donor car. These are really to be considered as service parts and therefore are easily available after market or from Marlin. Honda donor parts required When stripping the donor, you will need the following:
The Rover donor The best donor would be the 200/25 (bubble shape) with a K or T-series engine assembly (all initial development and builds were completed using these donor cars). The kit was designed as a one donor kit i.e. the vast majority of required components can be obtained from one car source. Any specialist parts come with the kit and further parts required are either available from us or on general sale. It should be understood that you can also use a 400, 600 or 800 as a donor but the further away from the base 200/25 you move, the more parts you will need to change e.g. 1) The 200/25 supplies everything except a pair of rear discs and calipers. 2) Use the 400 and some parts will need changing to the 200 type parts. The heater assembly and pedal box assembly for a non hydraulic clutch). These can be obtained from most scrap yards very cheaply. 3) The floor gear change shaft will need to be shortened or changed for the 200 part. 4) Use a 600 or 800 and these cars will supply the power plant & gearbox plus all associated powering components up to but not including the drive shafts. Rover donor parts required When stripping the donor, you will need the following:
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