776 replies to this topic

[rally515]

ahh yes Had thought you might have done it for coilovers.
& I will take your word for it on the weather front but still not going out

[kcchan]

Nice, I got some of those waiting to go on. I did consider buying new arches and tubbing and turretting them away from the car like you have but the decided I couldn't be bothered and just do it like everyone else.

Not looking forward to welding inside the boot though. Its a horrible ol' job

Edited by kcchan, 17 November 2012 - 08:40 PM.

[mini93]

yeah, thought i could do a better job off the car.

Im not tubbing off the car though, because the rest of the floor isnt in it will be too difficult to reference the arch anywhere in order to get the tubbed arch into the correct position. So im going to quickly put the arch lined up to the heel board edge and along the rear 1/4 arch edge (only quickly on the arch as its getting lopped off again). once i have that in place i can put the rear boot floor in to the correct reference points and then i can finally tub away.

Then its time to do the front end and the cage i guess.
I need to take some measurments and do some drawings but hope the cage wont take too long

Not sure what im doing about the front inner wings around where my webber box was. Sure ill figure something in due course

[mini93]

Had chance to brave the cold today and got a bit done on the shell.
1st went on were the arches

Nothing too stressful there. I only put a few plug welds along the rear 1/4 as it will get cut off for tubbing at a later date.
Same on the other side obviously...

Even that stiffened up the shell some-what.

And with that done it was time for the boot floor...

Mocked up into place it appeared the back end of the car had been pushed forward since removing the old floor this bowing the rear 1/4s outward and such the new boot floor didnt line up very well. bit of head scratching it was simple enough and sorted after i simply grabbed hold of the back pannel, foot on heel board and pulled outwards.
Mocked back up, holes drilled for plug welding and weldy-mc-weld on it was.

The plug welds were quite easy in the end, altho i wasnt looking forward to it, it seemed ok in the end, seems strong enough too.
It didnt line up the best to the arch edge however, but the arch seems to hang fairly low in anycase so ill be trimming that to make a useful flanged edge that i can weld to (haha I said flange)

[kcchan]

Any progress in the cold is good progress!

[Mini-Mad-Craig]

Your arches and roll cage mounts are awesome Dave... well done good job

[mini93]

Cheers guys, Doesnt seem so cold when you have long thermal socks, hat, gloves, tshirt, hoody and overalls on... its just the whole going out side in the 1st place which is off-putting.
Still gotta think about how im going to do the rollcage with harness bar incorperated so that it doesnt get in the way of the aluminium bulkhead i have planned. I cant just have it on the main hoop back stays as that would be behind the planned bulkhead and i cant have the harnesses there, so with that i think ill have a cross and a bar between then futher up.... time to go to custom cages webshite and look at cage diagrams.

[kcchan]

What kind of aluminium bulkhead? An exact copy of the old one but in Ali or a custom one?

[mini93]

Here ya go... similar pattern to this above, at the back end but with the arch joins going further back to the new shock absorber mount, like below


The ally bulkhead will be a custom one. Will no doubt be absolutly horrible to make but once its done, swaged etc im hoping it looks quite good... i have a picture in my mind at least

Edited by mini93, 01 December 2012 - 06:56 PM.

[mini93]

Bit more done today. Really just carrying on with yesterdays bit


Heres the trailing edge of the arch, seemed to carry on rathr far round so i used this to make a flange


Cut and hammered back i was able to make a flange, welded from the inside and stitched from the outside (urgh over head welding is crap!)


The inside welded bit... not the neatest welding but strong enough. Done a little bit of dressing on the welds but i cant get to the very back, the small space, so need a die grinder, not that i have one...

Other wise, after that I just tidied up some other small bits, welded up some spot welds around the rear window.

On another note, i dont like these early nights. Working on the cars a pain in the arse.

[mini93]

Hopefully crack on again tomorrow! if i get my arse out to bed early enough i wont be forced to work in the dark either!

[mini93]

Not a whole lot done in the end as i washed the Audi and some other bits n bobs instead.

Welded the old filler neck which iv meant to do for a while now.


Didnt get a photo of it welded as it looked a bit messy haha so only an after grinded photo below...


After that Iv just been welding up some old spot weld holes around the window frames (from the old C piller, seat belt pannels)
Their a bit of a pain as their so close to the edge but the brass used for heat sink really pays off here... Still a bit messy at the moment so no pictures, but its another thing iv been avoiding which turned out to not be as bad as i thought it was going to be.
Its suppost to rain tomorrow so i doubt ill get round to doing the other side soon

[mini93]

THE SHELLS READY!!!


Ready for me to carry on working on it I hate bodywork...
So, I spun it round to do some on the front end







And its starting to surface rust means my pre-paint prep costs are going to go up

[Artful Dodger]

looking good!!! going to be a monster rally car when its done!

for the surface rust.. get a knotted wire wheel attachment for a grinder and go over the rust, will completly get rid. then under coat ASAP. i have had to do mine because of surface rust. will 100% be cheaper in the long run.

[rally515]

looking good!!! going to be a monster rally car when its done!

for the surface rust.. get a knotted wire wheel attachment for a grinder and go over the rust, will completly get rid. then under coat ASAP. i have had to do mine because of surface rust. will 100% be cheaper in the long run.

Knotted wheel is brill cleaned up my floor pan inside & out in no time, but beware if using one on a 4" grinder with no guard nearly ripped my fingers off as the knotted wheel in question was meant for a bench grinder .....I will never learn