Fenders and paint, part deux
Posted by PAddy
Patrick McVeigh Elite Moderator Location: Toronto, ON Join Date: 12/21/2005 Age: Midlife Crisis Posts: 358 Rally Car: Student Loans |
The purpose of this thread is to demonstrate the risks and benefits of drinking whilst working on the car. I begin with photo evidence:
Exhibit A. A charming day, not too hot, nice breeze, no rain in the forecast. Grab a rickards and strip that body. 
Exhibit B. Once the outer rocker cover was bent up, essentially 50% of the inner sheet had rotted away. Here is the view "before", with the new box tube bolted in place under the door frame. 
Exhibit C. Inner brace repaired. 
Exhibit D. In a rare moment of beer-induced genius, I decided to change my plan for fixing the outer rocker cover. Rather than the complicated stepped-in process I went through last time to match the factory appearence, why not just make the damn thing flat? Worlds easier.. 
Exhibit E. Since it was still nice out, call up 2 hulking gentlemen to invert the car once more. Rotisseries are for sissies (though the shell is getting a lot heavier with all that cage nonsense in it). Drilled out the spot welds holding the old rear bump stops in place. 
Exhibit F. With the aid of a jigsaw and another round (it's getting hot out now), some nice 12ga plates were designed to support the frame rails under the load of jacking/stands. Welded them in: 
Exhibit G. Now everything goes off the tracks. This is the view of the underside as it rested - notice all the undercoating remaining on the bottom of the car. I should have removed this with the LN2 back in the fall, but since I had no idea how much we were using, only the seams were stripped at the time. The remaining undercoating is soaked in a terrible mixture of gear oil (smelly) road dirt and crud which is impervious to all pressure washing, rendering it completely unpaintable. 
Exhibit H. Rather than accept this smelly undercoating, I had the great idea to attack it with a wire wheel on the angle grinder. 4 HOURS LATER, everything in sight is covered in little bits of smelly undercoating bits and I have a tan made of gunk. 
Exhibit I. What this SHOULD have looked like months ago: 
Exhibit J. Some tremclad for my troubles. I was running out of time in the day and had to flip the car back down, so anything which could reasonably be done on jackstands was left for later... 
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Patrick McVeigh Elite Moderator Location: Toronto, ON Join Date: 12/21/2005 Age: Midlife Crisis Posts: 358 Rally Car: Student Loans |
Grant Hughes Elite Moderator Location: Whitefish, MT Join Date: 01/11/2006 Age: Midlife Crisis Posts: 6,818 Rally Car: BMW |
Patrick McVeigh Elite Moderator Location: Toronto, ON Join Date: 12/21/2005 Age: Midlife Crisis Posts: 358 Rally Car: Student Loans |
John Vanlandingham Mega Moderator Location: Ford Asylum, Sleezattle, WA Join Date: 12/20/2005 Age: Fossilized Posts: 14,152 Rally Car: Saab 96 V4 |
Pete Remner Super Moderator Location: Cleveland, Ohio Join Date: 01/11/2006 Age: Midlife Crisis Posts: 2,022 |
Brian Klausen Mega Moderator Location: Denmark Join Date: 03/21/2006 Age: Midlife Crisis Posts: 388 Rally Car: VW Golf GTi 16V |
Pete Wrote:
------------------------------------------------------- > I've never had to really deal with that weird > German Undercoating von Hell, though. Oh - it's bad - trust me! LN is pretty hard to come by here in Denmark, so I had to settle for dry ice. Used it for the tar-stuff on the floor of my Golve. Tar-crud/crap came off real easy after 15 minutes of freezing - but that seam sealer crap? Holy smokes - tried freezing some of it for close to an hour by putting the dry ice on it. Never really worked - so I had to go at it with the wire wheel. It isn't that bad though - it makes some weird little boogers all over the place - but it's still way better than the tar that smears everywhere. Brgrds Brian 
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Patrick McVeigh Elite Moderator Location: Toronto, ON Join Date: 12/21/2005 Age: Midlife Crisis Posts: 358 Rally Car: Student Loans |
Well since I got back from a motivating journey to Sleazattle, I decided to get my ass in gear and get some
more stuff done on the car: Welding shut drain holes in driver's side (seat mounts visible): 
Re-welding the swaybar captive nuts, since they like to spin and are inside(!) the damn frame rail: 
Making up some creased patch pieces to reinforce the cheesy factory floor: 
Driver's side in place: 
Passenger in some detail: 
More fender rot, holes in wheel arches, wheel well: 
Beginning to patch it all up: 
Filled with foam: 
Onto the fenders, first patching up the plastic body cladding holes: 
Welding on a tab to convert the fenders to bolt on, instead of the 51 factory spot welds: 
Fender support doohicky I cut out by accident earlier: 
Bolted in place: 
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Brian Driggs Infallible Moderator Location: Glendale Join Date: 06/08/2006 Age: Midlife Crisis Posts: 832 Rally Car: Keyboard. Deal with it. |
Patrick McVeigh Elite Moderator Location: Toronto, ON Join Date: 12/21/2005 Age: Midlife Crisis Posts: 358 Rally Car: Student Loans |
One of the side reasons for my trip to Washington state last week included picking up some items and shipping
them back to myself truck freight once I got it all (300lbs) back into Canada. Let's see here, nice big boxes: 
Nice LSD out of a Supra with a 4.3 final drive: 
RX7 Oil cooler: 
Cossie 2wd intercooler: 
Close up of IC inlet: 
Power steering cooler: 
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Patrick McVeigh Elite Moderator Location: Toronto, ON Join Date: 12/21/2005 Age: Midlife Crisis Posts: 358 Rally Car: Student Loans |
Lift pump for a fuel cell out of some Saab:
Volvo expansion tank with nice bracket: 
Rad fans off a turbo Saab: 
Sump guard center support - this prevents the sump guard from smashing into the oil pan and lets you run a thinner plate: 
Close up of center support mounting point: 
Cossie fuel pressure regulator (nice as it doesn't bolt to the rail!): 
Euro headlamp wiring connectors: 
Bracket to mount a master cylinder to the stock handbrake location to make it hydraulic: 
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Patrick McVeigh Elite Moderator Location: Toronto, ON Join Date: 12/21/2005 Age: Midlife Crisis Posts: 358 Rally Car: Student Loans |
Saphire knuckles and matching TCAs:
Nice shot of the pinch bolt mounting on the knuckles: 
Motorsports cosworth exhaust housing: 
You'll not the wastegate bracket is beefed up, and the attachment points slotted so that you can remove it in about 2min with only a small amount of clearence: 
Adapters to connect the supra diff to stock halfshafts: 
Beefed up motor mounts made from hacked up stock units. These are copies of the motorsports units which mount directly to the chassis rails, and not to the front crossmember, some assembly required on the sheetmetal! 
Big bushes: 
Metal to make boxes: 
Brake hats: 
BIG rotors compared to stock POS's!: 
What's in here? 
Nice! 
For scale... 
Also went and picked up a spare motor yesterday afternoon, thanks Ian! It was a tight fit in the trunk... 
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Brian Driggs Infallible Moderator Location: Glendale Join Date: 06/08/2006 Age: Midlife Crisis Posts: 832 Rally Car: Keyboard. Deal with it. |
John Cassidy Senior Moderator Location: Maine Join Date: 07/29/2006 Posts: 161 |
Mustafa Samli Super Moderator Location: Arizona Join Date: 01/10/2006 Age: Ancient Posts: 824 Rally Car: Gaylant VR4 |
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