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Post by Deleted on Dec 21, 2008 20:20:03 GMT
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Post by Deleted on Dec 21, 2008 20:22:26 GMT
Can't get all of the photos up in the same post so here's the rest of the pre:
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Post by Deleted on Dec 21, 2008 20:24:09 GMT
And now, pauses for the drum roll, what I did!
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Post by Deleted on Dec 21, 2008 20:30:17 GMT
That's a bit drastic now isn't it! ;D The next stage is to clean up the cuts and start to rebuild the edges so that I can mount a bonnet latch on each side. I wil then trim the edges to make a rain channel and lip and a similar one on the bonnet. You may otice that the adjusters are now in the front beam and that will be cleaned and rebuilt soon, the first part to actually be finished! Once I am there, or if my friendly welder comes up trumps on the bits, I will start on the roll cage for the main tub. Now it is sitting on the chassis it is easy to see where it has warped and needs "fettling" to fit. I guess I am going to get used to fiberglass before i finish this one! Still it is nice to actually achieve something I have been thinking about for a couple of years. Now all I have to do is turn all of my ideas into reaility! Roll on 2009.....
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Post by Peter on Dec 22, 2008 12:49:13 GMT
Ouch!! Well a bit too late now, hope it all goes OK. What are you going to do with the HUGE exposed sill area created by the massive dropped floors and the body spacer?
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Post by Deleted on Dec 22, 2008 14:54:47 GMT
My plan is to go back to my first inspiration, the Mura, and have a false sill. I will rivit, possibly, a thin sheet of metal to the flat ridge on the body, it looks like it is designed to locate the central tub but is about 2 inches away and streight (!), then curve it down to the new floor. I was then going to paint it an oppsing colour to the main tub. I am currently toying with a blue/purple and pewter mix. Hope that makes some sence! Next time I'm in the garage i will tape a piece of paper in place and will try to get a photo to demonstrate. Jon Edited to add: Found this on the internet and it does show what I mean. I will have to play with it a bit as the Mura's side was quite laft and the SS is very dished but it should look ok.
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Post by Deleted on Dec 22, 2008 15:08:58 GMT
Having slept on it and had a good think about my plans I am going to have to clamshell the rear as well. I cannnot get any of my simple roll-cage ideas to fit and allow the tub to come off over it. I will, therfore, make the central tub and roll-cage one piece and I can then feed the roll-cage bars through holes cut into the central tub. This will allow me to take the whole thing off in a singe piece. It will also give me very good access to the engine and rear assemblies.
The major problem with this is exactally where to make the shutline. For the front there is a very obvious location but the rear is more complex. I think that I will try and get it between the two rear window slots, if that makes any sence, and then run down at an angle to the rear wheel arch. That should allow me to put a piece of galss at the back of the main tub and another in the rear clamshell which will help with minimising road noise.
As an aside before I start does anyone know if any of the bars in the body run down there? I found one either side on the front, I bought a recipricating saw for the task and was using a metal cutting blade as it has the finest teeth so it is not a major drama, I would just like to know first!
I will keep taking photos and update when I have more news.
Jon
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Post by Deleted on Dec 22, 2008 15:12:26 GMT
Just thought I'd add a roll-cage is a necessety not just for safety but also to stop the roof sagging and allow me to get the doors to fit properly! I may have to cut out the bars that are there now but, hopefully, will be able to work around them. They are not acctually attached to the chassis at any point and are now starting to rust and distory, hence the sagging roof!
JON
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Post by terryrob on Dec 22, 2008 22:25:29 GMT
Wow Jon, you are a man who does not do things by half's. LOL
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Post by Deleted on Dec 23, 2008 20:22:36 GMT
Never seen the point in doing half a job, "if a jobs worth doing, it's worth doing properly" is what my father always used to say, and then he'd go on and take 4 hours to hang a picture! ;D
Still it's taken me this long to get to the stage where i can do something so I may as well go hammer and tongs and try to do it properly. I also have access to a few people who can help and a large workshop so I may as well take advantage.
I hope to get back in tommorow or at least later in the week so I'll post again when I do.
Jon
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Post by Deleted on Dec 26, 2008 10:31:05 GMT
Well the DCOS, Domestic Chief Of Staff, has said that I can go back into the garage this afternoon, sooooooooo where do I cut the back off?
I was thinking that I would start between the two rear window opening and then drop vertically for about 6 inches before slopeing gently towards the rear wheel arch.
Any thoughts?
If not just wait for the pictures! ;-)
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Post by Peter on Dec 28, 2008 13:39:46 GMT
Hope this helps, done from memory and you know what a mess that is. In either case foward or rear flip you need to securely fix the boot lid into the rear before you cut anything so it doesn't go all floppy. (excuse tha speeling mistykes, I rushid it) Good luck
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Post by Deleted on Dec 28, 2008 18:19:39 GMT
Peter, Your image dosen't appear to want to load! well I got a bit more done but not any cutting of the shell, some will be pleased to note! I found that the petrol tank will definately be in the way of anything I do at the back so I got that out, sounds easy dosen't it, well it wasn't. It really wasn't! I also had another go at fitting the tortion bars back through the torsion tubes and the adjusters, that did not go well either! Still I did take some photos of the side profile so that Italo can have a look and advise on the revised styling. A small (very) step forward but a step none the less. Pics: This is a stitch together of the side view. It is supposed to show the outline for the new side vents and the revised sill. The sheet i used for the outer sill has sagged and does not, quite, follow the line of the chassis and you cannot get a sense of the wheel size, but it does show some of the ideas. I am thinking that the rear clamshell will hinge at the top and the proposed shutline can be seen in black pen. This is the original that I am working from You can now see the revised sill line and the side vents that I am trying to get. Next time I am in the garage I will try to get a better shape on the sill, probably using card not sheet, and place the wheels so that you can get some idea of the scale and form. So any comments? Jon
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Post by Deleted on Dec 28, 2008 22:09:08 GMT
looking good Jon. Drastic but good. Keep us up to date with progress.
Regards
David
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Post by Deleted on Dec 29, 2008 15:25:42 GMT
That looks very good Jon..........but is the rear flip shorter?......are you going mid-engine with the new car. ?
What can help you, is to mount the right size wheels, 16-17 in. I guess, and then it will make it easier to get the shape of the wheel arches right.
You could use the Focus Rs or Audi TT wheel arches as templates for your design, and if need be, you could make a different shutline for the rear.
Talk to you soon
Ciao Italo
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Post by Deleted on Dec 29, 2008 15:59:18 GMT
Italo,
No the shell is exactally the same, just a different angle for the photos! I am going mid-engined but that was always the plan the only thing that changes is the engine! ;-)
I will try and get into the garage tommorow or Thurs so should have more photos then with the wheels in place, or at least the old wheels in place.
I was thining about the Focus wheel arches as they have the same sort of profile as the ones in your sketch, well I thin so anyway. I was driving to the shops today and saw an old style Hyundi Coupe and that had symilar style as well. It is a case of what I can get hold of to mould and then adapt to fit. I was thinking of incorperating some sort of vent to the rear of the front wheel arch, as I like them but am still unsure wether to go for a small shape, such as the Hyundai, or go large such as the Jag XK8 style.
Still I have a long way to go before then! ;-)
Many thanks,
Jon
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Post by Deleted on Jan 3, 2009 10:33:17 GMT
you could even shorten the rear overhang from the sketch I made.......
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Post by Deleted on Jan 25, 2009 10:09:02 GMT
Well, I got into the garage last night and assembled , disassembled , reassembled , disassembled , reassembled ;D , disassembled and finally assembled correctly ;D ;D my front suspension with the adjuster in! The instructions are not as clear as, well very thick mud , and it took that many tries to get it right . I will now weld in the adjuster tomorrow and cut the lower beam to fit the adjuster there. If anyone else has tried to feed all of the spring leaves through the torsion tubes they will understand my point! Well I managed to get a few photos stitched together to show the side view. Still working on getting the whole thing but here you are.
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Post by Deleted on Jan 25, 2009 19:08:29 GMT
Not a great hour or so in the garage tonight! I went in to tidy up a few loose ends and get things ready for welding tomorrow, but ended up getting depressed over all of the jobs I know need doing, most of which I have no idea how to do, and thinking of all the unforeseen problems that are going to crop up! I put one of my sets of seats into the car, as the body is currently fitted, and was trying to work out where I need it and thus where the pedal-box and steering wheel will go. It all seems such a long way off and I am going to have to move again in the summer, probably back to England, and that means getting al of the car pieces transported, again, and that costs and is hassle and etc, etc. I guess we all get like this at some points through our builds but I cannot seem to see the way forward at the moment and it is starting to get me down. I need to finish the front suspension so that I can trial fit the front wheels and ensure that they don't foul on the slight alterations I made to the drivers foot-well to allow a pedal box to be fitted that I can use, big feet! I then need to cut off the engine forks and fit the Porsche 944 suspension that I have lying in the garage so that the chassis becomes a rolling one! I can then think about the steering rack, steering wheel, pedal box and engine mounts. That leads onto the gearbox and sighting the gear change which leads onto the seats, etc, etc, etc. I can then turn my attention to the modifications that are required to the bodywork, and there are lots! for the doom and gloom but it's just one of those days I guess. Jon
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Post by terryrob on Jan 25, 2009 20:38:24 GMT
Hi Jon, I know how you feel trying to figuer out all the answers in advance, I've done the same but now I try and concentrate on getting one area completed at a time. The only problem is that what you've done can affect something else later . Stick in there mate, its going to be a good un
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Post by Deleted on Jan 25, 2009 23:44:49 GMT
Try not to get despondent Jon. I don't doubt the task ahead but if you break things down into small jobs that you start to tick off your list it is a great feeling when it starts to come together.
It will be fantastic when it is finished, just try to remember the dream.
David
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Post by Deleted on Jan 26, 2009 9:25:51 GMT
Well it is 0900 hrs Monday morning. I am in work and fighting fire, the welder has just turned up and life is very busy! I just keep looking at this and hoping!
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Post by Deleted on Jan 26, 2009 9:47:48 GMT
Well it is 0900 hrs Monday morning. I am in work and fighting fire, the welder has just turned up and life is very busy! I just keep looking at this and hoping! Jon, It will be a great looking one-off project and in a few months you will remember this period as just a passing moment.....
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Post by Deleted on Jan 26, 2009 9:49:48 GMT
Jon I did send you these some time ago to update your website, but i guess you never got them......... Here you go mate, maybe this will get you going.... Ciao Italo
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Post by Deleted on Jan 26, 2009 10:43:20 GMT
Jon I did send you these some time ago to update your website, but i guess you never got them......... Here you go mate, maybe this will get you going.... Ciao Italo Italo, As ever you are my saviour! Those look great and I will have to try and get my website updated to show them off. Did you get my message about the other ideas? I have been chatting to my welder friend, he is about to start work, and I will, hopefully, have the rear clamshell cut off later in the week. Did you have any final thoughts about the shutline? Many thanks again, Jon
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Post by Deleted on Jan 26, 2009 10:49:12 GMT
Just spent about an hour chatting about the way forward and am feeling a bit better about the whole project, ask me again at the weekend when we have not managed to actually do anything!
Plan of attack:
Stage One: Weld in the top adjuster and cut and fit the bottom one. This will allow a trial fitting of the front suspension and wheels to check for any fouling.
Stage Two: Mark out and cut off the rear clamshell. This will allow access to the rear suspension and roll bar.
Stage Three: Sort out and fit / weld in rear IRS suspoension from the Porsche 944. This will make the main tub a fully rolling chassis (I hope).
Stage Four: Design and fit a rear roll bar to take the seatbelt mounts and support the roof. It will also provide the mounting frame for the engine cradle.
Stage Five: Design and manufacture the engine cradle.
Stage Six: Steering box, pedal box, gear linkage, cooling and drive shafts.
Stage Seven: Manufacture fuel tanks, in outer sills on both sides.
Stage Eight: Start thinking about the bodywork!
I'll keep you all updated!
Jon
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Post by Peter on Jan 26, 2009 12:49:22 GMT
Sounds like you have a few boxes to tick Jon but at least you can see the plan clearly now. I was a bit concerned about you putting the fuel tanks in the sills for the same reason they stopped doing it in racing cars, side impact, it would turn your car into a potential fireball in an accident. better to put it up front over the front suspension as beetle or across rear bulkhead as in mine or infront of the rear wheels as in Lotus. Peter
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Post by Deleted on Jan 26, 2009 13:40:48 GMT
Back in from the garage and I have achieved more in the last 2 1/2 hours than for a long time! The front torsion tubes are now finished with the adjusters welded in and checked. There should not be any fouling issues, this will not be 100% certain until I have found, bought and fitted the final wheels, but I have carefully checked the tolerances and am happy to move forward. I need to clean up the welds but then they are ready to go, with the A-arms, to get acid dipped and powder coated. I can then fit new ball joints and assemble the front suspension complete, less shocks! A definite move forwards and Stage One almost complete. It is amazing how much you can get done when you have help and a clear run at things. Just talking to someone else while looking at the problem helps to focus the mind, needless to say I am feeing a little better about the whole project! Jim, my master welder friend and able assistant, will be back on Thurs and can give me two full days of his time. I am going to try and take the two days off as well and, hopefully, we will get a lot done. Projects for me to complete before then are to clean up the front torsion tubes so he can check the welds for porosity and mark out the cut for the rear. Next job is cutting off the back so that we can get to the rear suspension. Any comments / concerns before then gratefully appreciated, any "I told you so" keep to yourself.
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Post by Deleted on Jan 28, 2009 19:39:50 GMT
Got about an hour done this afternoon in anticipation of Jim coming back tomorrow. Unfortunately I have to prepare two "Character Assassinations" for Orders tomorrow evening so I may not be able to join him as much as I would have liked.
I did manage to finish cleaning up the welds on the front beam so, as long as he is happy, that can go for acid dipping and powder coating this weekend. The suspension arms will also go at the same time and I can then assemble the entire unit and forget about it!
No-one has commented on my shut-lines so I am going to go with them, heaven help me if I'm wrong. I have received the brackets for the rear A-arms so, hopefully, we will get started on the rear suspension tomorrow.
More later,
Jon
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Post by Deleted on Apr 28, 2009 16:29:45 GMT
Well it has been a long time since my last update, and to be honest nothing has changed since it! I have received a Posting Order so I am now moving back to Deepcut at the end of July. In order to achieve this I either have to be able to push the SS onto a trailer or I will have to scrap it. Not wanting to do the latter I am going to have one last push to try and get a lot of work done in the next two months. (Anyone who fancies a holiday assisting in NI is most welcome to come over, free bed and board to all! ;D ) I will be in the garage later tonight and will take some bold steps, hopefully, so will get a few pictures uploaded this week. I am still trying to get a board done for Stoneleigh as I will not be there but everyone have fun for me. Jon
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