small french hatchback

[davenport]

right.. them last 2 rust holes....

either side.. lurking where the rear seatbelt bracket is spotwelded onto the shell..

being a complicated pressed shape.. the best bet was to cut the section out of an old shell...


cue the 3 stud assassin!! (girlfriends old car that has developed engine issues and is due for the nackers yard imminently)

now.. when i got to the other side... there was of course the fuel filler neck to worry about.. sensible types would have removed the tank + neck to remove the risk of fire/explosions/angry parents wondering where there workshop had gone..

but time was short so (health an safety types look away!)

the bits were trimmed and cleaned up and the `box repaired..

 

[davenport]

well after a little wait my cage has finally arrived...

gotta say despite a longer than quoted wait the finished product looks good...

packaging was safe and secure.. all individual tubes labelled.. 2 discs 1 showing a 15minute video of a similar cage fitted and 1 showing some pics of what i SHOULD end up with... some test tubes that i need to do and end back for testing and (fingers crossed) certification for the cage..

some of the notched tubes have been cut with a plasma so they`ll need cleaning up before i commit with the TIG and i need to get some A18 filler wire...

all thats left is pray i can get close to this standard:

and atempt to get it looking like this:

alo need more argon.. quite important i beleive!!!

 

[Dogruffracing]

What an excellent thread, built better than when it came out the factory no doubt

 

[BChild]

Thats a lovely cage....... Some nice features

 

[davenport]

aye tis a bit of a monster... and in all honesty is quite daunting when all the tubes are layed out on the floor... but if a jobs worth doin..... an all that... theres a fresh bottle of argon ready for the job i know that much...

also pressed up the box for the fuel cell.. 1.2mm descaled mild steel.. about 710 x 345 x 200 ish internal (also pressed a nice X in the base to keep things from flapping round like a geritrics knockers) when the ally tank gets made should be roughly equal to the std 45litre tank... just need to fully weld the end plates in and it`ll be time to hack a big ass hole in the bit where the passenger seats used to be and sink it in about halfway (anymore and the zorst will clash)..

cheers for the kind words folks.. have a new phone now so will get some pics of progress..

 

[davenport]

had a few hours free today....

firstly we have the holes where the std fuel pipes go into the cabin... dont like them.. cant use them due to cage foot.. and a bit of rust appearing... only 1 thing to do:

and make a suitable patch:

it was at this pint i discovered 2 things...

1- my new phone has a better camera that my old 1
2- i`m a twot and ha left my decent welding screen at work!

the ol chap had been naggin that he wanted his tow rope back for a while and couldn`t accept it was more use to me as a rotisserie locking device!!!.. so i got my ass into gear and fitted my brace...

then i decided to unpack the cage and start laying the tubes out..

nothings been fitted yet as they need de-greasing and thoroughly cleaning around the joints...

a couple of head scratching moments but once i worked out what order the tubes go together everything lined up ok.. the front legs need a bit of trimming to sit right against the A post and i think the pads i welded in ages ago for my old cage are in the right place for this 1..

as well as everything in the car theres also this lot:

main hoop X and gussets and also the A post support bars..

gotta say the quality looks good a few of the joins need a tickle but overall very close:

 

[davenport]

right.... box for the tank....

needs the ends fully welding but was busy at work today...

pressed a cross in the base as its only 1.2mm sheet and din`t want it to flap about.. rigidity FTW!!

also pressed the ends to include a flange that sits on the inside to keep things flat and i can MIG inside too.. (outside will be TIG`d)

measurements are about 710 x 350 (ish) x 200... so once the ally tank is fabricated to sit inside it should/may/might be somewhere near std capacity of 45litres...

gonna sink it in about 75-100mm into the floor section where rear seat bases fit

 

[davenport]

managed to weld the tank box ends in place at work satuday afternoon..

all marked out (about 8 times as i did not want to screw it up!!!)

disc cutter + shell = MAJOR oooooh ass nipping moment...

BUT luck was on my side.. only tacked in but it fits and its in...

 

[davenport]

started fitting the cage properly over the past few days....

once the doorbars were fitted i had a sudden concern over room for my seat..

SNUG! was the diagnosis but it fits and i can always make some new sidemounts to pull it over slightly if needs be...

holesaw`d the scuttle panel for the cage-to-turret links (no dimnesions were given with the kit so just had to guess and go for it...

also did some cutting and shaping for the A post supports.. initially i tried doing them directly but unless i plan on useing a button for a steering wheel hand room would be minimal..

so went as the sites pics and ran it in 2 steps..

ran out of argon again so off to BOC dealer tommorrow.. or maybe fit the bars in the rear section up and get gas friday...

 

[davenport]

well had a think and a play about with the bare seat sat on the seat rails..

and...

rude not to put them in isn`t it...

also cut and shaped the dash bar but needed some help forcing the front bars apart wide enough to get the bitch in...

i had 2 options...

either get on the steroids wait a few months and rip the sukkas apart but time was aginst me so i settled for 2nd best..

porta-power ftw!!

dash bar in place!

fresh bottle of gas tommorrow and good weekend push and it should be pretty much done.. thank god!!

 

[Macoli]

This is such a good and inspirational thread.

 

[davenport]

many thanks..

well i know theres a few techy types on here so i`ll try and remember a few details for ya...

torch - parweld WP9
ceramic - #5.. and #4 (about 10mm diameter)
tungsten - 1.6mm (sharp and pointy!!)
gasflow - ummmmm enough to tickle when fired into my ear...
filler wire - ESAB mig wire A18 1mm diameter cut into approx 600mm lengths...
gas - pure argon from local BOC place.. bottle size Y....


around the tops of the roof bars there were 2 occasions were i simply could not get in to weld fully (not even when i removed the lens from the screen and taped it to my head!!)

so i had to blob it up with the MIG (horrible dirty things they are!!)

its a decastar150?? 180?? god knows its a yellow thing with a useles short harness!!! 0.6mm wire


any other questions i`ll do my best to answer...


oh ahhh weld prep....

the notched tube that was plasma cut was cleaned right back to shiny metal using either a P120 flap disc 115mm or a 30mm diameter bobbin/drum thingy....

the tube near the join was then degreased and wiped down and then tickled with a BROWN 3M scotchbrite flap disc.. (i think dronco also do them)....

 

[davenport]

HALLELUHAH!!!!!!

still got a pile of gussets that would put a knicker factory to shame left to put in but structure-wise the bitch is done....

i feel a celebratory stella or 2 are in order!!!!!

 

[TheJoker]

Crikey! That's a helluva lot of tubes! Amazing! Well done!

 

[Weldingartisan]

Have you worked out how to get in it??? W/A

 

[davenport]

your not the first to comment on access issues.....

i do think a quick release steering wheel will be needed though

 

[davenport]

GUSSETS!!!!

remember that flaring tool i made a while back??? finally it got some use today..

the plan was this:

so i found some mild steel hiding behind the guillotine at work (hmmm cant think who hid it there last month... ) 1.5mm desc.. measured and chopped out the blanks at 210x130 pressed the end at 22.5mm (internal).. maked out the hole and boshed the 30mm holesaw through..

tool in.. a big yank in the fly press and.....

they still need cutting to match the angle of the doorbars (as shown on the top one) but other than that were in buisness...

 

[M@tt]

fantastic work mate!! absolutley cracking read

have a look over on http://forum.205gtidrivers.com you'll be a hero over there as we love our old french ****boxes (106's included ), i've pointed them in this direction

 

[fast_eddie]

Just read it all. Just followed matts link from the 205gtidrivers forum and have to say your dedication is amazing!
I have a few bits and bats of welding to do on my 309gti project and I have been putting it off for ages-ok I dont have half of the stuff that you have at your disposal tool wise but your thread has given me a little burst of inspiration.
keep up the good work!

 

[davenport]

inspiration and motivation are the key buddy...

i will admit i`m spoilt greatly with equipment and it does make the jobs easier but please dont think you HAVE to have them to attempt things.. preperation and patience are just as, if not more so, important..

(f**k i sound like a old to**er now..... sorry!!)

get that 309 done fella! dont let it become a cheap wide track conversion for the 205 boys hahahahahaha