small french hatchback

[davenport]

been trying to pay more time on the house and "the missus" recently so aint done much.. but...

made the panel for the dash to mount the toggle switches...

even the weasel approves...

that got mounted via some diddy ally brackets which were quite frankly a fcuking ass to make.... looks cool though....

i then had a small issue with the front gussets.. due to the cage being so close to the A post the hole swages i made were simply too big (25mm + 30mm) (thats just under and inch and a bit smaller than 1 1/4)

the options were:

leave them plain
get some writing laser cut into them
make ANOTHER smaller hole swager...

needless to say option 1+2 were gonna be half measures so i fired up the lathe and made another tool to suit 16mm (5/8`s)
front gussets are pretty much sorted thanks to the smaller hole swager...

to say i`m pleased with them is a MAJOR understatement...

 

[davenport]

a little bit done the other day....

with my posh top mounts done and fitted up i needed to machine up some "top hat" bushes to go inside the 20mm bearing and allow the 12mm damper top to pass through...

et voila!

stainles to so i dont have to worry about corrosion/plating them


unfortunatly due to the extra depth needed on the damper to pass through these + spring top cap + nyloc they need machining..

the lathe at work isn`t big enough so a good friend (who works at a hydraulic ram refurbishers) has been draughted in for the task....

 

[davenport]

nothing to major done today...

blocked the heater/air vent up that goes int the cabin...

the weld still needs a tickle to hide it fully but that can wait till i`m feelin better

 

[oz.]

ooh shiny sh1t they must have set you back a small packet

 

[davenport]

ooh shiny sh1t they must have set you back a small packet

what shiny bits?? the top hat spacers??? i knocked them up at work during a lunch break...

 

[oz.]

I meant the bearings. Tidy work

 

[davenport]

front dampers..

12mm diameter section too short for my topmounts.... BOOOOoooooooooo

spanky the machinist in full handle cranking flow... WOOOOooooop

top mounts fitted... HUUUUUUUUUUrahhhhh

also managed a few other litle jobs

the turret tops i fitted a while back have been welded underneath for extra strength

a couple of holes in the floorpan that were used to secure the old battery box were welded up and ground off...

and i managed to get 1 side of the front gussets fully welded up and the other side tacked in place...

quite happy with how they come down real low and also tie in with the bar that runs to the strut....

then spent a LOT of time trying to get a ceratin MK2 golf belonging to spanky going.. then following it back to the workshop.. then trying to find a fuel pump....

 

[davenport]

FINALLY!!

started on the tank today...

doing the bolt on top plate tommorrow that`ll hold the fuel level guage feed+return fittings and also the filler cap and that bolts over the hole in the top of the tank...

 

[oz.]

using the standard 106 pump?

 

[davenport]

noooooo

low pressure (probably facet) to feed swirl pot then a high pressure (probably bosch 044 i think) to feed the fuel rail....

 

[davenport]

got busy with the ally and made myself a top plate for the tank.. (it still needs holes for breather/feed/return/fuel level guage.. but you get the idea)

then sat down and thought..... hmmmm

the more i looked at the HOOOOFIN gurt M8 bolts in the top plate the more they ****** me off.. so...

made another with M6 fittings... made a nut ring to go inside the tank.. ordered a gasket from ATL.. baffles cut.. end plates cut... with a bit of luck the c**t will be done over the weekend...

i then decided seeing as i`d been welding sainless for the past 2 years i better see if i can still TIG ally...

beads could be little closer but i was in a hurry...

for the geeks...

125amps... miller synchrowave 300... 4mm tungsten.. #7 shroud (i think).. torch BLOODY big!!.. gas flow - enough to tickle my ear!!

 

[TheJoker]

Very nice, very nice!!

 

[davenport]

well its been a while...

been having a few weekends off the car recently.. family/bird/mates etc etc have been made prioroty but fear not progress is still chugging along!!

TANK!! done!!

ok.. when i say done its not fully done as i still need to drill some holes for fuel level guage/breather/feed an return.. bt the hard stuff IS done...

baffled like a thick c*nt doing maths!!:

check dem welds :

the swirl pots nearly done but need to get some weld on -6 and -10 fittings..


a big thanks to stu @ realistic motorsport (evo owners take a look) for the high pressure pump..

bosch 044 in ze haus.. gotten himmel das ist ****y Ja????

 

[harry69koi]

You are one super skilled man cant wait till it finished then you can weld my terrano up lol

Well done m8ty

 

[oz.]

Progress looking good.

Oh and some nice terminology there -

baffled like a thick c*nt doing maths!!

 

[BChild]

a big thanks to stu @ realistic motorsport (evo owners take a look) for the high pressure pump..

bosch 044 in ze haus.. gotten himmel das ist ****y Ja????

What pressure?

Need a new external pump for my track day car - current one can't get the fuel pressure above 2.5 bar and I need at least 3.5 bar for the throttle bodies I plan to fit soon

 

[davenport]

i beleive the 044 peaks at 8 bar but can hold 7 quite happily....

1 pump will handle 400 bhp without too many issues...

 

[lchris21]

love it

 

[davenport]

deliveries and collections today...

delivered- facet pump and faulkner springs

swung by mothers and initial findings are sweet!!!

my (once 90mm internal) pug sport coilovers are now a much easier to obtain 2.5" internal springs..


and when i finished work i swung by BGCmotorsport for some bits for the fuel system..

left to right we have:

* 3x -6 and 1x -8 weld on fittings for the swirl pot

* 2x -6 bulkhead fittings which will go through the top plate of my tank (1 for return and 1 with pipe for pickup)

* 2x -6 fittings for the facet lifter pump

* 1x sytec filter c/w -6 fittings (and motorsport kitteh approval)

* tank breather + shut off valve (will also go in tank top plate)

bosch 044 pump with -8 fitting...


and finally... the start of my swirl pot...

once evrythings nailed in place i`ll worry about getting the lines made up....

 

[TheJoker]

Nice... especially Motorsport Kitteh!