jonomisfit
Club Retro Rides Member
Posts: 1,789
Club RR Member Number: 49
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I only got a quick slot in the garage today as was elbows deep in dead washing machine  new stuff arived. A radiator  P1030510 by jono_misfit, on Flickr its meant to go onto 20mm upstand mounts that used to be here. I'm not sure why they were partially removed. The hex hole in teh centre is where a captive nut of some description used to be.  P1030512 by jono_misfit, on Flickr now fully removed  P1030513 by jono_misfit, on Flickr radiator sits here. fairly far back, so an intercooler can fit in front of it.  P1030514 by jono_misfit, on Flickr need a new mount cut some steel  P1030515 by jono_misfit, on Flickr mark, drill, weld on captive nuts  P1030516 by jono_misfit, on Flickr drilled out the holes in the chassis leg large enough for the nuts to fit in  P1030517 by jono_misfit, on Flickr  P1030518 by jono_misfit, on Flickr and welded on  P1030519 by jono_misfit, on Flickr  P1030520 by jono_misfit, on Flickr the gaps in the welds are to allow any moisture to drain out, rather than be trapped and rot the nuts radiator in for assessment. mounted on 5mm plastic spacers as I may make an nylon bush to sit under it.  P1030521 by jono_misfit, on Flickr  P1030522 by jono_misfit, on Flickr top mounts bolt up to the top panel  P1030523 by jono_misfit, on Flickr  P1030524 by jono_misfit, on Flickr its quite a reach, so will require a spacer bracke. the huge gap is to allow intercooler pipes to come over the top. i then started measuring up where i think the sump guard mount should go  P1030525 by jono_misfit, on Flickr |
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jonomisfit
Club Retro Rides Member
Posts: 1,789
Club RR Member Number: 49
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Not much picture progres today. I need some weld in bobbins for mounting the sumpguard mount to. Started with this stock.  P1030526 by jono_misfit, on Flickr abused my rage saw (i really need to wire in the 3ph converter and use the poweer hacksaw!)  P1030527 by jono_misfit, on Flickr turn turn turn  P1030528 by jono_misfit, on Flickr end up with this.  P1030529 by jono_misfit, on Flickr  P1030530 by jono_misfit, on Flickr make some friends  P1030531 by jono_misfit, on Flickr I then spent ages going round the car cleaning back bits, and finding any more little rust repairs. Not much to see but took a while.  P1030532 by jono_misfit, on Flickr  P1030534 by jono_misfit, on Flickr this seam needs a thorough dose of wire wheel to clear it out, and some rust inhibbiter.  P1030533 by jono_misfit, on Flickr |
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jonomisfit
Club Retro Rides Member
Posts: 1,789
Club RR Member Number: 49
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My sump guard mounts arrived. Weighty bit of kit, but then again Its supposed to take a fair force transfer. Laser cut ali  P1030536 by jono_misfit, on Flickr first things first. look at the mounting holes. Oh, 12mm  P1030537 by jono_misfit, on Flickr ooooh, 10mm  P1030539 by jono_misfit, on Flickr bobbins i've made are too small for it. Will make some more on the weekend. I think i'll probably machine up some 3mm plate and weld a nut on the back this time though. It'll mean I can have a larger load spread area than my turned bobbins (due to stock and machine size limits). Mount goes approximately here.  P1030542 by jono_misfit, on Flickr |
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jonomisfit
Club Retro Rides Member
Posts: 1,789
Club RR Member Number: 49
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interesting.
I've just spent a while looking at pics of escort cosworth group A shells, and it looks like the way the sump guard mount are large welded on washers on the outside of the legs, with welded in crush tubes through the legs.
The sump guard then just bolts through the leg via the crush tube with a normal nut on the inside.
I guess this makes it easy to repair / place on a rally. And if alignmnent is out you can still hammer it in and get a nut on the end.
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Woah. Those will be the heaviest things on the car!
No room for speed holes I guess..
How does the guard fit to those mounts? Have you got/shown/made that bit yet?
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jonomisfit
Club Retro Rides Member
Posts: 1,789
Club RR Member Number: 49
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I've not made it yet, but will be soon.
There are cross bars that bolt in to these, then the sump guard bolts on to these cross bars.
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jonomisfit
Club Retro Rides Member
Posts: 1,789
Club RR Member Number: 49
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Started looking at the radiator top mount.  P1030543 by jono_misfit, on Flickr If i don't put a steady on it, it'll rattle and crack a weld somewhere threaded stud through the mounting hole  P1030544 by jono_misfit, on Flickr Allows me to measure the distances from C to C of the fixing holes  P1030545 by jono_misfit, on Flickr sketch out a bracket in CAD  P1030546 by jono_misfit, on Flickr trim  P1030547 by jono_misfit, on Flickr fold  P1030548 by jono_misfit, on Flickr Hmm, a lot of unused material that looks better, and far more overly complicated, just as I like it  P1030549 by jono_misfit, on Flickr trim some ali sheet  P1030550 by jono_misfit, on Flickr mark out and start cutting ready for folds  P1030551 by jono_misfit, on Flickr overly complicated bracket folded up, and swaged holes added, cos, you know. Swaged holes.  P1030552 by jono_misfit, on Flickr  P1030553 by jono_misfit, on Flickr welded up, with corner gussets added  P1030554 by jono_misfit, on Flickr fits like so  P1030555 by jono_misfit, on Flickr  P1030556 by jono_misfit, on Flickr start the second one  P1030557 by jono_misfit, on Flickr I then started folding it, but reveresed the direction of the folds, so i wasnt making two right hand brackets, as it'll be symetrical obvs.... except it isnt. LH and RH are the same. The radiator top mounting hole is offset on the passenger side. Cut out some more material....  P1030558 by jono_misfit, on Flickr setup ready for welding  P1030559 by jono_misfit, on Flickr welded  P1030560 by jono_misfit, on Flickr both brackets in  P1030561 by jono_misfit, on Flickr  P1030562 by jono_misfit, on Flickr  P1030563 by jono_misfit, on Flickr I'm pretty certain these will have a good chance of cracking over time, but i'd rather they are the weak link that stress the tabs on the radiator and crack that. |
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jonomisfit
Club Retro Rides Member
Posts: 1,789
Club RR Member Number: 49
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I ordered the bits I need to fit the sump guard mounts, but ETA is mid next week so it'll be another week before I'm working on that. Sump guard mounts to a bar that looks a bit like this.  Sump guard support bar v1 by jono_misfit, on Flickr Which goes between the two mounts. |
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jonomisfit
Club Retro Rides Member
Posts: 1,789
Club RR Member Number: 49
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May 10, 2020 18:17:59 GMT
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I did a sketch in CAD and printed it out to give me something to follow  P1030564 by jono_misfit, on Flickr started turning up some inserts  P1030565 by jono_misfit, on Flickr  P1030566 by jono_misfit, on Flickr ended up with these  P1030567 by jono_misfit, on Flickr tapped  P1030568 by jono_misfit, on Flickr need some box, mark it out  P1030569 by jono_misfit, on Flickr drill it and put two inserts in  P1030570 by jono_misfit, on Flickr  P1030571 by jono_misfit, on Flickr hit with the magic glue gun  P1030572 by jono_misfit, on Flickr  P1030573 by jono_misfit, on Flickr dress back  P1030574 by jono_misfit, on Flickr cut some more box  P1030575 by jono_misfit, on Flickr rinse and repeat  P1030576 by jono_misfit, on Flickr also cleaned back  P1030577 by jono_misfit, on Flickr then to make the end mounts. Some 10mm thick ali  P1030578 by jono_misfit, on Flickr passed throught the rage saw  P1030579 by jono_misfit, on Flickr cut them in half, then cleaned up the edges in the mill (being lazy I used a small cutter in the drill jaw)  P1030580 by jono_misfit, on Flickr gave me these  P1030581 by jono_misfit, on Flickr drilled and tapped  P1030582 by jono_misfit, on Flickr bolt through like so  P1030583 by jono_misfit, on Flickr  P1030584 by jono_misfit, on Flickr cut some triangles of 3mm ali sheet  P1030585 by jono_misfit, on Flickr assembles like so  P1030586 by jono_misfit, on Flickr I want to wait until i've fitted the mounts until I trim to length the cross bars and weld. This will likely be next weekend. |
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Last Edit: May 10, 2020 18:49:23 GMT by jonomisfit
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jonomisfit
Club Retro Rides Member
Posts: 1,789
Club RR Member Number: 49
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May 10, 2020 18:22:36 GMT
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Some of the welds on the car (by others) werent great, so I cut them back, cleaned up, and started re-welding. Mid progress  P1030587 by jono_misfit, on Flickr  P1030588 by jono_misfit, on Flickr Looking at my Escort Group A / WRC pics I noticed a few places that they welded but I havent yet. I cleaned back the seams on the front inner wheel arch close outs.  P1030589 by jono_misfit, on Flickr seam welded  P1030590 by jono_misfit, on Flickr  P1030591 by jono_misfit, on Flickr  P1030592 by jono_misfit, on Flickr I also had a go getting this seam cleaned up, ready to use rust killer on it.  P1030593 by jono_misfit, on Flickr  P1030594 by jono_misfit, on Flickr Defintely getting there with it. |
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May 10, 2020 18:31:53 GMT
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Really nice brackets. You do have a lot of patience. A joy to follow
Peter
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jonomisfit
Club Retro Rides Member
Posts: 1,789
Club RR Member Number: 49
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May 10, 2020 18:47:43 GMT
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You do have a lot of patience. Peter Thanks. Anyone whos met me off the internet would find this amusing though. I have noooooo patience. I want everything done now, immediately, if not sooner. Faster if you can. Oh, and perfect. If I could learn a little patience, I could produce much better quality things. I struggle. |
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Last Edit: May 10, 2020 18:48:03 GMT by jonomisfit
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It must be hard having little patience but lots of perfectionism.  Saying that, the only corners I've seen being cut are the ones on bracketry as a weight saving effort.. |
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jonomisfit
Club Retro Rides Member
Posts: 1,789
Club RR Member Number: 49
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Hotwire. Please can we have a groan button?
😂
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Dear Mr Misfit, I'm no medical expert but I very much recognise the clear symptoms of your OCD disease on a daily basis - sadly there is no known cure
Yours sincerely
Mr Grumpy
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jonomisfit
Club Retro Rides Member
Posts: 1,789
Club RR Member Number: 49
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May 11, 2020 19:09:11 GMT
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In accordance with the law of sod, the bits I ordered arrived first thing today.
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jonomisfit
Club Retro Rides Member
Posts: 1,789
Club RR Member Number: 49
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May 15, 2020 19:27:17 GMT
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As above, the metal turned up on monday.  P1030609 by jono_misfit, on Flickr drilled and counter sunk holes  P1030610 by jono_misfit, on Flickr cut some crush tubes  P1030611 by jono_misfit, on Flickr squared them off in the lathe set them up on the bench.  P1030612 by jono_misfit, on Flickr tacked on with the tig flipped over  P1030613 by jono_misfit, on Flickr welded round  P1030615 by jono_misfit, on Flickr 3 other made and linished back  P1030616 by jono_misfit, on Flickr marked up, drilled holes, and trimmed back another plate that was in the way  P1030617 by jono_misfit, on Flickr sits in like so  P1030618 by jono_misfit, on Flickr protrudes through on an already welded in plate  P1030619 by jono_misfit, on Flickr making sure alignment is right.  P1030620 by jono_misfit, on Flickr I cant do the last mount (front mount) each side until I take the jig out of the front as it covers where it needs to be. tacked in until i'm certain its all in the right place  P1030621 by jono_misfit, on Flickr I used some 12mm threaded rod as a I havent bought bolts the right length yet. through onto nuts  P1030622 by jono_misfit, on Flickr Once welded in fully I'll carefully tirm back the stubs to the minimum length. drilled the other side ready for the tubes  P1030623 by jono_misfit, on Flickr  P1030624 by jono_misfit, on Flickr Should hopefully get them all welded in on Sunday. |
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Last Edit: May 15, 2020 19:31:11 GMT by jonomisfit
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jonomisfit
Club Retro Rides Member
Posts: 1,789
Club RR Member Number: 49
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May 17, 2020 18:32:58 GMT
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I was out early, so didnt want to start the day making too much noise. A lot of escort rally cars have a strengthener plate added here. They tend to bend a bit with loads / crashes.  P1030626 by jono_misfit, on Flickr made a template  P1030625 by jono_misfit, on Flickr cut some steel and marked it out  P1030627 by jono_misfit, on Flickr cut and file  P1030628 by jono_misfit, on Flickr clean back  P1030629 by jono_misfit, on Flickr add a couple of strengthening ribs. My bead roller really really did not like doing this (despite multiple passes) so I stopped before I got the depth on the beads i really wanted. I'm pretty certain i'd have broken somethign if I kept going.  P1030630 by jono_misfit, on Flickr welded on  P1030631 by jono_misfit, on Flickr  P1030632 by jono_misfit, on Flickr and other side  P1030633 by jono_misfit, on Flickr |
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Last Edit: May 17, 2020 18:40:47 GMT by jonomisfit
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mk2cossie
Club Retro Rides Member
Posts: 3,062 
Club RR Member Number: 77
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May 17, 2020 18:33:38 GMT
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Does this help?
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jonomisfit
Club Retro Rides Member
Posts: 1,789
Club RR Member Number: 49
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May 17, 2020 18:46:02 GMT
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Welded in the sump guard mounts  P1030635 by jono_misfit, on Flickr you can see on the passenger side where they hadnt fitted a plate they had on the drivers. I'll add this in later  P1030636 by jono_misfit, on Flickr and welded the stubs  P1030637 by jono_misfit, on Flickr  P1030639 by jono_misfit, on Flickr cleaned back the welds a touch where needed then fitted the sump guard mount  P1030638 by jono_misfit, on Flickr then on to the front mounts. I had to remove the jig at this point, so took the chance to relieve the front mounts around where the nut will stick into the chassis leg. With the way the panels join on the front of the leg, the is about 2mm more recessed than the other mounts cut some steel and drill  P1030640 by jono_misfit, on Flickr Tig on some captive nuts  P1030641 by jono_misfit, on Flickr put into position  P1030642 by jono_misfit, on Flickr  P1030643 by jono_misfit, on Flickr glue on  P1030644 by jono_misfit, on Flickr  P1030645 by jono_misfit, on Flickr# bolt up solid  P1030646 by jono_misfit, on Flickr |
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Last Edit: May 17, 2020 18:53:40 GMT by jonomisfit
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