Sealing up the cut out tunnel top and under the rear seat was to be the next stage but first I decided to make some new beefed up engine mounts. The originals I had made from a mixture of 3 and 4mm steel were probably fine but i wanted to move the crossmember backwards away from the engine for a little bit more clearance. So while I was at it I thought it best to use thicker steel.
To start with I made a jig based off the original mounts. Now there were datum points to build to, allowing for extra clearance while I was at it.
I popped into G3 engineering where I get a lot of my steel offcuts from and grabbed some 4mm plate. I had 5mm at home for the main backing plates.
Used the hefty steel bender..
Tigged the majority of the welds except the inside ones I couldn't reach which got mig welded. Plenty of heat. These wont fail.
Added gussets just to be sure...
The new mounts now set the crossmember further back by about 5mm. I could now drill the holes through the chassis rails. I made up a new pair of backing plates with extra holes and captive nuts. The plates extend further forwards to line up with the holes that Datsun crossmember bolts through. I can now easily bolt in either crossmember.
I was super happy to discover that due to the flat six being only 3 cylinders long I have enough room to pull the engine back so its gearbox bobbins are clear of the gearbox crossmember. I can then raise the car up and away from the engine, all without having to remove the rear bumper and valance.
Now the engine was in its final position I could replace the lid on the tunnel, now 50mm higher. I started with this bit and had to cut out a section to allow for access to the toyota spec gearbox speedo sensor plug...
Making sure there was ample clearance all round so the box cant knock the tinwork on rough roads I proceeded to box the tunnel back in...
Kneeling down on folded up bits of foam and towels was my home for the next few hours...
Cardboard trials, then steel, cut, trim, tack, check, weld...
Finally boxed in. Another access hole let in so I can get to the top universal joint and lube the gearbox selector shaft if needed.
It was a very good part of the build to finish. Seeing it all sealed up, strong again. I have yet to check the rear seat squab but I feel confident it'll fit with some modifications to the wire frame within.
Underneath looked neat...
Hannah has now painted the tunnel inside and out with Epoxy paint.
After I have finished any other little fabrication bits or hole filling/drilling in the engine bay I'll give it a flick of blue paint (hopefully not making everything else in the workshop blue like the first time)
Now it was onto the rear suspension arms. I am using the set that came on the green imp 2. Surface rust needed wire brushing off outside...
Painted with KBS rust seal (Aussie por 15 clone)..
Another bit I could have got away without doing but I thought best to make while I'm under the car was this brace...
Pulling up tight to the floor via spreader plates under the seat base...
I have added it to brace the floor halves inline to help keep the suspension mounts inline during hard corning. Like said, I'm not sure if its essential but it might just help avoid any weird effects like rear steering. I know its a bit ugly but hey, at least its hidden under the car.
On the subject of bracing I also made this little brace...
To help stiffen the top of the tunnel near the shifter so it doesn't flex. again, not really needed but I do want a really positive shift action without an excess movement.
So now my next job is to run out the brake/clutch/fuel pipes back along the tunnel and then reassemble the rear suspension so I can setup the handbrake cables. I'll have to paint some bits too. The crossmember, mounts, fuel tank etc. The work area looks like this with bits everywhere...
In other news we had these treats turn up in the mail, a surprise present from my brother in Wales...
He had gone to a big collectables/toy and model show local to him where he then spent a good amount of time asking at the various collectors stalls for any Hillman Imp models and found what is quite a rare and sought after Dinky toy car...
Plus a cool little Imp police car ..
They turned up in the post yesterday as a surprise and made our evening. Very cool. Thanks bro!
(I’ll get my coat)
