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Oct 28, 2016 17:20:06 GMT
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Welcome back Chris, so glad your back on it. Those CAE shifters are a proper piece of art! Great to see the "temporary" engine is finished to such a high standard too.
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Oct 29, 2016 11:42:31 GMT
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Thanks guys! The CAE is a really nice piece of kit, i am probably going to fit my Quaife gearknob onto it though if it'll go as it's a bit better shaped. I'll be heading home in a few weeks time, plan is to make some progress in the engine bay with a new front panel and some gussets in the engine bay. I've decided i'm going to sell the Safety Devices bolt in cage from it and have a custom one from Protection and Performance, already done some CAD for how it's going to shape up. Annoyingly, the spacing of the throttle bodies on my engine is slightly different to that of the 2nd hand airfilter i bought, so i'll have to buy and new back plate and re-cut all the holes to suit my setup Great: Not so great:
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New welding setup means infitely more progress is possible, right from the comfort of my own garage. Yay. I managed to stitch all the chassis legs in and the strut towers in no time as i'd done a load of prep before hand removing sealer
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qwerty
Club Retro Rides Member
Posts: 2,416
Club RR Member Number: 52
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Excellent work!
Have you done any strengthening to the NSF chassis leg?
Tom
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Nov 26, 2016 10:53:23 GMT
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Awesome to see you back.
Thread well and truly bookmarked!
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1990 VW Polo Breadvan Berg Cup'd - Project Breadbin 1986 944 Lux 1987 944 Turbo 1971 Covin Turbo Coupe
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Nov 26, 2016 15:33:59 GMT
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Thanks guys, it's been really good to start making some progress on the shell actually!
I have stitched the legs on both sides and both strut tops.
the intention is to weld in gussets to both chassis legs where they meet the bulkhead, and to plate up any old holes that aren't used as I go.
I am only back for a fleeting visit, so i'll be making a cutting list quickly in the garage this afternoon and getting all the gussets laser / waterjet cut for when i get back in a couple of weeks time
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Nov 26, 2016 21:35:22 GMT
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One of the other jobs i did today was to make a new backplate for the PiperX filter to do that though, i first needed to do some reverse engineering: I transferred that to a masking tape template and used it to mark up a sheet of 2.5mm aluminium, then used a couple of sheet metal punches and a step drill to put the relevant holes in.
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Excellent work! Have you done any strengthening to the NSF chassis leg? Tom Hey Tom, I have stitched the NSF chassis leg and strut top in just like the other side and then stitched all around the gearbox mount too. I'm picking up working on this for this week as i have some time off, so i'm hoping to get as much of the welding in the engine bay done as possible.
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qwerty
Club Retro Rides Member
Posts: 2,416
Club RR Member Number: 52
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Nice work! I need to get on with mine!
Tom
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New up tonight: Made a plate to blank off the old fuse box hole, it's not actually flat so the existing hole needed a fair bit of re-shaping to make it all fit. Next job to tackle is the aftermath of the old pedal box / servo mount, which has resulted in me having to chop this hole in the bulkhead. Luckily it's all flat so relatively easy to repair. There's another bit of damage in a really tricky place there too next to the steering rack mount, which is giving me a bit of head ache to repair
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Some more progress today: Plate to infill the hole where the old gearstick resided Much welding and grinding back later Marking up the tunnel for the new internal linkage Et Voila But why?! All revealed shortly
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I drilled out the standard studs and replaced them with captive nuts and then mounted this CAE shifter! It's really nice and moves most of the linkage in board. It also looks like it's going to play nicely with my hydraulic handbrake
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Job for this morning, starting on engine bay gussets Card 1.5mm Steel Punched and swaged Weld Replicate on other side Boom. More gussets to come to stiffen the strut towers
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Next job - fabricate some uprights to stiffen the strut towers. Some people do this with a 38mm roll cage tube, but i've chosen to do it with a fabricated upright with swaged and flared holes in it. After taking some measurements, i figured these were easier to CAD up and get plasma cut in 1.5mm mild steel.
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jonomisfit
Club Retro Rides Member
Posts: 1,782
Club RR Member Number: 49
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Looks good and swagey holes are always excellent.
On the strut stiffener is it worth putting Mouseholes at the bottom so you don't end up with a water trap? Either a half hole onto the chassis leg or back corners cut out?
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Looks good and swagey holes are always excellent. On the strut stiffener is it worth putting Mouseholes at the bottom so you don't end up with a water trap? Either a half hole onto the chassis leg or back corners cut out? Yeah, when I turn the cad into a flat panel I was planning on putting some cut outs in the corners at the bottom for drainage. I'm going to print these out and mock them up in card today as I also need to profile the bottom edge to fit the curve of the chassis leg
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Mar 24, 2017 19:31:11 GMT
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So, literally 10 years ago i had some aluminium centres laser cut to make some vernier pulleys. I sold a few sets along the way, and kept a set of centres for myself and never got around to machining them into pulleys I stayed late after work one night this week and got the pulleys drilled and tapped to take the centres. I'll then machine a slot out of the pulley to split the keyway'd centre from the outer to make them into verniers. I used the auto tapping function on our mill to drill and tap the holes which saved loads of time I'm a few bolts short so have ordered some more M6's on eBay. Once i've finished machining everything i'll get the centres anodised too.
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Jul 24, 2017 17:00:04 GMT
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Back home again this week to make some progress on the Polo. I've been putting off repairing two rather tricky bits of the bulkhead which i managed to get done - one down the side of the steering rack and the common battery tray. I've also now ordered a new front panel which i should get on this weekend along with the last few gussets I also bought these Speedline competition wheels for a rather barganous price off eBay - i'm on the fence about the colour but that can be changed
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Some new bits turned up this weekend First i got a decent pattern front panel, purely to nick the headlight bowls from. I'll be cutting the centre section out and making quick release to make working on the car easier. Great to see the car with a face again! Next was a 3 paddle clutch plate i scored for 25 quid, it needs re-sintering but i'll use this with the Sachs group A cover and bearing i already have I have had the gussets i designed a few weeks ago water jet cut and started turning them into gussets. They need a bit of fettling but will go in finally next time I'm home
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Some mighty good work occuring here! You looking to use it on gravel or tar? id be tempted to fab up & fit some strut top reinforcing plates & stitch inside & outside of the strut top bottom (if that makes any scence!)
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Take the Next slot right coming up on the left.
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