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Post by perthwa on Oct 9, 2020 11:07:21 GMT
Been working but not blogging. Radiator install. Partially welded in four mounts with rubber bushings installed... but not shown on top supports. Cleaned up the bits that were near the welds but slackness stopped me getting all the green stuff... Will clean them up soon... Rubber bushes are pushed on the Aluminium spigots but not placed inside the welded brackets... as I have yet to finish welding them in I would just have to take them out again so they don't melt. This is the reused Focus fan. I trimmed off about 30 cm of plastic from one end. Then I used a stainless steel door from my old dishwasher to make a shroud. then I used a couple of pieces of 3mm steel to make up a bracket to hold the shroud to the radiator. Radiator is from a mate and I think it was from a honda civic. The view from the front and I tested the bonnet and it clears. I have also been stripping back some of the wiring. starting with anything that does have a purpose AND if it is not connected to the CAN bus... Isn't wiring fun... I did have a minor Heart failure when the car electrics would NOT talk to me at all... Eventually chased every earth contact and made sure that they were actually earthed... to NO avail... So I then started looking at the CAN bus resistors and while checking wires either side of one of the wire harness plugs... the electrics started working... So I am checking plugs are fully home when I am playing with the harness. Eventually I will hard wire all the wires and remove the harness plugs. That should eliminate future failure. More to come... this link may help link photos.... photos.app.goo.gl/3oE5WJRoG8X7fWWp8
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Post by wishful4444 on Oct 9, 2020 15:10:43 GMT
The photos are not showing.
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Post by perthwa on Oct 11, 2020 14:10:53 GMT
not sure why that do not show... added a link to the google photos folio above??? Just to prove I am not too slack... I cleaned and painted the brackets. Then painted the almost finished frame bits.... and added the grommets. here is a close up of the lower one. and the radiator in place Then I moved to the engine compartment and realised that my water overflow container bracket was mounted to the engine and to the engine mount... Not smart. So I modified it so it just mounts to the engine. Still need to paint it a bit more now... Then I needed to make a bracket to support the back end of the airbox... so I decided to added a rivnut to the side of the airbox and then I can bolt this to a bracket coming off the Engine mount on the engine side. The bolt and bracket is the engine mount attached to the frame of the car. I will NOT be using this to attach it to. More to come. Then I located a Power brake booster than came with my Clubbie purchase... I have cleaned it up and painted it and then I will see if I can get it to fit the Sonic set up. Looks close to fitting with a bit of bracket modification. More to come with this as well..
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Post by buildityourself on Oct 11, 2020 20:05:17 GMT
Bruce,
Just looking through your photo album. You will need to add some braces to the rear suspension upright plates. The early cars bent the 6mm steel without these.
Stu
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Post by perthwa on Oct 30, 2020 12:34:12 GMT
thanks for noticing... Had a plan to do something. BW
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Post by perthwa on Dec 24, 2020 5:01:25 GMT
Holidays! 40 in my shed yesterday! Brake master cylinder attachment. Measure twice cut once and test fit as many times as possible. How could I attach a master cylinder 90 degrees off? Easy, obviously... Mark II, Weld up a better version because when you attach the reservoir... it is such an angle that it would be only half full when overflowing... The original setup was at about 25 degrees off vertical... Bolt on the bits and fit in place. It still looks at a bad angle but I think this is more of an optical illusion. It is on a slope, but it should hold fluid and not activate the low fluid signal...I will test it soon.
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Post by snowbird1 on Dec 24, 2020 14:08:32 GMT
Not seeing the images
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Post by perthwa on Dec 26, 2020 13:48:56 GMT
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Post by perthwa on Dec 26, 2020 13:57:43 GMT
looks like I didn't actually put them in the album... even though I uploaded them....
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Post by perthwa on Dec 27, 2020 9:01:55 GMT
Fitted the steering column support bearing to the firewall. I made it ages ago and had it sitting in place but actually drilled some holes and bolted it in place. Here it is in place Next!
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Post by perthwa on Dec 27, 2020 9:26:31 GMT
Next job - Body fixing to the frame.
At this stage the body is not fitted and yet it is quite sturdy but there is no visible means of support. As I wish to take it off so I can do brake lines and radiator pipes, I need to be relatively confident that I can get it back in the same spot as it currently is...
So I better add some fixing points. It doesn't meet the frame underneath the body as nice as I see some of the kits in this forum. Time for a few tabs and a few rivnuts... Update soon...
Did I say how bl_oo_dy hot it is in my shed... Looking at some insulation for ceiling only need 47.3 sq m... T'was 40 degrees C in there again... Might have to go for R3.0 Batts (@$256) as R5 is $10 per sq m...
I do have a 5kW reverse cycle air conditioner that my son just dropped off... it needs fitting, plumbing and electrical...BUt i figure it could be a good plan long term. (needs both insulation and air....)
...
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Post by perthwa on Dec 28, 2020 13:37:25 GMT
Got distracted by the brake lines. I have decided to reuse my Focus brake lines; so I straightened them, passed the longer two sections down the side pods. You can see a small triangular section at the top of this photo. The line fed easily through this section and was almost exactly the right length. Now looking for a couple of Tee pieces so I can go from the 1/4 " pipes from the master cylinder to the 3/16" lines to each of the wheels. Also looking at best way to support brake hoses form callipers to the body... And need to borrow a flaring tool from someone in our Sports Car Builders Club here in Western Australia. I will also need to find a way to support the brake line in the triangle section. The left hand side also has some wiring fed through this triangular hole and likewise it will also need support. Just saw link to Jeggs for Brake Line Bolt Tab & Clip Kit... I will make 4 of these tomorrow. and also saw Dr Brian's advice about length and location of brake hoses.. looking good. Need also to locate some more 3/16" line and then run a clutch line from master cylinder to the clutch. Then I got distracted by the interior compartment. Removed the seats. Fitted the fuel tank isolation compartment (this goes behind my seats). Found some polymer sheeting that I will used to sheet the passenger compartment interior sides. I have some 3 mm x 20mm x 1.15m strips of Aluminium that I will use with rivnuts to the hold the fibre glass and the polysheet to the metal frame. I do need to put in a couple of brackets to hold the end of the sheet on the fire wall end and also the dashboard end. One side of sheeting has been cut out and roughly fitted and also one of the metal strips. rinse and repeat for other side tomorrow. Then properly connect the isolation tank to the newly sheeted side pod so it completely removes chance of fuel contact with passenger compartment as per DOT. This will also allow the seat belt to have a clear access so that there is no chance of snagging (also DOT requirement). Then a couple of snaps to show progress. then back to body fitment... well that's the plan... Only 34C today... 39C tomorrow ...
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Post by perthwa on Dec 29, 2020 4:17:06 GMT
early start Driver's side and Passenger side below. Fuel Isolation tank in place. checking for clearance Drivers side towards seat belt and roll bar checking for clearance. Now need to fix in place with a few screws and my nice shiny strips of Aluminium which will go across the gap between the black and the white.
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Post by perthwa on Dec 29, 2020 13:37:57 GMT
9.30pm and still 30C - better that 36 at 7pm... How can 3 rivnuts and a few holes take so long... and I still have the last rivnut and two welded tabs to go on the driver's side before moving to passenger side. Here is strip one covering the overlap. Both base materials are about 3mm. The end holes are onto some 25mm steel angle pieces that i will weld in place as drilling was impossible due to the cross bracing in the side wall. I need to round the edges a bit more and polish it just a bit. I will simply add a few screws to hold the bottom section flush with the floor. The seats runners will just about cover up the ugly cutouts for the floor structural members. this was taken ten minutes ago and it is now 9.45 pm More of the same tomorrow.. finish this side... weld tabs on other side. Drill and fit 4 rivnuts. trim and clean the metal strip and fit all together.
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Post by perthwa on Dec 30, 2020 13:49:39 GMT
Started out with car building on the menu... Son turns up.. trip to the rubbish depot... trip to Bunnings Home depot supply... $400 later we have 47 sq m of R4.0 Wool ceiling batts... 16 man hours later.. So, lets see how pleasant that makes working in the shed... Unfortunately, the first two hours tomorrow will be a few battens to hold up the chicken wire that is holding up the batts... The next two hours will be cleaning up the shed as we had to shift just about everything... BUT at least I will be cool!!!. Reverse Cycle Air installation is next...
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