Month: September 2011

Drivers footwell constructed

Spent most of my shed hours today getting the aircon (that I bought almost 3 years ago!) wired up, as I’ve got someone coming out this week to hook up the refrigeration lines.

So I’ve put the wall insulation up behind where the Aircon is being mounted, and ran the power cables from the head unit (the indoor bit) to the outdoor unit and hooked it up.  The wires for the head unit are all terminated and just need to be screwed onto the terminals once the AC guy has hooked up the piping and put the unit back onto the wall mount.

Once that was done, I got started on completing the drivers side footwell of the car.  The first task was to make the small in-fill panel to join up the panels that I built last time.

Then I had to remove the master cylinders from of the pedal box.  Next was making up cardboard templates for the last few panels.  I managed to get quite a complex shape in just two panels.  The panel sits directly behind the pedal box, with a recess cut out behind the accelerator, to allow room for its linkages to move.  You can see it in the pic below – taken from the other side of panel (ie. in the engine bay)

Once all the new panels were cut out they were all tacked into place into the car.  Then I used the pedal box mount as a guide and drilled the matching holes through the panel – this is where the master cylinders will bolt back in, sealing this back up.

And the final result.

And that was all the time I had left today. Next job is to get the passenger side and and dash area into the same state, then I can take the motor out and finish weld all these panels.

Just a quickie

Got two hours in the shed tonight and got  my new fuel pump bracket fitted.  I got it for $5, cause it had one if the tabs 1/2 cut off.  Suited me fine cause if I bought a new one I was going to have to cut both tabs off anyway.

So much lighter, and nicer than the rusty steel one that used to be under there 🙂

More significant progress tomorrow hopefully…

Fires and walls

Got a couple of hours done late this arvo.  Started work on the firewall, this separates the engine from the inside of the car, very good especially if there is a fire in the engine bay 🙂

I started working on the drivers side, as this is going to be the most complex side, due to the tight spaces around the pedal box.  I started by making the whole piece in sections of cardboard, all stuck together with tape.  Once this was all done, I had a template to start the metal work.  I decided to make it in two large pieces, with a third piece to form a complex angle that joins the two panels together.

So, the two large pieces are tacked into place.  I’m making this side out of steel and will be welding it in, as this is the side where my feet will live.  The panels on the other side will be in alloy and will be removable panels to allow easy access to the engine.

The oval slot, middle top in the pic, is for the steering column  to pass through.  The gap between the sheets, center of pic, will be filled with a separate panel that will run at an angle to the two sheets that are visible in this pic.  This angled piece is to allow clearance for the intake on the engine, but to also keep enough room for the clutch pedal to be fully depressed (clutch pedal not attached in this pic.)

The left side panel has three small bends in it to make it fit nicely against the existing tube work in the car, with another bend at the bottom to make it fit snugly under the pedal box but still leave enough room for a clutch foot rest (it’s going to be a small one!).

The next pic shows the right side panel nicely tucked into the roll cage, with a single 90 degree bend in it – bent on the folder that I made 🙂

I have tucked the interior panel into the cage like this as the original metal behind this area is full of different holes, not allowing a nice place to seal the sheet metal to.  Also, the longer term plan is to remove the factory material that is behind this section, so doing it this way allows this to be removed but leaving the inside of the car sealed off.

From the bottom of this right side sheet, another panel will run from here down to the back of the pedal box, sealing that section off.  This will leave the brake cylinders inside the engine bay as this is going to be the easiest way to access them if work needs to be done on them and it will keep all the brake lines outside of the cabin.  I could have built the firewall to keep the cylinders inside the engine bay, but it would have been so tight around the cylinders it would have made them really hard to access and the whole pedal box would have to be removed to change a cylinder.

I ran out of gas for the Mig welder, so that’s where progress stopped for the night.  Next on the list is the two remaining panels to seal off this side of the car, hopefully tomorrow night will see a little bit more progress.

I finally feel like the car is getting more complete, rather than further destroyed…

Steering complete

Got some time in today and got the steering rack mounts all complete, and the steering column all complete.

This is the mount for the steering rack.  The round hoop sections at the bottom of the pic is where the steering rack goes.  There are then two other hoops that bolt on underneath, holding the rack in place.

These are now painted all nicely in gloss black (still just in undercoat in these pics).

Then it was onto finishing off the rest of the steering column.  I had been out in the morning at some car wreckers and found a spline of the correct type to fit the universal joint that I was using.  So I cut the splined shaft off the part of steering that I got from the wrecker, machined part of it down in the lathe so it would fit inside the steering column that I had made previously.  So once this was circular and also plug welded (don’t want this bit falling off :)), then painted it was complete.

That pretty much finishes up the the work on the main mechanical systems on the car.  There is a small bit of welding to finish off once I get the motor out, but that will have to wait.  Next on the list to do is to construct the firewall and the small piece of floor in the rear section of the car – where the original rear floor will meet the new ‘aero’ floor.

A little update

Went and picked up a ‘big boys bed’ for little Cody, so spent the morning collecting and setting that up.  The did the lawns, played with kids etc.

Once they were in bed, got another few hours in the shed.

So now the passenger side is 95% done, just need to finish weld one tube.

This is how it looks now underneath.

Now all I have to do is all of that again on the drivers side :/

A big day

Started the day planting some more plants, go some freebies from the parents and another lot from the next door neighbors.

So I didn’t get out to the shed until about 3pm, but that was the start of a long day.

First job was to get the left side suspension fitted.  I had to machine down a bunch of the spaces to fit the new mounting points.

I then compressed the front suspension and strapped it up at the point that the wheels will be when the car is sitting normally on the ground.  I’ve done this so that I can align the steering rack up to get it all spaced correctly for when the car is sitting normally on the ground.

I then started work on the passenger side mounts for the steering rack.  I made up the two hoops to clamp around the rack, then it was onto connecting these to the chassis of the car.

I wasn’t happy with the stiffness of the brackets on the car frame, so I came up with a new idea.  The old idea was designed so that I had some adjustment.  As it turns out there is quite limited space down there in front of the motor, so this time we are going a fixed mount.  So, the new idea…

I’ve decided to put some inserts into the main cross tubes, and then make more of a lattice type structure to hold the rack in place.

So, after a bunch of work with the hole saw, we had 5 new holes.  I then made up 3 different sizes of inserts to weld into these holes.


A bolt will pass through these inserts and into a threaded stud (shown in some of the pics already bolted on).  This threaded stud will have the other tubes that connect to the steering rack.

Some more random pics of progress.

These will probably make more sense over the next few days as I progress.

I also made some progress on the last component for the steering system, adding the short link and a universal joint.  The last bit that I need before the steering is complete is a short section of spline to fit the universal joint.

Time for bed!

It’s Friday night

Spent some time cleaning up, and making some new bits up for the lathe and the shed.

I drilled and tapped some proper mounting points for the extra axis that I purchased for the lathe, so that’s now all ready for use the next time I need it.

I had also gotten some new tips for the cutting tools on the lathe, so I fitted them as well.  I then got to lining all the tools back up in the lathe, getting the tool heights correct again.  I also fitting the new parting off tool that I got.

Apart from that, a bunch of cleaning and packing away getting ready for a big day tomorrow.