fair play man, some serious work there,

timmy......
that BDG is a work of art, gorgeous !!

 

@ Brian......sure my whole car isn't worth the price of that engine

Tommy, i wouldn't even dream of taking a grinder to yours.......jesus im not that bad

Not changing much of the running gear philip, new engine, same gearbox been rebuilt and just giving the axle a check over.
Might be running new carbs,we have a set of custom twin 50's i like to use so we'll see how that goes.

Cheers lads for the comments

Doesn't look like much was done but i finished stitch welding most of back of the car and tidying a few loose ends .

Now for some of the scary stuff

As you can see the front was not in good shape, i also found fractures in the bulkhead and around the footwells, so the front could not stay on it as no point in going this far and leaving this in it. and there was no way i could repair the front as it was just patched to many times.

So a quick call to blackmagic last sat nite and i landed this 4dr, he had it for parts for his mk2 build and was mostly finished with it.
The shell had some good and bad points but the bad outweighed the good, but lucky for me the front of the car was in near perfect condition.

So early sunday morn i got to work.

Ready for the chop

Decki couldn't figure out what was wrong

So i started stripping and i now have a newfound hate for spot welds

Sent it of to get sandblasted and a coat of primer, i was actually surprised how good it was.

Just a small bit round the bubble, but i'll be moving this back so all is good

So i Started bracing the front of the car before i took it down of the spit, i used as much steel as it took until i was happy it was well braced.

I tacked on 2 small bits of angle each side of the doors to mark where the original position of the front pillar, just so i wont be purely be relying on measurements to line up the doors .

Thats all for the moment, i hope to get at it this weekend .

 

OH MY FCUKING GOD.... PUT THE GRINDER DOWN WILL YA.

Will it still be out for March?

 

Too late Dave, the deed is done, hope to start tacking the cage in sunday nite all going well.

Ah im hoping it will be ready, iv all the rot cut out out now so at least im working with proper metal now

 

some tidy welds and sheet bending, weldone.

someone really does have an itchy grinder finger

you remind me of father ted, trying to knock the One tiny dint out..then gets out of hand lol
looking good,keep the pictures coming,interested to see how this matches up...

 

Rust is lighter than Carbon Fiber.

 

QUOTE (Dieseldave @ Feb 5 2011, 08:54 PM) <{POST_SNAPBACK}>Rust is lighter than Carbon Fiber.

 

thats some statement........i suppose a ton of lead is heavier than a ton of feathers too

I'll have a wee update later on .....stay tuned for some shocking photos

 

Right now for the update yee were all wondering will i feck up

So i started measuring every angle of the car to get a comprehensive shape of the car before i chop it, i also have a std mk2 shell here aswell that i cross-reference measurements just to be sure.

And just in case i lost the piece of paper

I used a fairly simple method of making sure the car would be straight before and after the front is taken off and put back on, but it worked so im happy enough.
I made sure that both the front and rear shock tops were identically level so that suspension travel would be kept the same throughout the car to make sure that on landing after a jump that all 4 shocks would be taking the load in equal measures.

Now next i had to figure out what was the best way about going about the next part of the job.

I am replacing the 2 chassis legs and instead of trying to match up the new front with the chassis legs that are on it and they try and fit the new legs i decided to attach them onto the new front before i offer them up to the car,

These are fully re-enforced inside so should be very strong.

Started drilling all the spot welds.........i hate them now :rofl:

New leg offered up, nice fit !
Measured once....twice....and 50 times

So with all this done.........the time had come

I stripped back the inner and outer parts of the pillar and staggered the joints, i left the outer part further up the pillar and cut the inner one lower, the gussets to the roll cage will add extra strength to the pillars when the time comes.

The chassis legs were a bitch to pull together.....good tight fit.

I needed a little help to pull the 2 together.

 

Starting to look like a car again

I threw on a door and wing to see how things were looking few gaps but i was happy enough, its a rallycar after all.

I stitched up the front legs

Happy enough everything is still level, but i have to admit as much as i tried to keep things perfect, the distance between the front and rear shock tops are off by 2mm when measured diagonally, its small but im hopeful it wont affect the handeling

Thats about all for the min, absolutely shattered now now a bottle of bulmers will be had now me thinks.

 

Fair Play enda that some job your doing
You can retire the grinder now

as for that 2mm id bet orignal car wasnt perfect when new!!

 

Brilliant work

 

Serious surgery there sham. The company you buy the thin cutting discs off can close now,money made.

 

holy sh1t, fair play to you man,

not bad for a sparkie,,,

you deserve a crate of cider man for that work..

 

QUOTE (timmy @ Feb 5 2011, 10:34 PM) <{POST_SNAPBACK}>Fair Play enda that some job your doing
You can retire the grinder now

as for that 2mm id bet orignal car wasnt perfect when new!!
Cheers buck, i'm happy that im this far because this is really the make or break part of the job, if i got it wrong and handles like a bag of bottles it would be a wasted attempt.
But thank god its looking good, I still have alot more to do with the grinder yet

QUOTE (jamied @ Feb 5 2011, 10:39 PM) <{POST_SNAPBACK}>Brilliant work

Cheers

QUOTE (Dieseldave @ Feb 5 2011, 10:41 PM) <{POST_SNAPBACK}>Serious surgery there sham. The company you buy the thin cutting discs off can close now,money made.
On last count 50 stainless discs......not including the few you brought down

QUOTE (sintek @ Feb 5 2011, 10:41 PM) <{POST_SNAPBACK}>holy sh1t, fair play to you man,

not bad for a sparkie,,,

you deserve a crate of cider man for that work..
And then i'll make a balls of wiring it

 

Fair play, some undertaking there and nicely done too. Must give ya shout some of the nights I'm up with the lads in cooloney.

 

fuck me, fair play, at this rate ull be well ready for march . . . . witch rally do u hope to have it out for . . . .??

 

QUOTE (Brian47 @ Feb 6 2011, 03:51 AM) <{POST_SNAPBACK}>Fair play, some undertaking there and nicely done too. Must give ya shout some of the nights I'm up with the lads in cooloney.

Sound, give me a bell before ya call could be anywhere

QUOTE (trilly @ Feb 6 2011, 09:12 AM) <{POST_SNAPBACK}>fuck me, fair play, at this rate ull be well ready for march . . . . witch rally do u hope to have it out for . . . .??

Ah alot done a hell of alot more to do. first event is connacht sprint on the 10th of April but its still very tight going, i cant afford any more delays.

So anyhow, i didn't get as much time at the car today as i would have liked but i got alot of loose ends done.

I spent alot of time getting the sills right which meant taking the doors on and off about 15-20 times a side until i was happy with the gaping......not perfect but they'll do.
So then i started on the front floor sections and inner sills, you'll notice that there is a gap between the front and rear floor sections, bit of a balls but they wouldn't line up with the presses in the chassis rails if i moved them, so a small plate would be put over the joint.
Also i had to cut a little more than i would have liked out of the p/s footwell as it was slightly rotten so again another joining plate would be needed.

I also spotted the inner and outer sills in a few spots, i'll get a proper spot welder and finish these later.

And repeated process on drivers side

Looking a little better

I got the gearbox tunnel in place, i kind of made a balls of the joint between the prop and gearbox tunnel, but i'll be able to rectify it when i get it back on the spit.

Thats about all for the min, i hope to get an evening or 2 this week if i can.

 

Looking a bit beter now alright. You will have to cut holes in the new floor now to weld the top of cage.

 

QUOTE (Dieseldave @ Feb 6 2011, 10:27 PM) <{POST_SNAPBACK}>Looking a bit beter now alright. You will have to cut holes in the new floor now to weld the top of cage.

I know feckin cryin shame.

I spent an hr at the cage tonite, got the foot plates in place and the main hoop and a pillars in place, I didn't have the laptop with me so couldn't see the pics, only after seeing now the places i have to beat the shite outta to get the a pillars sitting snug, and the same spot as the 106 you were saying on the windscreen.
Had to take a nice bit off the main hoop pillars to get it sitting tight on the plates.

Looks ok so far so i'll see during the week if i get a nite or 2 at it to get it tacked and the tops done.

 

Unreal work Enda. Fair play.

 

Great skill Enda. Following this with interest.

 

savage work. it like one council worker said to the other "i have had the same brush for 5 years , it has had 4 handles and 5 heads but same brush"
replace the roof next and it will be totally original!!! great work

 

Cheers lads....and Paddy

, couldn't have put it better myself

 

Serious work Enda fair play, can't wait to see it flat stick round the stages, must call in for the look one of the days