|
|
Jul 19, 2015 13:17:48 GMT
|
Hey folks! Wowzers, it's been almost a year since the last post. Lately I started to notice that progress just isn't happening, due to how far the car is, the working conditions, money, time, etc - and decided to pull my finger out promptly, as it'll actually go backwards otherwise and end up a massive pile of rust, mould and slug wibblepoo. So, I found it a new home - somewhere that's clean, dry and just about large enough. It's still nearly an hour away from home (that's what you get for living in bloody london!), but it's a nice enough drive and having a frugal mule helps. No power though, which is a bummer. But I have a solution! Equipped myself with a massive curse word-off vice A trip to wickes for some shelf build-materials And off she goes (massive focus fail lol)! And work begins! The plan is: - Strip down, - On the spit - Tidy shell - Bend myself a cage - Engine build - Re-mould the front end - Finish it - etc etc Basically starting from scratch, but this time proper and final
|
|
Last Edit: Jul 20, 2015 22:43:40 GMT by lolface
78 Kadett C 2.0 8 valve turbo, holset, rust&other stuff..
|
|
|
|
|
Jul 31, 2015 21:24:18 GMT
|
Been making steady progress! Built an enclosure for a small genny, since there's no power in the unit. Plan was to silence it, but I underestimated it's persistence lol. It works well enough, at least for venting the CO out of the garage and not annoying the neighbours! It's double skinned - there's a good inch of rockwool in the cavities. The black bits are 3d printed. inlet and exhaust fans And noise before/after: Verdics: too much bloody effort for not much result Since then I've made an external cold air feed/takeoff. It runs better but still noisy. At least I can still watch a bit of initial D as its subtitled, while it charges the battery bank lol Anyway. After all that procrastination, some work happened. More stripping - front and rear subframes out rediscovered what I though was an acceptable level of spaghetti 6 years ago is NOT an acceptable level of spaghetti (this was about halfway through the stripdown!) Jeesh what a mess: Then this happened: To start with I was all like, 'measure everything dude' Then I was like curse word it, I'm only going to be doing this once Then realised I'm gonna have to cut some more Then realised the chassis leg to footwell bracing is going to have to go. Will figure out something to tie those back together later. And this is how the gearbox fits now. The plan was to enlarge the tunnel so it accepts the omega box without bruises, all tucked up nice, and then maybe one day a bigger box. Also I wanted to push the engine as far back as possible, because you know, that's what people do . Naw I was thinking when the 4 banger gets boring I can put a 2JZ in there or something, and it won't be swinging around over the front end like an anchor. Then I got the trusty measuring tools and sharpie out and started auto CAD I only had the cardboard box I've been sitting on, but it did the job nicely: I didn't want to cut too much away to compromise on the rigidity of the thing while I crawl around inside, so I'm leaving the old tunnel in for now, then weld the new stuff in and cut the old one out from underneath. It's tight for pedals but there's just enough space. I wanted to keep the corsa booster/master cylinder/pedal combo, so I'll have to box that in but I'm happy with that: And metalwork begins! It's like making a Tshirt, but more manly Slicing, cutting and bending, checking the angles: and an hour later there was this: Bazinga! I'm chuffed with that so far! I've made enough space to push the engine back 250mm hopefully. The prop was made with a sliding joint and has a couple of spacers in so hopefully that won't need work! The new metal is all 2mm sheet and the scuttle panel is very very thin stuff, so will have to TIG it to the body. It's too thin for MMA and I really dislike the results my mig gives, so better get practicing
|
|
Last Edit: Jul 31, 2015 21:30:52 GMT by lolface
78 Kadett C 2.0 8 valve turbo, holset, rust&other stuff..
|
|
bstardchild
Club Retro Rides Member
Posts: 14,901
Club RR Member Number: 71
|
|
|
Well found this thread for the first time and killed a morning reading it from start to finish
Really good work and quite inspirational
Now bookmarked
|
|
|
|
|
|
|
Hey bstardchild, thank very much - sorry about the time you won't get back What sort of ££ would you like for the slide-hammer-pin-shifter device? I'm a little bit sceptical about how effective it'll be though, now that i've chewed the pins good and proper from hammering them
|
|
78 Kadett C 2.0 8 valve turbo, holset, rust&other stuff..
|
|
bstardchild
Club Retro Rides Member
Posts: 14,901
Club RR Member Number: 71
|
|
|
Hey bstardchild, thank very much - sorry about the time you won't get back Time well spent so inspirational stuff for my projects What sort of ££ would you like for the slide-hammer-pin-shifter device? I'm a little bit sceptical about how effective it'll be though, now that i've chewed the pins good and proper from hammering them OK Price to RR peeps is £30 plus postage £7.50 UPS Next day I'll be sticking the spares onto Ebay at £50 Posted shortly It took the pins out of my 1972 Opel Commodore out no probs at all and they were very well stuck in I'm assuming here that they are the std 8mm roll pins that can be drawn out in either direction so if you've damaged one end then I'd pull them out in the other direction to get clean contact - the tool doesn't car which direction you pull them out in - as long as you can get the 5mm shaft through the roll pin it'll work fine. It's not big impacts that is the key to removing the pins it's multiple repetitive taps on the slide hammer to free them - once they start to move same approach sees them out without too much effort.
|
|
|
|
|
|
|
bstardchild - PM'd! I've just finished with my rollcage design, wanted to get people's thoughts. Unfortunately it's going to be heavy blue band, since I can't afford t45. Still a big difference in price between blueband and CDS and not much difference in weight. Medium wall 42mm mind you, not the ultra heavy stuff. Around 65kg according to my maths Lets see if this gif works. For benefit of the internet - this adds up to about 23m of tube. 45mm x 2.5mm CDS is about 2.3kg/m T45 is same density but stronger, so you can use thinner wall tube for less weight. 42.5mm x 3.2mm ERW BS1387 "Blueband" is about 3.1kg/m. The plan is to tub the rear arches for coilovers so they need tieing up in to the cage, and also the rear beam mounts which I'll re-do, they'll connect to the cage too. Not sure if the A-pillar to front wing is needed given how much strength there will be in the bulkhead/wings, but given the pair of tubes is only about 3kg I figure why not eh?
|
|
Last Edit: Aug 1, 2015 19:04:32 GMT by lolface
78 Kadett C 2.0 8 valve turbo, holset, rust&other stuff..
|
|
bstardchild
Club Retro Rides Member
Posts: 14,901
Club RR Member Number: 71
|
|
|
This was my plans for mine Had to consider some other issues
|
|
|
|
|
|
|
Ahh interesting. Similar, apart from the diamond shape bracing of the rear triangle. I removed one of those bars and ran it to the opposing side in the middle triangle. I was thinking about where the forces would go if it landed on the roof sort of thing.
Great idea about trackday wheels too!
|
|
78 Kadett C 2.0 8 valve turbo, holset, rust&other stuff..
|
|
bstardchild
Club Retro Rides Member
Posts: 14,901
Club RR Member Number: 71
|
|
|
Ahh interesting. Similar, apart from the diamond shape bracing of the rear triangle. I removed one of those bars and ran it to the opposing side in the middle triangle. I was thinking about where the forces would go if it landed on the roof sort of thing. Great idea about trackday wheels too! Well I got to test mine in a roll - the cage is strong - the roof not so much
|
|
|
|
|
|
|
Really! I'm sorry to hear this. Hope you came away unhurt? Maybe I'll stick a smaller gauge cross in the roof perhaps :/
|
|
78 Kadett C 2.0 8 valve turbo, holset, rust&other stuff..
|
|
|
bstardchild
Club Retro Rides Member
Posts: 14,901
Club RR Member Number: 71
|
|
|
Really! I'm sorry to hear this. Hope you came away unhurt? Maybe I'll stick a smaller gauge cross in the roof perhaps :/ I didn't need one
|
|
|
|
|
|
Aug 11, 2015 12:07:04 GMT
|
Hey all, Been at it again a few times. In typical fashion, there's a bit of procrastination to start with. My battery-charging genny would keep cutting out, because it would suffocate in it's little box. So I 3d printedd a cool air intake/filter box coming off the carb and going outside the box, but now it was loud again because of the induction noise . So made a half 3d printed/half pringles can airbox/resonator/muffler thing, which surprisingly works great! Another few db's quieter. Then onto proper work. Managed to get 3 of the 4 door pins out using this chopped stainless cap head welded to an odd socket I was never going to use: Then you do this and smack it round the top hard enough for the extensions to all pop out of each other: It worked great! One didn't budge at all, so had to chop the hinge off Will need to drill it out somehow. Also tacked up the transmission tunnel pieces using steel bars to twist it and push it into shape so it's straight and even, using a little inclinometer (?) angle finder thingy. (1.9 degrees is roughly the garage floor. It's not off by 1.9 lol) Then out it comes for seam welding. I wanted to TIG it, since some of the gaps were larger than I'd comfortably arc weld, but needed some practice. Started off with some bits I had lying around. Left-to-right getting the hang of it. And while it's not perfect, it's good enough for me to get started. I then realised I was doing it wrong-handed! Switching hands didn't really make much difference to the quality of my welds lol. I actually got hooked to TIG welding. It's amazing how much control you have - even without a pedal! You can take your time and really control the weld pool. Also it's amazing how sometimes depending on the weld, you don't even need filler rod! You're just using the arc to melt material together. Awesome. It feels strange to me though as pulling the arc back from the weld pool reduces the heat, and with MMA (stick) it's the opposite! Also the tunnel cost me 2 whole Hobbyweld bottles of argon. That's like 40 disposables! At about 13L/min flow. Bloody expensive, but then I'm slow Tacked into place and cut the old tunnel away Then stuck a mock-block and gearbox into place to get an idea of how much space I have: Loads of room! Tunnel still has lots of space to push back but will need to cut a section of the new bulkhead out, so might leave it where it is. And this is me in the engine bay, with the engine in front of me LOL It's pretty much mid-engined now ... Also I got my rollcage tube! Decided on CDS in the end - got 5 lengths (28 metres ish)of 41.28mm x 2.03mm tube, and with this tube the cage should be under 50kg which is awesome for a 10-point It cost about £180 all in with next day delivery from Hub Le Bas - which is literally half the price of some specialist online suppliers! Really good service too, well chuffed. Also getting it ready for the spit, so welded up the mounts and some strengthening bars at the back that link to the chassis legs, to stop the tailgate from flexing, it's right flimsy. Next I'll be 3d printing a mandrel former for my DIY bender, since I'm tight and also want to do an experiment on 3d printed plastic strength. Would be ridiculous and awesome if it works!
|
|
Last Edit: Aug 11, 2015 12:08:28 GMT by lolface
78 Kadett C 2.0 8 valve turbo, holset, rust&other stuff..
|
|
|
|
Aug 13, 2015 16:28:59 GMT
|
Aaaand she's in the air! Well chuffed with my DIY spit - and it worked just how I planned I was starting to think the tubing would be too small - 33mm BS1387 steam tube, but it's perfect. What a relief! Had castors but I took them off since the garage floor is a little sloped. Didn't quite get the centre of gravity right though, it's still a little bottom heavy so needs some support when on it's side, but I won't be needing the flywheel-come-locking device since I'm ok with using planks of wood Safer that way too I reckon. The m12 treaded bar sits on a thrust bearing here: It's wound through a studding connector above, and the whole thing slides up and down the upright. And it raises up ridiculously easy, very little resistance! (And down)
|
|
Last Edit: Aug 13, 2015 16:31:51 GMT by lolface
78 Kadett C 2.0 8 valve turbo, holset, rust&other stuff..
|
|
|
|
Aug 13, 2015 19:07:38 GMT
|
Glad your back on the kaddet, used to follw you on migweb some years ago wheni was building my track nova.
|
|
|
|
|
|
Aug 13, 2015 19:18:07 GMT
|
Thanks Paul, - yeah it took a little while but back on it, feels great Were you novashed? What happened to it, is it still about?
|
|
78 Kadett C 2.0 8 valve turbo, holset, rust&other stuff..
|
|
Potter
Part of things
'E who dares wins,eh Rodders??!
Posts: 304
|
|
Sept 10, 2015 18:02:36 GMT
|
Yo dude, currently off work sick and I found this post while searching for something else.Sat down and read all 17 pages and all I can say is,You sir are a freakin LEGEND! Love your 'I can't afford that so I'll make it myself' attitude and your ridiculous work rate!! Feeling pretty ashamed of myself now,I've got a garage with right under the house and I don't pay a penny for it[still live with my parents] and I haven't done a decent days work on my projects in ages! I'll be sure to give this a look from time to time to keep the mojo up!
Keep up the great work mate!
By the way,most of the pics on pages 14,15 and 16 didn't work for me,though that just might be me crappy laptop.
|
|
More cars than sense or money!🙄
|
|
|
|
Sept 14, 2015 16:01:34 GMT
|
Hey dude, Thanks for the kind words Being a student/low wage meant I had to make stuff but that's really slow... A lot of it didn't work out, but it did teach me to do things properly I now need to get some time off work again to get more progress made to keep up the momentum! Yeah I self-hosted those images on my own server to save money but that broke and I lost them I think . Will hopefully have some more progress in the next few weeks time, fingers crossed.
|
|
78 Kadett C 2.0 8 valve turbo, holset, rust&other stuff..
|
|
deejay
Part of things
WELSH DRAGGIN'
Posts: 634
|
|
Oct 22, 2015 23:37:29 GMT
|
Chop chop Ives, get to it man! Lol. Long time no speak dude...
|
|
|
|
|
|
|
Good to see some progress - makes me feel like getting my finger out too lol
|
|
|
|
|
|
Oct 28, 2015 21:57:29 GMT
|
Chop chop Ives, get to it man! Lol. Long time no speak dude... Loooong time no speak!! How are you dude? Anything interesting in the works? Count vauxalot - finger needs to be removed immediately! After getting the old bucket in the air, I poked many holes in it and swore lots. Then while waiting for new sheet metal to arrive, I got sidetracked (for the last few months!): More on this when it's done
|
|
78 Kadett C 2.0 8 valve turbo, holset, rust&other stuff..
|
|
|