Roll Cage Etch Primered

Managed to get all the cage sanded and most of the interior but with this rain it was not ideal as the cage was rusting very quickly so we put a coat of etch primer on it to protect it from the elements. I grabed a

Rear boot floor coming along, using sikaflex 225 which is the structural bonding agent rather then just the sealer. This will assist in adding strength without too much weight, i am riveting and bonding these sections on so the flat aluminium panel can go in over top.

 The back section is not flat so it is difficult to work with but managed to get it on this aluminium angle so i could mount the flat sheet too.

Cutting Rear Boot Floor

 Dave having a play on the plasma cutting around the frame rails

I have to trim around and then drill out the

Cutting out sections from interior

 Removing sections of no longer needed steel from inside the car as this is extra weight, it cleans it up a fair bit as well which is nice.

Cutting Boot Floor Out

Wanted to reduced as much weight as i can from the car overall. I cut out the rear section with a plasma

Had to cut the frame rail separately so i

Stripping doors

Got the compressor back but it still wasn't working right so calling them again tomorrow. I still managed to trim around the edges with the saw and also trim out the main bar

 Was

Stripping Doors

So my compressor is in getting fixed so i can't use my air tools to cut with yet, had to resort to useing the Wiss snips boubt and angle grinder. Didn't go right to the edge or remove everything but after cleaning everything up in the shed i wanted to tackle something and keep the momentem going.

 I unbolted everything but just

Tig Welder

i was pretty bad today and with the 20% off @ Total Tools it bought the price of this down about $300 cheaper then i had ever seen before.

So i bought it.

New Tools

Was at Total Tools today as they had a 20% off everything sale and pciked up some impact sockets

And a new

Rest of suspension and intercooler

Pulled the rest of the suspension out with the front sway bar and also the section where the castor rod bolts to. I will weld in a brace but need some steel to box it in with so will have to do latter but before I send it off to the powercoaters.

Also pull the front end apart and mocked up the inter cooler when it will go, much shorter piping length  which should improve throttle response and also better sealing up of the air from the front bar.

New chicago pneumatic tools

Ordered these at Chrismtas and they finally arrived today, unfortunately they sent them in a fruit box and it was confiscated at customs which held everything up but managed to finally pick the, up today.

Air saw which will hopefully make light work of any

Removed fuel pump and more seam sealer

Tonight I pulled out the pump and surge tank and drained the fuel in the lines, this is the surge tank and I want to redesign it a little

 I then started on the rear of the car and removed most of the seam sealer as there was

Repairing Holes, Removing Bolts and Pedals

 

After welding up the subframe this morning i started back on the inside and removed the steering coloum and pedals to make it easier to sand and paint behind.

 The old bolt in cage had left

Weld in subframe bracing kit

I installed the weld in subframe bracing kit this morning, was pretty happy with how it turned out and by the end of it my welding had improved a bit as well. Was a pain to work out which bit wend where as i didn't have the instructions and cant remember if it actually came with instructions.

I ground back

Stripping Car - Interior - Sound Deadening & Sealer

Today i started to remove all the excess

New Turbo Install - Borg Warner EFR

Replaced the std wastegate spring with the upgraded one, really easy to change this over

 Replaced the internal BOV

Replacing Injectors

Pulled off the intake manifold to replace the ID1000cc injectors with Bosch 2000cc ones and found the back bolt in the fuel rail was missing.

 Then found i had purchased the

New Bits and Pieces

Finally after ordering these on the 24th December they arrived

Suspension prep for powder coating

I had some S15 rear hub, arms and other bits so rather then replacing the bsuhes on the S14 one i amd going to use these S15 ones.
Took some picks of it all stripped so i could send off to get a quote from the powdercoaters, here is a shot of all the left over bits and pieces.

Put a ruler on the pieces so they can guage the size

Picked up paint

Picked up the paint today ready for when i get everything prepared for it.

Base colour which is Artic White

 

Mig Welder

Finally bit the bullet and bought a gas cylinder today, it has been a fair while but unfortunatley the mig wire i had was rusty, i didn' have any tips and also the 15amp socket i needed to make up a 10amp plug for it so could not use it tonight.

Stripping Car - Rear Subframe

This afternoon i thought i would try and get some more done as tomorrow afternoon is meant to be really hot. With the interior i pulled the cable handbrake out as i won't need it anymore and then pulled out the exhaust from the de-cat pipe back

 And also dropped the subframe all out

Stripping Car - Wiring Loom, Doors, Bonnet, Guards and remaining interior removal

I got started in the afternoon after i cleaned up the shed and storage, stripped the front bar, guards and bonnet off as well as the entire wiring loom and doors.

 

Storage Finished

I finished off the storage and put all of the crap off the ground from the car, makes it much easier to work around now.

Roll Cage Complete

Picked up the car today after the cage was finished, pretty quick and i was happy with the whole process.

 

Extra storage added to the ceiling in garage

Been busy building some extra storage that comes down from the ceiling in the garage. The aim is to put up some of the stuff laying around so it is out of the way and away from getting damaged. Will also help me get the shed a little more organised neat and tidy, i have over enginered it a bit so i could put heavy items like wheels etc if needed or dead body's...

I have now lots more extra plastic pannels and bits and pieces from stripping the car more so i can put all this up out of the way in here now. I plan on putting some more lights over the bench as well to give extra light.

Here i have built all the frame and just finished screwing on the first piece of 9mm ply, i did all this on the 41deg day so was absolutly buggered.

This will be trimmed but becasue of

Roll Cage Progress 2/3 Way Through

The cage is progressing well with all the main welding complete and the triangled pieces into the front of the car. The box sections are being made up and a few of the extra bars yet to be added in.

Rear section bar welded to the strut tower,

 

Waterproof Connectors

Purchased a set of weather-seal waterproof connectors to use to re-wire the car with, they arrived today and here is a couple of photos of the set,