377 replies to this topic

[blue blood]

So today I got round to fibreglassing the aluminium brackets to the boot lid today. It has really added rigidity to the panel :)







I also got round to fitting the quick release poly engine mounts and without the top engine steady they allow the engine to move around loads!!







That is it for today again.

Regards Blue

[Tupers]

I also got round to fitting the quick release poly engine mounts and without the top engine steady they allow the engine to move around loads!!

Yup they're horrid things, although it's what I've come to expect from poly. The engine will rock about a fair bit without a steady but these are just silly, I know I wouldn't want my engine held to the frame by two pieces of 6MM round bar.

Nice work on glassing the ally brackets into the boot lid by the way.

[blue blood]

So I managed to get a bit of time in today in the garage. I sanded down the air vents that are on the top dash (so I can have a smooth top dash) and only have two holes for the wires from the heated front windscreen. I also sanded the door aperture, I don't have any pictures of these but they are pretty uneventful.
Now after waiting for about 12weeks I have cut out my bonnet to fit it in place (keeping it with all the extra bits on means it keeps its shape, due to the extra rigidity. The reason for this is because it needs to cure and by curing it keeps its shape). Anyway here is the new bonnet which is smoothed, thicker and has a better fit in terms of gaps:







Another purchase of mine was the minispares uprated 8.4 disc upgrade drive flanges. They are made in EN24 steel as apposed to the standard EN8 ( stronger harder wearing steel type) I wanted to use these over something like the alloy ones as I don't feel alloy ones would be a good choice if ever there were two much strain through the drive shaft (as I want to upgrade my engine to a 2.0L unit at a later point in time). Anyhow here they are mid painting and the finish product:






I also painted them in the rust bullet paint, which is like hammerite and por15 made babies which were given steroids!!!! Its that good, but expensive.

Any how hopefully I will get some more done on this soon as I have some new ideas as to how the boot will open (so may possibly be selling my alloy internal boot hinges I made, so keep an eye out for them if you like them)

Kind regards Blue

[blue blood]

Another up date for today is of cutting and fibre-glassing the boot floor. I want to mount my fuel cell further back in the boot but there was an outcrop in the one side for holding a spare wheel in place (which of course I don't need). So I set about angle grinding the floor and also cut the battery box out as my battery will be going behind my drivers seat:













I first made a template covered it in cling film and taped it in place. For the edges I used some fibral filler to arch the gap (but will be sanded off from the other side once I had laid the fibreglass matting on the top). I will eventually sand everything down once it has had time to cure:











And a few images from yesterday of the door recess' and front windscreen heater vents:





how the doors look un cut:

and cut:


Thats all for today.

Regards Blue

[MrBounce]

Fantastic work! I love this!

[blue blood]

Fantastic work! I love this!

Thanks mate. Its very itchy work!!

Blue

[jessticles]

Wow, looking good blue ;) It's asif this has had a female touch!!!!!!!!

I can't wait to see the end product.

Ha

[blue blood]

Wow, looking good blue ;) It's asif this has had a female touch!!!!!!!!

I can't wait to see the end product.

Ha

Thank-you babe. I'm not sure what you mean by female touch though as you well know I am male!! ;)

[jessticles]

Wow, looking good blue ;) It's asif this has had a female touch!!!!!!!!

I can't wait to see the end product.

Ha

Thank-you babe. I'm not sure what you mean by female touch though as you well know I am male!! ;)

Your loyal and devoted other half is female though!

[jefinabox]

What an inspirational build! Making me want to start my van again before it's finished!

[blue blood]

Got round to doing a bit more on the minus today.
I layered up a bit more fibreglass on the corner section I had taken out and made a template to use for the battery hole I have to fill:





I also took the time to work (with the help of my girlfriend) out where the the holes for the rear roll cage back legs have to go:







And finally I made templates and filled in the front air vent holes which I will sand back once cured:







Thats all for now.

Regards Blue

[danoz24]

Blue, your build is very impressive....your passion for detail is even more so. I haven't been on the forum for ages and to come across this story is truly awesome. The materials that you are using are very very nice indeed and remind me of the time and effort I have spent on my build which sits at about 80% complete after 5 years. I haven't posted mine on here as I wanted to keep as a surprise but there are definitely similarities in the way we work, mate.

See you at Santapod perhaps ;)

[blue blood]

Blue, your build is very impressive....your passion for detail is even more so. I haven't been on the forum for ages and to come across this story is truly awesome. The materials that you are using are very very nice indeed and remind me of the time and effort I have spent on my build which sits at about 80% complete after 5 years. I haven't posted mine on here as I wanted to keep as a surprise but there are definitely similarities in the way we work, mate.

See you at Santapod perhaps ;)

Cheers man I really appreciate it. At the end of the day its a car I want to keep and I hate second class standards and bodge jobs!! Again with materials I want this to stand the test of time. I'd be interested to see what you have if you do have any pictures pm me (may get some inspiration). As for Santapod maybe one day in the future ;)

Regards Blue

[danoz24]

pm

[blue blood]

So been at it a bit more toady whilst the weather is nice. I started by making a piece of flat fibreglass by covering a flat pice of glass in cling film then layering the resin and matting on top using a roller.




I then made a template of the rear battery box hole marked it on the piece and cut it out with an angle grinder. Once that was done I taped it into place from the underneath and layered some fibreglass strips in place on the top. Then for thickness and strength added two final layers that blanket and sandwich all the strips against the pre-made piece.




As you can see the alloy fuel cell fits perfectly in place now with now high points.





Then I turned my attention the rear brake arms pins. Like mentioned before they are made from titanium but the pins that the engineers put in them were steel and I have a fond dislike to rust so I ordered some stainless clevis pins cut them down re drilled holes in them added washers and a cotter pin and hey presto I ended up with these:





Well thats all for now to show folks still plugging away at it.

Regards Blue