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Discussion Starter · #381 ·
I decided to run the front brake lines through the chassis (rather than under or over it), so made up these bosses which will be welded through the front chassis members. These started life as two ugly bits of steel bar



Which were turned down to fit through a 16mm hole:



Then drilled through, and tapped at the ends:





The banjo fittings will be on the inside of the chassis, and run straight into the hard-lines. Neat and not intrusive.
The male fitting will be on the outside and connect directly to the flexible brake lines.
 

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Discussion Starter · #384 ·
More flange....
Turbo's have large 6-hole exit flanges, so I knocked up these to suit.
They started as a sheet of 10mm steel with lots of holes drilled in strategic spots:



Which were then cut out and shaped using a variety of power tools:





And then had 'V-Band' fittings welded on:


I seamed around the inside too!


"V Band?" I hear you say, "Have you won the f*ck*ng lottery????"
As usual, these came pre-loved, with both of the clamps and the other fittings for $60 (about 30 quid). :)
 

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Discussion Starter · #387 ·
Back on the more substantial bits, I managed to get the upper seatbelt mount plate in place between Sunday and yesterday.
The plate is 5mm steel, drilled and chamfered as required:



Left and right-hand:





The plate is seam-welded underneath the wrap-around bar in the vicinity of the mounts, and stitch-welded across the span.

Under each side there are these triangular gussets which have again been mercy to the drill:



The cage now looks like this:



As there are so many joints, I've been red-oxide painting each joint as it's finish-welded so I know which ones I've done.
 

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Discussion Starter · #388 ·
Brilliant weekend working on the car.
I've now managed to finish-weld all of the rollcage joints and all of the main chassis joints (and the shifter mount, handbrake mount, seat crossmembers, gearbox mount, lower harness mounts etc etc..)
I even managed to add this 'new' crossmember at the rear which will have the mounts for the rear radius rods welded to it. You can't see well from this angle but it is curved down in the centre to miss the prop-shaft.





Next project is the body mount brackets. Stay tuned!
 

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Discussion Starter · #389 ·
...and as if by magic - the body mount brackets:

Long one at the back is the rear body mount. This will bolt across the rearmost crossmember and weld to the bottom bracket of the (new) boot.
Wider square brackets will weld between the 'A' pillar and the rollcage.
Narrower square brackets will weld between the 'B' pillar and the cage.
Missing from this picture are the very front brackets, which will be welded to the front-most section of the body (where the inner-wing would normally bolt to) and bolted to the engine bar sections of the cage. These were manufactured months ago and are probably already rusty!

The smaller 90 degree brackets are the 'revised' front engine mount plates.
 

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Discussion Starter · #390 · (Edited)
Here is the shortened driveshaft/propshaft (depending on which part of the world you live in)



This started life as a Jaguar XJ6 shaft which has now had 460mm (about 18") removed from it's length.
One problem I didn't foresee is the different diameter of the front and rear fittings, so there is a stepped steel ring which is welded between the tube and the rear yoke.
Also in the picture is the re-modified gearbox flange adapter. This was made a while ago, but fitting it revealed a couple of necessary improvements that would make life easier in the future.
 

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Discussion Starter · #393 ·
Another good weekend with lots done.
The body mounts are now in place. It's nice to have it stiff and not floppy any more (fnarr fnarr).
'A' pillar mounts:


'B' pillar mounts:


Front mounts, welded at the very front of the steel shell and will be bolted through to threaded bosses in the engine bars:



Rear mount. This spans the full width of the chassis ladder and is welded to the boot-lid hinge panel:


There are also a few of these appeared around the cage:




Which are now red oxide of course:


These will allow the wiring looms to pass through the rollcage tubes and keep everything looking super-neat.
Many a nice car spoiled by having the wiring cable-tied or taped to the rollcage and chassis!
 

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Discussion Starter · #395 ·
Didn't get a lot done over the weekend as I was crewing on the works Topolino altered at the Nostalgia nationals (Got runner up!).
Managed to get the first angry snail in it's proper position:





This is the worst side as it has to clear the steering, bottom hose and oil system as well as having to miss the tyre on full lock/full bump and tucking into the wheelarch without getting too close. I could have just put them in front of the engine (which would have been easy) but as soon as I planned twin-turbos I knew where they had to be.

I also did a few of the smaller jobs.
The dashboard mounts are now welded to the cage, and it's bolted in place:



The 'chute release is in place:



Along with these tags to mount the 'chute release cable:





I really don't want cable-ties anywhere around the cage.

More soon!
 

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Discussion Starter · #396 ·
Not much photo-worthy at the moment.
I have managed to get hold of an 850DP which I'm now modifying for blow-through:



That should do it!

Also modified the engine mount brackets to take countersunk bolts:



Currently I'm trying to fit the second 'angry snail', then onto the inlet manifold.....
 

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Discussion Starter · #399 ·
Having got the carb I suppose I'd better modify it for blow-through. Just as well, and someone has obviously had 'a play' with it in the past and the jet sizes and power valves are all over the place. It would have run fine on the primaries, but gone very weak on the secondaries. Wonder why they sold it? :beuj:
Still, no matter as all of that stuff will need replacing.
So I took off the choke horn and smoothed what was left:





A little trick I've learned through the years of doing this is to cut the List number out (as it's on the choke horn and would usually be discarded) and re-affix it somewhere else on the carb. I usually screw it to one of the threads made redundant by the removal of the choke.



Also redrilled the power valve passages to 0.084"



Lots more to do. The whole thing needs a thorough clean, and the smoothing needs a bit more smoothing, but as all of the above work only took half-an-hour I guess I can spend a bit more time on it!
 

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Discussion Starter · #400 ·
Flange 2.0 or 'Beware the internet'....
Having spent what felt like months cutting steel flanges out of pieces of sheet, I thought I'd take the easy option and buy the two wastegate flanges I needed from the internet.
'Wastegate flanges x 2' the advert read. '38mm wastegate' it continued, '$11'. I hit the 'buy now'.
What arrived was these:





Which, being quite switched on with this type of thing, I decided were too large.
So formulating a plan, I spun these seats up:



Which were press-fitted into the flanges and then seam-welded:



Then marked and cut the correct size flange:



Smoothed, drilled & tapped into these:



With the left-over bits which will probably become the front chassis tie-down brackets. I love it when a plan comes together!
 
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