Scaffolding poles + old VW bits + Rotary engine....

Scaffolding poles + old VW bits + Rotary engine....

Author
Discussion

leglessAlex

5,384 posts

140 months

Saturday 26th April 2014
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Oh my days that looks epic.

How much longer will the rebuild take?

PhillipM

Original Poster:

6,515 posts

188 months

Saturday 26th April 2014
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Should be finished next month, but then we need to strip everything back, paint it all, and put it back together with all the correct hardware/loctite, etc, etc.

Well, I say finished, but there's still a hell of a lot of other work to do even when it's running...

Edited by PhillipM on Saturday 26th April 00:37

PhillipM

Original Poster:

6,515 posts

188 months

Saturday 26th April 2014
quotequote all
Well, bit more wiring and bonnet work today, and a depressing hour totting up the list of stuff left to do after the above comment about timescales.

Whilst the car will be ready soon, there's also lots of other more routine stuff being done as well as the big engine change/suspension, etc. All the brake calipers are being refurbed (rears are done but I need to do fronts), need to sort some new front and rear pads, all new brake flexies and hardlines need making, because we've changed master cylinders and reservoirs, new lines and plumbing for hydraulic clutch, new throttle pedal, cable and a linkage for the throttle body because it now points towards the back of the car - doh.
There's also the hydraulic lines on the front dampers to replace, the new canisters to add, some new lines for interlinking the suspension to plan and make, the front uprights need to come apart to repair some wear on the king-pins and at some point the beam is getting chopped down and another set of front arms made, the fire extinguisher needs remounting, new floor and skidpans to make, seat-belt mounts need altering because the seats have been moved to get the transaxle/airbox in, battery and PAS pump need new trays and re-mounting, the front bull-bars/nerf rails are getting cut off and remade in aluminium, ditto the side tree-bars...that's before we even start painting the thing.

Yep, take a breath, we're not done yet - new windscreen needs cutting and fitting, new polycarb will need cutting and forming for the doors because it's scratched and scuffed beyond machine polishing out, the rear mudguards have distorted from being sat outside in the sun for a year so they need fixing/replacing, the frame needs gussets welding in the side bars, a-pillar and roof cross so it meets the latest regs in case we go racing in France, and just to top it off, we've a lot of heatshields/belt guards to make around the new engine, and it really could do with a couple of pairs of new rear tyres - can you still get money trees, I need to plant a few....hehe

And once it's actually moving all the damper and spring rates will be to hell, so it's going to be a long time retuning everything.

/depressing bd mode. wink

abbotsmike

1,033 posts

144 months

Saturday 26th April 2014
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Bloody Hell.

Erm, I might know a miracle worker if you need to hire one, or ten?!

PhillipM

Original Poster:

6,515 posts

188 months

Saturday 26th April 2014
quotequote all
Does he work for Jaffa cakes and coffee?

Still, should be running and moving under it's own power soon, that'll be a motivator biggrin

abbotsmike

1,033 posts

144 months

Saturday 26th April 2014
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If I didn't live so far South, and didn't have final year exams to deal with, I'd come and work for jaffa cakes and coffee!

PhillipM

Original Poster:

6,515 posts

188 months

Tuesday 3rd June 2014
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Well, I can't say it's particularly pretty, given there's now a scoop on the scoop and it makes it look top-heavy, but needs must I suppose:


Ranger 6

7,042 posts

248 months

Tuesday 3rd June 2014
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Looks good - keep the pics coming thumbup

PhillipM

Original Poster:

6,515 posts

188 months

Tuesday 3rd June 2014
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leglessAlex

5,384 posts

140 months

Wednesday 4th June 2014
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Looks good, looks real good.

Do you know what would really set it off perfectly? A massive wing/spoiler biggrin

PhillipM

Original Poster:

6,515 posts

188 months

Wednesday 4th June 2014
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Lots of louvers to come yet too!

PhillipM

Original Poster:

6,515 posts

188 months

Thursday 5th June 2014
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Cardboard aided design is out again:




rhinochopig

17,932 posts

197 months

Thursday 5th June 2014
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Why ally Phil - I know you like working with metal? I'd have thought thin poly-carb/lexan sheet would have saved a chunk of high-up mass.


PhillipM

Original Poster:

6,515 posts

188 months

Thursday 5th June 2014
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Yeah, don't ask, I've been there and we've had that arguement, I just wanted to cover the tube in some fabric and dope hehe
But to be honest, it's only really got used because it's easy to mock up and work with/alter as you see fit, and it's going to have a composite mould taken off that bonnet at some point anyway, so it won't be on there forever.
The bulk of the tubing underneath will be cut out and the panels thinned down when the curves and welds get blended anyway, so it's not quite as bad as it looks, most of the tube work is just something to work to.

rhinochopig

17,932 posts

197 months

Friday 6th June 2014
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PhillipM said:
Yeah, don't ask, I've been there and we've had that arguement, I just wanted to cover the tube in some fabric and dope hehe
But to be honest, it's only really got used because it's easy to mock up and work with/alter as you see fit, and it's going to have a composite mould taken off that bonnet at some point anyway, so it won't be on there forever.
The bulk of the tubing underneath will be cut out and the panels thinned down when the curves and welds get blended anyway, so it's not quite as bad as it looks, most of the tube work is just something to work to.
That'd be an excellent idea - and then painted up like a Sopwith Camel!

PhillipM

Original Poster:

6,515 posts

188 months

Friday 6th June 2014
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I'm trying to keep the thing on the ground, not encourage it to spend more time in the air! hehe

PhillipM

Original Poster:

6,515 posts

188 months

Saturday 14th June 2014
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Not being too happy with the temporary air inlets for the manifold and supercharger, and having a spare bit of billet from another project, Ed make a small mountain of swarf today and replaced the manifold one whilst I was swearing at the cam sensor (I had to make a plug for it, because we couldn't get a connector to fit it for love nor money):




PhillipM

Original Poster:

6,515 posts

188 months

Sunday 15th June 2014
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Okay, photo's should be back up again, sorry about that.

thecremeegg

1,952 posts

202 months

Monday 16th June 2014
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Just read the whole thing hence the time I'm posting this! Fabulous read, keep it up biggrin

PhillipM

Original Poster:

6,515 posts

188 months

Monday 16th June 2014
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thecremeegg said:
Just read the whole thing hence the time I'm posting this! Fabulous read, keep it up biggrin
Just out of interest, how many days of your life do I owe you back? hehe