Project Beetle !
- Thread starter Dead Dog
- Start date
Yestaday got to weld up a four bits of small nastiness.
Took off the front calipers sanded em, da'd the surface rust off the discs and painted the centers & calipers both are silver nothing flash, but a wee bit better than the turquiose & purble they used to be
Today my better 1/2 picked up the other wheels from being blasted, so I'll have a set of 4 1/2 & 5 1/2 for me and a set to sell when painted. (I 1st got a set of four 4 1/2, but then got a set of five 5 1/2's)
Took off the front calipers sanded em, da'd the surface rust off the discs and painted the centers & calipers both are silver nothing flash, but a wee bit better than the turquiose & purble they used to be
Today my better 1/2 picked up the other wheels from being blasted, so I'll have a set of 4 1/2 & 5 1/2 for me and a set to sell when painted. (I 1st got a set of four 4 1/2, but then got a set of five 5 1/2's)
Right!
Engine back out, 'adjusted' the exhaust manifold so it clears the turbo and made a wood(it's the future) spacer between the manifold and turbo so the turbo clears the power pulley and pick-up ring 20mm will do the trick!
Smacked the rear wheel bearing off again, inner cover has vibrated loose so now is in two pieces / great another job.
Was cleaning off front end chassis under fuel tank for protective paint found a few more holes, that are now welded up.
Been making extra jobs for myself lately so would be a bit further on than is - but they did need doing and MOT man would have found the holes so better sort them now whilst wings are off and more room / less to accidently damage. Just need to fix inner cover or get new 'un and re-fit bearing and all the extras are finished.
Today at work had a bit of time to prep, etch & high build the wheels, now they just need prep & paint.
Think thats it.......
I HATE laying under a car and welding
Engine back out, 'adjusted' the exhaust manifold so it clears the turbo and made a wood(it's the future) spacer between the manifold and turbo so the turbo clears the power pulley and pick-up ring 20mm will do the trick!
Smacked the rear wheel bearing off again, inner cover has vibrated loose so now is in two pieces / great another job.
Was cleaning off front end chassis under fuel tank for protective paint found a few more holes, that are now welded up.
Been making extra jobs for myself lately so would be a bit further on than is - but they did need doing and MOT man would have found the holes so better sort them now whilst wings are off and more room / less to accidently damage. Just need to fix inner cover or get new 'un and re-fit bearing and all the extras are finished.
Today at work had a bit of time to prep, etch & high build the wheels, now they just need prep & paint.
Think thats it.......
I HATE laying under a car and welding
In the garage today I think I've managed to clear up all the little jobs I'd managed to add on, finished the welding, ground the welds, sealed up all the welding good 'n thick.
welded up the inner plate on the axle tube fitted that, axle boot and wheel bearing.
Then seem as I won't be going anything for a short while 'cos of the hernia op tomorrow had a tidy up, put all the tools back where they belong as opposed to the floor
Hope I'm back in there soon
welded up the inner plate on the axle tube fitted that, axle boot and wheel bearing.
Then seem as I won't be going anything for a short while 'cos of the hernia op tomorrow had a tidy up, put all the tools back where they belong as opposed to the floor
Hope I'm back in there soon
OK I have:
Painted the arches & front chassis & f/beam ends with some black epoxy primer/paint (one-coat) so that should do a good job of protecting.
Took f/pads out and f/flexi ready to change / couldn't get hold of any sat morning, so ready for when I get them.
I decided to get adjustable rear spring plates, so I've unbolted r/shock & r/axle ready to slide off and change when I get them.
Put guages in place, oil temp & pressure, volts and boost guage / need to get 2 teeny nuts & 6 teeny washers to finish the fit.(then wire it up)
Fit the f/ number plate!
Fit r/light surrounds to r/wings
Relocated ext. oil cooler, when I put it 1st time the gearbox was out and now its in the clutch cable is very close to it, so moved it.
hummed & harred about where the charge cooler stuff is going to go, and set about altering the rad so it'll go where I want it.
At work one of the wheels is finished, hopefully by the end of the week they all are / or at least another two so I've got all the wheels I need & fit their rubber.
Was very tempted to fit the wings, but I'll hold till f/brakes & rear suspension is sorted / not long / famous last words
I'm actually starting to feel the end is in sight
Then onto tricky / oh god/
/
Painted the arches & front chassis & f/beam ends with some black epoxy primer/paint (one-coat) so that should do a good job of protecting.
Took f/pads out and f/flexi ready to change / couldn't get hold of any sat morning, so ready for when I get them.
I decided to get adjustable rear spring plates, so I've unbolted r/shock & r/axle ready to slide off and change when I get them.
Put guages in place, oil temp & pressure, volts and boost guage / need to get 2 teeny nuts & 6 teeny washers to finish the fit.(then wire it up)
Fit the f/ number plate!
Fit r/light surrounds to r/wings
Relocated ext. oil cooler, when I put it 1st time the gearbox was out and now its in the clutch cable is very close to it, so moved it.
hummed & harred about where the charge cooler stuff is going to go, and set about altering the rad so it'll go where I want it.
At work one of the wheels is finished, hopefully by the end of the week they all are / or at least another two so I've got all the wheels I need & fit their rubber.
Was very tempted to fit the wings, but I'll hold till f/brakes & rear suspension is sorted / not long / famous last words
I'm actually starting to feel the end is in sight
Then onto tricky / oh god
//since last time :
All the wheels are finished and the spare set is sold
Fit front brakes, shocks and anti roll bar.
Decided to strip off the rubbish from the front inner arches too, sealed up where needed and paint with the epoxy black primer/top coat.
Also decided to carry on the 'make a load of mess' theme and I've started striping the under neath I've just bought a air needler, to 'hopefully' make this a quicker job.
Fitted the adj rear spring plates.
Fit one side of the rear brakes, this would have been both sides, but like a nob I'd previously lobbed out one side of the shoe assembly - so need to get spacer bar & hand brake bar.
Fit the trans strap.
I've also cut off the rear apron to allow clearance for the turbo, this was a job I didn't want to do as it all painted 'n shiney but was hoping that leaving for as long as poss, somehow it'd all of a sudden fit :crazy:
Welded on the larger diameter fuel outlet to the fueltank and painted it, this was done at work.
Fit new res feed pipes prior to:
Fit the tank / turns out it's quite tight for room and fits very nicely / this is luck you understand another 1cm or so another direction and I'd have been cutting 'n re-doing !
here are some pics / they aint too good and the car prob doesn't look too much different to last pics of car - but I have been working on it honest guv
oh yeah nearly forgot - I painted the horn & fit - pimping
All the wheels are finished and the spare set is sold
Fit front brakes, shocks and anti roll bar.
Decided to strip off the rubbish from the front inner arches too, sealed up where needed and paint with the epoxy black primer/top coat.
Also decided to carry on the 'make a load of mess' theme and I've started striping the under neath I've just bought a air needler, to 'hopefully' make this a quicker job.
Fitted the adj rear spring plates.
Fit one side of the rear brakes, this would have been both sides, but like a nob I'd previously lobbed out one side of the shoe assembly - so need to get spacer bar & hand brake bar.
Fit the trans strap.
I've also cut off the rear apron to allow clearance for the turbo, this was a job I didn't want to do as it all painted 'n shiney but was hoping that leaving for as long as poss, somehow it'd all of a sudden fit :crazy:
Welded on the larger diameter fuel outlet to the fueltank and painted it, this was done at work.
Fit new res feed pipes prior to:
Fit the tank / turns out it's quite tight for room and fits very nicely / this is luck you understand another 1cm or so another direction and I'd have been cutting 'n re-doing !
here are some pics / they aint too good and the car prob doesn't look too much different to last pics of car - but I have been working on it honest guv
oh yeah nearly forgot - I painted the horn & fit - pimping
Under the tank :
Today I knocked off the loose paint 'n rust on the sills and floorpan, I got an air needler/descaler for this - it's a cracking tool shifts anything not on 100% in seconds / next best thing to sand blasting.
Found one small patch with a few teeny holes, was going to bodge it (they were that small), but I thought thats silly I've got all the stuff so I plated it, sorted it properly
Sealed that up and also ground around were I'd cut off the rear apron and sealed the edges too.
Today I knocked off the loose paint 'n rust on the sills and floorpan, I got an air needler/descaler for this - it's a cracking tool shifts anything not on 100% in seconds / next best thing to sand blasting.
Found one small patch with a few teeny holes, was going to bodge it (they were that small), but I thought thats silly I've got all the stuff so I plated it, sorted it properly
Sealed that up and also ground around were I'd cut off the rear apron and sealed the edges too.
Fantastic project fella, I'm sure a LOT more people are reading this with interest than appears; people just don't reply that much
well it hasn't been the fastest project done on here
OP 21st Nov 2006
Update time
went to bleed brakes master cylinder borked, this was on a friday luckily DG had one so was able to fit it sunday, which did happen! then bled brakes.
fit fuel line.
fit front wings and soldered wiring for lights n' indicators and fit lights
fit one of the rears, left the other cos I need to cut more of the inner arch out for exhaust clearance.
got a stainless steel flange made up 20mm thick, big thanks to swede (aka forum botherer ) for his contacts and getting it.
turbo fitted w/flange clearance is A OK
fit front wheels to find they catch on the caliper, so bit of 'modding' needed.
went to bleed brakes master cylinder borked, this was on a friday luckily DG had one so was able to fit it sunday, which did happen! then bled brakes.
fit fuel line.
fit front wings and soldered wiring for lights n' indicators and fit lights
fit one of the rears, left the other cos I need to cut more of the inner arch out for exhaust clearance.
got a stainless steel flange made up 20mm thick, big thanks to swede (aka forum botherer ) for his contacts and getting it.
turbo fitted w/flange clearance is A OK
fit front wheels to find they catch on the caliper, so bit of 'modding' needed.
Had friday off work (jay / eldest sports day !), so I had time to go and get the oil lines made, one of those jobs I can't normally get done can't get to them during the week and they aint open sat. so was good to get them sorted.
oil feed to turbo is proving to be a pig!, I took it to a local place that has every nut and bolt under the sun and found out turbo side is m10/1.25 and the thread on my elbow on the oil pipe I have is UNF 3/8, at last I thought found out the thread on the turbo I can order one - computer says no! - rand 2 places no joy / sulk.
Today :
I fit the lines
Solder up the wiring for the EFI as this was cut to remove from fastfugatives mota.
After checking here about the alternator wiring nearly finished that I need a couple of female spades for a thicker wire.
Bolted back up the body bolts after removing them to clean descab paint & stone chip underside.
Remove window mechs lubricate, refit, clean up glass / get all overspray off from when it was painted.
think thats it!
oh yeah on the friday polished up the 2 centercaps I had, and ordered 2 new'uns shame they sent the wrong ones really
oil feed to turbo is proving to be a pig!, I took it to a local place that has every nut and bolt under the sun and found out turbo side is m10/1.25 and the thread on my elbow on the oil pipe I have is UNF 3/8, at last I thought found out the thread on the turbo I can order one - computer says no! - rand 2 places no joy / sulk.
Today :
I fit the lines
Solder up the wiring for the EFI as this was cut to remove from fastfugatives mota.
After checking here about the alternator wiring nearly finished that I need a couple of female spades for a thicker wire.
Bolted back up the body bolts after removing them to clean descab paint & stone chip underside.
Remove window mechs lubricate, refit, clean up glass / get all overspray off from when it was painted.
think thats it!
oh yeah on the friday polished up the 2 centercaps I had, and ordered 2 new'uns shame they sent the wrong ones really
Turbo oil feed sorted with a HUGE thanks to PIRTEK, took the turbo & oil line to them, couple of mins later sorted. also went back there when I needed to sort the oil drain fittings out, they lent me the tools to do the job! so that also is just awaiting fitting.(I feel turbo tecnics need a mention through their dedication to lack of knowledge and ability not to help)
Just done some odds 'n ends really nothing major, fit n/s running board & rear lid to see what clearance is like between engine stuff & lid, should fit quite snug!
Modded rad for where its going to go, enough room for it above gearbox. and fit the res tank.
Cut the inlet pipe about for it to fit and have some silicone hose on order, when thats here that can get finished
It's getting close, so I thought better charge the battery up, and downloaded the omex MAP3000 software
Mirrors arrived this morn so they will go on next time.
Just done some odds 'n ends really nothing major, fit n/s running board & rear lid to see what clearance is like between engine stuff & lid, should fit quite snug!
Modded rad for where its going to go, enough room for it above gearbox. and fit the res tank.
Cut the inlet pipe about for it to fit and have some silicone hose on order, when thats here that can get finished
It's getting close, so I thought better charge the battery up, and downloaded the omex MAP3000 software
Mirrors arrived this morn so they will go on next time.
Made up the air inlet for turbo > throttle body all welded up & ground, will take to work & paint.
Tightened up gearbox braces.
Would have filled with oil but fill tube has gone awol so need to sort one, job for next time now.
Proberly bolted up fuel pump and cut & fit fuel lines.
Jay decided to clean the rear no plate so I fit that after!.
Made a bracket to hold rad for the charge cooler in place, one more to make.
Fit last wing.
Oh and mirrors.
couple of pics for you!
Bit dusty innit
Tightened up gearbox braces.
Would have filled with oil but fill tube has gone awol so need to sort one, job for next time now.
Proberly bolted up fuel pump and cut & fit fuel lines.
Jay decided to clean the rear no plate so I fit that after!.
Made a bracket to hold rad for the charge cooler in place, one more to make.
Fit last wing.
Oh and mirrors.
couple of pics for you!
Bit dusty innit