steve200TDi

Steve200TDi's New Racer!!

207 posts in this topic

The silicone hoses turned up last week and so with a bit of pondering I came up with a plan and set too with the stanley knife and I came up with this:

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Just need to make some brackets for the snorkel and finish the end off as it will go across the roof, but apart from a bit of paint and jubilee clips that job is DONE!

Now I can sort out the front shock hoops and get them welded into position.

I've also been playing with a plasma cutter I borrowed as that's for the lower shock mounts.

The tube for the rear shock mounts has arrived and I've also received another parcel too.........it's got FOX on the box :D:wub::)

Steve

 

 

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I wish you'd get round to 'squirting it so you can delete that ratty old airflow meter, cluttering up the engine bay!

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To be fair, looking at the condition of the AFM multi-plug boot, you could probably delete it now and not notice :P 

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On 3/7/2017 at 3:58 PM, FridgeFreezer said:

I wish you'd get round to 'squirting it so you can delete that ratty old airflow meter, cluttering up the engine bay!

It's working fine at the moment!

If the forum wants to sponsor a Megasquirt install then I'm not stopping you!

I've spent all my money on shocks! More progress with those this week hopefully.

Steve

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Update time!

Shiny parts have arrived:

2.5 Fox remote reservoirs, 12 inch travel

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Tomcat front springs all round inline with Tomcat guidelines

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Paul from Tomcat was very helpful with recommending and advice for everything!

I borrowed a plasma cutter and my god it's so easy and useful, it's definitely going on the Christmas list!

As the lower shock mounts are welded to the axle the spring seats and spring seat mounts need to be trimmed.

In future I will invest in a pair of lighter shade goggles, as I was using my welding helmet on its lightest setting, hence the slightly jagged edges!

Spring seat cut:

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Spring seat mounts cleaned up and cut:

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With the chassis cleaned up I was ready to offer up the upper shock mounts, do loads of measuring and weld them on.

With a couple of pieces of angle clamped to the chassis I could rest the shock hoops on the chassis while I cycled the suspension and adjusted the hoops to suit.

I also shaped the lower mounts and offered those in position too. Once I was happy I tacked them, checked again and then fully welded them in position.

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Also welded in the lower spring seats.

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And then obviously had to fit the shock :D:D

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So the front suspension is done!

I will be making a strut brace between the hoops, but I'm unsure of what to do until I get the bonnet to fit again! I have a few ideas in mind.

So it's onto the rear shock mounts!

I had bought the tube, so I chopped a bit off and started shaping!

The Air die grinder with a burr worked quite effectively after hack sawing and filing the rough shape.

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One down, three to go. The positioning is going to be interesting as I need to make a jig to find the bolt position as it's in mid air!

Steve

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Enjoying watching this come together Steve. Some nice work.

Will have to try and get down to watch a race one time.

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So the burr was so good I thought I'd invest in a new one and use the wonder that is amazon prime! So it would be here for my days off :)

After getting a plan in my head I notch a piece of tube and put it in place with the tabs to form the rear shock mounts.

After a few tacks I was able to test fit the shock.

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And the same for the other side.

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With a little bracing tube as well.

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The new burr came into its own here!

I'll be timing the tubes down and fitting these little tube caps. Handy when you have the tools at work!

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I then welded the rear mounts fully, welded the lower mounts and added a spring seat too just like the front.

For storage purposes I wanted to fit the boot lid. I knew it wasn't going to fit and needed some tlc like all my panels!!

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I started by drilling out the rivets of the large back panel, remove the lower bit (where the exhaust exited, it was only held there by the short tube in the centre, the edges had twisted off and friction was holding it all together!) and test fit it knowing only too well I would need to cut out the piece of box section.

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I was pleasantly surprised as it cleared!

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So plan is to add a tube just under the grilled panel with all the lights on as it needs a bit a bit of stiffening as its all rattling about. Then that box section can go as I'll be boxing in the shock towers and the reservoirs will be around there too. I'll be incorporating some defender grills as the ventilation holes too, but not too sure what I'm going to do yet.

So in the mean time my next task is to sort out the strut braces. I'm going for a full cross at both ends, but whether I can have that and provisions for a winch, I'll find out tomorrow when I do some measuring and pondering.

Steve

 

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Looking good Steve, be interesting to see how those nice shocks will transform the ride at high speeds :) 

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I'm also interested to see how it goes! Should make a good difference and even more so as you can tune them. 

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I really want someone to pull all the metal off that rear clamshell and re-do it in wafer-thin fibreglass.

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1 hour ago, FridgeFreezer said:

I really want someone to pull all the metal off that rear clamshell and re-do it in wafer-thin fibreglass.

I think your welcome to do it Fridge ;) 

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Oh you don't want me doing it, any more than you want me painting things or Nige in charge of health & safety... :ph34r:

I'm deliberately not saying who you do want doing it as he's a very busy bunny.

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I feel an A-Team quote coming on........

If you have a problem that no one else can help, if you can find him, maybe you can hire..............Mike Tomcat!! dum der dum dum! :D

But I don't think he's wanted by the government!!

Steve

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I made a start on the strut brace today.

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Will be putting in a cross from the top tube down to the ends of the rear stays which will clear the winch and just need an extra funnel to refuel!

Steve

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After some sexy tube notching.:wub:

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The rear strut brace was done! :)

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Now onto the front. I already had bought the tabs to weld to the front hoops, so just need to make everything else!

One tube.

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1.5 tubes.

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All done!

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Now to fill in all the semicircles!

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Weld and grind smooth

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Still need to cap off the rear shock mount tubes!

I made a start on the boot lid, by adding in a tube with some tabs to support the upper part along with a piece of ali angle to give rigidity. It'll all be shaped and the bolts changed, but you get the idea!

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And I chopped more out of the bonnet! And added in one tube!

It's round 3 of the SCOR 4x4 Comp Safari this weekend and I'll be helping with time keeping as I wont be racing!

Steve 

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I've done a bit more this week.

I still wasn't convinced about fitting the whopping great silencer I had purchased so found a smaller, cheaper box and fitted that! It's part number: NTC1665 and I'm much happier now! So its mounted and just need to sort out the rear most bit now.

I also made a heat shield to go between exhaust and fuel tank to try and keep the fuel cool and had a look at where I'm going to mount the remote reservoirs. I would quite like to route the hose round the back of the shock hoops (this is the front) so they're protected if I get to near a tree!. I think i might have a plan, they'll either be mounted to the strut brace or new tube just above the chassis rails.

Steve 

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Lots of hard work being done !

Looking very good.

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New silencer, a lot smaller!

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Just need to finish the end section.

And the racer has been sanded down and primered by my girlfriend!

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More painting next weekend and things might start to go back on!

I've also ordered a flaremaster 2 from sykes pickervant.

Steve

 

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Seeing all those dangly belts reminds me why I went serp!

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14 hours ago, FridgeFreezer said:

Seeing all those dangly belts reminds me why I went serp!

Seeing all those extra bearings and tensioners to go wrong reminds me why I don't run Serpentine :P Granted, on the V8 its only one extra bearing and a tensioner, but on the 200/300 tdi there's a completely redundant pulley with a bearing that can't be replaced :D 

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Yes, converting to serpentine maybe good, thicker belt and all, but as I understand it, there isn't an easy way to convert. I may be wrong, so do let me know if it's an easy conversion!

Come on weekend, I want to play with the racer!

Steve

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