Freestyle GT Build

[jason_l]

*** mini update ***

Well got up to TGT on the weekend and spoke to James about a few things. As i have my operation date now i have  ok'd the next lot of work to be done on the buggy as i have a bit more cash to spend on it now.

I got the radiator and the twin fans on the car, actually helps visualise how the front will look better.

I Have an idea in my head of how i want the front to look now. Large centre intake with an adjustable front diffuser. Did a quick photoshop (and i mean quick) and here is how it came out, second one is probably the best version. Still needs a bit of work but you get the general idea. If anyone wants to have a go themselves then by all means have a go.

Jason

 

[jason_l]

*** Design finalised ***

Ok, just a small update but worth sharing me thinks

Got home yesterday and my bro had done a few sketch's of what he thinks the buggy should look like. He did graphic design at uni and his drawing skills are a little better than mine. He did a quick sketch and im in love!!!! This is pretty much the plan now on how the buggy will look.

As this is going to take a while to do then its not going to get done straight away, plan is to get the thing up and running and hopefully road legal over the summer. Then if that happens it will undergo the transformation over the winter months when i won't be using it. The first picture shows what the first stage will look like then the side panels will be changed over later. If i don't get it road legal by the summer then i will go for the full kit straight away and hopefully have it oin the road and looking like the second picture by next summer.

First design..............

And what i will be aiming for............

I absolutely love this look and think it looks great but would love to hear your thoughts people

Jason

 

[jason_l]

Thought i should add a little update on this as i haven't updated this topic in nearly a month now, not that there is much to update  : Im sorry for those people that will log on to see that i have posted in this topic only to be disapointed by the update  ;D

Well TGT have my lexus in at the moment for repairs/service so work has shifted away from the buggy and onto that. I hopefully pick my lex up in a week or so when i am allowed to start driving again. Im dying to drive! Haven't driven a car in nearly 4 weeks now and im going nuts stuck at home.

I have been doing what i can though while im in this state, which isn't much. I have been told to not lift anything heavier than a kettle so can't really do much on the buggy. Plus i can't actually drive up to work on it. 

I have ordered a few parts and stuff is strating to roll in slowly so that when im back to health i can go full out on it. Brand new exedy clutch arrived last week. Very happy with it, its only the standard version but as the buggy is so light i don't think i will need anything stronger. As im swapping over to the LSD box shortly it makes sense to just put a new clutch in. I don't know what state the old clutch is in but its stupid not to swap it while its off.
I have a pair of black gel coat arch's on order also, was going to order a full set but didn't want to risk it in case the quality isn't right, or incase they don't fit properly. Plan is to cut the arch's down a LOT. Im aiming to have the smallest arch's possible while keeping it legal. I have mocked out a template and need to make a final version that will mount to the hubs so i can get the placement correct but the arch's should be really small. This will mean that the weight is kept right down and you will be able to see more of the wheel/tyre which i think will look better.

This morning i have sent off the remaining chassis parts to be laser cut from steel and hopefully these will be in production shortly.

I am also waiting on a few replys on parts, f1 style mirrors, green harnesses etc.


Apart from that all i have been doing is sitting here reading the IVA manual from front to back. God this thing is boring but i need to read it!!!!

When i start driving again i will be up working on the buggy, mainly all i will be doing is painting bits as thats all i can pretty much do in my state. Hopefully James will be getting the engine out and on a stand so that i can get the block cleaned/prepped/painted and then back in with all new shiney parts.

Its getting there people, slowly but it is still going! Sorry for the essay................

Jason

 

[jason_l]

*** Update ***

Well got up to TGT on wednesday and started work. Work was slow with my condition but i have plodded along with it at a steady rate. People expecting a big update will be dissapointed as im working at such a slow pace as not to put any pressure on my chest.

This is how the engine started off in the morning.......

Wednesday i managed to get the inlet manifold and fuel rail off the block and started clening up the block as much as i could. I have several diffreent engine degreasers etc so just went to work with them. I managed to get the engine mount off the block and got the old bush cut out of it. Took me a while as didn't want to feck up my chest so was sawing gently, for quite a while. :lol: Also got some ngk leads on, and a HKS actuator for 5 minutes.
Got the old actuator off the turbo and there is a huge crack in the turbo and there is also some shaft play so its going in the bin. watch this space for new sexyness  8)

Wednesday i left the engine looking like this........

Got home wednesday and a few more sexy bits had arrived, Stainless exhaust clamps. Almost have everything i need to make the exhaust system when the engine goes back in the demon now. One of the first jobs when its back together

and also the sexy Race Tech oil line for the turbo, shame the turbo is fecked <_<

Then today i got back up there and continued with the cleaning....... :mellow: Driving me mad but i got there in the end. Managed to get the crap turbo off and also the standard manifold as someone is donating a stainless one to me for £30. whoop whoop! Started painting the engine silver but not sure. I think it will look ok with a bright green rocker cover and other green bits.

and also changed the one of the gearbox mounts for poly........

Im cleaning everything as i go and painting what i can but progress is slow at the moment. I won't be back up working on the demon till Monday now as i want the weekend to relax, which is what i should be doing. I also have a cambelt kit on order and a few other secret sexy parts.

Comments welcome as always.

Jason

 

[jason_l]

*** Update time ***

Well i got up to TGT yesterday and got a little done, not much but was one of those days when you walk away feeling happy with what was achieved and knowing whats coming.

The plan for the day was to get the gearbox to a reasonable condition and talk through the next stages of the chassis work with James.

James managed to get hold of some cleaning stuff that he recommended for the gearbox, its acid bassed so was watered down to a 1:1 mix. This stuff is toxic like you wouldn't believe but my god its amazing. They put some neat onto a cylinder head and left it for a hour os so to see what it would do. It actually started eating the cylinder head, luckily it was a old crappy one.

I sprayed the solution on the gearbox, left it for a minute or so and the steam/pressure washed it off and it now looks like a new gearbox. The gearbox was pretty clean anyway, having only done about 40k. I can talk all day about this stuff but like they say, 'A picture says a thousand words'......so here they are.

Before the clean........

and after............

Friday i also picked up the remainder of the laser cut steel profiles that will finish off the majority of the chassis work and hopefully shortly see the engine and new gearbox go back in. James has some free time next week from Tuesday so we are both going to crack on with it and more updates will hopefully follow next week.



Jason

 

[jason_l]

*** Update ****

Well yesterday i was up in Basingstoke and cracking on with it again. Although it seems to be going backwards now.

Yesterday we started looking at the suspension setup on the rear. The new coilover setup i will be going with has meant BIG changes and i only have myself to blame for it. Because of where the coilovers sit there is currently no way of fixing them at the top to the buggy. We discussed options for well over an hour and the outcome was that the exising towers at the rear are going to be modified substantially. This has meant a slight setback as alot of the work that was done before is now getting changed again.

The Demon will now be getting the rear clip welded to the chassis, rather than have a removable rear part. To keep it as a removable piece just means more work as new plates need to be made where the join together. This will mean a stonger buggy i guess.

We started with removing the current top mounts, or whats left of them!

After this was done the existing mini 'towers' had the tops completely cut off. The new plan is to get some new tower covers lasercut that will blend into the light unit parts. Its hard to explain but when its done i will get some pictures up and im sure people will agree that it will look 100% better than before.

Its a bit of a shame really as all the hard work that James put in before re-enforcing the chassis where it bolts together has now been wasted and is all getting removed. We both agreed that if we had done it this way originally we would have made a new rear subframe rather than cutting up the mini one. However its too late now and so much work has been done on the current setup that some of it needs to be salvaged.

Today i managed to pick up some HUGE box section steel pieces that will be shortly put to good use and fixed to the frame.

The problem with a project like this is you spend ages thinking about how to do something right and go through all the options. You think you are doing the best option then later what you did comes back to bite you in the arse meaning it needs rechanging or something else needs to be modified.

Im sure we are now on the right route and will keep everyone posted on the changes. Bit of a setback but will work out for the better in the longrun. However i am now doubtfull that it will be ready this summer/year

Jason

 

[jason_l]

*** Small Update ***

Well was up at TGT today, only for a few hours or so but got a few pics and a bit of an update.

Since i last updated the rear has been removed from the buggy and the subframe has had the 'bolt together' parts removed and the area that is getting the new welded parts has been re-enforced. The existing mini suspension towers have been cut up and currently look like this.....

This area needs some serious building up work to make it stronger to take the new coilover setup but will be worth it i hope.

The back currently is in pieces but hopefully will be going back together in a week or so when i have the new laser cut tower parts. The Suspension towers are going to blend into the rear light units, will make complete sense when you see the final design.

The last laser cut parts also included these brackets, these will hold the gear change cables from the mr2/starlet and be mounted to the frame where the two cables meet and will need connecting together. Needed a little bit or cleaning up and bending into shape but they are a good fit now.

Also got this yesterday, not taken long to deliver, just 5 months or so!!!!! but worth the wait, looks pretty sexual and will look nice with that clear cambelt cover that will hopefully not be long!

While i was up there today i have begun work on the front end, not much but i don't want to rush this as its a main feature of the buggy. I have a design in my head and don't currently have anything on paper. Im trying to work out how to build it so will probably work on this for the next few months at a very slow rate. I have removed the front headlights as i don't think i can keep them in their current location because of the IVA regs but not sure as of yet??? With the headlights off though you can really appreciate the shape and i can visualise the front better.

Added a nice MDF splitter just to check that the design im going for doesn't stick out to far and i think it looks about right. Its the shape that is penciled on the mdf, so will be more curved and angle inwards slightly. Don't know how this will work with the radiator hoses yet???

Nose will be built up with a selection of templates/foam/parts/cheese until i have a rough shape that will work and i can get a rough design from. There is no point me taking months making a perfect mould just to make a one off front nosecone so don't epect the mould to look 100% as it won't. If i am really happy with the final design i may make a decent mould so that if i have a crash/front gets damaged i can make another front piece.

Been working out what i still need to purchase and what i have got that needs fitting and although the list isn't as long as it could be the parts that remain on the 'need to buy' list are relatively expensive and working out funding has made me realise something. I want this thing built AS SOON AS POSSIBLE as im dying to use it. However i would rather it gets done properly first time round so with that in mind i don't see it being ready this year! I think its going to be a push to get it done for next summer even Sounds crazy i know but i just don't have the funds to throw alot of money at this thing. The next few months i am going to be VERY tight for cash so work is going to SLOW down on this alot!!!!! I will continue to carry on with it but don't expect regular updates, there are a few parts on there way and i will update now and then, especially when i get the new inlet manifold from Ricky

but don't worry people, THIS PROJECT WILL SEE THE ROAD!!!! even if it kills me!

Jason

 

[jason_l]

*** Mini Update ***

Got up to TGT yesterday to pick up a few little bits from the Demon so i can work on a few bits at home. Money is tight this month and next so plan is to work on a few bits that won't cost me much money.

Got the Rocker cover off the engine and the plan is to convert it to a race spec one and polish it up to a mirror finish. By the time im finished with this thing it will be like its made of chrome. James got the AN6 weld on fittings welded in place. Was going to go for AN8 fittings but im not going for 300hp or anything so i think AN6 will do. They are bigger than the standard size so its uprated.

This is what it looked like after the fittings had been welded........

and after a few hours of sanding, not much difference i know but when its done its going to look insane next to the polsihed Inlet manifold from Ricky

James also welded up the extra pipes on my RX7 intercooler! Was going to keep this for the moment but after i had a little play with a monster Supra intercooler i changed my mind.

Here is what we are planning with the intercooler, this was just a mock up but its going to look insane. We plan on making full hardpipes for it as well. Rather than some kits you see fitted that have pipe-silicone hose-pipe-silicone hose-pipe etc

What do people think of this.............

James thought it will be funny when i come up against people at the lights and they see that thing strapped to the back Not much rear vision but oh well, not like this thing is normal is it LOL

Jason

 

[jason_l]

*** Little Update ***

Yesterday the Mandrel bends arrived for the 1st exhaust system (with screamer pipe) and everything is there and ready now to make the exhaust system the second the engine and gearbox is all back together and is sitting back in the Demon.

Must have spent about 5 hours sat in the garden just sanding the rocker cover as well yesterday, the casting is so crap its unreal! Takes flippin ages just to get rid of the little pits that are all over the thing. I haven't even started using the powered polishing kit yet so this is going to come up like chrome! Im still using 120 grit paper and it looks like its getting pretty clean already! Got rid of most of the really bad casting marks around the edge and getting in between the groves/letters is a nightmare. I did polish up one corner with 400 grit and a bit of polish just to see what it will come out like, WOW! looks pretty good, and im going to take this thing to about 800-1000 grit before the polisher even gets on it so will be uber shiney!

I also ordered the standard Thermostat housing and oil filter housing as im going to polish them up also! Should look amazing polished rocker cover, Race Tech inlet manifold, intercooler pipework running either side of the engine and then engine parts polished as well

The plan is to not spend another penny this month on the Demon so will just be sat in the garden sanding and polsihing bits up!

Jason

 

[jason_l]

*** Small Update ***

Well i have been sanding and polishing for days now and im just not getting anywhere. The castings from parts are so crap that you need to put in so much work its unreal!

Still sanding down the rocker cover and its slowly getting there. Thought i would have a break from this and spice it up a bit...............so i decided to start sanding/polishing another part

Started looking at the oil filter bracket and did a little, well i say a little but i have actually spent about 8 hours on this part

started off like this.....

and after 8 hours...............

Still needs work. but will be worth it when all the polished parts come together.

I decided that im going to need something to get into all the small parts and the lettering on the rocker cover so started looking at Dremel type kits on the bay. Found a nice draper kit on ebay with 56 extra bits for £21.50 shipped. Thought this was a pretty good price but then i checked his pictures and they where just stolen from Amazon.com. So i thought i would check amazon and RESULT!!!!! its only £16 on their site new and comes with free delivery!

So i have a tidy little Draper multitool coming from Amazon and i have also ordered loads of spare sanding/grinding/polishing tips from ebay.

This should hopefully speed things up and give a better finish also, should of just done this from the start.

I am also speaking to Ricky at Race Tech about some modifications to the Inlet manifold i have being made, should be pretty sexy when its ready

Jason

 

[jason_l]

*** mini update ***

Well today was a better day, was like a mini crimbo. Started off with my draper multitool turning up in the morning, great service from Amazon. Only ordered it yesterday at about 2pm. Then about an hour later i had 3 packages arrive New replacement oil filter, Aero locking fuel cap for the fuel cell i will be making and loads of grinding/polishing/cleaning tools for the multitool.

Got out into the shed workshop and started with the multitool and i have to say its fantastic, for only £16 its worth every penny and then some. Got the oil filter bracket all sanded, smoothed and polished in a few hours of using it. Its not 100% perfect and the bottom is a little less smooth but its not really going to be noticed.

Here is the outcome........

and the Aero filler cap, already changed the bolts over for black hex head ones as i didn't like the ones that came with it!

Have started back on the rocker cover with the multitool and its going loads better. It just eats through it and leaves a pretty good finish. Going to be a few days of sanding but will look amazing when done. I need to get a bigger polishing kit as well as the small one isn't really ideal for large items and leaves slight swirls in the alloy.

Got a few other things that im working on and hopefully the Demon will be back to a rolling shell shortly

Jason

 

[jason_l]

*** Little Update ***

Well the last few days have been great!

On Sunday me and my mate went up to Birmingham to the National kitcar show and had an absolutely fantastic time! Spent all day on my feet walking around and still didn't see everything! Was great meeting you all and picked up some really good idea's also. Big thanks to Max for letting me know about the brakes from Rally Design.
I took £250 with me on the off chance that there may be a few bits to pick up.......and i spent the lot!!!!! lol

I tried to stick to getting items that where cheaper at the show and maybe a little hard to get hold of elsewhere. Ended up buying Rally Design rear calipers with built in handbrake mech, Willwood pads, Stainless mandrel bend for exhaust (thats the full length of the finished exhaust in the picture!!!!), stainless bolts and fixings, green cable ties, edging trim, black F1 style mirrors, remote radiator fill point and cap, detailed electronics book and some polishing bits for the dremel.

This is what £250 of parts looks like laid out, doesn't look like much but im well happy!

Rally Design rear callipers..........

Sexual slimline mirrors, these will be going on later as mister IVA won't like them much.....

Then today the 2.5' intercooler pipework kit arrived at my house! This cost me £57 off of ebay and was worth every penny!!!! Im not using any of the silicone connectors and most of the pipework is going to be welded together as this looks better. Its all mandrel bends and is already polished up to a mirror finish.

There is more than enough to make the whole pipework and will even have a little left, im using a tiny leftover piece to make a minature oil catch tank with earl fittings The pipework is also pretty dam thick, nearly 2mm, which is great.

I got up to TGT yesterday and they have planned to work on the Demon towards the end of this month as i have now maxed out my budget for this month. I have LOADS to do now so will really be cracking on with it again. Im back to work finally on monday so will have a lot of parts to go back with and continue getting done. I have 3 main jobs that are on the list for this month.

1: Start making wiring loom, i have everything i need to begin making the custom loom from scratch. The electronics book really helps out and shows basic wiring diagrams. I have drawn up a diagram of the buggy with all dimensions so i can work out cable routing and lengths.

2: I have already picked up some Mini disc hubs and these are getting stripped down and shot blasted before they go off to the machinest to be adapted to fit the Rally Design calipers. The brakes on the back of the buggy are drums so this is well overdue.

3: continue with the polishing, the oil filter bracket is done and looks like chrome. The rocker cover is getting there slowly but we have more equipment at work so this will really come along soon. Also have a thermostat housing to polish and hopefully this week my 'Race Tech' inlet manifold will be here

Also have a few little other arts that need doing, hopefully squeze these in as well if i find time!

As you can see im going to be really busy but after seeing all the kitcars over the weekend i REALLY need this built!!!!!

Jason

 

[jason_l]

*** Hell Yes ***

Been a good week, and its not over yet!!!!!

Finally got back to work on Monday and its great being back and i get so much more done on the buggy its unreal. Just the fact of having all the correct tools and all in the same place is just fantastic! And im working less on the buggy than i did when i was off. I do 30 minutes before work, 45 minutes on my lunch and then a few minutes after work.

Feel pretty tired going from doing nothing for 3 months to full on again but i love my job and being busy!

Anyway, i started off the week with getting the hubs taken apart. My god that was a hard job! The ones i picked up off my mate have been left outside so where just mullered. One of the calipers was seized one and had almost welded itself to the disc. Took me hours to get it off, but i did.

Here is one of the hubs broken down and you can see how bad the rust is!

All these bits where put into a Vinegar bath overnight and they have come up pretty well, the hub has gone in for another 24h but will be cleaned up tomorrow.

Got the NEW disc mounted up and will be painting parts of it black shortly.

Then before the hubs get painted they are going off to be machined to accept the new hydro-callipers. May have found a place locally to do this but not sure yet???

Then today this bundle of sexualness arrived at work! Been waiting ages for this but im so happy, the welding is just fantastic!!!! Needs a little cleaning up and its getting all polished up anyway.

Race Tech manifold with 65mm throttle body, fuel rail and fittings, Fuel lab FPR and Earls fittings, braided line and 2x cat converter flanges for the exhaust systems im making up. Ricky has put a lot of work into this and it really shows. Im over the moon, the Demon will look great with this on it

Few more closeup pics of the Inlet....

Im thinking of filling the Race Tech logo with paint and then polishing the rest?

Have already started polishing up the fuel rail and should pretty much be there tomorrow when i get it on the buffer at work. Its in really good condition to begin with so is pretty straight forward to polish it.

Tomorrow will continue cracking on with it more!

Jason

 

[jason_l]

*** little udate ***

Well today i went to my work's workshop to get a few little things done.

Have spent all week stripping down the mini hubs and getting them cleaned up and hopefully in a few weeks they will be getting machined to accept the new discs. I managed to get the disc flanges cleaned up and bolted up to the new discs. While they are all clean and the rust starts building up again i got a coat of black hammerite on them.

I spent about an hour sanding the fuel rail. Starting with 180 grit, then 400,600,1000 and 1200 grade until nice and smooth. The fuel rail was in really good condition and you can see that Ricky has taken care not to scratch it while making it. Then got it on the buffing wheel and it now looks like chrome

Thats now wrapped up safely and put in the big box of parts that are waiting to be fitted.

Got the thottle body taken off the inlet so i can get the main body polished up and have made a start with hand sanding. Again you can see that Ricky has taken really good care with making the manifold and there are very few scratch's on it so will come up really nice.

throttle body taken off.....

Inside of manifold.......

I spent a little bit of time sanding the top and back of the manifold and you can see how nicely it has come up! This hasn't been on the buffer yet and its looking fantastic.

Now that the hubs are all cleaned up and ready for the machineing im going to continue with the polishing now this week. Im waiting for the laser cutting company to get back to me with the quote for the fuel cell parts but they have promised that they will this coming week.

Hopefully i will get a chance to get up to TGT next Saturday with any luck and see what is going on with the chassis. Hopefully they have found time to do a little bit???

Jason

 

[jason_l]

*** Sunday Update ***

Well its been another busy week but im happy with the direction its going and the next few months are going to be interesting

Started off the week by cutting a small section off of my intercooler pipework to look at making a custom made oil catch tank. There is plenty of bends, straight etc so just cut a 120mm piece off. The oil catch tank is going to have AN6 earls fittings with a bottom bung to drain the oil. Not going to have a site tube on it as it looks messy, will just empty it every now and then.

Top end......

Bottom.........

Its not welded up yet but James will do it when the intercooler pipework gets done. Will have a small bracket added and will attach to the side of the engine somewhere so i don't have to run stupidly long hoses.

Then started with one of the jobs i have been meaning to do for some time now, sort out the arch's for the wheels. As i have new brackets made up for the front and rear i needed to make a template to work out what size arch's i need and where to mount them. Im going for the smallest arch's i can get away with as i like the wheel being on show more. Im going for close fit arch's that fit as close to the tyre as possible. 15mm above to be precise, but as the arch moves up and down with the hub this shouldn't be a problem and shouldn't ever touch the tyre.

After alot of measuring, angles, more measuring i have a template.........

You can see the small arch that is possible and the template is mounted directly to the hub to work out the correct placement of the arch, the template is reverseable so i can do both sides!

Now came the arch's, the only arch's i can find that i like are the carbon mods ones, and im not paying £200 a pair!!!! So i have decided that the rest of the project is custom i may as well make the arch's from scratch! My bro has moved to Japan for a year or two and left alot of resin, fibreglass and gelcoat. So in theory the arch's won't cost me anything but time to make!

So after a few minutes thinking about how to do it i started knocking up a template.....

finished mould, rounded the corners ever so slightly.......

The arch's are 220mm wide so i can run some wide slick tyres for track days and the arch curve should match exactly to that of the template so i can mount them properly. I have found some proper woven fibreglass material so hopefully will knock out a arch or 2 during the week.

Also got up to TGT yesterday and they have started work back on the buggy! Its looking good and the back has been welded onto the main chassis so is almost in one piece again! It still needs the topmounts welding on the rear and i have to get some steel tube to reinforce the back. I don't have any pictures but give me a week or so and i will. Plan is to get up there next saturday and hopefully this should see most of the fabricating work on the chassis finished off. This will mean that the engine should be going back in shortly after and i can begin getting the driveshafts made, and connecting things up! WHOOP WHOOP!

Also had a little chat about paint while i was up there and this has changed, AGAIN!!!! Plan now is to spray the chassis Matt black and have bright green arch's, nosecone, sides, spoiler, engine cover etc. Should look better in Matt black against all the polished engine parts.

thats all for now...........

Jason

 

[jason_l]

*** She's Rolling ***

Been a busy old week really, as usual at the moment :lol:

Took the nice MDF mould i made for the arch's and spent the evenings during the week fibreglassing up the first arch. I didn't know if the fibreglass would stick to the mdf or if the mould release would actually release the arch. Took a gamble and it paid off. Came out pretty easily to be honest and the second arch is currently in the mould awaiting its final layers. I have used 2 layers of woven fibreglass and 3 layers of CSM so the arch's are really thick!!!! They are about 4-5mm thick so i can get away with having no edging trim and just round the edges over. Im going to try and see if i can support them just at the side also and not have any metal under the arch. This means i can get them closer to the tyre, aiming for a 15mm space between arch and tyre

in the mould.........

taken out.......

and trimmed down, the template shows the smallest arch legally possible and i am just over the limit, you can see how thick the fibreglass is........

Here is what the arch's i bought before look like on the wheel, you can see that they don't follow the wheel radius well and they are quite big in size.....

and my design, follows wheel radius perfectly and is tiny in size

I think these arch's will look great when they are properly on!


Whoop Whoop! Well got up to TGT yesterday morning at 9am and got things rolling, literally, yep thats right she's back to a rolling chassis
Spent the day getting the rear frame welded up to the main chassis and its all there. When i had arrived James had already got the bottom welded up but we just needed to sort out the topmounts. Sleeved the downtubes and got the new topmount plates in place.

and welded up.......

the gaps are getting filled with metal/weld and then ground flush so the topmounts and light brackets sort of blend into one another........

Rear engine mount has been removed also as the location will have changed with the work and new one will be going on shortly.

Also managed to knock up the seat bars, these will get welded to the bars that are along the floor.

I have also got a few things on order, the laser cut pieces for the fuel cell have been ordered and should be here tuesday. As well as some rather nice Green TRS harnesses and a knock off HKS SSQV BOV. Yes its a knock off but if its really that bad i will buy a proper one and swap the internals over so it looks all new and shiney. Will give me the chance to weld the adaptor to the pipework and mock things up.

I owe James for 2 full days labour but if my budget can stretch to it this month im aiming to get the suspension brackets on, cambelt change and new Cam pulley installed, and the engine and gearbox going back in the chassis...............fingers crossed.

Next jobs are to start working out the fuel cell. I have a fuel pump form a starbo, it is missing a few bits but its mostly there! as always i will keep the updates rolling.

Jason

 

[jason_l]

May as well update now as im not planning on doing anything much on the Beast this weekend, going to just spend the weekend chillin out with the misses.  I think this has come along quite well now so going to have a few days off, but don't worry guys come monday morning at 7:00am i will be back on it

started to modify the fuel filler cap. I would have loved to of just left it as is but under IVA regs it must lock the key in position or be tethered to the tank. Checked the cap and the key can still be removed when the cap is off the main unit so my only option is to have it tethered to the tank. So its getting modified, won't be too bad hopefully........

Then finally my fuel sender arrived on Thursday. Its a 180-0 Ohm unit and the gauge i have reads 100-0 Ohm so the tank will read full until its about 60% remaining then will read right down to empty. The important part is that at full tank the gauge will read FULL and at empty it will read EMPTY.

I like this fuel sender as its more compact and doesn't have a huge swinging float like some others do.

Then got the flanges for the back box drilled, i have 2 of these as im making 2 exhaust systems. I have most of the parts for this now so when the fuel cell is getting welded i will get James to switch over to Stainless and knock up the exhaust.

Then got these........

Don't really need words do they?  God i love them, im going to pop up to TGT tomorrow to double check they fit but im 95% sure they will. Will get a few pics of them drapped over the sexy white seats.

Finally got hold of the laser cutting company and they lost my address, hence why my parts have not arrived yet  but they have promised me they are going out today so should have them monday/tuesday and i can begin making the fuel sell, from scratch.

Im also planning on having a steel box welded in in the rear compartment. I have room for one just to the side of the fuel cell. This will be big enough to hold a helmet and steering wheel (when i eventually convert it to a removable type). Will be lockable also...........flippin chav's!

Hopefully next weekend i will be up at TGT really cracking on with it again.

Jason

 

[jason_l]

*** Update ***

Well been cracking on throughout the week as usual and been concentrating on the fuel cell this week.

Monday my laser cut parts finally arrived at work, been waiting ages for these but finally have them so i can crack on with the fuel cell now

Firstly i got the flange for the filler cap drilled and tapped. The flange is 12.7mm thick and gets welded inside the tank to allow the filler cap to just bolt onto the outside, finished off the tethered part also so now the filler cap will be fixed to the fuel cell. I just need to chop the filler neck part down a bit and it will get welded to the flange.

Then started looking at the fuel sender itself, using the standard setup as a template i started looking at remaking the whole thing. I didn't want to just use the standard setup as it will look pants fitted to a nice new fuel cell, im aiming on using a uprated in tank pump and will be bassed on the original starlet setup.

Here's the original mess.........

And here's my own version.........

Started by drilling out the main holes for the parts........

Then drilled the weld in tank flange to match and made a rubber sealing gasket from some thick 3mm rubber we had lying about......

Then looking at the standard setup in detail it was clear i would need some sort of breather for the tank. There is a feed pipe, a return and a breather pipe. The standard setup has a small cylinder inside the tank that acts as a breather. I took it apart and had a closer look. I could get air to escape through the valve but i couldn't get air to go the other way. I don't know how the valve works and im not sure if its bust or is ok. Most of you know by now that im not the sortof person to just make do so i started looking for a better replacement. After searching for hours on the net i finally found what is know as a 'roll over valve' from Merlin motorsport. I thought it was quite expensive but i needed one so just bought it!

It gets mounted in the top of the tank and does 3 main things. 1: lets air into the tank as fuel gets used 2: Lets air escape when filling up with fuel and 3: If the car rolls over it seals itself to stop fuel escaping.

Added it to the sender plate along with the stealth black AN6 bulkhead fittings and dowty seals and even used a waterproof connecter block to finish it off.

And finally with the wires connected up for the fuel pump.....

The wires pass through some Nylon bolts so they don't touch the metal part and effect the connection. Ordered some standard fuel line for inside the tank and the AN6 connectors for inside as well. Just need to make some brackets for mounting up the fuel pump and connect wires inside and its pretty much there!

Then Today i went up to see James at TGT and measure up for the fuel cell (again, just incase i got it wrong the first time) and measure up for a steel lock box that im going to weld to the chassis. This will go next to the fuel tank and will fit my race helmet and stearing wheel for extra safety when im parked up.

Got a picture of the engine now it has a new cambelt kit and the adjustable cam pulley fitted........

Clear cambelt cover will really set it off

And also chucked the remote fill point on for the cooling system. This is the highest point of the system as the radiator sits alot lower at the front so had to put it here to ensure i get all the air out.

Thats it for this week. Tomorrow i will be at work doing a few little bits but nothing major. Im pretty strapped for cash now this month but will be able to buy a few pieces of alloy and steel to start making the pieces for the fuel cell and lock box and at the end of this month the engine will be going back in and the suspension setup at the rear will be done. James is on holiday for a few weeks but his first job back will be the buggy.

More updates soon..........

Jason

 

[jason_l]

*** Small Update ***

Well its been a pretty slow week as although i have loads of parts in my room, with the buggy and under my desk at work i don't have much to do till the engine is in! James is away on holiday at the moment but when he gets back he should be back on it and start working on the buggy. Also as its aproaching the end of the month i will have some money to pay him so this is when the majority of work gets done, when he knows he's getting paid shortly :lol:

Got my stealth black fuel line fittings and the only part of unbraided fuel line im using on the whole project, these look really nice and its a shame they go inside the fuel cell so knobody will ever know the work that went into making these parts........

Fitted to the bulkhead fittings...........

Connected up through sender plate........

Then started looking at mounting the fuel pump, im still missing a few bits but will have these when i order the uprated fuel pump at the end of this month.

These are the only parts kept from the original setup, the small piece of pipe shown was later binned as i didn't need it and the uprated fuel pump will replace the stock item later. So the only things that are used from the existing setup are the fuel pump connector block and the small piece of metal on the end to house the pump filter.........

This part then gets bolted to the alloy arm, all it needs now is the alloy arm welded to the top plate and the connector block wired up and its finished!

with the pump roughly in position.......

Payday will see the uprated fuel pump ordered and the alloy material needed to make the fuel pump. My bro has also said that he will probably stay in Japan now for good, and as he has some nice motorsport parts lying about i will be buying them hopefully. First to come is a nice Simpson race helmet, very similar to the stigs helmet B)

Next Saturday im planning on getting up to work on the Demon myself, im hoping James lets me do some welding work on it. Im sure he will if he's about so i will hopefully get the centre consol welded in and make up a few templates. Also with any luck i may get the seat rails made up and welded in. With any luck the engine will be back in the Demon around the end of the month and the rear coilover mounts will also be done

Jason

 

[jason_l]

*** update ***

Well its been a slowish week but next week will be better.......as the engine is going back in! Whoop whoop!

Not been doing much during this week as i have been a bit strapped for cash but i have managed to do a few little things. Firstly i got some adaptors made as i need to modify one of the lower seat belt anchors to extend out slightly. Then yesterday i was passing by halfrauds and i thought why not i will give it a go.
Went in and asked about paint mixing and they said they can mix any colour if i have the paint code. Didn't think they would have the Porshe 'Viper Green' im interested in using but she checked the system and it was there.

Just bought a single spray can of the green to try out and see if its any good, all i can say is i flippin love this colour!!!!!

Had a quick test spray on a old lexus wing mirror cover i had lying about and i personally think the colour looks great! Doing the frame black and the rest of the bodywork will be this colour.....

What you guys think?

Checked it against my bro's kawasaki jetski and its close but the porsche colour is alot deeper and looks loads better.

Then today i got up to TGT and got a little done, its flippin hard working in this heat but was going to crack on with it. Got the centre console welded roughly in place and it looks pretty good, will be adding a full cover to it later but its in now!

Then spent a little time welding in holes and grinding them flat. A few hours later and i was flippin nackered.......

Got a few templates made for a couple of parts im going to make during the week and payday is wednesday so i will be back on it more now. I need to get a solid piece of 2.5' alloy to make a reducer up for the intercooler pipework. It basically needs to go from 1' - 2.5'. Nothing like this exists so will make it from scracth.....as with the rest of the kit.......
Turbo flange and intercooler pipework.....

Also i made a cardboard template for the side pieces, still unsure if i will add them but i guess it will help channel air around the buggy and deflect the odd stone etc....

what do people think???

was thinking i could mount a few of the gauges in the drivers side one.....

Got to the point while i was working on it that i just had to walk away as i was starting to get really pissed off with it and started thinking i really can't be bothered anymore. Second i started driving home all those thoughts dissapeared! Its hard working on this thing when the weather is so nice outside, but the second im out in the sun i start thinking 'DAM, it would be awsome driving about in that buggy'

Jason