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Old solid rear disc versus 300mm MT conversion

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Mock up of Reyland hydraulic conversion

I bought a 205 gti pedal box and started chopping it away and testing the master cylinder for movement. Here it is tacked in place for mock up purposes

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Checked it all moved together and then checked it passed through the bulkhead without hitting the 4 inch down pipe, it does but I am building a heat proof barrier to also protect the 205 servo and 405 master brake cylinder

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Welded it all in place and added strength bars behind to stop any flex and then boxed it in so that the bulkhead has a rubber air tight seal exactly as a standard 205 does.

I do not think the likes of MK have to worry about me pinching the welding from them.

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I tidied up the welds, then seam sealed for neatness and painted it up.

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Before paint, but you can see how the master will work. I will post up a pic with it in place soon with the servo etc.

My 308 mm Reyland front discs are arriving soon and MT have just sorted me out with some new rear bearing carriers and he kindly shot blasted them so I can get new bearings in this week and painted up.

Before I painted the mock up above I did clean ALL the rust off and rust treated it!

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Where the rose joint joins the pedal I drilled the pedal for the bolt supplied but welded that to the pedal, added the rose joint and then made up a welded brace over the top to stop and flex in the bolt so in effect it is sandwiched between the pedal and brace. Seems to work really well.

All of the welds on the pedal have been welded from both sides for strength, I know I am not the neatest but I know it will not break either. Once the servo is in place it nicely hides all of the fabrication too.

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Today I painted up my new 4x4 hubs that MT Motorsport supplied and sand blasted for me, I had new bearings pressed in on Friday so they are now ready. I soaked the 4x4 calipers in bilt hamber C (concentrate) in a water solution and the rust literally brushed off in the morning. I thoroughly cleaned them, painted them and then rebuilt them with a brand new seal kit...quite an easy job really. I have all new bolts from MT too.

I then started welding up all the redundant holes in the drivers side of the engine bay ready for paint before the new pedals and servo etc go in. I just need to make up some heat shielding between the clutch master cylinder and the 4 inch down pipe. I have wrapped the down pipe and then painted it in the correct protector.

I have wrapped the last bits of the wiring under the bonnet and I have re routed some cables that were messy.

Once the new rear bearing hubs are on the car I can build up the rear brakes. Does anyone know the torque setting for the rear wheel bearings?

wide ka

Top work, looks great

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Here you can see the added strength for the rose joint on the clutch pedal.

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4x4 hubs shot blasted, new bearings and then paint

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I refurbed the poedal box and servo then added the clutch master, I have new rubber pedal covers to go on

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servo trial fit

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Here you can see a caliper after it has been dipped in bilt hamber C rust remover

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painted and new seals

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I forgot to add that the Burmese cat is called Cosworth...his sister is called Porsha.

in fact his full pedigree is "Talitoe Drifting Cosworth" and he really has been chipped!

MrCapriScort

Nice pair of pugs mate. Glad you have changed the exhausts

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Yeah, the exhausts always seemed a little over the top to me, very max power from back in the day.

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A few people on pistonheads have been asking about my Bomber 72v Electric Bike so I thought I would post it up here too. 50mph, 4.5kw so around 10hp (think) and 50 mile range on one charge. 9 speed sequential gearbox in the hub for the pedals. wheelies are easy

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Here I am jumping it.

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Video on you tube:

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ajamesc

Cool bike! Do you do ride that up caesars camp.

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I havent done yet but I have ridden all the army land around Bordon and Liphook and then all the commons, Punch Bowl, Witley,Broxhead etc.. all up and around the A3. It is a bit like having a green laning bike but without the noise that upsets the walkers and they do not look like motorbikes....when I see walkers I tend to slow down and just pedal...so many of them ask questions and seem to like it...I used to green lane and always felt guilty.

The power delivery of leccy bikes doesnt destroy the paths like a motorbike would and they weigh so much less.

Do they not mind bikes at Caesars?

ajamesc

There fine with cycling up there but motor bikes are a big no no

smiley

Kool bike mate

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I sent the rear bumper off last week to have the old exhaust holes filled, I will post a pic when it is back with the new exhaust on.

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Here you can see the bumper with the twin exahaust holes filled and painted and the T16 style single exhaust.

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another angle, you can see the big brakes in this pic too.

RSLUBBY

iTrader: (19)

That is epic love it totally old skool

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Today I bought a skyline gearbox with a cossie bell housing welded on it plus a load of other bits so hope to get it running again fairly soon.

tutuur

Lovely ramp for in a shed like that! Shed is nice too btw, wish i had one of those!

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Thanks, I do enjoy my time out there, I have a workshop on the side which is nearly a double garage, it all has heating and a wicked sound system from songs with a sub and Internet streamed music. I finished the ring main today for compressed air so I can plug in where I want. It is dried air and has oiled outlets along with dry outlets.

tutuur

Sounds like a dream! I have an unheated shed where only one car fits in

smiley

Nice one toby shaping up to be quiet a monster with all the right bits on

Focosmitch

iTrader: (1)

Looking good mate, rear brakes shouod make a nice difference!!

graham c

iTrader: (5)

who did the skyline box do you no

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Mk did it.

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Today I cut out the floor pan to allow the transfer case to fit, I have decided to leave the other shape for the Cosworth box in case I ever want to go back.

Once I have the box mocked up to fit I can weld the tunnel back in an work out the mounting after that it is getting the hydraulic clutch ready, prop shafts made up and then send the box off for a rebuild whilst I get the 2wd / 4wd pump and lines mounted.

The box is quite heavy (about 20kg more than the mt75) but all the weight is at the back which makes it hard to balance for jacking it in and out of the car.