xr4x4rs

iTrader: (5)

rite ive finally started to sort some pics out of my newest project

as im not very well my mate is doing most of the work but i have ben helping aswell

unfortuantly i my camera broke before i started the project so couldnt really take pics of going along

but heres what we have done so far

you can tell the welding i have done becuase its crap but penetrated good anyhow, thankfully not a lot will be seen of mine anyhow
i havnt welded in over 7 years

well heres athe car as it started life until the tax and mot ran out end of january




we then stripped the car completely alls thats left on it is wiring loom and glass

the whole car will be stich welded to improve a bit of strength and stiffen it up

we have done most of the car suspension mounts and inside the car just underneath to do

ther has been and still needs to be a lot of welding, its had a new battery tray as teh original was non exsitant, this caused bad rot patches on my tunnel lucky they didnt go through but have been plated anyhow, all seats mounts aswell

floor to sill has been fully seam welded, its surrising how much of a sierra is just glued together

not this one though when its finished

heres some pics of what we have done so far



















heres a pic of the engine
its done 80k, so i put a cometic wrc headgasket on it and arp stud and nut kit
when i took the head off the bores still had honing marks
and has not been rebuil nor the head as ever been skimmed

ive had teh rocker cover powdercated and machined for my breather, all my inlet, engine mounts and stat housing have been polished

new water pump and cambelt and top end gaskets

the engine should be sweet as a nut but im not convienced on the gasket as i never had any skimmed but had them checked out and they didnt need doing, so if it goes it goes



will get more pics later on as it stuck in the corner

i have bought all new bolts from ford for underneath

every thing i could have powdercoated has been underneath aswell

pics up when i put it back together

next on the job list is to finish the welding

ive just ordered 2 wings, 2 sills and 2 rear arches
the wings have gone on bumper mount so only using this bit, i will change the complete sills as these are rotten and have had repairs before alos what bits of teh rear arches i will use, dont want to use a complete arch if i dont have too

then fully stich weld underneath to finish it

will get pics as i go along as this is done most days and i have 80% of the bits to do it

heres how the car stands at the minute

Bungle

Nice one rich about time ya got a thread up cheeRS, Grant.

xr4x4rs

iTrader: (5)

just a little update

mty wings,sills and arches have turned up and will be starting these tomorow

but just finished the inside of the car of the welding that needed doing so nothing spectacular just yet


first disatster of the day was i snipped through my grinder cable when cutting the metal sheet for teh floor got a bit fo shock to say the least



and just finshed welding the tunnel , i put all 3 layers back in to give the strength again just got to finish underneath


floor to sill seam welded




another patch at the front floor


and finsihed of the stich welding along teh seat mounts and tunnel



next will be to start prepping underneath once the panels are done, ive already half done it but my batteries are flat so there on charge until tomorrow

Brian

iTrader: (2)

Brian

xr4x4rs

iTrader: (5)

another update

got to thanks to my friend karl (sexr3i) who came round again and done most of teh welding for me

we started on driver side with the front wing repair, cut the old bumper mount off and welded a new one on off a new wing



next was the rear arch repair, now i dont want to replace the complete rear arches as they dont need doing, its just the back bit at the end of the arch so this is what he done

original hole


all rust cut out



panel cut out of new arch what was needed



lined up to check fit



welded in and snaded down



carnt see much from this pic as it was a top view to see how flush we got it



but overall very happy in the way it turned out, we did have a sliht panel problem that the rear quarter pushed out due to heat, but the body shop will have to sort this at a later date

heres a pic of how the undrside looks at the minute



not far off from completetion on teh floor side anyhow, couple more days i rekon

trial fitted my rear strut brace



and same with front but drilled the holes in teh struts



next is to get the passenger side sill onand do the rear triangle repairs then start on the drivers side which is basically the same as passenger side except the rear arch is rotten front and back

ive just been out this morning and bought a new grinder as both ours died yesterday, got some brusable sealent so i can go over all the joins that we have welded and also panel wipe to get any excess oil from the underside floor pan

will update again shortly

Paulo P

It's a shame your photos don't seem to be working

xr4x4rs

iTrader: (5)

hmm

so thay dont

will try and sort them out

xr4x4rs

iTrader: (5)

pics sorted, was becuase i madea folder and they use different codes

bloody shit photbucket

Paulo P

Nice work There's one hell of alot more work there than I thought! The seam welding looks cool

Bungle

Nice one rich, What colour is the car mate? looks cool as fuck in certain light

RichieST

iTrader: (2)

top work mate, you going to keep it standard on the outside??

xr4x4rs

iTrader: (5)

the colour is smokestone blue mate

the car wont be left standard, as if i did i would have no aorflow to my intercooler

the car will have a full rouse sport kit on with 17s 6 spoke comp mos in dark grey

martrs

looks good mate looks like you have been busy give us a ring when you are out and about in the garage

xr4x4rs

iTrader: (5)

martrs

mainly my mate thats been dong all the work

decided this is my last one now as i just havnt got the energy anymore to work on cars as i used to, id be fukt without my mate coming round to help

anything im doing lately im exhausted afterwards

xr4x4rs

iTrader: (5)

ok

well i had a go at doing a sill and this is how it ended up

this is where i cut the old rt out and was ready to start it



i welded a plate on the insid eof the rear traiangle to give me the inner sill back aswell

inside the sill was rot as usual so i went about building the inner sill up first



made a strengthening plate for the inner sill to attach all the insides back together for strength



one i was happy with this it was time to clean the sill up and fit the new sill

new sill fitted



and all welds flatted down and smoothed in with the original sill so only a little bit of filler required






the bottom of the sill i drilled holes a long and spot welded it to the inner and then grinded off the lumps of weld so it ws smooth again

overall im happy the way its turned out and you can feel the strength going back into the car

dont think i did a bad job for my first ever sill

next was cut the old sill out which is done and the same again but ill do that the start of next week

i also repaired the chassis leg as this was non existant

1st pic shows a plate i welded in as ive had to build the strength back up into this aswell





unfortuantly my batteries died on the camera but this is no done

i plated all the insides to get the strength then plated the top aswell and joined them all then 1 last plate that goes round the chassis leg this just needs grinding the welds off

will get pics of it next week when i start the other sill

cossie4i+

iTrader: (15)

Good work Rich

Its more rusty than my XR4i lol

Steve.

xr4x4rs

iTrader: (5)

cossie4i

rust isnt the word mate

but its only metal and can be fixed

xr4x4rs

iTrader: (5)

well the welding has finally finished nw so i can crackon with getting the shell back to a car again

heres the final pics of the welding

driver side inner sill getting repairs and strengthing again like the other side






outer sill on



wing finished




found another hole so this got plated




rear arch sorted




then i started to seam seal all the semas with brushable sealent ive used 2 tins so far and still got loads to do









so next week is to sound deaden the whole car again, finish preping underneath, stonechip and paint, and then paint the engine bay ready to start building

smitsturbo

looking good mate, i fancy seam welding my s1 but i get sick of welding after half an hour

is that a tommy feild cossie engine? (going by colour of cam cover)

keep it up tho mate

xr4x4rs

iTrader: (5)

just s standard cossie engine mate, with cometic gasket and arp studs and stage 3 nothing special


rocker cover i just had powdercaoted in light blue

xr4x4rs

iTrader: (5)

update again

ive changed plans on a couple of things noe as i need to get the car on the road, so no hydraulic clutch or aeroquip, ill do these later on

to save myself money i didnt bother painting underneath as the car is going to be used daily so i undersealed it instead of painting just saves on ceaning underneath every other day

well heres the pics

first was to get the underside all stonechipped up as i scrapped all the original stuff off





then once all this was dry i masked all the holes up in the bay as i was going to shults underseal arches and entire floor pan

th sis how it turned out and came out better than i hoped nd very happy with it





once all this was done i painted my engine bay



now i can start building the car

so i needed to finish laying the sound deadening matts




then its was all the bulkhead deadeing



wiring being sorted





inside sound deadening matts have been installed aswell



next on the list is to fit the fuel and brake lines

then it will be the rear beam to get the back end rolling again

xr4x4rs

iTrader: (5)

ok little update

got my fuel and brake lnes in just std items for now, but still contemplating on wether to go aeroquip fuel lines

depends if i can sort the funds out or not

had my bushes arrive and 4 new calipers but the fronts are wrong so they are going back monday

heres some pics anyhow nothing much just parts mainly



new black diamon drilled and grooved discs front and rear so brakes should be ok for now



rear calipers


rear wheel bearings, i have to take these in next week and have them fittied into my hubs and onto my arms as i have no vice to do them, will be getting new rear driveshaftfs atthe same time



engine bay tidied up

fitted my strut brace peoperly all bolted down alos my breather catch tank



shiny map sensor bracket (thanks shorty for holding it for me) and fitted my 3 bar aswell



interior loom all in now and tidied up just a little bit left to do



main beam bushes in (what a bitch to do with no press)



pic of my wheels going off for refurb soon, they are 8x17 will get 18s at a later date, but they do have yokohoma paradas aswell that ca,e with them


pic of my coil overs had new rear spring platforms and gaitors arrive from avo so these have all been cleaned and painted and greased ready t be fitted


thats it for now

just waiting on rear shims and a poly diff mount of mike rainbird then the rear beam can be fitted and the back should be rolling soon hopefully

then the engine and box will go in

Richie.

iTrader: (5)

Good work Rich, coming on well

Twellsie

iTrader: (1)

Nice work Rich, looking good

Did Chad ask you if i could borrow your workshop manual?

Rich

xr4x4rs

iTrader: (5)

yes mate

its sat here ready for one of you to collect mate

Shorty

iTrader: (1)

Havnt looked at this post in a while..

You havnt been hanging about have you

coming along nicely now, some proper bits too, i like the wheels

xr4x4rs

iTrader: (5)

new update

finally got all my bits together to do the rear beam so this is all fitted now

my rear arms with he new wheel bearings in, unfortuantly i didnt have any paint to paint the hubs etc so sod it afterall there going to get covered in brake dust and you dont see them



new driveshafts one is the wrong one so this was changed next day



all new nuts and bolts for the rear end



diff fitted into beam



new brake lines and rear diff mount



all ready to go in, except i put the diff mount on the wrong way but this is now sorted, also fitted a cossie roll bar and new straps for the bar



new calipers and brakes fitted and my coilovers





all fitted



also finished sound deadening the boot floor and fitted my strut brace that you can just see



next is fuel tank anf uel pump, tank should be here on tuesday and ill get some wire to rewire the pump

also ordered a grp a gasket set as im getting rid of the cometic and arp studs as ive heard these arnt very good

so will do this once they arrive

Dan

Nice project there mate! Done well so far, looks good now!

Shorty

iTrader: (1)

Looking good fella, keep up the good work mate

CosKev3

Nice work

xr4x4rs

iTrader: (5)

Matt J

i dont mate as the only part of an xr4x4 on my car is the shell
everything else is cosworth

put it up for sale on xroc or fsoc

well ill do an update tomorrow

just spent half the day rewiring the fuel pump

problem is wen i went to fit the fuel pump in the cradle its very loose

so going to need the rubber pads that goe round the original if anybody has any

cossie4i+

iTrader: (15)

Looking very good Rich

Steve.

Roosie

iTrader: (8)

looks good mate

- Sim -

cool work, but I won t put any soundkiller in. just weight that is not needed

But very good resto work!!

xr4x4rs

iTrader: (5)

the sound deadening is there becuase im having a stereo build in the boot and dont like rattles

plus im having the middle nox removed so hopefully will help with that aswell

this car isnt about perfromance so im nt bothered about weight either, id be quite happy with around 330-350bhp which i think is plenty for the road

CosKev3

How close is the top bolt on your new diff mount to the ARB m8???????

Mine was touching when I first fitted it,so had to grind the head of the bolt down to give the ARB room to move up and down

xr4x4rs

iTrader: (5)

CosKev3

its touching mate i think

was a pain in the arse to get the roll bar in tbh

im going to dee how it goes it should be alright as it does give a little movement anyhow but not a lot

i think the mount needs to be redesigned as it sits further back from the original

but as they were desgined in the states for the mekur im led to believe the roll bars are in different places to the safe

CosKev3

Thats why I modded top bolt

ARB goes lower when you put the car back down on the floor,and mine was getting stuck on the top bolt

Asked a certain supplier of this mount who posts alot on here if he had had any problems and he said no!

So could be slight differences/sizes of the mount

Pic of mine with modded top bolt

xr4x4rs

iTrader: (5)

hmm

i may have to modify it when i get my grinder back then

ill see how it goes though as it will be simple enough to do even when the cars finished