steven mc kay

hello paul. my car you could more or less say is finished , the digital dash that's been fitted to the car needs set up to configurate with the t6. the cars away at the moment to have this done.
life has changed for me now with becoming a dad so I don't have near the same time on my hands for the car, I do hope mabie to get out in it a run at some point this year. I must get a few photo taken to up load so you can have a look.


cheers steven

Scott_Rst

Great build! looking forward to seeing this built up!!
keep up the good work!

zetaboostboy522bhp

hi steven cheers , i know exactly where your coming from mate my little lad has just turned 6 months old and time goes so fast its unreal.
some picture would be great as i always like to see these cars finished and to be fair i have been waiting for months for a update on your thread lol.
cheers paul

zetaboostboy522bhp

another little update , not got to much done but they are all little shitty jobs that need sorting and they are crossed off the list of things to do which is as long as my arm lol.
i cut the battery tray out of the shell as it was sitting to low to the floor pan and water and shit from its rallycross days had collected underneath it with no way of cleaning it etc , i had to butcher it out which left the weld tags fix to the shell so all destitched , welded and ground back.



next was the plates i made to cover the shitty bolts and plates fitted to the side of the tunnel , there was only one small problem , the plates i made was not with the car un wrapped which fitted perfect apart from the swaged holes were right where the bolts are so you could see them through the hole , as they was a bastard to make i decided to plate over the top hole and i think they still looked good enough to use .





next was to weld the seat bar plates to the shell





a picture of the repaired tunnel , a bit of filler to smooth and a lick of paint job done



as i will be running a zetec turbo the inlet is on the opposite side of the engine so there was all fuel lines running through the bulkhead etc on the exhaust side so they needed blanking off , had to cut all the circles but got there in the end , all tacked in and primed






and finally weld up all the holes that had to be drilled to remove the fuel tank tray



oh and had a little helper , and hopefully future racecar driver with lots of money to look after dad and mum





laughing his head off at me make broom broom noises , i bet the neighbours thought wtf

cheers paul

craigk47

WOW. It's took me from 9 o clock this morning off and on to read through this whole thread but f*****g right it was worth it! The fab work and sexy shiny bits the whole way through were unreal!!! Couldn't believe it when I read that you sold the shell after all the work on the 15 or so previous pages but hey, looks like you've still got a great bit of kit in the new one and like you say - it would have still cost an arm and a leg to finish the old one! Cannot wait to see it done now! Keep up the hard work, this thread's been inspiring mate!

craigk47

Congrats on the birth of the wee man too! I've got two girls myself - none of my projects go at the pace id like them too any more :/

robp-tt

iTrader: (1)

Good to see your making progress with it paul

zetaboostboy522bhp

little update , not had a great deal of time with the young one , shit weather and life just passing me by so fast. really in need of a secure work space so looking into a big garage for next year as carrying tools , welders etc and setting up really pisses me off and takes at least half a working day away and it makes you feel like giving up . it will be so good when all i have to do is open a door and crack on with work lol.
anyway sorry for boring you all , lets get back onto the car.

had to cut battery tray out of the shell because it sat to low to the floor and was covered in shit and water ran underneth and was worried about it getting rusty etc so copied the old one and made stronger brackets and lightened as much as possible







this will be welded to the shell but not decided where yet.

next was the fuel cell tray, that also got cut out as it only had something like a 10 litre tank due to only doing 6 laps a race . this is certainly no use to me as i would need a fuel tanker behind me every time i go out lol so had a measure up and just got enough room between the rear cage to get a 45l pro alloy fuel cell in there so ordered a 45l fuel tray and started to make the in car brace to make the fuel tray level and has something to bolt down to as it goes over the dip in the rear seat bench and also the water pipes for the rear radiator comes through the boot floor so they will need looking at but that wont be a problem.
had some metal bent by jim at alloy racing fabs as my bender will only do 600mm.
swaged and lightened as much as possible and rivnuted for pro alloy tray mounting holes.

new brace next to the old one





with pro alloy fuel tray mounted







bodykit swapped for new one as wanted different mountings etc

rear bumper off and custom made crossmember that will be remade out of t45 tubing



front wings off , front bumper off and crossmember which was shit and again will be remade in t45 tubing with bumper mountings fitted into it and towing bolt.



cleaned up , there was shit everywhere but still in need of some tlc



rubber matting ripped off rear quarter panels , will be replaced with carbon fibre near the end.





side skirts taken of the shell as they are fibreglass and like the front bumper has paint chips/crack and they just dont do it for me so these are being remade by jim at alloy racing fabs in 2mm alloy so they will be stronger less flexing and hopefully no chipping and cracking etc



done some more but need time to load pics so will update again soon

cheers paul

M K

iTrader: (9)

Nice to see some progress Paul

Richie.

iTrader: (5)

Nice to see you're still enthusiastic about it Paul


Liking the fab work

zetaboostboy522bhp

only just mate , not getting any younger and sometimes its just so hard not having a garage etc to work in but i will keep plodding along .

cheers paul

smiley

I can see you take pride in your work mate

zetaboostboy522bhp

another little update .

iam going to be running corsa b power steering as its a well proven setup and pretty cheap to convert . so first up was buy the column and start to look what needs modding and what needs making etc .
first was the threaded and splined end where the steering wheel locates and the nut tightens down . the splines was machined off and the threaded extended this was to allow the splined boss on the quick release steering wheel boss to the be machined and tapped all the way through and then to be wound down where it will then be drilled , dowelled and pinned before being spot welded for strength.



boss spline wound down on thread , not decided weather to tig weld or pin and spot weld yet



next was to make the gun barrel style steering column complete with bearing carrier , bearing and c clip allowing nice and smooth steering . i had a few bearings sitting around and one fit on to the lip thats on the shaft perfectly so a stroke of look.





i wanted to use as many original parts of the steering column as possible as its still got to be collapsible for sva test so i wanted it to look standard so decided to use the standard corsa uj . drilled out the pins and separated to two parts as one will need modding to convert it to fit the wrc steering column that was already fitted to the car.



the part on the left of the above pic will need to be machined to the same fitment one side and then tobe machined round to fit in the cut down wrc shaft.





you can see the different profile



part fitted in the uj , this will be again drilled , dowelled , and spot welded

cut down wrc shaft



all fitted up ready to be plug welded and tig welded around the end.



whole column mocked up ready for welding but need to double check lenghts etc and tha means getting the car out and weathers been shitty again.





also gave the ecu and bracket a spray in gloss black





next was to make a new front crossmember as the one fitted to the car was original with a shitty bit of box section welded to it . rusty , cut and shut and bashed up isnt going to cut it with me and i purchased a new ford one years ago .

i cut the large middle section off the end plates and welded some bosses i had machined some time ago.



welded t45 tube with end pipes again with the male boss so it became a crossmember.
also squared the end plates up as the holes in them are massive so it would twist and not be straight when fitted to the car , made and welded some plates to mount to the original 6mm threaded holes on the end plate to keep it nice and straight





welded a towing boss on



nearly complete crossmember



just have to fit to car and make some brackets for mounting the bumper

had some m8 threaded bosses made up for mounting the front and rear bumpers.



also had some alloy mounting bosses and rings made for mounting the front bumper on to the crossmember

front boss



lock ring



you can see the two parts together bumper will fit between the both parts.



next got the car out finally and decided to check the fuel tray in the car as it was built off measurements and the old small tray.

fits nearly perfect , only slight mods needed for the water pipes for the radiator which is staying in the boot





next on the list was to fit the new bodykit , front bumper , wings and rear bumper to be replaced.

wings fitted





front crossmember fitted with front bumper and bosses



custom made brackets that fit on to the front crossmember and allow it to be bolted under the top cutout on each side of the bumper with m10 bolt





you can just see the front crossmember fitted







towing strap fitted , got the luke ones as its a nice little touch as thats my lads name and seeing as he will probably be driving it before me lol



wanted to keep the original metal headlight panel but you cannot fit headlights in so had to cut a fiesta headlight panel up for easy fitment





next was the rear crossmember again a rusty cut and shut box section and again doesnt really do the car justice so had to be changed .
new plates made and t45 tubing used and m8 bosses used again welded with a boss for the towing strap.









rear bumper fitted , all lined up pretty well







thats all for now folks and hopefully update again soon if i get chance

thanks for looking

cheers paul

smiley

Nice work mate

COLEYST200

iTrader: (3)

Nice to see you getting stuck into it mate

zetaboostboy522bhp

a little update , no to much as been feeling like shit over chrimbo and been very busy with my excited little man lol . i had the fibreglass sills made from alloy so they look alot straighter than the fibreglass one and should hopefully last longer too .
drilled all new holes a they took a few hours of fettling but they now fit perfect and iam happy how they look , ive stainless steel rivnuted all the holes in the sills and made 2 alloy bracket plates that bolt to the lower quarters. all that i need to do now is mark the predrilled holes in the sills , take them off and drill and rivnut m8 then they are done.

drivers side



took some pissing around to line it up with the front and rear arches



looking down the car



passenger side







also purchased a new kevlar tailgate from xsport , must say great service and a very fast turn around was here in 3 days . moulding looks very good but not had time to see if it fits or not.

cheers paul

AustenW

Any updates Paul?

creator

Thread revival as austen says any updates paul? I lnow youre circumstances have changed abit since you started this project i.e your a dad know lol but surely youve been able to do something on it �� lol

zetaboostboy522bhp

Hi lads , not much to update tbh as I've been so busy with work , planning the garage build and my little lad that times just flown by. I've been doing little bits and collecting parts for the build but only had the car out about 4 times this year as the weather has been total shit with rain nearly every weekend.
Things I've done are , neatened all the holes in the body shell interior where they used to hoover all the shit out of the sills. Welded in the passenger seat rails and seat belt ancor points, had to cut the rear bumper fan cutouts out and fibreglass , fill etc as the original was fucking shocking with mesh just self tapped to the boot lid. Got the front bumper and body kit all lined up , new metal bonnet fitted and aerocatches cut and test fitted and also cut the vents out in the bonnet. Tailgate fitted just needs trimming up slightly.
Also started work on the steering column which I had to get bits machined up so took longer than expected.
Also turned my attention onto the engine by porting the jenvey inlet manifold which took weeks to do as I purchased austens billet trumpets and everything needed opening out but all finished and ready to bolt back together.
I will post pics up when I get chance

Cheers paul