H686 ODA Sapphire Cosworth Fast road/Track
22-02-2011, 01:28 PM
#41
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Its that time again, a long weekend just pasted with two full days on the car!
So we have:
No rear suspension
Rear spit arms fitted to chassis of the car
Same at the front
Front was so light i could lift it by myself and fit the stand
Got the back up so far
Car turned, before we started work on it!
Bracing for the boot floor
All the underseal and oily dirt cleaned off
A couple of the bad bits, but not too bad :O
Rear chassis legs
Rear inner sills
Front jacking point and floor strenghtening point
Gash bastards! just use the correct place on the car to jack it up!! pet hate :/
Floor cleaned up
And to finish some close ups of my nice welding, amazing what you can do when the metal is nice and new
Thats all for now, ordering metal to sort the underneath out then will treat all bare metal before turning the car back over ready to fit the cage, which i hope is being made.
James.
So we have:
No rear suspension
Rear spit arms fitted to chassis of the car
Same at the front
Front was so light i could lift it by myself and fit the stand
Got the back up so far
Car turned, before we started work on it!
Bracing for the boot floor
All the underseal and oily dirt cleaned off
A couple of the bad bits, but not too bad :O
Rear chassis legs
Rear inner sills
Front jacking point and floor strenghtening point
Gash bastards! just use the correct place on the car to jack it up!! pet hate :/
Floor cleaned up
And to finish some close ups of my nice welding, amazing what you can do when the metal is nice and new
Thats all for now, ordering metal to sort the underneath out then will treat all bare metal before turning the car back over ready to fit the cage, which i hope is being made.
James.
22-02-2011, 01:30 PM
#42
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Thread Starter
Because thats an origanal Ford Motorsport car i would of thought it would of come with the car when he bought it, iv been looking for one, found loads of people that make them, but none quite like the Ford Motorsport one!
28-02-2011, 12:35 PM
#44
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Thread Starter
Well another update for you all,
One chassis leg now repaired...
Big job this! and took me a good 6 hours to get to the stage its at, started cutting the bad metal out and it just kept going down the leg both ways, i managed to as far as the spring cup to find go metal at the back end of the leg, moving forward i had to cut out the beam mount and found good metal just after at the beam plate mount, i sat back and had i think of how i was going to tackle this as i had, had to cut out the main beam mount from the chassis! luckly i managed to save the mount its self and that cleaned up very well for refitting, before cutting out i took a load of measurements using the mounting plate, and refitting the beam mount in the right place was easy, i wish i had taken some more photos of this stage, but i have the other side to do so will try and take more on that one now i know what im on with.
Rear arches being cleaned out...
Drain holes in the floor being plated up...
Car was moved to a different angle to help with the work on the chassis leg and the arch cleaning...
One side of the floor with no drain holes
Lots of other little jobs being done at the same time.
Cage builder have said my cage should be ready by Wednesday
cant wait!!
Thats all for now James.
One chassis leg now repaired...
Big job this! and took me a good 6 hours to get to the stage its at, started cutting the bad metal out and it just kept going down the leg both ways, i managed to as far as the spring cup to find go metal at the back end of the leg, moving forward i had to cut out the beam mount and found good metal just after at the beam plate mount, i sat back and had i think of how i was going to tackle this as i had, had to cut out the main beam mount from the chassis! luckly i managed to save the mount its self and that cleaned up very well for refitting, before cutting out i took a load of measurements using the mounting plate, and refitting the beam mount in the right place was easy, i wish i had taken some more photos of this stage, but i have the other side to do so will try and take more on that one now i know what im on with.
Rear arches being cleaned out...
Drain holes in the floor being plated up...
Car was moved to a different angle to help with the work on the chassis leg and the arch cleaning...
One side of the floor with no drain holes
Lots of other little jobs being done at the same time.
Cage builder have said my cage should be ready by Wednesday
cant wait!!Thats all for now James.
01-03-2011, 08:59 AM
#49
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Thread Starter
31-10-2011, 12:07 PM
#51
Advanced PassionFord User
Thread Starter
Well......
Its been sometime, summers gone time to attach the track car again.
Basically i finished the underside and moved onto the cage just before summer, so first i will show you the main hoops going in and the door bars, then we will move onto the cage looking complete when i started work again 29/10/2011 (My Birthday).
Rear Strut strenghtening bracket
Popped a seat in to see what it was like
Project Restarted.... 29/10/2011
Big fast forward, some of the work is not covered by photos but you will get the idea, roof bars/ cross going in.
Firewall that i made months ago now cut round the cage and in place.
Been doing lots of other fab work which i will document in the next update.
Cage is nearly complete just the front turret bars to install now, but i need a hole cutter for the bulkhead first.
Update soon, James.
Its been sometime, summers gone time to attach the track car again.
Basically i finished the underside and moved onto the cage just before summer, so first i will show you the main hoops going in and the door bars, then we will move onto the cage looking complete when i started work again 29/10/2011 (My Birthday).
Rear Strut strenghtening bracket
Popped a seat in to see what it was like
Project Restarted.... 29/10/2011
Big fast forward, some of the work is not covered by photos but you will get the idea, roof bars/ cross going in.
Firewall that i made months ago now cut round the cage and in place.
Been doing lots of other fab work which i will document in the next update.
Cage is nearly complete just the front turret bars to install now, but i need a hole cutter for the bulkhead first.
Update soon, James.
31-10-2011, 06:29 PM
#55
Too many posts.. I need a life!!
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Great work mate.I have the ford motorsport saph prep book here if you want any ideas on the shell,it shows some good stuff where too plate or double skin but no measurments
07-11-2011, 03:33 PM
#56
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Thread Starter
Well not much to report this week fans, only got sunday on the car and half a day at that, i needed an easy day and something to make me think i had achieved something rather than getting metal splinters and hot rocks all over my body haha.
So i dry fitted my side plastic windows and started building the sliders.
NS
Looking in the slider window, dome head bolts for holding the rail on for the sliders
OS
Inside NS
Slider window in place fitted with stopper/ knob
And open, just top rail to make and fit
Also got some new work units and storage for free, just need a worktop
Hope to be making the rest of the sliders on tuesday night, and ordering the rear screen plastic soon too, just need to make measurements
So i dry fitted my side plastic windows and started building the sliders.
NS
Looking in the slider window, dome head bolts for holding the rail on for the sliders
OS
Inside NS
Slider window in place fitted with stopper/ knob
And open, just top rail to make and fit
Also got some new work units and storage for free, just need a worktop
Hope to be making the rest of the sliders on tuesday night, and ordering the rear screen plastic soon too, just need to make measurements
09-11-2011, 11:24 AM
#57
Advanced PassionFord User
Thread Starter
Morning all,
Small update from last night in the workshop.....
Battery tray area fabricated and welded in.
Sliders finished on the plasticwindows.
Firewall now sealed.
Battery tray
Windows
Firewall
More to come soon, hoping to be having a big weekend on the car.
James.
Small update from last night in the workshop.....
Battery tray area fabricated and welded in.
Sliders finished on the plasticwindows.
Firewall now sealed.
Battery tray
Windows
Firewall
More to come soon, hoping to be having a big weekend on the car.
James.
09-11-2011, 11:45 AM
#58
Advanced PassionFord User
Thread Starter
Just looked though this thread as im bored haha, and realised that i have never added an update on one of the most important bits
The revised engine plans
COSWORTH
That is all!
The revised engine plans
COSWORTH
That is all!
16-11-2011, 01:21 PM
#60
Advanced PassionFord User
Thread Starter
Update time all,
SUNDAY 13th
First some none car related bits.
Got myself a project white board for the workshop
And me and my mate modded the outside wood burner, it now has as nice flow lol!
And gobbing some flames lol
Now onto the car....
Lots of bits been going off, some i still have to record.
Boot has been cleaned of all surface rust, red scotched, blown out and panel wiped, then etch primer and seam sealer.
Still got the firewall to etch prime, but will remove it to do that.
Firewall marked out, drilled and a couple of pop rivits to hold it in place.
More of the firewall created by welding the holes in the car up, just sealer need now.
TUESDAY 15th
A good friend of mine that works in motorsport came for a look at the car, and recommended a few extras for the cage!
SO......
Iv added the tunnel brace in the bottom photo that links the tunnel and seat mount for the chassis to the main hoop, and then added the cross into the main hoop.
Got lots of bits on order too, just waiting on my etch primer and L angle to finish the fitting of the firewall.
Bought a set of hole cutters yesterday to finish the roll cage through the dash/ bulkhead into the engine bay.
Also trying to source some 1.5mm sheet steel to make up my gusseting for tieing the cage into the shell better, going to be making a tool for making the pressed holes in the gussets i hope too.
Just trying to source the Lexan Polycarbonate for making my rear screen.
More to come soon.
James.
SUNDAY 13th
First some none car related bits.
Got myself a project white board for the workshop
And me and my mate modded the outside wood burner, it now has as nice flow lol!
And gobbing some flames lol
Now onto the car....
Lots of bits been going off, some i still have to record.
Boot has been cleaned of all surface rust, red scotched, blown out and panel wiped, then etch primer and seam sealer.
Still got the firewall to etch prime, but will remove it to do that.
Firewall marked out, drilled and a couple of pop rivits to hold it in place.
More of the firewall created by welding the holes in the car up, just sealer need now.
TUESDAY 15th
A good friend of mine that works in motorsport came for a look at the car, and recommended a few extras for the cage!
SO......
Iv added the tunnel brace in the bottom photo that links the tunnel and seat mount for the chassis to the main hoop, and then added the cross into the main hoop.
Got lots of bits on order too, just waiting on my etch primer and L angle to finish the fitting of the firewall.
Bought a set of hole cutters yesterday to finish the roll cage through the dash/ bulkhead into the engine bay.
Also trying to source some 1.5mm sheet steel to make up my gusseting for tieing the cage into the shell better, going to be making a tool for making the pressed holes in the gussets i hope too.
Just trying to source the Lexan Polycarbonate for making my rear screen.
More to come soon.
James.
24-11-2011, 03:27 PM
#62
Advanced PassionFord User
Thread Starter
Update time...
This is from last friday as i had the day off.
Cage is noow complete apart from tidying some welds.
Floor Plates in and tunnel bars.
Firewall complete, holes drilled and a couple of pop rivits to hold everything in place.
Over view of the car/ cage.
Lots of discussions being had with my main man RC on the project, some very nice ideas coming on.
Plans now is to start dressing the shell and moving closer to having everything etch primed and sealed.
Next bit oof fab is the driving position, need to find the money for a pedal box!!!
More soon.
This is from last friday as i had the day off.
Cage is noow complete apart from tidying some welds.
Floor Plates in and tunnel bars.
Firewall complete, holes drilled and a couple of pop rivits to hold everything in place.
Over view of the car/ cage.
Lots of discussions being had with my main man RC on the project, some very nice ideas coming on.
Plans now is to start dressing the shell and moving closer to having everything etch primed and sealed.
Next bit oof fab is the driving position, need to find the money for a pedal box!!!
More soon.
25-11-2011, 08:27 AM
#64
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15-03-2012, 08:03 PM
#67
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hi james project looking really good, its come along a lot since we handballed it onto that trailer in david yard, just in the middle of building a double and a bit garage in garden at home.then we can continue with projects, this is getting my enthuasium building to get g800 out of the lockup all the best brian
02-05-2012, 09:59 AM
#72
Advanced PassionFord User
Thread Starter
Hi all,
Thought i best pop my head in and give a little update.
I had lost my way with the hole car thing for the last four months or so and just havent been feeling whole cold metal thing lol, but! im now making a good return and have started working on the cars agin and enjoying them, just hope the feeling lasts really.
Ordered a lot of new bits and done a fair bit of work, so will pop a photo update in soon, thanks for the comments and thanks for keeping an eye on the project.
James
Thought i best pop my head in and give a little update.
I had lost my way with the hole car thing for the last four months or so and just havent been feeling whole cold metal thing lol, but! im now making a good return and have started working on the cars agin and enjoying them, just hope the feeling lasts really.
Ordered a lot of new bits and done a fair bit of work, so will pop a photo update in soon, thanks for the comments and thanks for keeping an eye on the project.
James
03-05-2012, 02:36 PM
#73
Advanced PassionFord User
Thread Starter
Update time peeps
Started refitting some panels and parts of the car to make it look like a car again and spur me on
Me front brakes bought at a steal, cheers Matt
Top mounts
Aero Catches
Drivers and passengers foot rest + Battery holder
Swaging tool for making me cage gussets
Got a front and back bumper and mirrors
Aero Catches fitted to the front
And back
Dash cut round the cage and bits and bobs sat in place
Battery holder sorta in place may not be the final resting place
Me standard beast on its first outing of the year to Cadwell, only viewing no track for her lol
Rear catches nearly done
Started making Gussets for the cage
Moving ever closer
Cheers all
James
Started refitting some panels and parts of the car to make it look like a car again and spur me on
Me front brakes bought at a steal, cheers Matt
Top mounts
Aero Catches
Drivers and passengers foot rest + Battery holder
Swaging tool for making me cage gussets
Got a front and back bumper and mirrors
Aero Catches fitted to the front
And back
Dash cut round the cage and bits and bobs sat in place
Battery holder sorta in place may not be the final resting place
Me standard beast on its first outing of the year to Cadwell, only viewing no track for her lol
Rear catches nearly done
Started making Gussets for the cage
Moving ever closer
Cheers all
James
04-05-2012, 10:13 AM
#76
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Thread Starter
Cheers Neil.
Andy, cant thank you enough for your input and time, you spec and info is second to none!!
The cage is big and proberbly a little over engineered, but i hope it will be strong, and im not going out to prove anything or compete so it will be fine for what i want
.................................................. ..
Ok,
Pictures do a fear bit of talking, but i feel a bit of waffle would go a miss
Main aim for the coming weeks is :
To get the inside of the shell cleaned up, cage finished and start Etch priming the inside.
Iv got a few bits to start dry fitting but they can only really happen once i have a bucket seat to mock up and start getting driver and passenger positions, just lacking the funds right now for the bucket seat and bits that go with it.
there is a small amount of work to finish the firewall then that can also be etch primed, im now tempted to change the poprivts for rivnuts on the firewall too which isnt a big job at all and would make removing it easier if needed.
Im looking into Group A engine mounts at the moment, continplating making my own as the price people ask for them is outragous! just talking to a couple of people regarding the spec of materials needed to make them.
A strut brace is needed, and im looking at making this from roll cage tub and getting something thats bent back towards the bulkhead and tied in for extra stenght, justr need to measure up.
Also need to take measurements of my sills for the sill stands and then work out how to install them so they are level in the car.
Lots to do, and think about and i have ideas coming into my head all the time.
Looking forward to getting the car looking one colour even if thats just etch primer.
Going to Tinme Attack tomorrow, but hoping to be in the workshop Sun and Monday
CheeRS all
James
Andy, cant thank you enough for your input and time, you spec and info is second to none!!
The cage is big and proberbly a little over engineered, but i hope it will be strong, and im not going out to prove anything or compete so it will be fine for what i want
.................................................. ..
Ok,
Pictures do a fear bit of talking, but i feel a bit of waffle would go a miss
Main aim for the coming weeks is :
To get the inside of the shell cleaned up, cage finished and start Etch priming the inside.
Iv got a few bits to start dry fitting but they can only really happen once i have a bucket seat to mock up and start getting driver and passenger positions, just lacking the funds right now for the bucket seat and bits that go with it.
there is a small amount of work to finish the firewall then that can also be etch primed, im now tempted to change the poprivts for rivnuts on the firewall too which isnt a big job at all and would make removing it easier if needed.
Im looking into Group A engine mounts at the moment, continplating making my own as the price people ask for them is outragous! just talking to a couple of people regarding the spec of materials needed to make them.
A strut brace is needed, and im looking at making this from roll cage tub and getting something thats bent back towards the bulkhead and tied in for extra stenght, justr need to measure up.
Also need to take measurements of my sills for the sill stands and then work out how to install them so they are level in the car.
Lots to do, and think about and i have ideas coming into my head all the time.
Looking forward to getting the car looking one colour even if thats just etch primer.
Going to Tinme Attack tomorrow, but hoping to be in the workshop Sun and Monday
CheeRS all
James
08-05-2012, 10:12 AM
#78
Advanced PassionFord User
Thread Starter
Well................................
Big mile stone for the project, and im very happy!
Two days solid work, prepping and putting those finishing touches into the cage and a couple oof other area's bring the near finish of the cage, now etch primed.
From front of the car
Arty faty side view
New addition to the rear stay cross, nice little box
From thhe rear
Fire wall
Front
More
Bottom of the Firewall all sealed
Got a couple of little bits to tidy up, then prep the floor inside and underneath. also measured up my sill stand mounts just need to order the metal
More soon.
James
Big mile stone for the project, and im very happy!
Two days solid work, prepping and putting those finishing touches into the cage and a couple oof other area's bring the near finish of the cage, now etch primed.
From front of the car
Arty faty side view
New addition to the rear stay cross, nice little box
From thhe rear
Fire wall
Front
More
Bottom of the Firewall all sealed
Got a couple of little bits to tidy up, then prep the floor inside and underneath. also measured up my sill stand mounts just need to order the metal
More soon.
James
