WRC cosworth Tarmac track car
#41
10K+ Poster!!
Great job and what an improvement! The welds look great...makes me want to get on and buy a TIG as well. Thanks for sharing
#43
I'm Finding My Feet Here Now
Thread Starter
Few more shots as I quickly realised I have to do alot of the gusset and bracing work before moving on.
And had a go finally with my dimple dies, great investment and will save me a fortune by the time I'm finished.
And had a go finally with my dimple dies, great investment and will save me a fortune by the time I'm finished.
#44
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How do you find the tig upside down? Or do you turn it over on a spit
#45
I'm Finding My Feet Here Now
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@Caddyshack I'd really not fancy it upside-down, I've been taught that you always tig uphill, if I didn't have the spit it would be a nightmare so yeah I'm turning it as I need to get at the weld as best as possible, I'd say the biggest problem I have is that I'm improving with every weld and after a week I'm looking back on the week before's work and wishing I could do it again lol.
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Caddyshack (25-03-2017)
#47
10K+ Poster!!
Nice work, are they steel or ally?
#48
I'm Finding My Feet Here Now
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@Caddyshack, everything is steel, the cage is T45 thin wall tubes, the gussets I've matched the 18 gauge steel that Custom Cages gussets are made in, you don't want it too thin as it is easy to burn through when the metals are to different in thickness. Going to need 3 gussets for each door cross and 4 for the rear cross and 4 for the front cross, these are actually pretty easy to make, simply bend round a steel bar by hand, came out really well, just another 13 to do lol
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Caddyshack (25-03-2017)
#49
Advanced PassionFord User
@Caddyshack I'd really not fancy it upside-down, I've been taught that you always tig uphill, if I didn't have the spit it would be a nightmare so yeah I'm turning it as I need to get at the weld as best as possible, I'd say the biggest problem I have is that I'm improving with every weld and after a week I'm looking back on the week before's work and wishing I could do it again lol.
#50
I'm Finding My Feet Here Now
Thread Starter
@Jonfoc as a rule no, there's 2 options you can "dry wash" the weld which is generally considered bad practice and only done if really needed, basically running the torch over to make it prettier without filler, or you can run over it and put a cap on the weld with more filler which just makes the weld bigger and adds heat that shouldn't be needed, best to get it right first time.
to be honest I've only had 2 beads I wasn't happy with and I've sorted them accordingly, I more meant that I can make an even nicer weld as I've welded more, not so much the old welds where bad, just not as pretty to look at, and I went through about 4 metres of tube before I even touched the cage, wasn't about to destroy nearly 2k of tubes
Made lots of these test pieces, considering tube has to be about the hardest thing to learn on but really satisfying when it finally came together
to be honest I've only had 2 beads I wasn't happy with and I've sorted them accordingly, I more meant that I can make an even nicer weld as I've welded more, not so much the old welds where bad, just not as pretty to look at, and I went through about 4 metres of tube before I even touched the cage, wasn't about to destroy nearly 2k of tubes
Made lots of these test pieces, considering tube has to be about the hardest thing to learn on but really satisfying when it finally came together
#51
Advanced PassionFord User
Yeah I had a message from a very very good welder and he said anymore heat would make it brittle and ruin it. If it's just aesthetics I'm sure you can live with that.
#52
Advanced PassionFord User
Nothing wrong with that welding , by the time it's had a coat of primer and paint you won't even see the weld. It's very had welding tube especially a roll cage .
Keep up the great work looking forward to more updates
Cheers paul
Keep up the great work looking forward to more updates
Cheers paul
#54
10K+ Poster!!
Great welding that! Car look like its going to be a monster when done.
#55
Advanced PassionFord User
#56
I'm Finding My Feet Here Now
Thread Starter
As Zetaboostboy says it's mainly to add even more structural support, they're pretty much standard fitment on any rally car. Usually cost an arm and a leg so I bought the dies instead, even made a sheet metal roller today to roll the metal into shape.
Anyway the next step I was really not looking forward too which is fitting the first 4 of the 6 firewall tubes, for anyone else thinking about it you basically need to cut 4 big holes in the firewall so that once the cage is tacked together you can ratchet strap it closer so you can do the reverse sides, it city ally went really well, alot better than I thought it would, had to remake both horizontal bars though as the ones Custom Cages sent had been trimmed wrong on the ends.
Anyway the next step I was really not looking forward too which is fitting the first 4 of the 6 firewall tubes, for anyone else thinking about it you basically need to cut 4 big holes in the firewall so that once the cage is tacked together you can ratchet strap it closer so you can do the reverse sides, it city ally went really well, alot better than I thought it would, had to remake both horizontal bars though as the ones Custom Cages sent had been trimmed wrong on the ends.
#58
I'm Finding My Feet Here Now
Thread Starter
Well finished these braces, welding them on the door side only for now so the cage can be located in its final place.
shame noone will ever see that bit lol, that meant that after alot of double checking and using a mirror to check all the joints where complete and I haven't forgotten anything the cage can be located on 8 out of ten hard points and tacked into its final position, just really hope I haven't forgotten anything
Got the front and rear cross members to do tonight so update later
shame noone will ever see that bit lol, that meant that after alot of double checking and using a mirror to check all the joints where complete and I haven't forgotten anything the cage can be located on 8 out of ten hard points and tacked into its final position, just really hope I haven't forgotten anything
Got the front and rear cross members to do tonight so update later
Last edited by reese646; 29-03-2017 at 06:46 PM.
#59
I'm Finding My Feet Here Now
Thread Starter
Finished tacking most of the cage together now, cut the firewall using a plasma cutter, made a cross cut either side then lots of test fitting till I was happy with it on the front cross member.
showing the cuts made, these flaps will be beaten back down onto the tube and welded shut.
Then tacked the rear cross and seat belt tubes, but wasn't happy with the drivers tube so I'm going to redo that one but it's coming together now.
showing the cuts made, these flaps will be beaten back down onto the tube and welded shut.
Then tacked the rear cross and seat belt tubes, but wasn't happy with the drivers tube so I'm going to redo that one but it's coming together now.
#60
Advanced PassionFord User
Stunning work, and a very nice project.
#61
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looks like you are having fun with the tig,you are doing a great job,its coming along now,will be a very nice car,keep up the good work,its a credit to you and your hard work
#63
I'm Finding My Feet Here Now
Thread Starter
Update again, the bulk of the cage is done, finished the door and rear cross gussets and mig welder the cage completely tithe shell, still missing the rear cradle support tubes but thanks to Ian Sibert providing some top info on the rear cradle that will be done asap, front gussets and a few others to do, then sill stand tube, seat runner bar...the list is endless lol
#65
I'm Finding My Feet Here Now
Thread Starter
Lol yeah David few more metal work bits left yet, then try to figure out how I'm gonna shoe horn the engine in, then I think works gonna take priority for a few month unfortunetly
Been looking at the radiator situation as well, its going in the back the same as yours but I think I'm going to go for the later design with the window scoops exiting through the floor as I don't think my carbon skills are quite up to yours .
Been looking at the radiator situation as well, its going in the back the same as yours but I think I'm going to go for the later design with the window scoops exiting through the floor as I don't think my carbon skills are quite up to yours .
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cossiedevil (29-04-2017)
#66
Advanced PassionFord User
Reese I have some top mounts here that may help you out they have been machined wrong but will out your bearings in the right place on the front....
Dewitts just sent them me I was about the send them back when I checked and it'll match yours as the bearing section has been machine wrong side...
If you're interested you can have them for what they cost me.... My numbers 07764499867 if u want a pic as I don't come on here much
Dewitts just sent them me I was about the send them back when I checked and it'll match yours as the bearing section has been machine wrong side...
If you're interested you can have them for what they cost me.... My numbers 07764499867 if u want a pic as I don't come on here much
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reese646 (28-04-2017)
#68
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@Jonfoc as a rule no, there's 2 options you can "dry wash" the weld which is generally considered bad practice and only done if really needed, basically running the torch over to make it prettier without filler, or you can run over it and put a cap on the weld with more filler which just makes the weld bigger and adds heat that shouldn't be needed, best to get it right first time.
to be honest I've only had 2 beads I wasn't happy with and I've sorted them accordingly, I more meant that I can make an even nicer weld as I've welded more, not so much the old welds where bad, just not as pretty to look at, and I went through about 4 metres of tube before I even touched the cage, wasn't about to destroy nearly 2k of tubes
Made lots of these test pieces, considering tube has to be about the hardest thing to learn on but really satisfying when it finally came together
to be honest I've only had 2 beads I wasn't happy with and I've sorted them accordingly, I more meant that I can make an even nicer weld as I've welded more, not so much the old welds where bad, just not as pretty to look at, and I went through about 4 metres of tube before I even touched the cage, wasn't about to destroy nearly 2k of tubes
Made lots of these test pieces, considering tube has to be about the hardest thing to learn on but really satisfying when it finally came together
#69
Too many posts.. I need a life!!
Lol yeah David few more metal work bits left yet, then try to figure out how I'm gonna shoe horn the engine in, then I think works gonna take priority for a few month unfortunetly
Been looking at the radiator situation as well, its going in the back the same as yours but I think I'm going to go for the later design with the window scoops exiting through the floor as I don't think my carbon skills are quite up to yours .
Been looking at the radiator situation as well, its going in the back the same as yours but I think I'm going to go for the later design with the window scoops exiting through the floor as I don't think my carbon skills are quite up to yours .
Yes the radiator in the rear is a good setup but make sure you work it out well Alan as it takes up a nice bit of room and the pipe work as well. I have my pipes all running up the passenger side pic below.
Last edited by cossiedevil; 29-04-2017 at 04:37 PM.
#70
I'm Finding My Feet Here Now
Thread Starter
There a lot involved in getting these to wrc spec and more so if your a one man show as well .your moving along well for sure Alan.
Yes the radiator in the rear is a good setup but make sure you work it out well Alan as it takes up a nice bit of room and the pipe work as well. I have my pipes all running up the passenger side pic below.
Yes the radiator in the rear is a good setup but make sure you work it out well Alan as it takes up a nice bit of room and the pipe work as well. I have my pipes all running up the passenger side pic below.
hopefully get back on it next week needed a bit of time off. Cheers for the kind words lads
#72
10K+ Poster!!
Is the benefit of having rad in boot for weight distribution or allowing the intercooler all the room in the front / keeping heat out of bay?
#73
Too many posts.. I need a life!!
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