PassionFord - Ford Focus, Escort & RS Forum Discussion
Here I have cut out the turret and folding the new metal going in.
Here I have cut out the turret and folding the new metal going in.
0 2022/05/12 13:04:45
The exhaust will need to go up through the floor, over the cradle and back down through, I have cut off the inlet to the rear silencer here and just tacked it as I need to get the angles right. It will need purging and tig, I think.
The exhaust will need to go up through the floor, over the cradle and back down through, I have cut off the inlet to the rear silencer here and just tacked it as I need to get the angles right. It will need purging and tig, I think.
0 2022/05/12 13:07:45
There are lots of holes in the shell where rear seat belts or speakers would have been, I am playing over these. New plasma will help. All the little screw holes are getting migged and then dressed.
There are lots of holes in the shell where rear seat belts or speakers would have been, I am playing over these. New plasma will help. All the little screw holes are getting migged and then dressed.
0 2022/05/12 13:15:22
0 2022/05/12 13:16:06
0 2022/05/12 13:20:04
Stripping all the under seal, will tidy all this up to make it factory straight again.
Stripping all the under seal, will tidy all this up to make it factory straight again.
0 2022/05/12 13:20:15
I have started to cut a recess in the old metal that was added in the 90’s as the supra diff hits the cross member with the cradle in there. The cross member no longer does anything but I will leave it for some strength.
I have started to cut a recess in the old metal that was added in the 90’s as the supra diff hits the cross member with the cradle in there. The cross member no longer does anything but I will leave it for some strength.
0 2022/05/12 13:20:24
Had a bit of a seat / cage interface issue. The bar would not let the seat go all the way back and the big brace was too close to my head for comfort so I have cut out the bar behind the seat and that brace too. I will add back a brace tight to the hoop and then add in a harness bar at the correct height for the fia allowed safety angle of 15 degrees max.
Had a bit of a seat / cage interface issue. The bar would not let the seat go all the way back and the big brace was too close to my head for comfort so I have cut out the bar behind the seat and that brace too. I will add back a brace tight to the hoop and then add in a harness bar at the correct height for the fia allowed safety angle of 15 degrees max.
0 2022/05/12 13:25:06
0 2022/05/12 13:25:13
This bar stops the seat coming back about 4 inches so I could not straighten my legs in the car. I will probably put in a moving tilton pedal box.
This bar stops the seat coming back about 4 inches so I could not straighten my legs in the car. I will probably put in a moving tilton pedal box.
0 2022/05/12 13:25:19
3d printed notch shape with a toilet roll for extra cad…this will be the replacement brace which is away from where a head could hit.
3d printed notch shape with a toilet roll for extra cad…this will be the replacement brace which is away from where a head could hit.
0 2022/05/12 13:30:00
Bit of an issue on the diff in the cradle.
Bit of an issue on the diff in the cradle.
0 2022/05/12 13:34:18
The adapter hits the tube so the diff doesn’t fit straight.
The adapter hits the tube so the diff doesn’t fit straight.
0 2022/05/12 13:34:25
0 2022/05/12 13:34:34
Bits of the cage gone now. Some more will be going back in.
Bits of the cage gone now. Some more will be going back in.
0 2022/05/12 13:35:55
Diff fits the cradle now that I have notched it with 3mm plate to re-enforce it. You can see the cross member notch to allow the diff to fit as it was hitting the boot floor, 2mm steel will go back in to close the notch, I am not too worried as the cage above ties it all together.
Diff fits the cradle now that I have notched it with 3mm plate to re-enforce it. You can see the cross member notch to allow the diff to fit as it was hitting the boot floor, 2mm steel will go back in to close the notch, I am not too worried as the cage above ties it all together.
0 2022/05/12 13:37:19
Mocked up the front end and had a small issue getting the bonnet to close.
Mocked up the front end and had a small issue getting the bonnet to close.
0 2022/05/12 13:50:07
I have chopped off the new top mounts and re-welded them under the strut top.
I have chopped off the new top mounts and re-welded them under the strut top.
0 2022/05/12 13:50:18
Making up a ring that will add strength to the top mount.
Making up a ring that will add strength to the top mount.
0 2022/05/12 13:50:38
The top mounts that came from Anembo, they really helped me as I needed them for mock up and ordered one day, arrived the next with enough bolts for my bearings too,
The top mounts that came from Anembo, they really helped me as I needed them for mock up and ordered one day, arrived the next with enough bolts for my bearings too,
0 2022/05/12 13:51:06
Welded in the strength plate on top. I have welded from underneath as well so I am confident these won’t come off.
Welded in the strength plate on top. I have welded from underneath as well so I am confident these won’t come off.
0 2022/05/12 13:51:37
Stripped nearly 2 kilos of under seal from this one front wheel arch.
Stripped nearly 2 kilos of under seal from this one front wheel arch.
0 2022/05/12 14:03:51
0 2022/05/12 14:04:04
Found some old patches under the under seal which need doing properly so these will come out tomorrow.
Found some old patches under the under seal which need doing properly so these will come out tomorrow.
0 2022/05/12 14:04:27
If you look at where the new metal meets the old (highlighted) I will need to consider how to finish these. Either with a plate or a seam seal…suspect it needs a plate welding over. I will back fill any cavities with a rust proofer….like a pump in wax as there are quite a lot of bare metal panels on the reverse that you cannot get to.
If you look at where the new metal meets the old (highlighted) I will need to consider how to finish these. Either with a plate or a seam seal…suspect it needs a plate welding over. I will back fill any cavities with a rust proofer….like a pump in wax as there are quite a lot of bare metal panels on the reverse that you cannot get to.
0 2022/05/12 14:08:43
I have started to clean up each area. This seam was flapping around open so needed attaching to the new floor.
I have started to clean up each area. This seam was flapping around open so needed attaching to the new floor.
0 2022/05/13 08:56:46
These circles were put in from above and you can see the welds have penetrated through fine but I wanted to go over from below before I l dress them back and paint over.
These circles were put in from above and you can see the welds have penetrated through fine but I wanted to go over from below before I l dress them back and paint over.
0 2022/05/13 08:57:09
I cut back the overhang as I welded, it isn’t perfect as was hard not to blow through, I will seal over them anyway and it is stronger than it was.
I cut back the overhang as I welded, it isn’t perfect as was hard not to blow through, I will seal over them anyway and it is stronger than it was.
0 2022/05/13 08:57:25
Welds starting to flow better, just need to tighten my technique, these have not been dressed at all, just cleaned with a wire brush.
Welds starting to flow better, just need to tighten my technique, these have not been dressed at all, just cleaned with a wire brush.
0 2022/05/13 08:57:40
Put the drivers side door on to try it.
Put the drivers side door on to try it.
0 2022/05/15 09:19:06
Started mocking up the exhaust going through the boot space. The pipe won’t be pocking out that far, needs another 90. At this point it might go oval.
Started mocking up the exhaust going through the boot space. The pipe won’t be pocking out that far, needs another 90. At this point it might go oval.
0 2022/05/15 09:19:14
Here the exhaust snakes over the cradle. I re-used the old pipe which already had a join in it.
Here the exhaust snakes over the cradle. I re-used the old pipe which already had a join in it.
0 2022/05/15 09:19:20
0 2022/05/15 09:19:27
Tacked a bit of thread in place to hold the pipe whilst I tack it.
Tacked a bit of thread in place to hold the pipe whilst I tack it.
0 2022/05/15 09:19:33
I found a few more welds that have not been completed. These are where the cage passes through the floor and connects to the cradle mounts.
I found a few more welds that have not been completed. These are where the cage passes through the floor and connects to the cradle mounts.
0 2022/05/16 09:51:13
I will need to go round and clean up the metal and then weld the floor to the tubes.
I will need to go round and clean up the metal and then weld the floor to the tubes.
0 2022/05/16 09:51:23
0 2022/05/16 09:51:40
A bit of fun with a bender after work….bit of cad and then mock up.
A bit of fun with a bender after work….bit of cad and then mock up.
0 2022/05/16 09:53:08
The case to create the tunnel over the pipe will contain some anti vibration mounts, vents to the underside and heat proofing. The pipe will either be zircotec coated like the down pipe or just wrapped in heat tape. Insides will be heat proofed too then an air tight lid to stop any fumes coming back in to the car.
The case to create the tunnel over the pipe will contain some anti vibration mounts, vents to the underside and heat proofing. The pipe will either be zircotec coated like the down pipe or just wrapped in heat tape. Insides will be heat proofed too then an air tight lid to stop any fumes coming back in to the car.
0 2022/05/16 09:53:19
The void in the curved end will have an extra exhaust hanger to make sure the pipe doesn’t knock.
The void in the curved end will have an extra exhaust hanger to make sure the pipe doesn’t knock.
0 2022/05/19 09:52:13