small french hatchback

  1. davenport Member

    Messages:
    496
    england, cambs
    well with the overgrowing throngs of "yoofs" taking over car forums with the big speakers and even bigger wheels i find myself browsing more forums like this and less auto based sites.. so what am i up to???

    despite being old enough to know better i`m having a go at putting together a 106 for a few track days and maybe a bit of hill climbing/sprinting..

    i`ve owned the car for a few years and had done a few things.. rollcage/suspension/changed the roofskin as the leaky french sunroof became too much.. converted it to run on yamaha R6 carburettors and it was a giggle on the back roads but during my ownership i`d noticed the dreaded rust appearing here and there so decided to go for broke and attempt to get the ol girl up to a higher standard....

    first up was a spit:

    http://www.mig-welding.co.uk/forum/showthread.php?t=9953

    this should make scraping/welding at awkward angles a bit easier/comfier..

    initial scraping went well and early signs were good...

    [​IMG]

    but then....

    ROT...

    i had an inkling there was something amiss with the drivers side chassis rail and inner arch but after the affected stuff was cut out i realised i had some patching to do!!

    [​IMG]

    first job was to replace the chassis rail as i was getting worried about it giving way on the spit:

    [​IMG]

    after a bit of whacking it was in... then i realised i needed to put the "crumple zone" creases in it... now i`m not sure if this is the correct method but...

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    some heat and some healthy whacks with the ball pein resulted in..

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    next up... the inner wing...

    [​IMG]

    decided to do this in 2 bits...

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    once TIG`d up i was (fairly) happy with the repair......

    [​IMG]
     
  2. davenport Member

    Messages:
    496
    england, cambs
    with them bits done.. i had 1 small hole left..

    [​IMG]

    a wiered shaped compound curvey thing... now i`ve watched chop-cut-rebuild/american hotrod/overhaulin so i`m aware there are all maner of posh shrinking and stretching tools out there.. me??? i had some hammers, old dollies and a bit of wood...

    [​IMG]

    i wont lie...... several pieces of metal were thrown across the workshop but eventually..

    [​IMG]

    we had a winner!!!

    [​IMG]

    [​IMG]



    what did i do then???? ahhh yes!

    next job was the gussety/bracing things under the shell which somewhere along the line some A-hole had decided were a good jacking point resulting in...

    [​IMG]

    1 caved in gusset and 1 rotten rail... actually 2 of each as the other side was the same!!!

    peugot parts were (as usual) half ass`d and could only get the panel for 1 side

    [​IMG]

    so i cut the crap out both sides..

    [​IMG]

    reapired both rails:

    [​IMG]

    and cut the important bit out of the pug panel and sunk that it...

    [​IMG]

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    the other side i ended up having to make my own repair section:

    [​IMG]

    thats about it for the time being...

    currently welding in some pads to weld the seat bars too.. (french tin aint the thickest so welding the tube straight onto the inner sill/tunnel would probably only last till i hit the first pothole..

    [​IMG]

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    will post again once i`ve done a bit more...
     
  3. madkayaker

    madkayaker Pro sparkey Pro Welder

    Messages:
    13,695
    Cumbria
    some good work. Keep the pics comeing
     
  4. andypocock

    andypocock Member

    Messages:
    304
    Langstone
    It's not just me then :clapping:
     
  5. davenport Member

    Messages:
    496
    england, cambs
    right... a little more progress today...

    had this catch tank tacked up for bleedin ages but i can now mark out where the fittings need to be welded on for the aeroquip hoses..

    [​IMG]

    also the 10mm plates arrived from the laser cutters for my inlet manifold jig.. the actual ally flange was cut a while back after i drew it up..

    [​IMG]

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    the top plate is split and will be bolted onto the 2 angled uprights and fingers crossed the spacing will match the gsxr1000 bodies i`m gonna be using..

    i`ve already rolled a section of 1 3/4 tube to form the inlet tracts and once theyre cut down flush with the top of the jig i can finish it off with these a CNC mate of mine turned up fo me..

    [​IMG]

    these taper internally to match the I/D of the tube to the I/D of the throttle bodies...
     
  6. Antsuno2 Member

    nice work, but doesnt look like you used any zinc primer in between your plates, pics 12,13,14, ish Ant!
     
  7. thirdtimeluckyfabricator Member

    Messages:
    8
    lincs
    It will never run you know that dont you!!!!!!!!!
     
  8. davenport Member

    Messages:
    496
    england, cambs
    ive used some UPOL #2 (i think) zinc rich weld thru stuff inside the cavaties and on the underside of the patches but i must admit i think i should have been more heavy handed with it...

    the local paint supplier also had some copper rich weld thru aerosol also by UPOL.. can this be used in the same applications as the zinc stuff??
     
  9. davenport Member

    Messages:
    496
    england, cambs
    lmao- hows "the racer" progress going andy??? :whistle:
     
  10. thirdtimeluckyfabricator Member

    Messages:
    8
    lincs
    Its going fine as you well know!!!!!!!:waving:
     
  11. looks like a good project you have going nice work . what throttle bodies are you going to use
     
  12. Chickenjohn

    Chickenjohn Morris Minor and Porsche 944 fan

    Messages:
    1,284
    Location:
    East Kent
    Nice work! Nice bit of panel work with the gas torch. Did you make the spit yourself? What gauge box section did you use and do you have a design we could look at?? It certainly beats lying on your back under the car getting claustrophobic and having welding sparks get inside your clothing!
     
  13. davenport Member

    Messages:
    496
    england, cambs
    the bodies are from a GSXR1000 K1...: and will be controlled with an emerald M3D ecu...

    which wil be plugged directly into a race technology digital dash display....


    the gas torch shaping was a bit of a long shot i`d never tried it before but figured red hot metal would be more willing to form shapes than cold there are still a few hammer marks in the grooves from the ball pein but there`ll be a thick coat of stone chip on there not to mention paint and that area is fulley covered with an arch liner also

    the spit?? theres a link to the details of it in my first post mate...

    the main end sections are 80x80x8mm wall box section... probably overkill compred to some ive seen but it was lying around at work so that was that decision sorted...
     
    Last edited: Feb 12, 2009
  14. thirdtimeluckyfabricator Member

    Messages:
    8
    lincs
    the main end sections are 80x80x8mm wall box section... probably overkill compred to some ive seen but it was lying around at work so that was that decision sorted...[/QUOTE]

    That wasnt lying around at work i wanted to use that!!!!!!!!;)
     
  15. davenport Member

    Messages:
    496
    england, cambs
    you snooze you looze!!

    done a bit more...

    1st - cheap channel is shite!! got the top sections bolted to the uprights, sat it on the channel and it rocked around like a porn star headboard..

    solution:-

    [​IMG]


    also thanks to "thirdtimelucky" i`m back in possesion of some argon so got the plates fully welded in for my seatbars and 2 of the tubes cut.. they would have been fixed in but i left my digi-level at work and din`t want to risk wonky buckets...

    [​IMG]
     
  16. eltis Member

    Messages:
    49
    Northumberland
    looking v.good to me..... nice welds...
     
  17. thirdtimeluckyfabricator Member

    Messages:
    8
    lincs
    PMSL :laughing:
     
  18. davenport Member

    Messages:
    496
    england, cambs
    lunch breaks = progress...

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  19. davenport Member

    Messages:
    496
    england, cambs
    [​IMG]

    seat bars are in (god bless the digilevel!!) just waiting on the tabs from the laser cutters..

    also blobbed up the old holes where the previous cage was bolted in.. all i can say is galvanised cars are horrible and on several occasions there was a "pop" resulting in my tungsten resembling a golf club...

    a couple more jobs to do then its orf for blasting and i can attempt to fit the new cage which (providing i dont eff it up) should resemble.....

    [​IMG]
     
    liammcl likes this.
  20. jazzbob Member

    Messages:
    24
    UK - Southampton
    looking really nice! - if you haven't already (I skimmed through a few pics) then I highly recommend properly seaming the boot to "arch" seam... as this failed spectacularly on mine during a recent road rally. The fabrication looks far better than my meager efforts could produce, and that cage is pretty ott for a few track days :D

    Random question, why did you choose to weld the plates for the seat rails in first, as opposed to tacking the rails to the plates first which allows you to seam the rails and plates outside of the car before seaming the plates to the chassis (I just figure that its easier to get good torch position my way... not that it looks like you had any trouble!)
     
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