My S13 Project Restoration and speedyisation

[Bumblebee]

Thought it was about time I Started a project thread

This is my first Nissan! And I’m giving it the same treatment as all the other Gal’s… ahem I mean cars I’ve worked on that are 16 years old and Japanese :P

Bought back in Feb from another SXOC member, you may reconize her ;)
http://photos-f.ak.fbcdn.net/photos-ak-sf2p/v192/98/117/519105700/n519105700_1109093_2863.jpg

http://photos-e.ak.fbcdn.net/photos-ak-sf2p/v192/98/117/519105700/n519105700_1109092_2510.jpg

So I thought I better start stripping her/ it down to see what I would need to patch up!
Can anyone see the mounts for a tow bar there ;)
http://photos-e.ak.fbcdn.net/photos-ak-sf2p/v234/98/117/519105700/n519105700_1125652_5394.jpg

Interior stripped
http://photos-e.ak.fbcdn.net/photos-ak-sf2p/v192/98/117/519105700/n519105700_1109116_4244.jpg

http://photos-d.ak.fbcdn.net/photos-ak-sf2p/v192/98/117/519105700/n519105700_1109115_3939.jpg

Fuel tank removed, will need to sort out new tank straps
Spot part of the towbar brace.
http://photos-g.ak.fbcdn.net/photos-ak-sf2p/v192/98/117/519105700/n519105700_1109094_3152.jpg

http://photos-h.ak.fbcdn.net/photos-ak-sf2p/v192/98/117/519105700/n519105700_1109095_3445.jpg

Now time for some rust killing and OMG! Really shocked to see the lack of underseal on these things!!
http://photos-f.ak.fbcdn.net/photos-ak-sf2p/v234/98/117/519105700/n519105700_1125653_5681.jpg

http://photos-g.ak.fbcdn.net/photos-ak-sf2p/v234/98/117/519105700/n519105700_1125654_5990.jpg

Started to cut out some rot and wire wheel back the rust but there are loads of it for a wire wheel and a drill
http://photos-a.ak.fbcdn.net/photos-ak-sf2p/v234/98/117/519105700/n519105700_1125656_6591.jpg

http://photos-c.ak.fbcdn.net/photos-ak-sf2p/v234/98/117/519105700/n519105700_1125658_7208.jpg

http://photos-h.ak.fbcdn.net/photos-ak-sf2p/v234/98/117/519105700/n519105700_1125663_8807.jpg

[Bumblebee]

So there lots of rust….. so in comes some toys to sort that out
Sand blaster, wire wheels, compressor, stonechip gun and stonechip, etch primer etc
http://photos-f.ak.fbcdn.net/photos-ak-sf2p/v192/98/117/519105700/n519105700_1107373_1126.jpg

Now I thought it would be time to get it in my garage… well, excuse for a garage anyway :P
http://photos-g.ak.fbcdn.net/photos-ak-sf2p/v234/98/117/519105700/n519105700_1146478_6673.jpg

Time to remove the Subframe assy for some tidying up
http://photos-h.ak.fbcdn.net/photos-ak-sf2p/v234/98/117/519105700/n519105700_1146479_7024.jpg

http://photos-c.ak.fbcdn.net/photos-ak-sf2p/v234/98/117/519105700/n519105700_1155106_321.jpg

http://photos-d.ak.fbcdn.net/photos-ak-sf2p/v234/98/117/519105700/n519105700_1155107_695.jpg

http://photos-e.ak.fbcdn.net/photos-ak-sf2p/v234/98/117/519105700/n519105700_1155108_1088.jpg

http://photos-f.ak.fbcdn.net/photos-ak-sf2p/v234/98/117/519105700/n519105700_1155109_1431.jpg

http://photos-g.ak.fbcdn.net/photos-ak-sf2p/v234/98/117/519105700/n519105700_1155110_1780.jpg

http://photos-a.ak.fbcdn.net/photos-ak-sf2p/v234/98/117/519105700/n519105700_1155112_2558.jpg

http://photos-h.ak.fbcdn.net/photos-ak-sf2p/v234/98/117/519105700/n519105700_1155119_5196.jpg

[Bumblebee]

Started to remove the Subframe bushes and get on with some rust killing
http://photos-d.ak.fbcdn.net/photos-ak-sf2p/v234/98/117/519105700/n519105700_1177739_8679.jpg

http://photos-e.ak.fbcdn.net/photos-ak-sf2p/v234/98/117/519105700/n519105700_1177740_9048.jpg

http://photos-f.ak.fbcdn.net/photos-ak-sf2p/v234/98/117/519105700/n519105700_1177741_9405.jpg

You can see where the rust has eaten into the metal
http://photos-f.ak.fbcdn.net/photos-ak-sf2p/v234/98/117/519105700/n519105700_1177749_1669.jpg

http://photos-g.ak.fbcdn.net/photos-ak-sf2p/v234/98/117/519105700/n519105700_1177750_2028.jpg

http://photos-h.ak.fbcdn.net/photos-ak-sf2p/v234/98/117/519105700/n519105700_1177751_2365.jpg

http://photos-a.ak.fbcdn.net/photos-ak-sf2p/v234/98/117/519105700/n519105700_1177752_2718.jpg

http://photos-d.ak.fbcdn.net/photos-ak-sf2p/v251/98/117/519105700/n519105700_1243227_647.jpg

http://photos-e.ak.fbcdn.net/photos-ak-sf2p/v251/98/117/519105700/n519105700_1243228_923.jpg

http://photos-f.ak.fbcdn.net/photos-ak-sf2p/v251/98/117/519105700/n519105700_1243229_1193.jpg

http://photos-g.ak.fbcdn.net/photos-ak-sf2p/v251/98/117/519105700/n519105700_1243230_1473.jpg

http://photos-a.ak.fbcdn.net/photos-ak-sf2p/v251/98/117/519105700/n519105700_1243232_2037.jpg

[Bumblebee]

I HATE these bushes, they won’t fit in my press 
http://photos-f.ak.fbcdn.net/photos-ak-sf2p/v297/98/117/519105700/n519105700_1521949_5423.jpg
http://photos-g.ak.fbcdn.net/photos-ak-sf2p/v297/98/117/519105700/n519105700_1521950_5768.jpg
New polly subframe bushes
http://photos-h.ak.fbcdn.net/photos-ak-sf2p/v307/98/117/519105700/n519105700_1597807_1513.jpg

All the rest of the arms and stuff all painted up and polly bushed including the spindles 
http://photos-g.ak.fbcdn.net/photos-ak-snc1/v264/98/117/519105700/n519105700_1612646_6707.jpg

Front Primera ball joint in the rear lower control arm 
http://photos-e.ak.fbcdn.net/photos-ak-snc1/v315/98/117/519105700/n519105700_1635940_7686.jpg

Now the rear Subframe assy is all sorted I thought I’d get to work on the chassis
Time to make a sequel to the beach lol
http://photos-d.ll.facebook.com/photos-ll-sf2p/v251/98/117/519105700/n519105700_1210219_8248.jpg
http://photos-e.ll.facebook.com/photos-ll-sf2p/v251/98/117/519105700/n519105700_1210220_8617.jpg

Etch primed
http://photos-h.ak.fbcdn.net/photos-ak-sf2p/v251/98/117/519105700/n519105700_1227183_7477.jpg
http://photos-a.ak.fbcdn.net/photos-ak-sf2p/v251/98/117/519105700/n519105700_1227184_7844.jpg

Stone chipped
http://photos-b.ak.fbcdn.net/photos-ak-sf2p/v251/98/117/519105700/n519105700_1227185_8194.jpg
http://photos-c.ak.fbcdn.net/photos-ak-sf2p/v251/98/117/519105700/n519105700_1227186_8553.jpg
http://photos-f.ak.fbcdn.net/photos-ak-sf2p/v251/98/117/519105700/n519105700_1227205_7242.jpg

[Bumblebee]

Subframe installed
http://photos-g.ak.fbcdn.net/photos-ak-sf2p/v307/98/117/519105700/n519105700_1597726_2956.jpg

http://photos-h.ak.fbcdn.net/photos-ak-sf2p/v307/98/117/519105700/n519105700_1597727_777.jpg

http://photos-h.ak.fbcdn.net/photos-ak-sf2p/v307/98/117/519105700/n519105700_1597903_8860.jpg

All was going well while I was putting the diff on but then the garage fell on its side!
http://photos-e.ak.fbcdn.net/photos-ak-snc1/v315/98/117/519105700/n519105700_1645652_5137.jpg

Old tank straps..
http://photos-d.ak.fbcdn.net/photos-ak-sf2p/v332/98/117/519105700/n519105700_1850835_4698.jpg

New tank straps at the total cost of about a tenner
http://photos-h.ak.fbcdn.net/photos-ak-sf2p/v332/98/117/519105700/n519105700_1850839_6290.jpg

http://photos-a.ak.fbcdn.net/photos-ak-sf2p/v332/98/117/519105700/n519105700_1850840_6682.jpg

http://photos-f.ak.fbcdn.net/photos-ak-sf2p/v332/98/117/519105700/n519105700_1850837_5496.jpg

http://photos-g.ak.fbcdn.net/photos-ak-sf2p/v332/98/117/519105700/n519105700_1850838_5897.jpg

http://photos-b.ak.fbcdn.net/photos-ak-sf2p/v332/98/117/519105700/n519105700_1850841_7082.jpg

Ive got more pics at home of the rest of the build so far so will add them in a bit.

Hope you all enjoy

There will be some fun stuff coming up next like shiney stuff and go faster bits up the nose end , just have to grab the pics off my laptop so stay tuned

[Chriscooke]

Thats some top class work mate:thumbs: I'd love to have the same done to mine, will be watching with interest:nod:

[CH1EF]

hey, CH1EF from the CRX forum here :D

looks like its going to be another top bit of building like your last crx...should be interesting to watch!

[Bumblebee]

Hey Chief!! how you doing?

yeah should be cool :) I thought it was about time I tried something different!

should be on the road soon dependant on time and funds etc.. Im getting the bits i need as i go along so im not sure how much its going to end up costing lol, Just hope the CA lasts a while, not sure what state its in at the mo because i haven't started it yet :smash:

[Davey3legs]

Nice to see attention to detail, really satisfying seeing the before and after pics. :cool: :thumbs:

Carry on. :)

[dread]

Good to see another one being restored :)

Good luck with it mate, looks like your doing all the right things :thumbs:

[Bumblebee]

Good to see another one being restored :)

Good luck with it mate, looks like your doing all the right things :thumbs:

Cheers mate,
I think i am lol its my 3rd build so i'll do the best i can with the time and money ive got :smash:

[nitrodave]

looks good mate, what else have you got planned for it?

[Ian200sx]

Your nuts, :thumbs:

[Bumblebee]

looks good mate, what else have you got planned for it?

Well at the moment its just being restored so that its a good clean blank canvass for my future plans, but as it stands i have the following to go on straight away

S14a T28
Braided feeds
Apexi filter and hardpipe trunk kit
FMIC
3" exhaust
Full polly bushes
Hispec monster4 calipers with 310mm floaters
DW braided lines
DW solid rack bush
ABS removed and all brake lines re-piped


To be done,
Walbro pump
Boost controler and guage
Oil temp + press guages
HD Stage2 chip (that will later be custom tweaked later)
ARB's
Adjustable arms,
Coilovers,
welded diff,
Full Uras kit (got it just need to fit)
Full re-spray
Advan SAR3's (got them just need new rubber)
JUN Arches with 25mm spacers front and 30mm spacers rear.
Corbeau sprint seat (got)
Nardi classic wheel (at some point)

Few other little toys but thats it for the moment :smitten:

[Bumblebee]

Your nuts, :thumbs:

thats the most beautiful thing anyone has ever said to me :D

[keggy]

how well does the sand blaster work mate?

[Bumblebee]

the sand blaster is ok aslong as you make sure the sand is really dry!

Being a Syphon blaster after prolonged use you have to keep blowing the feed out by putting your finger over the end and blowing any clogged damp sand in the breach.

This happens because compressors get alot of moisture in the airline after time and it accumulates in the breach clogging it... an in line filter would help though.

Make sure you have at least a 50ltr 3 hp compressor though otherwise you have to keep waiting for it to re-pressurise every 20 seconds.

I Just use kiln dried sand from B&Q works a treat :O)

[nitrodave]

sounds like you'll be busy for a while! wish i had time to continue with my s13. lost faith when the big ends went for the second time... and now my s14 has fecked up distracting my time and money away from the s13! seeing this thread has got me worked up to get it sorted though :)

look forward to seeing more progress matey

[Bumblebee]

Cheers mate, as I said alot more has been done to it than is shown above... just got to get the pics :thumbs:

im having a mare with a broken turbo to elbow stud at the moment and another couple of broken bolts holding the front caster rod brackets to the chassis.

but i can weld so if i get stuck i'll just mig it lol

[gonzomagic]

Super work, keeping an eye on this

[kingj]

wow,good thread mate,some class work your doing there:thumbs:

[Lou_Lou]

I cannot wait til this is done and we can go out driving again!!! :D

My s14 needs a driving companion!! :cool:

When can I start helping with the painting?? :D

[eddie_s13]

oi poo head is my car not good enough driving companion! But al serious dude finish the fricking car

[Lou_Lou]

oi poo head is my car not good enough driving companion! But al serious dude finish the fricking car

Erm..... oopsy.. hehehe

Ummm.. what it is Ed.. right.. is that your 14 is basically faaar superior to mine. Therefore would make mine look like utter crap, and I'd pretty much be that embarrassed that I'd never be able to leave the house again.. people would probably throw stones at me in the street :(

[Bumblebee]

Im seriously trying hard to finish the car real quick but at the end of the day it will never be as good as your car Ed.

I mean i think its harsh for you to rush me on this knowing that its going to suck in comparison to your grandad Clad S14!

lou hun no worries my sht box will be around for us to roll in real soon;)

[shaun_s13]

looking good mate keep it up

[Bumblebee]

Not much of an update unfortunatly due to weather, lack of light and time but here is a piccy of

The T28 im going to use on the left
http://photos-c.ll.facebook.com/photos-ll-snc1/v1174/98/117/519105700/n519105700_2224330_3147.jpg

And the FMIC i got from Jperformance
http://photos-d.ll.facebook.com/photos-ll-snc1/v1174/98/117/519105700/n519105700_2224331_4139.jpg

more to come this weekend hopefully

[xborninthefight]

Great work your doing there. Man thats a small garage, keep it up mate.:thumbs:

[Bumblebee]

Cheers mate, yeah its not the best circumstances i have for a full restoration but i like a challenge :)
http://photos-f.ak.fbcdn.net/photos-ak-snc1/v1763/98/117/519105700/n519105700_2256445_6593.jpg

FIT!!!!

[trancnd]

wow they look great where you get those from for such a great price :) project is looking good fella :thumbs:

[Bumblebee]

wow they look great where you get those from for such a great price :) project is looking good fella :thumbs:


He he he I got them from some dodgy bloke in cheshire:D lol:wave:

Cheers budy, its taking its time but should be awesome when its done

[Lou_Lou]

He he he I got them from some dodgy bloke in cheshire:D lol:wave:

Cheers budy, its taking its time but should be awesome when its done

Yeah man! He was proper weird!! lol :p

When do I get to paint damn it!!

[Bumblebee]

Yeah man! He was proper weird!! lol :p

When do I get to paint damn it!!

What colour do you want to paint it first?

then i'll decide if i trust you with my gun..... :D

[Bumblebee]

Right, Been a while I know but I’ve arguably had a lot to deal with over the last few months......

Not a lot has changed to be fair apart from the car being in a location that I can work on it as and when, I’ve managed to afford to buy some essentials like fuel pump and some sundries etc and I’ve dismantled the front end for restoration and engine re-build.
I can’t afford to up-rate any of the internals unfortunately so I’m praying that the pistons, rods and crank are in good order to re-use... I’d ideally like to replace the oil pump for a new one but we will see how it looks after close inspection.
Out comes the engine

http://photos-g.ak.fbcdn.net/photos-ak-snc1/v2713/98/117/519105700/n519105700_2911838_912760.jpg

On the stand it goes
http://photos-b.ak.fbcdn.net/photos-ak-snc1/v2677/98/117/519105700/n519105700_2898073_6560356.jpg

Off with the head, Look how much carbon crap is in the bores :O
http://photos-h.ll.facebook.com/photos-ll-snc1/v2713/98/117/519105700/n519105700_2914351_2170544.jpg

Turned it upside down to empty out the carbon crap and peeled the HG off.
http://photos-b.ll.facebook.com/photos-ll-snc1/v2713/98/117/519105700/n519105700_2914353_7829973.jpg

Cylinder head, I took the cams out before the head came off due to not being able to reach the headbolts with the tool that I had. I removed the retaining caps in four stages following the correct procedure in the manual and all was fine until I i went to lift the intake cam out and it was quite stiff!! It “popped” out with a bit of persuasion but does this mean the cam is bent :S
http://photos-a.ll.facebook.com/photos-ll-snc1/v2713/98/117/519105700/n519105700_2914352_4845399.jpg

Cam retaining caps in order as per the service manual removal and install order, can see slight amounts of wear or staining on them but I haven’t given them a proper clean yet.
http://photos-b.ll.facebook.com/photos-ll-snc1/v2713/98/117/519105700/n519105700_2914369_3474882.jpg

Camshafts, again, look a little worn......
http://photos-c.ll.facebook.com/photos-ll-snc1/v2713/98/117/519105700/n519105700_2914370_1138796.jpg

thats it for now, Ive since got all the front suspension/brakes/steering rack/Xmember etc etc off for restoration but i'll get picks of those in a bit.

[Jeffers_S13]

Be very careful when using sand for blasting stuff !

http://www.silicosis-injury-attorneys.com/pages/sandblasting_risks.html

[Bumblebee]

Thats interesting! I use a painters Mask when i'm sandblasting.. so hopefully i'm protected enough ;)

[Bumblebee]

Right, Engine and box is out as you know, ive been stripping the seam sealer back to remove rust and to weld it up...

http://photos-d.ll.facebook.com/photos-ll-snc1/v2749/98/117/519105700/n519105700_2944523_2492941.jpg
http://photos-e.ll.facebook.com/photos-ll-snc1/v2749/98/117/519105700/n519105700_2944524_4408278.jpg

nice hole where there was some rot that i cut out
http://photos-f.ll.facebook.com/photos-ll-snc1/v2749/98/117/519105700/n519105700_2944525_3161554.jpg

seam welded around the suspension turrents and chassis legs.
http://photos-g.ll.facebook.com/photos-ll-snc1/v2749/98/117/519105700/n519105700_2944526_7757362.jpg

seam sealer removed ready for welding
http://photos-h.ll.facebook.com/photos-ll-snc1/v2749/98/117/519105700/n519105700_2944527_5002738.jpg

welded up
http://photos-a.ll.facebook.com/photos-ll-snc1/v2749/98/117/519105700/n519105700_2944528_5441148.jpg

Other side welded up
http://photos-b.ll.facebook.com/photos-ll-snc1/v2749/98/117/519105700/n519105700_2944529_8289170.jpg

got a spare engine aswell that i will upload pics of :)

hopefully i'll get all the welds done, polished out, and the bay painted this week but the weather is not looking too primising :(

[Bumblebee]

Well last night i managed to weld up the GAPING hole i cut out from the chassis leg and suspension turret

nothing majorly exciting but i was proud that i got it all done start to finish before it got too dark and rained :)

http://photos-d.ak.fbcdn.net/photos-ak-snc1/v2749/98/117/519105700/n519105700_2949515_7230345.jpg

http://photos-e.ak.fbcdn.net/photos-ak-snc1/v2749/98/117/519105700/n519105700_2949516_3371393.jpg

http://photos-f.ak.fbcdn.net/photos-ak-snc1/v2749/98/117/519105700/n519105700_2949517_2333398.jpg

http://photos-g.ak.fbcdn.net/photos-ak-snc1/v2749/98/117/519105700/n519105700_2949518_5529213.jpg

Ive welded it round the other side too where the chassis leg meets it and all around the turret but it got too dark to take any decent photos.

[eloise]

what is the spec of the compressor ur using for blasting pal?

[Bumblebee]

what is the spec of the compressor ur using for blasting pal?

its a 3hp 50ltr compressor and it just about does the job on a syphon blaster. (Syphon blasters use ALOT of airflow).

[eloise]

guess my 2hp one got no chance then. you managing to spray ok with yours?

[Bumblebee]

yeah no worries with spraying.

the compressor kicks in after a while but keeps a steady pressure at the gun :)

[Bumblebee]

Engine bay completely stripped and Sprayed up after seam welding. Not the prettiest paint jobs in the world (rattle canned gloss black) but its functional and all i could be arsed to do at the moment lol. Looks ok I think :)
http://photos-a.ak.fbcdn.net/hphotos-ak-snc1/hs034.snc1/3254_88439045700_519105700_3005848_5439401_n.jpg

Front crossmember ready for the wire wheel on the drill and some painting
http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs034.snc1/3254_88439155700_519105700_3005849_8297364_n.jpg

All powersteering components back to gether and sprayed up. Going for the black and gold theme in the bay.
http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs034.snc1/3254_88439160700_519105700_3005850_2942171_n.jpg
http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs034.snc1/3254_88439195700_519105700_3005851_4177105_n.jpg

thats it for now

[Dave270r]

Looking good dude, I didn't know you had a project thread. I also thought your S13 was imaginary :wack:

[Bumblebee]

Looking good dude, I didn't know you had a project thread. I also thought your S13 was imaginary :wack:

LOL It may aswell have been imaginary but hopefully it will be out to play for the first time pretty soon in the year and a bit that ive owned it LOL

[Bumblebee]

http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs010.snc1/4185_99818680700_519105700_3192754_8099872_n.jpg
http://photos-f.ak.fbcdn.net/hphotos-ak-snc1/hs010.snc1/4185_99818695700_519105700_3192757_7468910_n.jpg

Brake line setup from removed abs
http://photos-g.ak.fbcdn.net/hphotos-ak-snc1/hs010.snc1/4185_99818700700_519105700_3192758_2362563_n.jpg

Home Brew intercooler brackets
http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs010.snc1/4185_99818705700_519105700_3192759_2902995_n.jpg

Bare metal revealed to weld them to
http://photos-a.ak.fbcdn.net/hphotos-ak-snc1/hs010.snc1/4185_99818710700_519105700_3192760_4290776_n.jpg
http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs010.snc1/4185_99818720700_519105700_3192761_392240_n.jpg

Left welded on
http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs010.snc1/4185_99818725700_519105700_3192762_747157_n.jpg
Right welded on
http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs010.snc1/4185_99818735700_519105700_3192763_4815750_n.jpg

Intercooler fitted
http://photos-e.ak.fbcdn.net/hphotos-ak-snc1/hs010.snc1/4185_99818740700_519105700_3192764_7004956_n.jpg
http://photos-f.ak.fbcdn.net/hphotos-ak-snc1/hs010.snc1/4185_99818745700_519105700_3192765_5441042_n.jpg

Cut loads of rust out and made a plate out of my old crx bonnet leaving a hole for the left intercooler pipe
http://photos-g.ak.fbcdn.net/hphotos-ak-snc1/hs010.snc1/4185_99818760700_519105700_3192766_8172001_n.jpg
http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs010.snc1/4185_99818765700_519105700_3192767_3860887_n.jpg

Quick coat of paint just to stop it rusting while I do some other bits and bobs, engine bay will be cleaned again and bits like this sprayed up propper ;)

http://photos-a.ak.fbcdn.net/hphotos-ak-snc1/hs010.snc1/4185_99818770700_519105700_3192768_7618596_n.jpg

[Bumblebee]

Update,

Dash out to mount guage pod mounts
http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs107.snc1/4612_104797720700_519105700_3280627_5144944_n.jpg

Holes drilled for the looms and boost pipe
http://photos-e.ak.fbcdn.net/hphotos-ak-snc1/hs087.snc1/4612_104797725700_519105700_3280628_840140_n.jpg

All wires properly souldered and heat shrunk
http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs107.snc1/4612_104797715700_519105700_3280626_4632312_n.jpg
http://photos-f.ak.fbcdn.net/hphotos-ak-snc1/hs087.snc1/4612_104797730700_519105700_3280629_5154267_n.jpg

Spaghetti junction :) All wires were grouped together (power, earth, sender etc) for tidyness and wired in parallel.
http://photos-g.ak.fbcdn.net/hphotos-ak-snc1/hs107.snc1/4612_104797735700_519105700_3280630_2299732_n.jpg

The end result!
http://photos-f.ak.fbcdn.net/hphotos-ak-snc1/hs087.snc1/4612_104796760700_519105700_3280621_1293504_n.jpg
http://photos-g.ak.fbcdn.net/hphotos-ak-snc1/hs087.snc1/4612_104796765700_519105700_3280622_468817_n.jpg

New Sill fabrication next. I cut the old ones out completely and welded in new 2mm thick steel :D
http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs192.snc1/6455_133608965700_519105700_3810546_5356758_n.jpg
http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs192.snc1/6455_133608975700_519105700_3810547_440220_n.jpg
http://photos-e.ak.fbcdn.net/hphotos-ak-snc1/hs172.snc1/6455_133608990700_519105700_3810548_6384605_n.jpg
http://photos-f.ak.fbcdn.net/hphotos-ak-snc1/hs172.snc1/6455_133608995700_519105700_3810549_3014136_n.jpg
http://photos-g.ak.fbcdn.net/hphotos-ak-snc1/hs192.snc1/6455_133609000700_519105700_3810550_425363_n.jpg
http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs192.snc1/6455_133609005700_519105700_3810551_7192891_n.jpg

Here you can see the Tpiece style peice of metal that ive used as the sill seam. I got two peices of 2mm thick angle Iron and seam welded them top and bottom into a T shape so ive got 4mm of steel as a jacking point the whole way along the sill :D. Ive also Given the inner sill a coat of waxy based underseal.
http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs192.snc1/6455_133609025700_519105700_3810553_4474218_n.jpg
http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs172.snc1/6455_133609030700_519105700_3810554_5759761_n.jpg
http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs172.snc1/6455_133609035700_519105700_3810555_3238144_n.jpg

I did the same on the other sill but can't find the pics :(

Here I cut out my rear arch to make way for bigger wheels and 50mm over arches.
http://photos-f.ak.fbcdn.net/hphotos-ak-snc1/hs172.snc1/6455_133609045700_519105700_3810557_2888190_n.jpg
http://photos-g.ak.fbcdn.net/hphotos-ak-snc1/hs192.snc1/6455_133609050700_519105700_3810558_6411584_n.jpg
http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs192.snc1/6455_133609060700_519105700_3810559_2301473_n.jpg

Slotted the inner arch and folded it out and seam welded to outer arch
http://photos-a.ak.fbcdn.net/hphotos-ak-snc1/hs172.snc1/6455_133609065700_519105700_3810560_3517339_n.jpg
http://photos-e.ak.fbcdn.net/hphotos-ak-snc1/hs172.snc1/6455_133609040700_519105700_3810556_1561705_n.jpg

Now the driver side over arch is partially fitted I thought it best to see how my new wheels fitted :D
http://photos-a.ak.fbcdn.net/hphotos-ak-snc1/hs172.snc1/6455_133808065700_519105700_3813968_2690478_n.jpg
http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs172.snc1/6455_133808070700_519105700_3813969_2603562_n.jpg
http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs192.snc1/6455_133808085700_519105700_3813970_7868340_n.jpg

Thats all for now Next up - Re-spray

[alanjuggler]

good work chap :nod: interesting ideas about the sill re-construction.

when you're welding upside down do you just do a line of spot welding - it looks as though you have but just checking. i did mine last summer but as it was the first job i'd learned to do welding, it was ... interesting quality to say the least :wack: so need to re-do them.

thinking about how best to approach it and the T shape at the bottom seems to be a good way :nod:

[Bumblebee]

good work chap :nod: interesting ideas about the sill re-construction.

when you're welding upside down do you just do a line of spot welding - it looks as though you have but just checking. i did mine last summer but as it was the first job i'd learned to do welding, it was ... interesting quality to say the least :wack: so need to re-do them.

thinking about how best to approach it and the T shape at the bottom seems to be a good way :nod:

cheers mate,
What I did was make sure the steel was VERY clean which makes the arc react less which means less chance of burning holes in the steel. Doing this allows you to run a higher wire speed and more heat on the welder.

The reason for using a higher heat and more wirespeed upside down is so you can get good penetration in short bursts... If you don't do short bursts upsided down gravity makes the arc drip and you don't get good penetration..

So, Clean metal, highest wire speed and heat you can get away with without burning holes but keeping a good deep penetration in short bursts :D.

I didn't spot weld it, I made sure the metal I cut was the EXACT shape and had good contact to the car just by holding it against the sill. then I got a hammer on a scissor jack and helt the work against the car and started welding, moving the hammer further down the closer i got to it.

It has deffinetly worked because The other side can be jacked up in the middle of the sill without it collapsing :wack: But I did use 2mm thick steel so that helps :thumbs:

[Pete C]

Very nice work - looks like it was quite rusty, good to see one being saved :thumbs:

Those wheels are going to look excellent too :)

[Cavdave]

Looking good bud
I carnt wait to get a s13 so i can get somthing like this started lol

[laze]

Very interested to see where this is going. Where did you learn all your skills from? Are you a mechanic/restoration expert by trade?

laze

[Davey3legs]

http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs192.snc1/6455_133808085700_519105700_3813970_7868340_n.jpg

Those wheels. :smitten:

[Bumblebee]

Very nice work - looks like it was quite rusty, good to see one being saved :thumbs:

Those wheels are going to look excellent too :)

cheers mate, yeah once It was totally stripped on the underside it was quite a shock to say the least :eek:


Looking good bud
I carnt wait to get a s13 so i can get somthing like this started lol

He he Good luck mate! It certainly is something to do to kill ALOT of time he he he


Very interested to see where this is going. Where did you learn all your skills from? Are you a mechanic/restoration expert by trade?

laze

Nope, I work in Finance for a Telco company :D Ive just always been Mad about learning how things work and being able to make/ fix things...
I built mountain bikes as a kid and then moved on to cars when I got my license, Im a Firm believe in "if one human can another can"....

Besides, there is no way I could ever afford to pay other people to do these things so Ive always thought I'd learn how to do it myself..

If I wanted to learn how to do things like welding and stuff I'd just read a book about it or look on the internet for tips etc and just practice doing it...
Practice makes perfect and all of that :)

[Bumblebee]

Due to being stupidly skint I can't afford wider fenders right now so I thought FK it and decided to make my own.. This is necessary to fit over my -19 offset wheels :D

I cut slots in the arch after drawing the dimensions on the wing

http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs192.snc1/6455_137402590700_519105700_3877431_1670353_n.jpg
http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs172.snc1/6455_137402615700_519105700_3877434_5211147_n.jpg

Then I bridged the gap with very thin ally mesh

http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs192.snc1/6455_137402645700_519105700_3877439_2542148_n.jpg

Then I got arty with the fiberglass matting, hardener and resin

http://photos-g.ak.fbcdn.net/hphotos-ak-snc1/hs192.snc1/6455_137402640700_519105700_3877438_252458_n.jpg

Then it was a case of fill sand fill sand fill sand etc till it was smooth.

http://photos-a.ak.fbcdn.net/hphotos-ak-snc1/hs172.snc1/6455_137402660700_519105700_3877440_4806319_n.jpg
http://photos-f.ak.fbcdn.net/hphotos-ak-snc1/hs172.snc1/6455_137402630700_519105700_3877437_4968485_n.jpg

Then it was time to get prepping/ priming

http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs172.snc1/6455_137402665700_519105700_3877441_139230_n.jpg
http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs172.snc1/6455_137402620700_519105700_3877435_2782854_n.jpg

Haven't finished the passenger side arch yet but you get the idea
http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs172.snc1/6455_137402670700_519105700_3877442_8213699_n.jpg
http://photos-e.ak.fbcdn.net/hphotos-ak-snc1/hs192.snc1/6455_137402685700_519105700_3877444_3074490_n.jpg
http://photos-f.ak.fbcdn.net/hphotos-ak-snc1/hs192.snc1/6455_137402690700_519105700_3877445_1314472_n.jpg
http://photos-g.ak.fbcdn.net/hphotos-ak-snc1/hs192.snc1/6455_137402700700_519105700_3877446_4598230_n.jpg
http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs192.snc1/6455_137402705700_519105700_3877447_489324_n.jpg

Thats where im at so far...

[eddie_s13]

This thing in the flesh is awesome!

[NickS13]

man those front arches look so mean!!! think you need to start producing copies. keep up the good work!

[laze]

Genius.

[rob192]

Fancy making me some of them tank straps in exchange for some silver?

[dandan]

Blimey those front arches look really good, top work. If you fancy doing another set some time next year, i'd be more than happy to chuck a load of money in your direction! :)

[Bumblebee]

Cheers guys,
Well the plan is after JAE and a few other bits are sorted, to take them back off the car, and i'll mould them and re-make them out of FG then if the copy is good then i'll make a few more and sell them to who ever wants/ needs them...

however they are a good 40 odd mm wider than stock so will need serious offset to get away with them... I only made them for that purpose (because ive got -19 offset wheels)

anyway, Had a go at spraying the car today and OMG I wasnt expecting it to be this.... um.......... yellow he he h e

http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs192.snc1/6455_138415350700_519105700_3891986_5655368_n.jpg
http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs192.snc1/6455_138415355700_519105700_3891987_3444009_n.jpg
http://photos-e.ak.fbcdn.net/hphotos-ak-snc1/hs172.snc1/6455_138415360700_519105700_3891988_6013419_n.jpg
http://photos-f.ak.fbcdn.net/hphotos-ak-snc1/hs172.snc1/6455_138415365700_519105700_3891989_8201556_n.jpg

feel free to take the piss he he:wack::hurl:

[eddie_s13]

like i said on msn dude it friking rocks, was dreading a jcb yellow car! looks sweet and i know you will make it mint as hell

[Bumblebee]

like i said on msn dude it friking rocks, was dreading a jcb yellow car! looks sweet and i know you will make it mint as hell

I'll deffo will in the long run
but im trying desperately to get it ready for JAE he he

[SidewaysThough]

i think thats tidy to be honest, its nice to see a different colour, and different ideas. Your fabrication is also rather impresive, im loving those front archs. Something i would be very interested in if you made copies!! Means i could run agressive fitment too!

[red_rider]

CRXXX

Look like a blinding job so far my, i see your in Reading if you ever need a an extra pair of hand feel free to give me a shout Im only down the road from you in slough.in Slough

[DanS14a]

I am liking it a lot! Think it would look good if you paint the light lids black! Why did you not finish the rest of the car though:confused:! As in the front of it!

[eddie_s13]

that was just yesterdays work mate, hes back on it today

[red_rider]

when you were welding did use gas and if so what id dyou use the big BOC argon bottel or the the 600g ones you get from diy stores...

[Bumblebee]

when you were welding did use gas and if so what id dyou use the big BOC argon bottel or the the 600g ones you get from diy stores...

I Use the ones you get from halfords.. CO2 for mild steel and Argon/CO2 mix for stainless..

so far ive used 4 CO2 cans and 1 argon/CO2 on this project :)

[Bumblebee]

http://photos-g.ak.fbcdn.net/hphotos-ak-snc1/hs172.snc1/6455_140852945700_519105700_3927838_3184207_n.jpg
http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs172.snc1/6455_140852950700_519105700_3927839_5160607_n.jpg
http://photos-a.ak.fbcdn.net/hphotos-ak-snc1/hs192.snc1/6455_140852955700_519105700_3927840_405290_n.jpg
http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs192.snc1/6455_140852965700_519105700_3927841_4614293_n.jpg
http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs192.snc1/6455_140852985700_519105700_3927843_2715540_n.jpg
http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs172.snc1/6455_140860245700_519105700_3927935_1885848_n.jpg

going to fit the front bumper next, do the light lids, petrol flap, rear light garnish and door handles in the morning, Let the paint harden till the weekend then flat it back and compound it till its like glass :cool:

[red_rider]

Update,


Now the driver side over arch is partially fitted I thought it best to see how my new wheels fitted :D
http://photos-a.ak.fbcdn.net/hphotos-ak-snc1/hs172.snc1/6455_133808065700_519105700_3813968_2690478_n.jpg
http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs172.snc1/6455_133808070700_519105700_3813969_2603562_n.jpg
http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs192.snc1/6455_133808085700_519105700_3813970_7868340_n.jpg

Thats all for now Next up - Re-spray


Hi can i ask were you get the arches from were are they based arches on mine are roten so need to replace them...

[shaboy]

how do alan, finally got around to looking at this thread, good to see what you've done with the sills, will deffinately have a look at doing mine that way when I actually start work on it :D

was a bit worried about your front arches when i saw the preliminary pictures but seeing them painted they actually look really good :thumbs:

[Bumblebee]

Hi can i ask were you get the arches from were are they based arches on mine are roten so need to replace them...

I got them for £150 off ebay.... Don't know what they are but they looked like what i was after so I got them and they were a good price :)

[Bumblebee]

how do alan, finally got around to looking at this thread, good to see what you've done with the sills, will deffinately have a look at doing mine that way when I actually start work on it :D

was a bit worried about your front arches when i saw the preliminary pictures but seeing them painted they actually look really good :thumbs:

He he he cheers man! Yeah prepare yourself for the sills.... It wa ALOT of work :eek:

:eek:he fron't arches are only to overcome my silly offset.. when I can afford to get propper front fenders I will :cool:

[Bumblebee]

http://photos-g.ak.fbcdn.net/hphotos-ak-snc1/hs240.snc1/8724_152796600700_519105700_4114342_4450072_n.jpg
http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs220.snc1/8724_152796620700_519105700_4114345_5520928_n.jpg
http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs220.snc1/8724_152796625700_519105700_4114346_1448191_n.jpg
http://photos-c.ak.fbcdn.net/hphotos-ak-snc1/hs220.snc1/8724_155591920700_519105700_4150498_324280_n.jpg
http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs220.snc1/8724_155591930700_519105700_4150499_8288019_n.jpg
http://photos-h.ak.fbcdn.net/hphotos-ak-snc1/hs240.snc1/8724_155705855700_519105700_4153015_51131_n.jpg
http://photos-b.ak.fbcdn.net/hphotos-ak-snc1/hs240.snc1/8724_155591980700_519105700_4150505_813517_n.jpg
http://photos-e.ak.fbcdn.net/hphotos-ak-snc1/hs220.snc1/8724_155591995700_519105700_4150508_640077_n.jpg
http://photos-d.ak.fbcdn.net/hphotos-ak-snc1/hs220.snc1/8724_155597735700_519105700_4150619_3040325_n.jpg
http://photos-e.ak.fbcdn.net/hphotos-ak-snc1/hs240.snc1/8724_155597745700_519105700_4150620_1901162_n.jpg


took my attention off the cosmetics and aimed it towards getting the car on the road MOT'd and Taxed for JAE....

Paintwork still needs wet sanding and polishing but I HAD to get it on the road because i was itching far too much to drive it :)

On the way there I was getting real problems with the fueling, IT was coughing and spluttering as if it was constantly hitting fuel cut....

It turns out there was alot of crap in my fuel tank that clogged up the filter sock on the walbro (thought it would be that because the pump sounded like it was seriously struggleing to pump fuel).....

After cleaning it out it runs like an absolute dream at 1bar :D :D :D

have to admit though.... stage 2 doesn't really seem that neck snapping quick......

I have a HKS front mount, stage 2 chip, stock AFM 3 inch turbo back exhaust, apexi filter, S14 T28 with zero in out or side to side play, Gizzmo boost controller set to 1bar.

The boost guage climbs very quickly and steadily to 1bar by 3200rpm and holds it steadily (no spikes) all the way to redline...

It runs very very well so I can't see there being any issues.... just doesn't seem that quick compared to my old CRX :(

going to get it on the rollers soon to check the fueling and make sure everything is ok before going further... maybe there are some underlying issues or maybe its just not as fast as I thought it would be....

seems to be running spot on though with no flat spots....

[laze]

Nice to meet you at JAE dude. Will continue to watch this thread closely.

laze

[Chriscooke]

That is one sexy s13:nod:

[royellison]

that is NIIICCCEE sits so well,looks spot on. well done mate.

[DanS14a]

That looks really nice mate, but I would definitely lower it a bit more especially on the front!

[Bumblebee]

Cheers everyone!

Yeah I haven't set up the suspension propperly yet, only the preload and dampening, need to get the alignment done so once its all finished i'll start setting up the chassis propperly :)

[Polo2]

Looking good Al:thumbs:

Needs to be lower:D

[Bumblebee]

Looking good Al:thumbs:

Needs to be lower:D

Well i'll need ALOT more front inner arch modification as on full lock its about 5mm away from the front and back of the inner arch due to the silly offset :D

I think im going to tub the front and smash the fk out of the back with a hammer and completely re-think the loom situation.

It is currently cable tied above the upper lip on the top of the arch so it is well out of the way but where the loom enters the cabin through the big rubber grommits it will deffo touch.

[Chris B]

Really starting to look good :)

[Debeli]

http://photos-e.ak.fbcdn.net/hphotos-ak-snc1/hs240.snc1/8724_155597745700_519105700_4150620_1901162_n.jpg


nice car color! i like it...but my is bether :P

copycat :P
http://www.pohrani.com/f/37/d4/2850JqoD/20090704-1000994.jpg

[AlanS13]

Sweet work dude! has inspired me to get off my ass and do some work! :thumbs:

[200jim]

car looks brilliant

[Bumblebee]

nice car color! i like it...but my is bether :P

copycat :P
http://www.pohrani.com/f/37/d4/2850JqoD/20090704-1000994.jpg

Fair play!!

That looks awesome!

How much did all that cost?

[M.D.]

i definately preferr yours bumblebee, i had that kit and just got rid of it, kinda wishing i didnt now ive seen it with wider fenders too lol, ah well.

did you use a spray gun outside bud, looks really good, i may well have to hire myself one lol

[Bumblebee]

i definately preferr yours bumblebee, i had that kit and just got rid of it, kinda wishing i didnt now ive seen it with wider fenders too lol, ah well.

did you use a spray gun outside bud, looks really good, i may well have to hire myself one lol

Cheers man! I know exactly what you mean about the kit with those arches! I originally wasnt' going to go wide body.... I bought the Kit of Rhys_sx, Fitted it and thought it looked to wierd with a skinny top heavy bottom kinda thing....

I used a compressor and gun outside yeah, Since using ALOT of wet sanding and some compounding it has come up a treat since those pics!!!

I'll put some pics up when im done (its taking a while) Im well chuffed with it :) may never be as good as a 1500 quid spray job but im damn well trying my hardest to make it so :D

[Debeli]

Fair play!!

That looks awesome!

How much did all that cost?

15.000 € :D maybe a litle bit more...

[Bumblebee]

15.000 € :D maybe a litle bit more...


Ahh right.... Fair play he he

I bought my car for £450.00 and spent a further £2683.00 to get it where it is now.....

:D

[The Panda]

Spotted your car @ Essex arena over the weekend and i've got to say it looks amazing :thumbs:
Having read this build thread it was nice to see it in the flesh...Good work that man :notworthy

[Debeli]

Ahh right.... Fair play he he

I bought my car for £450.00 and spent a further £2683.00 to get it where it is now.....

:D

rims & tires over 3500€
engine tuning around 3.000€

and more and more....

[Bumblebee]

Spotted your car @ Essex arena over the weekend and i've got to say it looks amazing :thumbs:
Having read this build thread it was nice to see it in the flesh...Good work that man :notworthy

Cheers man :thumbs: was a good night :D what car were you in?

[Kneel]

Ahh right.... Fair play he he

I bought my car for £450.00 and spent a further £2683.00 to get it where it is now.....

:D

Guessing on how much your wheels and tyres cost you thats a cheap build! I want front arches like yours as the overfenders I bought are absolute dogshite :( Nice work mate, I wish I had the skills to DIY my car.

[japdrifter]

how on earth can you keep track of how much you have spent on your car? i couldnt theres just too much plus i dont think id wanna know

[kingj]

awesome project fella:nod: dont know how Ive missed it up til now:wack:

[joshm8991]

car looks mint great work:thumbs:

[Bumblebee]

Cheers guys.

@ Japdrifter

When you are as skint as I am you deffinetly know exactly what youve spent on your project lol.

@Kneel
It was a cheap build in terms of money, but not in terms of time, blood sweat and tears!:eek:

I made a spreadsheet of everything I needed/ wanted and priced it up and planned when I could get what and what was more important etc....

I Part Exed a set of wheels for the RB's so got them cheapish ;)

Later this year i'll be getting a set of stock wings and re-doing them propperly and look into getting a mould of them and making a few copies...

They were only meant to be a temporary cheap measure until i could afford some propper front overfenders but They seem to have attracted alot of interest...

cheers for the comments guys :D

[Gearboxmurderer]

theres alot of resto hours gone in there mate nice one looks good for the effort

[Bumblebee]

Been a while due to paying off my old house and not having a decent camera but here is a couple to start off with.

In order to get these -19 offset wheels working on the front ive had to do this

http://photos-a.ak.fbcdn.net/hphotos-ak-snc3/hs491.snc3/26826_405272280700_519105700_5624951_3697640_n.jpg

http://photos-c.ak.fbcdn.net/hphotos-ak-snc3/hs491.snc3/26826_405272290700_519105700_5624952_612840_n.jpg

http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs491.snc3/26826_405272295700_519105700_5624953_6336032_n.jpg

http://photos-h.ak.fbcdn.net/hphotos-ak-snc3/hs511.snc3/26826_405272305700_519105700_5624954_1147909_n.jpg

I'll post up more of pics of how to make these tubs when I start on the other side as ive only just got hold of a camera

Also i'll show photos of my Fiberglass roof skin from SRB and how that fitted.

[EMENEAR]

nutter :D. Nice to see your back on the car

[Rob_SX]

this is a great project thread. Im in proccess of building a bright yellow S13 :) i wanted to call my thread summit along the lines of bumblebee but you've beaten me to it lol.

[Bumblebee]

Cheers guys, LOL @ Rob, Fell free to call it what you want, I'm not one of those people that cares about that sort of stuff :)

I just wish the Friking rain would hold off as I don't have a garage :(

[EMENEAR]

What happened to your garage? I got my engine out and home mate. You wouldnt believe the condition of the bottom end, very decent! Im going to rent a workshop unit in the summer once Ive done my foremans course. Perhaps in nine mile ride. I'll give you a shout nearer the time :thumbs:

[Bumblebee]

Cut a nice big hole
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs511.snc3/26826_407155100700_519105700_5673952_962007_n.jpg

make templates out of cardboard for the plates. Bellow ive already done this and had to give it a coat of hammerite due to the constant rain were having.

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs511.snc3/26826_407155105700_519105700_5673953_3493726_n.jpg

This is basically how I do it, trim up shapes out of card till they fit, draw it onto metal and cut it out with tin snips.
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs491.snc3/26826_407155110700_519105700_5673954_965629_n.jpg

This is what i do to bend the arch bit

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs491.snc3/26826_407155115700_519105700_5673955_283060_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs491.snc3/26826_407155120700_519105700_5673956_4070190_n.jpg

Start at the top and leave it hanging
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs491.snc3/26826_407155125700_519105700_5673957_2077828_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs511.snc3/26826_407155130700_519105700_5673958_2750767_n.jpg

Then weld the bottom and up the side
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs511.snc3/26826_407155135700_519105700_5673959_4293837_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs491.snc3/26826_407155140700_519105700_5673960_6983981_n.jpg

And thats as far as i got before it got dark.

[TM_S13]

nice stuff.
and I did liked that rolling/bending arch "machine" you have :P :P

[laze]

Such a talented young man - are you coming to the Weekender?

[kenta]

nice:thumbs:

[Bumblebee]

Cheers for the comments guys.

Yeah will go to the weekender, just need to pay up and stuff.

[Bumblebee]

Right well I finished the other Arch but I haven't taken pics yet because I started on other things.

I put up a post a while ago about a Vmount setup, After Studying Kev's Vmount :notworthy I thought I'd have a go at my own.

My Method differs to Kev's in the way that I want the intercooler sat lower in the engine bay and have the rad at more of an Angle (closer to that of an RX7 Vmount setup).

So far I'm just in the bracket and support stage but there is decent weather ahead so I'll keep it updated regularly.

Here are the new radiator supports, They allow the radiator to pass through the front of the crossmember section to allow room for the more shallow angle.
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs484.snc3/26496_408477605700_519105700_5717609_3400723_n.jpg
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs504.snc3/26496_408477600700_519105700_5717608_3148983_n.jpg
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs484.ash1/26496_408477615700_519105700_5717610_506291_n.jpg

Here is the proposed angle of the rad.
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs484.snc3/26496_408477620700_519105700_5717611_460328_n.jpg
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs484.snc3/26496_408477625700_519105700_5717612_2548662_n.jpg
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs484.ash1/26496_408477635700_519105700_5717614_5010825_n.jpg
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs484.snc3/26496_408477650700_519105700_5717617_1639665_n.jpg

You will notice the rad is upside down. The reason for this is because I wanted the inlet and outled ports to face upwards and not towards the floor which would cause hose routing issues.

The downside of this is obviously the rad cap being at the bottom not the top so I am going to use a Tpeice off the top rad hose to an MR2 Filler neck which will allow me to keep the filler at the highest point of the cooling system.

I then had to do something about the verticle struts that go to the bottom crossmember to support the bumper mounts and slampanel.

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs484.snc3/26496_408477645700_519105700_5717616_8075306_n.jpg
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs484.ash1/26496_408477665700_519105700_5717619_7599269_n.jpg

I am going to use some verticle box section from the top horizontal bar and the bottom horizontal bar to give the suport for the bumper mounts and the bonnect catch but that is where I left it last night due to feeling sick (too much coffee and not enough food).

That is where I am so far, Update tonight hopefully:thumbs:

[laze]

Where do you find the time?!

[Bumblebee]

Where do you find the time?!

Any time i'm not at my desk number crunching or its raining he he he.

Man I wish I had a garage!!!!

[riske]

Any time i'm not at my desk number crunching or its raining he he he.

Man I wish I had a garage!!!!

Dont i know the feeling!! In fact sod work im going home now to do some de-rusting!!

Well done mate i've started stripping mine out. Im going to start a build thread too. Where did you get your sandblaster from?

Keep up the good work!

[Lorrister]

wow, your spray job looks pretty good tbh. I was going to spray my car one or two panels at a time in my tiny garage but youve kinda inspired me to go alfresco and do it on the drive lol. Im sure itll save me some time

[Bumblebee]

Another update,

I have had to make a new Support bar system for the Bonnet catch, front bumper and slam panel. The old ones cover the mouth of the car so I had to Fab up a new way so that the Radiator can come through the mouth of the car.

Without this support between the slam panel and bottom crossmember, the Slam panel is really flimsy meaning wonky bumper fitment and the fact that the bonnet won't shut propperly.

I welded some nuts to two little sections that will bolt to the chassis legs and form the lower feet of the support bar
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs504.snc3/26496_409114725700_519105700_5734743_6059802_n.jpg

Here is one side of the support bar system bolted to the chassis leg
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs504.snc3/26496_409114745700_519105700_5734745_691623_n.jpg

Here is it all welded up and with a lick of paint
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs484.ash1/26496_409114750700_519105700_5734746_437653_n.jpg

Here is it bolted into place, Notice how it supports the bonnet catch, bumper mounts and the whole thing is bolted to each chassis leg rather than the bottom crossmember to allow the radiator to come through.
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs504.snc3/26496_409114755700_519105700_5734747_6399827_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs484.snc3/26496_409114770700_519105700_5734749_4039148_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs504.snc3/26496_409114775700_519105700_5734750_6954895_n.jpg

That is it so far, Next up is the intercooler mounting.

[Treacle]

Nice work on the car :thumbs:

Out of interest how beneficial is it to do a v-mount other than just as an engineering challenge? Anyone got any facts or scientific reasoning? The way I see it the air is likely to flow across the radiator rather than through it, making it less efficient rather than more?

I'm guessing it would be important to have well designed shrouds to direct the air and block it from just exiting in the gap between the rad and intercooler and into the engine bay.

[Bumblebee]

Nice work on the car :thumbs:

Out of interest how beneficial is it to do a v-mount other than just as an engineering challenge? Anyone got any facts or scientific reasoning? The way I see it the air is likely to flow across the radiator rather than through it, making it less efficient rather than more?

I'm guessing it would be important to have well designed shrouds to direct the air and block it from just exiting in the gap between the rad and intercooler and into the engine bay.

Look at Kev's project purpleyness He did a Vmount and noticed significant efficiency increases in engine cooling.

The reason I am doing it though is because I want the shortest possible intercooler pipes to reduce lag, but at the same time I fancied a challenge.

I will have seperate ducts top and bottom guiding air directly to the rad and intercooler seperately and the air will escape from the intercooler via a vent in the bonnet. The radiator air flow will be completely seperate to the intercooler air flow.

This system is mainly beneficial to situations where you need better engine cooling, because air is going directly onto the radiator and intercooler seperately rather than having to pass through an intercooler then the radiator. This is important because say for instance you are drifting, you are running the engine at high RPM but you aren't going as fast as you normally would be if you were driving at speed. This means a massive decrease in airflow accross the radiator, plus the fact that the air would have to go through an intercooler first only makes things worse for engine cooling.

Imagine being on a dyno, They use a massive fan to replicate the amount of air going through the radiator as if you were driving at speed. Now take away that fan and replace it with a little home type fan..... your temps would go up real quick.

That is kind of what happens I guess when drifting, the engine is working really hard and heating up but there is no air to cool things down because the speed is much slower.

This system helps the radiator be as efficient as it can be....

hope this makes sense and isnt' a lot of tosh lol.

[Treacle]

Yeah that all makes sense, but I think the important bit will be the quality of the shrouding and ducting. I would also be tempted to have a small shroud above the intercooler with a rubber seal where it meets the bonnet to ensure the air is sucked out of the bonnet vent efficiently.

Also a well thought out under tray with a duct for the air through the rad to exit would be good. Like the sketch diagram I've done below:

http://i109.photobucket.com/albums/n68/Treacle_GT4/200sx%20S13%20Track%20car%20build/V-mountDiagram.png

[Bumblebee]

Cheers,
Yeah I have thought alot about the ducting and have already planned how i'm going to do it.

It is basically exactly the same as your method howver I have split the airflow for the intercooler and the radiator so that the air that comes in through the bumper will be seperated and devided for the cooler and the radiator.

I am fitting the intercooler tonight after work. Once that is done i'll then start on the ducting and will post the pics up :)

Thanks for your input :thumbs:

[Bumblebee]

Oh

Also Im not venting the rad to under the car, I want to reduce the amount of air going under the car to aid front end grip at speed.

I'm venting it out through the bonnet, (Don't worry it will be seperate to the intercooler vent)

I'll explain all when I do it.

[Treacle]

Awesome, will be interested to see the results. For comparison do you have sensors/gauges to measure your water and intake temp before and after the conversion?

[EMENEAR]

Awesome, will be interested to see the results. For comparison do you have sensors/gauges to measure your water and intake temp before and after the conversion?

that would be cool. See what kind of gains the conversion makes

[Bumblebee]

Unfortunately no I don't... :(

But I know other people that have done before and after comparisons and it helps in a big way apparently.....

Just Read Kev's Thread (Project Purpleyness). He talks of the gains he saw with this kind of system on the Track and the Dyno.....

But to be honest i'm more than likely not going to be abusing the car as much as warrants this kind of setup.....

The main Reason I did it was to reduce the intercooler system to reduce lag... but i'm a firm believer in "every little helps".

Plus I Fancied something completely different...... So here it is he he he.

[Treacle]

Yeah fair play, I'm thinking about using an RS500 intercooler and rad for mine, could be made to work well either as a front mount or V-mount system I reckon. It surprises me that more people haven't used this system in the past as the dimensions seem to work well with the S13 and the inlets point almost straight at the turbo and inlet manifold so means short pipes and less lag:

http://i109.photobucket.com/albums/n68/Treacle_GT4/RS500.jpg
http://i109.photobucket.com/albums/n68/Treacle_GT4/RS500intercoolerandrad.jpg

The rad on the RS500 has a remote filler as well so you you don't have the issue with the filler neck and rad cap location. You can buy them as a pair for around £250 new, on ebay or from places like here:

http://www.racespecperformance.com/epages/racespec.sf/en_GB/?ObjectPath=/Shops/racespec/Products/%22RS500%20Cosworth%20Intercooler%20%2B%20Radiator %22

[Bumblebee]

Yeah I looked into using an RS500 Intercooler but Decided against it.... no particular reason.... I reckon they would work well!

I think Dan @ DB power has a bit of experience of using (from searching on the subject of RS500 coolers).

and they turned out good :)

[laze]

I am in awe at your work dude. Looking forward to having another chat with you at the Weekender and seeing how the car's progressed in the flesh since I saw it at JAE.

[Bumblebee]

I am in awe at your work dude. Looking forward to having another chat with you at the Weekender and seeing how the car's progressed in the flesh since I saw it at JAE.

He he Cheers man, yeah no worries, just got to get cracking and get it finished :thumbs:

Here is the final position of the intercooler please excuse the phone spec pics
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs484.ash1/26496_409652035700_519105700_5743970_6105031_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs484.snc3/26496_409652040700_519105700_5743971_3622942_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs484.ash1/26496_409652055700_519105700_5743973_5861645_n.jpg

Here you can see the angle through the front bumper, The ducting plates i'll make will block off all gaps and ensure airflow through the rad and intercooler seperately.
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs504.snc3/26496_409652050700_519105700_5743972_2998766_n.jpg

I have to take some gouges and re-weld my tubs to allow for some hoses.

I have already made measurements and am about to order what I need but im well happy with the position and the way its coming together :D

[Treacle]

Looking good mate :thumbs: what size is the core your using? Seems a good fit. It would be nice ultimately if you could get the inlets on the core moved and welded so they point straight at the turbo/inlet then you would have super short runs and a good low volume system, plus it would avoid your tubbed arches :)

[Bumblebee]

Looking good mate :thumbs: what size is the core your using? Seems a good fit. It would be nice ultimately if you could get the inlets on the core moved and welded so they point straight at the turbo/inlet then you would have super short runs and a good low volume system, plus it would avoid your tubbed arches :)

Its an Evo 4 intercooler, Can't remember the Dimensions off the top of my head but its 4inches thick with 60mm ports, I was thinking of Cutting and welding... May look into that in the near future but Im not sure how much an Ally welder will charge... (Ive never welded Ally)...

Here is some progress on my ducting.... And I have to say this is the first time Ive ever been really really really chuffed and proud of myself..... I managed to utilize every single vent o n the front bumper to duct air directly to the Rad/ intercooler...

I'll let the pics do the talking.

First off here is some better shots of the intercooler position as I got a propper camera again.
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs484.ash1/26496_410472555700_519105700_5771138_6333906_n.jpg
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs504.snc3/26496_410472550700_519105700_5771137_6409022_n.jpg

And here is what I spend Satarday doing Measuring, folding, Cutting and Riveting :D :D :D

This is what I started off with, No ducting.
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs484.snc3/26496_409652070700_519105700_5743974_2468238_n.jpg

Then I made a back plate and side plates
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs504.snc3/26496_410472495700_519105700_5771127_7950204_n.jpg

Here it is with the top panel on. The two pointy bits bolt on to the back plate that is bolted to the intercooler and radiator.
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs484.ash1/26496_410472500700_519105700_5771128_5418558_n.jpg

Here is the Center duct paneling finished and i'm quite happy! Then I decided to use the side vents on the Uras Bumper aswell, Back out with the cardboard for templates.
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs504.snc3/26496_410472505700_519105700_5771129_3119331_n.jpg

Draw the final net on the ally
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs504.snc3/26496_410472510700_519105700_5771130_1528608_n.jpg

Cut the shapes out... (this one was for the other side, forgot to take a pic of the left one but they are the same..)
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs484.snc3/26496_410472520700_519105700_5771132_673718_n.jpg
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs484.ash1/26496_410472530700_519105700_5771133_4709991_n.jpg

Here we go :D
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs504.snc3/26496_410472515700_519105700_5771131_2597582_n.jpg

I'm going to addsoem plates on the ends of the side vents to ensure air is captured.. But this is the basic Idea.
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs504.snc3/26496_410472540700_519105700_5771135_5503641_n.jpg

Through the main vent
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs504.snc3/26496_410472545700_519105700_5771136_504843_n.jpg

Through the bumper
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs504.snc3/26496_410472575700_519105700_5771141_2739816_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs484.ash1/26496_410472580700_519105700_5771142_5133081_n.jpg

The best thing is, Six bolts hold the entire thing on and it all comes out as one :smitten:

I need to get some U shapped Beading to go around all the straight edges so that they don't harm anything (and reduce any rattles that come about).

I also have to cut a hole in the left side duct for the bottom Rad hose to go through but that shoudln't be a problem..

I'm propper Chuffed with that!!!

Next up will be pipe work for Rad and intercooler.

then bonnet vent..

Thanks for looking :)

[Treacle]

Mate that is looking first class - excellent fabricating skills :thumbs:

[Pablo13]

Nice work, Ive been meaning to make some ducting up for mine for ages now.

[Bumblebee]

cheers guys :D

Its not that hard, just a bit of head scratching, some bendy ally, snips and lots of cardboard he he.

I was a bit worried with how much air would flow through a Vmount... Wile I was driving along at 30 I stuck my hand out the window and was pretty shocked with the force of the airflow...

So with pretty much all of the air going through the front bumper being forced over the rad and intercooler via the ducts Im pretty confident its going to keep the temps down massively!! :cool:

[Treacle]

Are you still planning on dividing the opening between the rad and cooler?

[Bumblebee]

Are you still planning on dividing the opening between the rad and cooler?

Yeah I think I will, but i'm going to leave that till when I fit the fans and the coolant pipes for the rad..

then i'll figure out how best to do it.

[Treacle]

Yeah I think it would be a good idea at some stage, as from looking at the set up I would say the majority of air is going to just pass across the rad and go through the intercooler - which obviously is great for your intake temps but not so good for the water temp.

[Bumblebee]

Yeah Thats what i'm thinking....

I'll see how much space the fans take up and then i can work it out....

hope I dont' need to extend the mouth upwards on the front bumper...

[Sideways Simon]

Just read the full thread now, fair play fella, an awfull lot of fantastic work gone into the car, it looks very well now and wheels are amazing!!! also love the unique design of the rad & ic setup, but how are you gonna fill it with coolant with the rad cap facing the ground???

[Bumblebee]

Just read the full thread now, fair play felle, an awfull lot of fantastic work gone into the car, it looks very well now and wheels are amazing!!! also love the unique design of the rad & ic setup, but how are you gonna fill it with coolant with the rad cap facing the ground???

Cheers mate :)

I had to run the Radiator upside down so that the inlet and outlet ports are facing upwards.

this means I'm going to be using a Remote filler neck off an MR2 spliced into the top hose in the engine bay.

I am going to seal the bottom rad cap so that it stays shut permanently.

[Sideways Simon]

Cheers mate :)



this means I'm going to be using a Remote filler neck off an MR2 spliced into the top hose in the engine bay.

I am going to seal the bottom rad cap so that it stays shut permanently.

ah, i see...:nod: a lot of thought going into this setup, the mot guy will be doing a bit of head scratching when he pops the bonnet!!:wack:

[TM_S13]

the rad cap up side down can also help a lot to remove "old" coolant faster =P

it's some serious job being done in your car... quite interested in seeing how it will turn out.

keep up

[Bumblebee]

ah, i see...:nod: a lot of thought going into this setup, the mot guy will be doing a bit of head scratching when he pops the bonnet!!:wack:

The guy I take to is an RX7 Nutter so i'm sure he'll know exactly whats going on with it he he.


the rad cap up side down can also help a lot to remove "old" coolant faster =P

it's some serious job being done in your car... quite interested in seeing how it will turn out.

keep up

Cheers mate, Im fairly confident its going to work well! I can't really see how it won't....

Just placed an order for loads of hoses couplings Tpieces and clamps he he he.

I cant' wait to see what its like :D

[Bumblebee]

Not been doing much because ive been feeling to great but here is a small update.

Got some hoses through from apmotorstore which had everything I needed.

Here is the route of the bottom Rad hose, I know the sharp edges of the ally arent good against silicone hoses, thats why I've got PVC beading turning up to line all edges of the ducting.
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs492.ash1/26876_412786070700_519105700_5832233_5569268_n.jpg

Here is the few of the hose orientation from the inside of the bay, from the top going down
1 intercooler cold hose
2 Radiator top hose with temp sender
3 Bottom Rad hose
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs492.snc3/26876_412786080700_519105700_5832234_1000783_n.jpg

I'm waiting to recieve the Tpiece for the remote filler neck and also the fan controller but there is JUST enough space between the thermostat housing and the top hose port to fit all these things he he he.

Then I set about measuring where the hole will be for the intercooler vent.

by using string, gaffa, ruler and pencil :D
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs512.snc3/26876_412786060700_519105700_5832231_6571528_n.jpg
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs512.snc3/26876_412786055700_519105700_5832230_5192514_n.jpg
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs492.snc3/26876_412786065700_519105700_5832232_5323658_n.jpg

Then shutting the bonnet and putting sting over the top of the bonnet in the same place the string is under the bonnet
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs492.ash1/26876_412786085700_519105700_5832235_4689547_n.jpg

Then I decided to make my stupidly loud 3" stainless exhaust a bit quieter by welding in a small mid silencer
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs492.snc3/26876_412786050700_519105700_5832229_3244204_n.jpg

Not sure how much difference it will make but hopefully worth the effort!

Thats it for now folks, Next up will be finishing the Air Idle hoses and relocation of the PAS resevoir and AFM/ Filter.

Ooooooohhh and some pics of the wire tuck I did a few weeks back as you will notice there is no wiring in my engine bay :D

[Treacle]

This is looking really cool, watching with interest :thumbs:

[Bumblebee]

This is looking really cool, watching with interest :thumbs:


Cheers mate, I just can't wait to get all the hoses done up, the exhaust put on and see how different it is :D

I can finally lower the front a bit more due to the tubs and wire tuck aswell :D:D:D

[EMENEAR]

some of your methods make me laugh. God knows how you come up with them, you should be an engineer. Crude, but effective with the string lol. Top work :thumbs:

[Bumblebee]

some of your methods make me laugh. God knows how you come up with them, you should be an engineer. Crude, but effective with the string lol. Top work :thumbs:

He he he cheers mate, I the string bit was by eye :smash: but it was all measured up with a ruler afterwards....

you are the second person to tell me I should be an engineer lol, Everyone in our office thinks i'm crazy for doing stuff like this as a hobby he he.

[EMENEAR]

He he he cheers mate, I the string bit was by eye :smash: but it was all measured up with a ruler afterwards....

you are the second person to tell me I should be an engineer lol, Everyone in our office thinks i'm crazy for doing stuff like this as a hobby he he.

So do my mates. Wheres the fun in fixing rust? :wack:. It's the satisfaction when you have succeded IMO. Taking something worn out and making it like new. I think I just love taking things apart lol :smash:. I am an engineer though, whats your excuse lol ;)

[Bumblebee]

So do my mates. Wheres the fun in fixing rust? :wack:. It's the satisfaction when you have succeded IMO. Taking something worn out and making it like new. I think I just love taking things apart lol :smash:. I am an engineer though, whats your excuse lol ;)

I bought my car as a £450 piece of junk....

Ive always been the same though, when i was young it was cardboard boxes and lego, then mountain bikes, then cars...

Just love creating things.... I so wish I was an engineer but at 26 years old i think ive probably missed my chance for a carreer change :cry:

what kind of engineer are you? I'd love to get out of the office environment but I really don't know how...

[EMENEAR]

I bought my car as a £450 piece of junk....

Ive always been the same though, when i was young it was cardboard boxes and lego, then mountain bikes, then cars...

Just love creating things.... I so wish I was an engineer but at 26 years old i think ive probably missed my chance for a carreer change :cry:

what kind of engineer are you? I'd love to get out of the office environment but I really don't know how...

Well, I left school with 3 gcse's as just messed about. From there I re-took maths then went to Henley college and did a BND in mechanical engineering. Once I passed that I got a job with my current firm as a CAD designer for roadwork layouts. they sponsored me to get a hnc in civils which Im currently in my last year of. In all I've been studying engineering for 5 years! However, my work is obviously infront of a computer and I desperately miss practical work. I guess thats why I have to have a project. The love of engines etc is also a factor.

[Bumblebee]

Couple of more update pics but im kinda stuck with getting it running till i buy some more bits.

Cut the hole out and made some side plates that go from the cooler to the bonnet.
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs502.ash1/29717_415303845700_519105700_5900773_6479948_n.jpg

Tacked the side plates in
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs324.ash1/28357_415635595700_519105700_5908130_4087902_n.jpg

Here you can see the back plate is a bit bent but i have a small mini box section to weld behind it which will straighten it out inline with the back of the cooler nicely :D
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs324.ash1/28357_415635600700_519105700_5908131_8235330_n.jpg

Here is the front plate
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs294.snc3/28357_415635610700_519105700_5908133_6802053_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs294.snc3/28357_415635615700_519105700_5908134_4899722_n.jpg

I have made the side plates too but it got too dark to carry on :(

[TM_S13]

really interested to see how will it turn out to be...
nice work

[Bumblebee]

Bit more work done on the vent

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs314.snc3/28357_415838615700_519105700_5911988_1248530_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs314.snc3/28357_415838635700_519105700_5911992_2429433_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs314.snc3/28357_415838640700_519105700_5911993_4352581_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs294.snc3/28357_415838650700_519105700_5911994_6795916_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs324.ash1/28357_415838665700_519105700_5911995_1092122_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs314.snc3/28357_415838675700_519105700_5911997_4375326_n.jpg

[dandan]

Looks cool, is that staying open like that or will there be some kind of cover on the top? You could lose small children in there!

[Bumblebee]

Cheers man, Going to leave it open i think :cool:

[TM_S13]

I just don't "like" the idea of the steel being that close to the intercooler...
I'd prefer to let a bit of gap between the intercooler and the vent so it can oscilate freely without making noise or damage de intercooler... ultimatly you can fit a bit of rubber for padding...

just an opinion/idea ;)
apart from that, thumbs up for the work you've been doing \o/

[Bumblebee]

I just don't "like" the idea of the steel being that close to the intercooler...
I'd prefer to let a bit of gap between the intercooler and the vent so it can oscilate freely without making noise or damage de intercooler... ultimatly you can fit a bit of rubber for padding...

just an opinion/idea ;)
apart from that, thumbs up for the work you've been doing \o/


Cheers man, Ive already thought about the proximity of the vent panels to the intercooler, Thats why i'm going to use the same stuff I trimmed the front air ducting with (haven't got any pics of that yet sorry). Its the U shaped PVC rubbery silicony stuff that is used to trim door and sill seams on classic cars :D I was going to run that all around the bottom of the vent. It has worked wonders for my front airducting!

[TM_S13]

nice then ;)

[Treacle]

The intercooler shouldn't move very much anyway, as it is solidly fixed to the car body, and there will be flexibility where it connects to the engine due to the silicone pipe joiners.

Looking good bumblebee, very inspiring :thumbs:

[EMENEAR]

Very nice Alan :thumbs:

[gonzomagic]

Very nice mate, well done:thumbs:

[laze]

Continue to be thoroughly impressed by this project and envious of your talents. Damn you.

[Bumblebee]

He he he Thanks everyone, Now I just have the ballache of having to fill and smooth the tack welds and re-spray the bonnet in this Gash weather :(

Just ordered stuff from apex £600 odd quids worth :eek:

Bushed camber, toe and traction arms
revotec fan controller,
water temp guage,
Thermostatic oil cooler

That hurt hard lol

[laze]

Didn't see you at Duxford. Was disappointed.

[Bumblebee]

Ahh sorry man, Ive been spending all my time trying to get it on the road lol.

Its going to be another month or so I reckon if the weather stays like this...

How was the show?

[laze]

Wet and windy! But the people more than made up for it. You reckon you'll be at the Weekender or JAE? Both?

[shaboy]

don't really read up on these prject threads any more, I've actually got work to do at work now :rolleyes:

But very glad I took the time to have a look at yours again :D

Some top work going on there and a great inspiration :clap: I'm an engineer (CAD jockey) but as I sit here now I couldn't fab up anything like that, very good effort to you and I look forward to having a proper butchers at a show over the summer :thumbs:

[Bumblebee]

Wet and windy! But the people more than made up for it. You reckon you'll be at the Weekender or JAE? Both?

Thats cool man, Yeah im deffo going to be at JAE and hopefully the weekender. Providing all goes to plan with the car...


don't really read up on these prject threads any more, I've actually got work to do at work now :rolleyes:

But very glad I took the time to have a look at yours again :D

Some top work going on there and a great inspiration :clap: I'm an engineer (CAD jockey) but as I sit here now I couldn't fab up anything like that, very good effort to you and I look forward to having a proper butchers at a show over the summer :thumbs:

:o he he he Cheers for the kind words dude, makes this all worth while because believe me, I have got to the point several times when I've thought "What is the point?!?".

Comments like yours, laze's, Emnear's, Treacle's, and everyone in here has made me see the point :D

Few more pics,

After nearly half a day wet sanding the bonnet it looked like this
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs089.snc3/15728_418664795700_519105700_5977942_2009190_n.jpg

After a coat of primer it looked like this
http://sphotos.ak.fbcdn.net/hphotos-ak-sjc1/hs089.snc3/15728_418664800700_519105700_5977943_4895964_n.jpg
http://sphotos.ak.fbcdn.net/hphotos-ak-sjc1/hs109.snc3/15728_418664805700_519105700_5977944_7314794_n.jpg

Then I fitted my twin fans that will be on the bottom of the rad sucking not blowing...
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs109.snc3/15728_418664810700_519105700_5977945_3423172_n.jpg

Now I have hit a proble with the fans hitting the front lower crossmember so I am revising this using box section and welding it further into the car... I'll post pics tonight after I've done it to show you what I mean.

Cheers everyone!

[EMENEAR]

coool! I love your cars style. When my engine is back in and I've rustproofed, I think I may seek your advice so we can conjur (sp) up somthing different :nod:. Keep up the good work!
Ive got a spare CA coming in a couple of weeks mate, guna use it as a reference guide for making sure I but mine back together correctly lol! Might build it up over time aswel for a spare! Fingers crossed that it doesnt rain too bad on Sat then we can both get some work done on the motors!

[Minkjedi333]

your creativity and fab skills are great! The V-mount looks so hooooooot! what you said earlier on about not being as quick as you thought. Are you still running one bar? I could have sworn my friend was running 18psi on stage 2! just a thought tho. :thumbs:

nick

[Bumblebee]

Cheers guys.

In response to my early comment about it not feeling that fast.... I had a knackered knock sensor that was pulling my timing and then I developed a misfire..

Since then It drives ALOT better, faster and more responsive... This whole Vmount thing for me is just an attempt at reducing lag but also because wanted something different :)

I think 15psi (1bar) is the max for Horsham Developments Stage 2......

[Minkjedi333]

Sorry, must have missed that part, after reading a few pages i scan stuff and dont pick up some stuff. My bad. as for no lag check this out!http://www.youtube.com/watch?v=AuJEXp-EKso

My Friend is defo running 18psi stage 2 but i dont know what chip he has.

Keep up the good work!

[Bumblebee]

Sorry, must have missed that part, after reading a few pages i scan stuff and dont pick up some stuff. My bad. as for no lag check this out!http://www.youtube.com/watch?v=AuJEXp-EKso

My Friend is defo running 18psi stage 2 but i dont know what chip he has.

Keep up the good work!

No worries man :)

Yeah ive seen that vid of the twincharged S15..... Its an awesome Idea but WAY out of my budget :(

[Quail]

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs504.snc3/26496_410472540700_519105700_5771135_5503641_n.jpg


That is a lovely piece of work mate! I may have to commission you to do mine when I finally sort out my bay! How long did it take out of interest?

[Bumblebee]

That is a lovely piece of work mate! I may have to commission you to do mine when I finally sort out my bay! How long did it take out of interest?

Cheers mate :)

Actually making it didn't take long at all, I spread it out over three evenings after work but most of that was headscratching and planning with measurements etc...

Have you got a Vmount aswell?

[Quail]

No but its a route I'd like to take :nod:

[Fake Ben Taylor]

upside down rad . . . . How are you gonna fill it or bleed the air or have the pressure system running properly? :)

[TM_S13]

I think he's going to fit a remote/relocation "thingy" on the lower pipe that is now the upper pipe...

[Bumblebee]

upside down rad . . . . How are you gonna fill it or bleed the air or have the pressure system running properly? :)

Like Treacle said,
I have a remote Rad filler neck from an MR2 that I am positioning high in the engine bay and having it T into the top Rad hose ;)

Oh, and the Rad cap on the radiator will be sealed

[Suprmek1]

Just read through nice prject the V mount setup definately works well on my car been running it for 2 years now it gets abused and never gets hot at all.
I got 2 10" fans on my intercooler wich I have on all the time but only need on when sat in traffic. I found with my setup the intake temps are down, alot more power :D and trottle response/lag has been reduced.

http://i176.photobucket.com/albums/w174/suprmek1/KDrift1/DSC00506.jpg

http://i176.photobucket.com/albums/w174/suprmek1/KDrift1/DSC00543.jpg
More in my project tread. I'm still yet to put in my airducting to which will make it much better :smash: I'll get to it one day.

Some theory behing V mounts: When you double the thickness of a cooler you only increase its cooling eficency by 50%. As it makes it harder for the air to travel through, and the air warms as it goes through the fins. With the intercooler and rad together the air has to travel through a larger restriction, and the air that hits the rad has already been warmed by the IC. Also with the 2 next to each other the IC can get heat soak off the rad. 'V' mounting them the air can flow through both the coolers better makling them more efficent and the air hasnt been pre warmed by the 1st cooler.

[Bumblebee]

Nice, Thanks for the info mate :thumbs:

Im looking forward to testing it soon :)

I'm just building a new front crossmember at the moment which i'll have pics of soon.

Was the Lag reduction really that noticable?

Im hoping so :)

[GtstTypeM]

So wish i could weld... And spray.. :(

Awesome thread

[Bumblebee]

Hey guys, Been a while but here's a small update.

I found that my Rad fans were hitting the front crossmember so, yep chopped it out and made a new one.

these are just a few pics, the finished article is triangular gusseted to the chassis rails so its going no where.
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs546.snc3/29887_426305940700_519105700_6156079_4401769_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs546.snc3/29887_426305955700_519105700_6156080_4533461_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs506.ash1/29887_426305960700_519105700_6156081_1853049_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs546.snc3/29887_426305965700_519105700_6156082_599930_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs546.snc3/29887_426305975700_519105700_6156083_1894470_n.jpg

Then I finally figured out the radiator top hose he he.

From left to right we have, T junction for the MR2 Remote filler cap i'm using, Then to the Revotec Fan controller, then to my water temp gage sender :D Bit tight but works he he
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs546.snc3/29887_426305980700_519105700_6156084_1058440_n.jpg

Another shot of the bottom rad hose
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs526.snc3/29887_426305985700_519105700_6156085_1027542_n.jpg

And finaly a shot of the two intercooler pipes I made up out of stainless.
http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs506.ash1/29887_426306970700_519105700_6156094_6429415_n.jpg

And a shot of how it kind of fits together :)
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs546.snc3/29887_426306980700_519105700_6156095_5325069_n.jpg

Incase you are wondering where ive moved all my wiring to, Most of it has been removed and both fuseboxes stripped down and re-located to behind my glovebox

http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs492.ash1/26876_412898460700_519105700_5835021_6330537_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs492.snc3/26876_412898450700_519105700_5835019_880613_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs512.snc3/26876_412898455700_519105700_5835020_6550995_n.jpg

When im happy that its all working, the whole lot is getting a clean/ polish to make it look shiney he he.

I will also get some shots from underneath so you can see how my new crossmember/ Fan setup works :D

Im really quite pleased with myself! My mum called me a clever wee boy he hehe he

[riske]

Is it pretty easy moving the fuse boxes? or have you got to know quite a bit about electrics?

[Bumblebee]

Is it pretty easy moving the fuse boxes? or have you got to know quite a bit about electrics?

I just started out with removing the entire loom, Ditching every wire I didn't need, then one by one cutting and re-soldering the wires I did need with the relays and fuse boxes in the position I wanted them.

If you take it one wire at a time you shouldn't go wrong ;)

The only wires going to the engine bay now (apart from the engine harness), is the headlight wiring, indicators, horn, brake fluid level, wiper motor, Oil temp, oil pressure, water temp gages and boost controller).

:)

[shaboy]

Continuing with the nice work, it's looking good dude :thumbs:

[smiff17]

I'm in awe as I read this thread. The work is genius. I'm loving the home modications and the sight of your bonnet cut to pieces mad me laugh so much. Outside the box thinking there. :clap:

I keep seeing you cut away pieces of the front chassis and re welding them in different places and the replacement with box section. I never realised this was allowable by MOT standards, I thought all chassis and body work had to be original? Like where you've technically shortened the chassis by chopping out the member and replacing it further back with box section. How did you know what is allowable thickness and size?

[Bumblebee]

I'm in awe as I read this thread. The work is genius. I'm loving the home modications and the sight of your bonnet cut to pieces mad me laugh so much. Outside the box thinking there. :clap:

I keep seeing you cut away pieces of the front chassis and re welding them in different places and the replacement with box section. I never realised this was allowable by MOT standards, I thought all chassis and body work had to be original? Like where you've technically shortened the chassis by chopping out the member and replacing it further back with box section. How did you know what is allowable thickness and size?

Thanks for the comments mate :)

I was unaware that it was a problem for mot??? I did the same to my CRX and that passed everytime....

I just used 2.5mm thick steel box section and welded on massive gussets at the chassis rails (havent got pics of that yet). And trust me its not going anywhere.. It hasnt' changed the Geometry of the suspension components at all.. The front crossmember is only really something that ties the chassis rails together at the front and acts as a second mount for the traction arm brackets....

[alanjuggler]

it shouldn't be an issue, many people change the front cross member for 2" box rather than the original rust trap cross member.

[steff777]

must say m8,lovein all your home made handy work!:thumbs: i myself like to do as much as i can n i should be gettin my project up here soon! :) [s13] but ive noticed how you and every1 else have all got large pics up,how do you get them up like that?? or am i just bein dumb! :o haha!

[aaron.nairn]

hey mate iv just stumbled across this thread and i love the V mount idea looks like alot of work but keep it up mate

[Stance200]

update? :D

[Bumblebee]

He he he I could do an update.... You wouldn't recognise the car though he he.

Its now black with new front wings, rear bumper, I have blended in the rear wider arches, In the process of fitting R33 rear brakes and Hi spec front brakes.....

I'll take some pics anyway to show where it is at now :)

[Stance200]

please please do because im getting rb-x's for my 13 and thinking about black so would be nice to see :) nice build dude!

[Stance200]

update :D

[Mike_S14a]

wow! awesome project! inspired me a hell of a lot! dont have the ability you have however. im going to give a few things a go. if i mess it up proper i can also get someone to put it back right again! haha.

[dgr]

looking forward to an update, good work.

[Stance200]

pleaaaase :P

[Bumblebee]

Really sorry guys, ive been stupidly busy and haven't had time to take pics.

Ive got my MOT wednesday so I'm racing to get that sorted. this weekend i'll be re-building my spare engine to swap over so i'll take some time out to get some decent progress pics.. Cheers for the interest!

[Bumblebee]

Well sorry I haven't got any pics yet.. Im having a right bout of bad luck at the moment...

Went to get MOT and I have a front lower ball joint to replace. On the way back I could smell burning oil. I still had good pressure and temps were good so I carried on the two minute journey to my house.

I got out the car, and saw a nice black line following the driver side of the car. Jacket it up and found the leak to be coming from the 45 degree elbow adapter for my oil pressure sender. On closer inspection, it is has snapped and the threads are stuck in the block :censored::furious:

At the moment Im building my spare engine so Im just going to finish that build and swap them over.

The next pics I will upload will be mostly engine build work but i'll take a couple of cheap shots of the car aswell.

[Macca]

this is a great project pal... enjoyed reading it.. fair play.. looks awesome. loving the rad i/c setup. very different.