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Thread: Project Phoenix

  1. #1
    Guest bigtone's Avatar
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    Project Phoenix

    as most already know we (Buffy and myself) are building an S13....
    --------------------------------------------------------------------------------

    so after the little fire we had while mapping my car (wheel spinning at 140mph )
    it was time for a new plan...
    with thanks to Mel B I got my hands on a new shell (well he gave it to Buffy and buffy then graciously passed it on to me )

    the end...


    the start...


    we had to get it back to Buffy's garage and as she was still drivable I drove it there, but I had to stick 2 in petrol (if that wasn't embarrassing enough Buffy took a pic of the fuel pump )
    once at the garage it was time to prep her....1/2 hr into the strip we got this far..



    at this point Mel B came around and said "that was a compleat car 3 hrs ago.."



    back to the shell prep...
    as we wanted to do something thats never been done to a 200 the thinking caps went on...
    ND came up with a few as did Buffy and myself
    so it was time to put them into practice
    first to go was this...



    Buffy set to it with some power tools.



    and a few hrs later the bastid was out...


  2. #2
    Guest bigtone's Avatar
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    then came the refit
    first off came the suporting bars to take the new fuel tank



    then the new floor



    then we made this



    to fit in here



    like so



    one new floor to house new fuel tank..

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    some of the crap we cut out...(more to come)





    after replacing the boot floor Buffy let me loose with the welder (well it is mine)
    so I welded up the back..



    we then got rid of all the sound proof stuff and started seam welding her..






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    as we seam welded we also primed..







    the whole boot floor also got primed..



    as we started welding we found the odd bit of rust so we fixed it..
    this one was behind the door hinges both sides..

    we cut out the rust..



    replaced and prime..



    the battery tray was next to go..
    sweet job dont you think..



    we also made a nice hole for a new air feed..
    Mike made this..



    for here



    and looks like this..


  5. #5
    Guest bigtone's Avatar
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    ok, now for some weight saving..
    the first thing we cut up was the doors...



    we also removed the lecy window
    loads of weight there



    as for the drivers door the lecy window will be staying..



    we then had a look at the bummper..



    now to lose more weight the subframe came under scrutiny..
    so off came the counter weights



    bit of a twaty job but we managed to remove all 4 lumps of metal..
    if its not needed its coming off...

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    before any work was carried out on the subframe we first had
    to get the old bushes out...

    a quick trip up to Merthyr to see Chris
    and no more bushes...



    with the uesless bits of metal now gone its off to the shot blaster for the
    subframe and other bits..
    before



    after



    also



    and a home made power brace



    then we fitted some solid bushes




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    re fitting the front subframe and power brace



    I have to say fitting the power brace was a pain...
    watch out for the captive nuts they can snap off, as did mine..
    so we cut out the side of the inner rail to gain access to the little bugger..


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    next job we had to do was get the shell's interior painted so the roll cage
    could be fitted...

    out came the spray gun..

    before



    after









    the big man in action (me)


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    now the painting of the shell is compleated its time for the rollcage...
    you would not believe the trouble we had finding a company to make us a cage..
    4 of us went to the autoshow at the NEC thinking we would find one...
    and we did, unfortunately they are based in Yorkshire...
    now the first challange we faced was to get the car to Yorkshire..
    as we didn't have a trailer Buffy came up with the idea of an A Frame...
    so we made one (it did an awesome job)



    I would like to say a big thank you to Protection & performance for an
    awesome job they did on the rollcage..

    The cage is all T45 to keep the weight down..








    and now all painted up..









    Last edited by Bigtone; 16-02-2007 at 17:29.

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    now its time for the car to go to its second home...ND's
    Mr Norris was kind enough to let Mike and myself have the run of his workshop
    all by ourselves
    so off we went to ransack I mean work in his garage..
    firts thing was to drop the rear subframe..





    then we stone chipped her..





    and the refit begins..









    Mike with the 1 finger lift..




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    now for the brakes...

    up rated brakes all around..

    rear (R33's)

    new



    modded



    painted



    prep and painted





    now to fit the new calipers and discs we had to cut away the dust cover



    front (4 pot brembo's with 330mm discs)

    spot the new ones



    with longer studs






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    now with all the pads in place its time to sort out the brake lines and as we are diching the ABS and servo we are fitting 2 new master cylinders...



    we are also fitting a line lock











    to the rear





    we bent the bracket slightly to get a nice stright fit (brake line to braded line)





    ok with every thing in place it was time to bleed the brakes

    with the first few pumps of the brakes we found 4 leaks

    1 at the rear T (the pipe going to the drivers side)
    turns out to be a fecked thread inaside the T so we need a new one

    the other T also leaked (we fixed that)

    and the thingy with the wire leaked out of both ends
    so we changed fittings and managed to stop the leak

    the only leak we still have is out of the rear T...we'll change that next time..




    fitting brake pipes is not the easyest job but if you have time (we didnt)
    you can do it (we need to slow down abit)
    the thing is for Mike and Myself time is something we dont have a lot of
    as we have to travel just over an hour to get to ND's before we can start work
    its not in Mike's garage anymore so you cant just pop up and do stuff..

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    now for the real twat of a job....
    setting up the brake bias..
    We are using .75 rear and .625 front cylinders with the bias bar attached to
    the brake pedal...

    Mike fecking about with the bias



    this is what it looks like under the dash



    by welding the tube on to take the bar



    we had to cut this away



    so it woulden't foul on the brake pedal when pushed..



    nothing is ever easy is it


    time to re bleed the brakes


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    ok.... some action shots




















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    Norris getting ready to receive a finger up his arse


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    now for the fuel system..

    the new tank..



    its baffled and foam filled



    it will sit inside the hole



    the fuel pump will sit here..



    and we ran the fuel lines..
    dash 8 to deliver and dash 6 return


  17. #17
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    so Dave could make a new engine loom we had to fit the engine
    so he could get the measurement right....

    so this is the first time this engine has been in this shell...



    allmost there..



    and in...well bugger me it fits..


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    going to try something differnt to the front so we cut away the slam panel



    and finished off the ends like this



    as far as I know this has not been done to a 200..
    we also plan to fit an angle bit of ally accross the opening to make it a removable
    slam panel.
    should also make it quicker to remove and re fit the engine if ever needed..

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    to save even more weight 1 of the wipers had to go..
    so we came up with a single wiper conversion...

    first off we had to cut up the 2 arms and re weld them together to get the
    correct lengh



    then shape them (bend, twist) so as they rotate they miss the bulkhead and give a clean sweep
    on the screen



    we also had to cut, shorten and re weld this to make the sweep the correct arc



    a bit trial and error to get the bend and lenth right..
    we also hooked the wiper motor up tp a battery to see what the final sweep was like..

    then we had to remove the screen (without any screen removing tools)



    that was fun..

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    now for the rear lights..
    didn't want standard or a set of Kouki's so went for R32 rears..

    first we cut away a load of waste metal



    then made new by placing the lights where we wanted them to sit and cut and welded in new metal to take up the space between them and the lights
    All the other 13's we'v seen have mounted the R32 lights in a way which requires cutting the tailgate. This was something we wanted to avoid doing, so we chopped the back of the car instead (explanation by Mike)
    The bodshop will make a new surround to blend the car and lights when finished.



    and fitted the new lights



    and should look something like


    and one with Mike in it...


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