The Project Pad

MORE UPDATE!!!!
So I built this catch can a while ago and got it welded up by Ryan, thanks again, and it was time to get it mounted in the engine bay. I wanted to have nice flat or slightly uphill hoses and it needed to be easy to drain.

I made a mounting bracket and tacked it to the body. I welded a m6 weldstud to a band clamp and used that for attaching it to my bracket.




It fits pretty well between/inwards of the coolant and washer fluid reservoirs.




I got started mounting my battery in the trunk right after that. Thanks again to Haydn, for this spare battery box he had kicking around. It’s mounted in place with two m8 coupler nuts welded to the frame rail and an m8 weldstud on the back/blindside so it’s much easier to get the nut started.

I also welded a m8 stud to the frame rail to use as a ground stud.
I mounted a 150A breaker to the top of the battery box, ill snap a pic of that later.



While I was hammering away on that Toph installed my hood pins. He recently installed some Aerocatch pins on his CQ with exceptional attention to detail so I had no problem letting him loosing drilling holes in my car.

Nice work Tim. The catch can looks familiar. Is it part of an evaporator from an UrS car?

yeah its most of it, theres an update a few pages back with its construction. its been cut apart and lengthened, as well as some down tubes where the inlets are.

heading back out to the garage for IM and boost piping mods, exh tip work, and some custom k24 cooling lines
update to come!!

nice idea on the intake end cap modding :wink:

glibobbo21 wrote:nice idea on the intake end cap modding :wink:

thanks, my local euro tooner parts delivery guy suggested it


new year , need a new car, back to wrenching

back to the lab

UPDATE!!!!
Ok a few small catch up things and then its on to the fabrication update!!

Got my light bar finished up, I need to wire it up and then POR it.
It should provide ample light


Customized up some trans/diff mounts. Race spec


I miss the old pre-fade orange, well fresh paint it will be then realtree blaze camo vinyl.



I got my rear trunk patch painted and now time to reinstall the trunk liner.


Cleaned up the AEB starter and its heat shield



And lastly the d11 v8 taillights about to be cutup for t-85 usage

UPDATE!!! I finally got a chance to get started on some of the smaller, rebuild/clean up/reassemble stuff that would need to get done, just getting to all the smaller tedious steps before it can run.

I popped my wastegate off and proceeded to tear it down. I already had a 1.9 bar spring, but I wanted to add a new diaphragm as insurance. Jim, glibobbo21, had also ordered a box of M5 cap nuts and washers in stainless, so I added those for a nice clean look.



I also got a chance to teardown and cleanup the t-44 brake master cylinder and my 4kq vacuum booster. The m/c got a bit of wire wheeling and the booster got a bit of sandpaper and some enamel. I was going to sand it down and recoat a few times but F it! It’s a brake booster and its now protected from the elements so that’s good enough!! I want to drive it!!



I also got a check valve from a porsche 911, PN 191 611 933F
It uses the same size booster grommet and vacuum line to the manifold, its extra nice and clean as it’s a 90 degree valve so it keeps the vacuum line tucked out of the way.

MOAR!!!
I got into the bay and got to finish welding.

Finished- clutch m/c brace, steering rack/strut brace, misc weld studs for lines and wiring, aux water pump mount, oil cooler and intake shields/duct work, etc etc
It’s all done and now for bay priming, sealing and painting.

And two pics, unsure where the rest are

The bay is getting another coat and then its reassemble time!!!!!!!!!!

my2000apb wrote: I cut and inch and a half into the frame rail and used some large steel plates to reinforce the area.

What will MOT say about this?
Anyway, good progress you make.

my2000apb wrote:I also got a check valve from a porsche 911, PN 191 611 933F

got mine and tophs for free from a chevy :-D

Val wrote:

my2000apb wrote: I cut and inch and a half into the frame rail and used some large steel plates to reinforce the area.

What will MOT say about this?

most inspectors in america are lazy :jerk:

UPDATE!!!!

Ok, so there’s those small projects that I’d always wanted to make but wasn’t going to tear the car down to do them. Well now that the car is all apart I had the perfect opportunity to dive in.



First things first, was to reinforce the fenders in general, these 4k’s are pretty flexi anyway, so anything we can do to help stiffen it up is very welcome. Then it was time to vent the front fenders. Im using a piece of 4kq hood vent from the raintray area. It has been bent to match the fender lines on the car.







I have to thanks Toph for all his hard work on the following. Basically a fender vented / fed air intake box and oil cooler ducting, so they both get good cold air but are tucked up out of the way of debris etc.

The air intake in the fender is pretty self-explanatory. There is an inner heat shield and an outer as well that sits in the fender. The air intake box sits very close to the fender and will be weather stripped on final assembly

Next up was oil cooler ducting

With the intake side done it was time to duct the oil cooler. The cooler sits inside the drivers fender in a small cage to protect it from us sliding into things haha

More update!

Im going to be running a hydro handbrake in this car for some good ole hooning fun. Ive bent up a neat little box with some weld studs to mount up the handbrake lever. It is going to be mounted/relieved into the trans tunnel. It will be a snug fit in the little car but should come out great. It will clear the o1e linkage, and I will just need to cut a small bit out of the ashtray, no biggie. This will allow me to keep my complete cable actuated mechanism. Although it is a bit harder to start the nuts on the weldstud vs going to a welded nut for mounting, this allows me to use washers to space/angle the handbrake lever for final positioning. Pics!!





Im going to be finishing up the final version of my t85 o1e linkage and will be welding the box into the tunnel later this week.

Looks like you are moving along nicely. Cant wait to see this in person.

UPDATE!!!
Ok with the main front bracing built and finished I set to making a nice undertray, misc debris guard. It was never meant to be a skid plate, but it ended up much stronger than I thought it would be.

The undertray mounts in four spots, the two front mounts are just inside the main lower front brace bar, and the two side mounts are rearward and outside near where the brace bar mounts to the frame horns. You’ll see in the pics.


The main frame is ½” 16 gauge box tubing, and the sheet is 16 gauge in the center and 22 gauge on the wings/sides. It is mounted with a slight downward angle from the lower front brace bar to the front of the subframe.








The middle pieces of the frame are “Lincoln logged” together. On side of each was relieved so they fit right together and are still very strong.

MORE undertray fab.

I got the framework all welded up with the sides as well. It is already a pretty stout piece.





Started skinning the bottom. The center is 16 gauge and the sides are 22 gauge. I could have made it all from 16 or 22, but I went with the thicker stuff in the middle as it will get a lot more debris, but 22 gauge on the sides to help keep weight down but also as there won’t be nearly as much rocks, sticks etc. coming in from the sides.





I also picked up one of these cool punch/flare tools for sheet metal last time I was at Summit. Its all-star products
http://www.summitracing.com/parts/aaf-all11074

It is a combo punch and flare, 2” hole up to 16 gauge!!! So I set about drilling pilot holes and getting my punch and flare on!!! This makes the panels much stronger! As well as look uber motorsport hah

Update!
Ok here is the tray installed back onto the car. You can see where the sides / wings come up close to help seal the bay from debris but not air tight by any means.

The brace itself weighs ~6 lbs., but when bolted to the chassis it can easily support my 180lbs barely flexing at all, damn is it strong. It might not save an oil pan if I bottom out super hard but it sure will keep most other stuff out of there. I need to punch flare the last few holes then it’s a full coat of POR with the rest of the front bracing.

this is quite the ralley build.

ill be pleased if my sport comes along like this, but your gonna miss the winter if u keep up this madness....
youd be suprised how fun a stock b2 chassis is w/ a 300hp 16vt, you couldve waited for allthis extra mayhem.

shit by the time this things tuned itll be spring time... but i suppose you fellas got plenty of dirt to go
slide about in, theres very few dirt roads down here w/out angry walkers on them.
CT yuppys suck

vagrant_mugen wrote:this is quite the ralley build.

ill be pleased if my sport comes along like this, but your gonna miss the winter if u keep up this madness....
youd be suprised how fun a stock b2 chassis is w/ a 300hp 16vt, you couldve waited for allthis extra mayhem.

shit by the time this things tuned itll be spring time... but i suppose you fellas got plenty of dirt to go
slide about in, theres very few dirt roads down here w/out angry walkers on them.
CT yuppys suck

no way buddy, this thing will be roadworthy in no time, gotten way too mcuh done to update, no going to take pics of basic rebuild/reinstallage so im making even more progress

and yes we have tons of dirt and loggin roads for hooning, ct yuppies do suck


fuel tray being built, IM being finshed welded and PC'd with a bunch of other parts, also have a batch goign out for hard black anodizing as well

Mini update, got a little bit of time in the garage last night.

I got my k24 coolant line adapters back from Ryan, and they look sexxxxy! I’m using a 3b coolant feed freeze plug with a low profile Aeroquip weld-on AN fitting. This allows me to still be able to press this plug in as its fits easily inside of a 19mm impact socket. I’m not sure where the flare portion came from, I think it’s b4. Either way, k24 cooling is just about finished; I just need to make the 6an lines to and from the adapters.


Most of my stuff has been blasted and its going to get black wrinkle powder this weekend, the cast and IM is all getting PC’d and all the billet / extrusions are all getting black hard anodizing. It’s going to be sexy


I managed to get the final coat of paint on the engine bay. The flash makes it look very gold where It’s really a much darker bronze color.



Toph, working on the v8 shorty taillights, more to come on those modifications



And similarly to the under tray I built for the front. I wanted to build a small shield for the fuel tray area. I had initially thought of just making a protective shield for all the factory tray/ filters etc., but then I thought why restore/clean/prep/prime/paint the old one, when I can make a new one and integrate the filter/pump mounting and the protective shield all into one. So I started making a nice little tray of ½” 16 ga. Box tubing and 22 gauge sheet. it will be more than strong enough to hold the fuel pump and filters but also protect the stuff from misc. debris



And we got the mega crimper of death from the neighbor who installs generators, so I can finish my battery and ground leads.

Go man go! AWESOME

Sweet. You're on a roll, I need some of that in my life! Haha

UPDATE
Ive finished up the fuel tray and its been por15’d. its ½” box with 22 gauge sheet, with flared holes. Its plenty strong. I got a few fuel pump and filter brackets powder coated over at Higbee Fab and mounted them up to the tray.




I also cleaned up the AEB oil pan that I had and compared it to the pan I got from Justin. He hooked my up with a brand new, late b5 pan! The difference being it has the spot for oil level sender but its not drilled. So I was going to use the AEB pan anyway but the coating is all cracked on the inside and I don’t want it coming off and clogging my oil pickup. So the brandy new pan got its drain tapped to ½ NPT and I was good to go.


Ill be installing it tomorrow with the new AEB oil pump and ABA ( possibly modded) windage tray / gasket.

and lasty i saw in Mr AngryTaco's 4kq thread how wornout his clutch pin was i popped mine out and look at that, its worn out as well, so i got another one of those from the dealer and itll go in when i put the freshly painted master cylinder back in.

i will make a comprehensive parts number list on page one shortly
clutch pin part number N0231531