584 replies to this topic

[El_Freddo]

Yeah mate this thing is going to be off it’s tits good and proper when it’s done!

Cheers

Bennie

[Barbbachello]

Gorgeous as usual

[RX25SE]

[JDWhiteWRX]

Just a small update for you guys.

 

I have mocked up the replacement firewall using cardboard templates. Removed the engine and now I am busy transferring those templates over to sheet metal to be welded into the car.

 

Removing the engine is fast and easy with the way I have designed everything.

 

[JDWhiteWRX]

I've had a bit of a break from working on the car but yesterday I spent the day turning my cardboard templates into a steel firewall. I don't really have much experience working with sheet metal and I don't have any tools for it either but I'm pretty happy with how this is coming together.

Just a video of the process for now, I'll get some photos once everything is complete.

https://www.instagra...id=MDJmNzVkMjY=

[allpaw4]

Very nice. Good to see more happening with this little puppy!

Cheers,
Ben

[RX25SE]

Glad to see an update after a bit of a break!

[El_Freddo]

For someone who doesn’t have much experience with the sheet metal, your video makes it look like a professional effort - and like it’s an easy thing to do! CAD for the win right?

Thanks for the update!

Cheers

Bennie

[JDWhiteWRX]

Some more work on the firewall replacement today. I have now finished cutting and bending all the sheet metal so now it's just a matter of welding it all in place.

 

 

I ended up using more than one piece of sheet metal to do the tunnel replacement, simply because it's easier to manipulate smaller pieces rather than one big complex shape.

 

 

I found that even if my cardboard template fits perfectly there was no guarantee I would be able to make the steel bend in the same way, at least with my skills anyway.

 

[allpaw4]

Nice work man, incredible skills! Its coming along nicely!

Cheers,
Ben

[El_Freddo]

It’s looking really good Joel!

Cheers

Bennie

[RX25SE]

Definitely getting there. Nice work!

[JDWhiteWRX]

Thanks guys, I really appreciate the support from this forum

[Barbbachello]

Killer as always. Gives me motivation to have a crack at fabrication too

[allpaw4]

We're not an overly large or active forum any more, but we certainly enjoy seeing this sort of project take shape! I'm pretty sure the others will agree with me!

Cheers,
Ben

[El_Freddo]

Amen to Ben’s comment above!

Cheers

Bennie

[RX25SE]

^ yep +1

[JDWhiteWRX]

Time for an update.

 

The firewall is finished. If you are late to the game the reason for the new firewall was that I am allowed to move the motor back 51mm behind the original firewall under the WTAC rules.

 

The original firewall was cut out, the engine was mounted in its permanent position, cardboard templates where made with the engine in place and then a new firewall was made based on those templates.

 

 

I used a plug weld technique to attach the new sheet metal basically mimicking the original construction. It was a lot of drilling around all of the perimeters. I used a weld-through primer on the back side before doing the plug welds with my MIG.

 

After welding there was a lot of grinding with a flap disc to give a smooth finish but I think it came up really good.

 

 

The whole lot has been primed now to prevent any surface rust while the build continues.

 

 

Here is a video of the inside and out

 

https://www.instagra...g_web_copy_link

 

With the firewall finished I am moving on with the front pushrod suspension. I have purchased all the rod ends and bearings for the bellcranks and pushrods. A friend at work has been putting my bellcrank design into Fusion360 so we can first 3D print the bellcranks for testing and mounting and then later have them CNC machined from aluminium.

 

[RX25SE]

Love it!

 

Those plug welds have the same look as OEM spot welds.

 

So you moved from Cardboard Aided Design to Computer Aided Design!

[allpaw4]

Very nice work. Glad to see this being updated. Love a good build!

Cheers,
Ben