clubhouse customs

snuck out at 10 last night to do a little work. Managed to get the new front support cut and welded in place. Now I can finally start creating mounts for the top of the bumper and the headlights.

Dan

Tues I finished welding up the ball joint plates. I also got the bearings pressed in and painted them.

Tonight I bolted one in.

The new flywheel came today. Tonight I got the flywheel, clutch, transmission, starter, cables, mounts, driver side suspension subframe etc etc all back in. I also pulled the struts and knuckles out so I can ream out the ball joint holes and Im going to shorten the strut tubes 3/4″.

Few pics of the rear suspension coming together. Im still short some hardware and I need new alignment shims.

And, pulled the trans and clutch.

Gota figure out what Im doing with the flywheel. If I should just have it resurfaced or I can buy a new Sachs one for $50.

Picked up the beam and my door panel skins from powder saturday am. Managed to get one door panel on. Which I think look much better than the raw alum.

 Dan

I got the new 3″ midpipe and mufller welded up on tues night. I still need to create a hanger for the muffler and make the aluminum Y and side pipes.

It hangs down like an inch or so, not bad.

Adding things up this new 3″ exhaust should be 17lbs lighter than my old 2.5″ with the cutout. Not bad.

Finished up the midpipe and its hanger tonight. Just need to paint it up now.

Also finally cut out the plates (again, with my trusty bosch jig saw) for the monoball setup. One is basically all done. I just need to make some relief cuts between the control arm holes so it can go all the way in (its short by about 1/8″). The other still needs the cup welded and the reliefs cut.

monoball plate vs. stock balljoint.

Dan

Back to working on the front end.

I picked up the steel brackets for the core support from the laser cutter on the way home from work. Managed to get them welded together, and welded to the car.

The new upper core support mainly done, including tabs for the hood pins.

And welded up what will be the new bumper support.

There is still a lot that needs to be done, but I almost have enough to start working on the bars for the headlights and grille. Im hoping to have complete by the end of next week.

The plan is for the bumper cover support and the upper core support, headlights, grille etc to all come out as one assembly by simply removing 4 pins.

Dan

Finished up the beam tonight, I think.

Other side hub plate, gusset etc welded on.

Added a small wedge next to where I had previously welded the flex joints. Im not sure if it was necessary, but it should add some strength and it def looks better

All finished up. probably.

One mockup K brace tube in place. I need to order the right tubes and hardware still.

And last for tonight, a shot of the spacer and brake backing plate (again, not the right hardware)

Dan

Finally got one new hub plate, gusset and K brace mount done. The other side should be done thrusday night.

I think it turned out pretty good. My welding is definitely improving. The new pyrex cup kit I got from HTP was definitely helpful for this job, no doubt.

Dan

More or less finished up the rear swaybar setup tonight. I just need a few longer bolts for the endlinks and to finish up the spacers for the lower shock mounts. (so I can use 3/8″ bolts)

I TIGd the mounts to the chassis, which was interesting on the inside ones. I had to lie on my back, squeeze the pedal between my knees, and do a couple parts left handed. All in all I think they turned out pretty nice.

I also finally finished cutting out one of the new hub plates. The other had the holes drilled, just needs the outside pattern cut. (yes, I made both of these using the drill press and a jig saw)

This is how it all goes together. The larger hole is where the alxe beam gets welded to, thus moving the bearing up 2.5″. MOre to come on that wed night.

Dan

Trunk lid showed. Its 10lbs as it sits.

The stock lid is like 40lbs. And the hinges, brackets and torsion bars I cut out were another 8lbs. So pretty good weight savings.

I need to order some dzus stuff asap.

Dan