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  #161  
Old 06-15-2016, 12:35 PM
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Finished modifying the floor for the fuel system. Removing the pinch weld here allowed more room for the surge tank and for the lines to route to the rocker area.

I failed to get a before pic but it looked just like the drivers side shown here.




And after. Was difficult to get a good shot of, but oh well.







I have a solid plan for the fuel filter mount. I should have that and maybe the surge tank mounts done thursday.

Dan
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  #162  
Old 06-16-2016, 07:42 AM
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Looking good. This is going to be the most detailed VW Cabriolet in the world!
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  #163  
Old 06-29-2016, 09:58 AM
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Haha, thanks. It sure is a lot of work, but its been pretty fun so far.


After more time than I care to comment on I finally have the fuel filter in place and the surge tank welded up and the mounting brackets done. Now I can finally order the hose ends I need to get it all plumbed up. I did get some 3/8" NICOPP to make the new hard lines with a couple weeks ago. Probably start on that later next week after I make a tubing straightener.


Fuel filter bracket. Trimmed a little of the lip off the pinch weld, cut a notch in the bracket, and slipped it over and welded in place.







Finished up the tubes for the subframe bracing and mounting tabs for the surge tank. I still need to bend up some plates for the front supports I sectioned as well as to tie into the floor pan in a few locations, but at least the tubes are set.






In order to route the fuel lines from the rocker area, instead of their normal routing I had to flatten a section of the one rib in the floor. Was really hard to get a decent pic of this.






Surge tank. Im a little rusty welding aluminum but it turned out ok and should be plenty good enough. On the mounting bracket I also did a 3/4" plug weld in the middle to the tank, just ground it smooth after. The crazy angle of everything makes for clean hose routing and clearance for the chassis etc. It wasnt my first choice but I think it worked out in the end.







Dan
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  #164  
Old 06-29-2016, 12:19 PM
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Quote:
Originally Posted by juicedz4 View Post
I did get some 3/8" NICOPP to make the new hard lines with a couple weeks ago. Probably start on that later next week after I make a tubing straightener.
I didn't think to use NICOPP for my fuel lines. I used terne-coated steel. Could you educate me on why one might choose one over the other? I assume the NICOPP is easier to bend/form.

Here is my version of a tube straightener using a vise and plastic rollers for a sliding door, for what it's worth: http://www.offroadfabnet.com/forums/...&postcount=379
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  #165  
Old 06-29-2016, 12:29 PM
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Im not sure I could educate you on that, haha.

I chose nicopp over stainless because I didnt want to have to deal with bending and flaring stainless, which was my first choice. I figured if it was good enough for brake lines, why not for fuel too. Also Ill never have to worry about nicopp rusting. I am going to be running some stainless spring rock guard over it for added protection.

Ive had your tubing straightener in mind. Which big box did the rollers come from? I looked at Lowes a while back, they seemed too only have smaller ones.

Dan
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  #166  
Old 06-29-2016, 12:50 PM
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I got those rollers at a smaller hardware store, Do It Best. Similar stores like Ace, True Value, or older mom & pop shops may also carry them. The warehouse stores are not good for this kind of thing.
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  #167  
Old 07-01-2016, 09:43 AM
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Wanted to make a little more room for a battery in the trunk.

Cut a hole. This took quite a while to get a nice fit.




Found some 14ga steel in the scrap bin at work. Made it into this.








It fits!




Need to do a little work on this edge to tie it in, but shouldnt be too bad.



Dan
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  #168  
Old 07-01-2016, 10:57 AM
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You know that you just sanded a weld smooth & because of that, well, it'tl break
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  #169  
Old 07-01-2016, 11:01 AM
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Haha. Exactly why I put big MIG welds on the inside.

Im also doing something on the outside of the box which should add some strength and make it look less out of place. Coming soon.

Dan

Last edited by juicedz4; 07-01-2016 at 11:07 AM.
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  #170  
Old 07-01-2016, 11:41 AM
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Very nice! Are you going to put the battery in a sealed box? I went with a plastic box to comply with SCCA and NHRA rules.
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  #171  
Old 07-01-2016, 11:47 AM
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Thanks. And i probably wont use a box to save room.

Dan
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  #172  
Old 07-13-2016, 09:52 AM
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Battery box is 3/4 welded in now. Im probably going to put the car down to do the other side so Im not welding it all upside down.

Couldnt just leave the battery tray a big flat box, so I extended the ribs from the well into the box. It was a quite a bit of work that no one will ever really see, but it was worth it. Im going to seam seal the edges to round them up a little more, plus Im chip guarding the whole underside so I think it will look pretty seamless once done.











Dan
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  #173  
Old 07-13-2016, 11:53 AM
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A little OCD, are you? lol. Good job.
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  #174  
Old 07-13-2016, 12:29 PM
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I have my quirks. I just couldnt leave it. This was more of a exercise in can I, not should I. hah

Dan
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  #175  
Old 07-18-2016, 09:27 AM
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Stopped by the powder coaters friday. Not much was done, just the charge pipes in wrinkle black, and some of the pedal car parts in ecoat.





I also picked up some 2.5" 0.125 wall square tubing to use for the subframe braces.

Sectioned in half, which was a pain. Had to do two passes on the band saw as half was a little tall still.


Perfect fit


Cut some notches


Turned this mess


Into this


And made some plates to tie the rear into the floor


Then it was time to weld everything together. First though, I desperately needed to change my welding helmet shields. Slight difference...


Welded up what I could while it was on the car.


Then removed the whole thing, which slid off easily. Total weight is 36lbs, which I didnt think was so bad.




Then I spent a couple hours finishing the rest of the welding, including some dome caps for the rocker rails


Still fits!



Some time this week I hope to get it welded on once I get it and some parts of the car primed.

Feels good to be close to having this "little" project nearly wrapped up.

Dan
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  #176  
Old 07-18-2016, 10:12 AM
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Quote:
Originally Posted by juicedz4 View Post
I have my quirks. I just couldnt leave it. This was more of a exercise in can I, not should I. hah

Dan
You too, huh? I'm slowly learning when to say when, but I still fall into that trap more than I should.

Looks great!

Amazing how gross the shield can get on your welding helmet without really noticing, isn't it? It's always amazing how much better a clean one is when you finally change.

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  #177  
Old 07-27-2016, 10:41 PM
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Forgot that I also picked up the fan shroud from powder a couple weeks ago, found it in the truck the other night.



Built a dolly to roll the body around for when I start priming and doing bodywork etc.



Finally removed the rear windows, window trim, and roll bar padding / trim etc. About all thats left is the windshield and door strikers.





And FINALLY I got the calipers powder coated. Since they required a little masking and care to be taken during blasting (bores) I did them myself using our small setup at work. To mask the bores during blasting and powder I bought some big tapered silicone plugs, they simply pressed in and worked great. My powder guy was nice enough to give me a few pounds of powder to do this and whatever else I might need. For my first time coating something they came out really nice, but its so simple really.









Dan
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  #178  
Old 07-28-2016, 07:44 AM
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The calipers look great!

One of the reasons I have a love/hate relationship with powdercoating is that it gets in EVERYTHING. What did you use to mask off the flat section of the mounting lugs? When you mask stuff, does the masking have to stay in place when it goes in the oven?
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  #179  
Old 07-28-2016, 09:12 AM
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The calipers look great!

One of the reasons I have a love/hate relationship with powdercoating is that it gets in EVERYTHING. What did you use to mask off the flat section of the mounting lugs? When you mask stuff, does the masking have to stay in place when it goes in the oven?
Thanks, Im pretty pleased

I used Kapton tape, only because we have copious amounts of it around here. But they make cheaper high temp masking tapes for this use.

The tape stays on during baking as it has a silicone adhesive and is rated for 500*F. It just peels right off after without leaving a bit of residue.

For holes silicone plugs work well and can be reused near indefinitely.

Dan
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  #180  
Old 08-01-2016, 09:54 AM
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Lots of progress this weekend. My girls were busy with dance and work and what not so I had more or less the whole weekend in the shop.


Assembled the calipers.

Fronts are super simple.



Rears take a little more work to get the internal ebrake assemble back in. Its not hard really, just a little annoying.








Then I decided it was time to test fit the MMP big brake adapter brackets. Turns out they typically require a little rework of the knuckle, mine were no exception.





After some careful grinding and filing.






Then, because I cant leave well enough alone I spent 30 mins smoothing the mold lines on the knuckles. Now I can drop these off to be powder coated (again) this week.






Next it was time to try out the Master Series Silver primer that I got for the subframe and other parts of the chassis.

First I spent an eternity scuffing the entire thing with 80 grit. Then brushed on two coats. I didnt need it to be perfect as Im going to be chip guarding the entire bottom of the car including the brace. Im super impressed by this stuff. After just a couple hours I tried to scrape a little off with my knife. I really had to work at it just to scratch down to metal. :tup:






Finally, as its about time to start on the hard fuel lines I whipped up a tubing straightener. I more or less stole Clint's design - Thanks!!

I got some cheap acetal pulleys from mcmaster, then turned them on the lathe to fit the 3/8" tubing, drilled a few holes in two pieces of aluminum angle, and bolted the whole assembly to my bench vise. It likely wasnt necessary for the NICOPP tubing, but Im sure it will come in handy in the future as well.






And it looks like Im going to need a better bender for this NICOPP. Probably going to order a Ridgid instrument bender today.



Dan
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