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  #221  
Old 01-29-2017, 12:17 AM
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Did a little more work on the "booth". Scored a 24" dog tunnel on amazon and cut it down to use as a fan duct. It works pretty slick and is easy to pop out of the window and move out of the way when Im not using it.



A guy that I work with has a small CNC at home that hes looking to get some practice on so I had him make me this. Its a simple block to keep the brake line fittings keyed on the firewall. I have a few other things lined up that hes going to be cutting for me as well. Ill prob have this nickle plated along with a few other things (door and hood latches etc).



Ive been working hard the last couple weeks trying to finish up the last of the fab on the engine bay, getting it stripped down to bare steel, and primed.

Welding and grinding done, stripped down bare.


Coated with Master Series Silver




And today put a good coat of 2k primer over the MSS.






Tomorrow Im starting on the filler, should be a ball of fun.

Dan
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  #222  
Old 02-01-2017, 03:57 PM
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CarterKraft CarterKraft is offline
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Dang, don't know what to say because you are so far above my level...

You might get a SpaceX contract if you keep this up. LOL
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  #223  
Old 02-03-2017, 10:42 AM
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Haha, lets not get crazy.

Filler has begun. As of reallly late last night Im almost done with the firewall. I just need to work on the lower transition to the OE firewall and a little around the corners. Hoping to finish that up, get some primer on it, and move on to the next section this weekend.



Dan
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  #224  
Old 02-06-2017, 02:12 AM
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Have you picked a color?
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  #225  
Old 02-06-2017, 02:18 AM
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Engine bay is going to be Audi silver. I THINK the bottom of the car is also going to be the same silver, but with black wheel wells.

Exterior and motor / trans are going to be Porsche slate grey.

Interior is going to be mostly black and grey with red leather seats (gona be a re-dye job).

Dan
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  #226  
Old 02-06-2017, 06:28 PM
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Will it be a metallic or solid/nonmetallic? I think darker grays like Slate Grey look better in a metallic, but I like lighter shades like Nardo Grey in nonmetallic.
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  #227  
Old 02-07-2017, 10:08 AM
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Metallic.

Dan
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  #228  
Old 02-10-2017, 01:22 PM
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Almost done with the firewall, still need to do the final glaze coat.

I started on the shock towers/ inner fenders.

Passenger side is pretty close, got the first coat of duraglass on the drivers side.





Where Im at as of last night.



If all goes well this weekend I may prime the firewall and pass side.

Dan
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  #229  
Old 02-22-2017, 10:44 AM
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Reached a pretty big milestone last night. Finished up filler and primed the engine bay. There are a few spots Im going to need to address. The biggest being on the upper part of the drivers inner fender (the wavy line there), and the areas around some of the oe "grooves" on the frame rails. But overall Im very happy with how its shaping up.















And just a reminder as to what I started with



Dan
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  #230  
Old 02-22-2017, 12:05 PM
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Damn that's smooth! Are you building a show car? Obviously has come a looong way. Hope your wife loves it.

I image the finished product looking something like this...
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  #231  
Old 02-22-2017, 12:16 PM
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Show car? Nah. Just something I always wanted to do. Id like to think of it as a modern 4cyl hot rod.

Also lol, love the pic.

Dan
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  #232  
Old 03-03-2017, 10:25 AM
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Didnt feel like hand sanding anymore so I thought Id take a break and get the wheel wells primed. So I spent hours with a pile of roloc discs and then primed with Master Series Silver. Tonight Ill spray some 2k primer so itll be ready for chip guard in a month or so.










Up next I need to finish up the motor mounts, and then drop the motor / trans etc in for a final mock up. I still need to finish up the oil cooler mount and double check where wires etc will be run. Then I need to turn some attention to the motor (cleaning up casting lines etc) before it goes out for a rebuild in a couple weeks.

Dan
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  #233  
Old 03-07-2017, 11:18 AM
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Last fri night I 2k primed the wheel wells. So at least now the whole bottom of the car is in primer. phew. Sat I pulled it out of the booth, got everything cleaned up (which took forever. so much dust) and removed the last few parts from the shell (windshield comes out tonight)





Sunday I worked on the motor mounts. I hated the way the transmission mount looked "unfinished". I simply extended the boxed in part so it was even. It still looks a little goofy but at least it looks finished. I also tried my hand at TIG brazing using silicon bronze. I added it over the oe welds to create a nice rounded fillet. Im now hooked on the stuff. Its so easy to lay down and grind and sands so easy.

Before:






Welded up:


Brazed and smoothed:







Next up was the front motor mount. Again, I didnt like the way the tube was just left open near the bracket. (for those that dont know a rubber "doorknob" goes on the end of this and plugs into the next piece that attaches to the lower core support)

Before:


After:





Then it was on to the above mentioned cup. This one wasnt so bad, the factory weld was just not even nor made a nice fillet. I tried using some Dykem as a sort of guide coat. It worked great to quickly identify the low spots as I was block sanding the top edge.







Then it was on to the pass side motor mount. Since Im not using the factory alternator mount, which slips under the motor mount, I brazed in a spacer. I suppose I could have tried to flatten it or cut it off and weld in a flat piece, but this was fairly simple and its sort of behind the timing belt anyway. Plus the brazing is fun. I still want to braze over the factory welds to smooth them out. Ill get to that tonight.






I then bead blasted them all.



And the new mounts arrived. I ended up getting the TT Tuning 65A HD replacements.



Dan
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  #234  
Old 03-07-2017, 01:35 PM
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What is the reason for brazing instead of welding? Is the brazing intended to be cosmetic or is it structural?
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Last edited by TheBandit; 03-07-2017 at 01:38 PM.
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  #235  
Old 03-07-2017, 01:46 PM
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Its 100% cosmetic.

I bought it to fill some holes on the pedal car body and thought Id try it out on these. Its nice because it flows at a much lower temp so you can just go over the base metal without melting it. It also grinds and sands easier so its faster to get it to the right shape and you dont need to worry as much about messing up the steel underneath.

I could see it being very useful on body panels to go over welded areas that wont finish perfectly. Anything to limit the amount of plastic filler.

EDIT: Most mfg's use this on roof to pillar joints where there is no trim or seam.

Dan

Last edited by juicedz4; 03-07-2017 at 01:48 PM.
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  #236  
Old 03-07-2017, 01:59 PM
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Cool stuff. It looks really good.
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  #237  
Old 03-14-2017, 12:39 PM
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Thanks!

Finished up the brazing on the top of the last motor mount. Now all the mounts are ready for a coat of MSS.







And bead blasted. The MSS should help fill the pits.




Bead blasted the OE master cylinder brace that I dimple die'd a few months back. I didnt like the uneven flange on the top edge so I trimmed that up and reshaped the lower flange a little.

Before


After





Last tues a friend and I pulled the windshield and I was surprised to find what lie beneath.







I scraped, wheeled, and ground out all of the urethane, paint, and most of the crusty rust. Also removed 14mils of paint from the window frame and wiper cowl. Whoever repainted this thing before was NOT shy with the product. Ended up with a few small holes which shouldnt be a big deal to patch up

Better






Pic of said paint thickness.




Finally sand blasted.



Tonight Im going to sand blast it again, brush on a coat of MSS and then hopefully spray a second coat over the channel and the entire window frame and cowl. Ill also spray a coat on the motor mounts.

Dan

Last edited by juicedz4; 03-14-2017 at 12:44 PM.
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  #238  
Old 03-16-2017, 11:11 AM
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Had a day and a half off of work b/c of the storm, naturally I spent a bunch of time in the shop.

Patched up the two holes in the window channel and did another once over with the sand blaster.



Brushed on a coat of MSS



Then sprayed on two coats of MSS on the widow frame, and the motor mounts. My first time spraying it, it goes down very nice. I used the purple $15 HF spray gun.





This pic of the motor mounts freaks me out a little. I swear they look like 3D models.



Then I put a couple coats of 2k primer on everything.




Next, since everything was already a mess and I had the sandblaster out I decided to tackle the quarter panel easter egg. I knew it was going to be a mess, but it was a little worse than I thought after grinding out 1/8" of filler...









It might be a while before I get back to this, so to seal it up I brushed and sprayed a couple coats of MSS on it.




Dan
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  #239  
Old 03-16-2017, 12:44 PM
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ranger88den ranger88den is offline
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Perhaps I missed it in a previous post, but, what is MSS? Thank you.
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  #240  
Old 03-16-2017, 01:55 PM
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Quote:
Originally Posted by ranger88den View Post
Perhaps I missed it in a previous post, but, what is MSS? Thank you.
Master Series Silver. Its a moisture cure urethane like POR-15. I get tired of typing it, hah.

Dan
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