SWB Quattro Project

[niall1]

A nice set of KW's to bolt to the uprights!

Did you have to change much to fit the 034 KW kit? I was onto KW directly and they suggested sending my struts over and they could manufacture a V3 set up from them. Obviously the off the shelf 034 kit would be a less expensive option.
Thanks
Niall

[Jonnybravo]

Yep I can understand why, I have one running off a Motec and another off a Link G4, they can't even answer the simplest questions with a straight answer so I have just had to work it all out myself. I'd love a Motec dash for mine but they are quite keenly priced for my liking !

[G60Rallye]

I was asked where I was based during one conversation. When I told them they said oh thats too far away for us to come and have a look. Needless to say I was a bit angry! They were trying to use me to develop the lead for my dash, I was having none of it! I would not recomend them to anybody who is looking to buy one!

[Jonnybravo]

Nice progress Hamish.

I am using the RT dashes in 2 cars but so far getting them working 100% has been hard work and as you say their customer service is bloody disgraceful, infact I am still waiting for them to return my call from months ago lol

[G60Rallye]

Been on with repairing the damage to the panles. First up was the front bar which took a hit to the out-riggers that the wings/ bumper bolted to. They used to have Dzus fastners on them but they were a pain to use so I decided to weld some bosses on and bolt them instead. Ignore the bolts I will be using some alloy bolts and washers.



Bolted back together.



Rear wing around the exhaust cut out fibreglassed back together.



The swage line on the passenger rear arch was always low compared to the door. Decided to take the chance to line it up as it always annoyed me.





Crack in the other rear wing repaired.



Front wing stuck back together and worked on the shut lines to improve them.







Same done to the other side.





Panels stripped off and taken to be sprayed.



The car is now up at a friends house having the roof filled then its going in this week to get painted.

My new dash binicle landed this week. Motec CDL which will actually work with the Motec ECU unlike the race technology which gave no end of trouble and their customer service was shocking.

Dash comes with shift lights, GPS module for speed and odometer. It also comes with a proper wiring loom so is an easy fit.





Hoping to still make GTI international and have some fun on the strip!

[G60Rallye]

If anybody fancys some inconel exhaust bends ideal to make a manifold or 2 out of then I have listed them on ebay:

http://www.ebay.co.uk/itm/3009114626...9#ht_63wt_1170

[G60Rallye]

Got a bit more work done on the car lately. The roof is now ready for a skim of filler. The welds are all ground down and the seams have been sealed up with tiger seal. I have also shaped some roll cage padding to support the roof skin off the roll cage as I am not putting the spars back in.











Next job I moved onto before it gets sprayed again was the sealer used around the bulkhead. I dont have any before pictures of it but the last time it was painted the guy decided to make it look like weld. No idea why he did it but it looked crap and I have wanted to sort it ever since so now was the perfect time. So its now smoothed in nicely with a finger.





The final job I have been on with is the steering column. It got bent in the crash and I was never happy with its height so decided to make it adjustable this time. Also went for a different universal joint which looks a lot stronger.



Tig'd in place.



Couple of bits of angle cut and shaped to allow the column to move up and down.



2 bosses machined up, knotched and welded into the tube.



All together.







I have lightened the new drivers door and welded in the plate for the mirror as per before. So next its onto the front bar which holds the bumper and wings. It got bent on one side and I want to remove the Dzus clips this time and bolt them on so they will be quicker to remove.

Bodyshop is booked for 3 weeks time so looking good to make GTI international.

[G60Rallye]

Its not exactly a daily driver so it hasn't suffered much damage at all yet. I will keep an eye on it. At least when its just painted you can see any issues straight away rather than hiding them behind underseal.

[Qwerty]

Ah right, that makes sens, I thought you'd maybe used something I'd not heared of that give a smooth finish.

Really like the finish of the underside, just not sure my 205 would last long if I just painted it lol

Will you just keep paining yours regularly to keep and corrosion under control?

[G60Rallye]

Glad that you like it. The underside has no underseal on its just painted.

[Qwerty]

Hi

Just wanted to say a huge congrats and hats off to this awesome project. I'm a big Quattro fan and this has been such an enjoyable read. I hope you dont mind but Ive posted the link to the project on the 205drivers forum and its sured quite a bit of interest. I'm really looking forward to the day I get to see and hear it in the flesh.

I was wanting to ask how you managed to get the finish on the underside of the car and what you did for underseal. I know I read it somewhere in the 50+ pages lol but I've scanned back through it and can't find anything about it. I'm currently building my first track car 205Mi16 (http://forum.205gtidrivers.com/index...owtopic=133408)


Thanks.

[Jonnybravo]

Ah I see. I already use Avon 10.5's and Hoosier 12.5's but thought you may have found a supplier for part worns! Could do with some tyres for testing rather than mess up the fresh ones.

[G60Rallye]

They are 9" the slicks. They came with the BBS E50 wheels I bought. Mixture of Avons and Yokohamas. Avon still do a good selection of slicks in 16".

[Jonnybravo]

As always great work, be nice to see it all back together.

I couldn't help but notice a huge pile of 16" slicks, what width are they and where did you get them from as 16" in any sort of decent width seem to be bloody hard to get hold of !

[G60Rallye]

Firstly I need to start with a huge thanks to Ray (A1quattro) for sorting me out with a roof and spending the time cutting it to a size to post for good money! Secondly thanks to Peter for sending me a door for free! I owe both you guys big time!

So I decided to start with the worst bit of the damage the roof. As mentioned Ray sent me a complete roof. Once I got it I had a good look and decided to seperate the skin where it was spot welded to the frame in the gutters and along the top of the windscreen piece. So out came the spot weld drill and after a lot of time it was free!



So I chopped into the old skin to see what was damaged. The top screen pressing had been pushed in badly so I decided I might as well replace that as well.



So a new one was pulled out of the new roof.



Old one just about chopped out.



New one plug welded into place.







Old roof spot welded drilled out in the gutters to leave it ready for the new skin:



Sprayed some weld through primer into the seams





Back of the old roof was punched so it could be plug welded onto the new skin.



Back edge of the new skin was joggled to go under the old roof. Cleared up the sound deadening and surface rust and primed it.



Then it was all plug welded on. Needs a good grind up but you get the idea.















So its done baring a grind up to flush off all the plug welds. I am not going to run any spars under the skin this time but use some packers from the cage to support the skin. Its welded in without warping or dropping so I am very happy. Used cold front when joining the two skins. It works brilliantly to soak up the heat from the metal.

I have also started to fix a few other bits that were damaged from the crash and the testing. Obviously the column was bent so I got the metal to do a new one. I also got a new universal joint as I wasn't very happy with the old one. Split it down and bored it on the laithe to take the steering shaft. So thats ready to assemble and weld.





The next bit I found was that the diff mount I made to hang the alternator off had bent under the power. This had caused the propshaft to rub on the transmission tunnel! I would have built it with a lot more strengthening to begin with but its tight for space with the alternator getting in the way!





So I decided it needed some extra metal adding to stop that happening again! I cant get any more metal around the alternator but I am happy thats going to solve the problem. Sorry for the crap picture I should have taken some before paint!



Also to help with this I decided to machine up some alloy bushes for the rear diff mount to help stop any twist.





They are different thicknesses as I run the rear diff offset to get the larger prop lined up down the tunnel.

So thats where its currently at. I am going to get the rear diff bolted back up this week and get it back onto its wheels. The roof needs finishing off. Then the door needs to be cut up to lightening it and a few fibreglass repairs to the wings and it can go for paint!