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Neil's Incident

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Post  nhazelwood on Mon Jan 23, 2012 6:33 pm

James,

Most of our suppliers love the scamp or the skip as its usually refered to.

Went to our lasercutters & came back with a boot full of 3,4 & 5mm plate for gratis, & an offer to fully weld the chassis up !

Our powdercoater is also onboard, as long as he's got a run of black on, he'll knock some brackets & the subby thro for a bit of cash. If i want yellow it will be minimum order £50....

All in all things are in hand, so to speak.

Hoping to get some more braces & tubes cut & machined at work this week, with a view to getting most of the chassis tacked together this weekend.
Just hope sunday isn't as windy as last weekend, kept blowing my coffee over Sad

On the subject of being converted...why has it taken me so long to learn about the fun of 1mm thick cutting discs....muhhhaaaa... as well as being the best invention since sliced bread, they dont do as much damage to hands...they cut deeper, but a nice thin cut that is easy to suture with duct tape Smile result
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Post  TRR Motorsport on Tue Jan 24, 2012 7:44 am

I disc-covered Laughing 1mm cutting discs when I did the Mini. There's no turning back now Wink
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Post  nhazelwood on Sun Jan 29, 2012 6:44 pm

A quick update with some dodgy pics, specially for Rob..

Spend a couple of hrs at work cutting tube this morning...plus trip to halfrauds for more welding wire...eventually started welding about 1:00.
Apologies for photo's, started getting dark v quickly tnt, least no wind this weekend Smile.
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Now run out of 1-1/2" box Sad

Got most of the parts cut for the new pedal box assembly, just got some plates to machine & lasercuts and bushes for the new pedals to order, ready for welding/assembly next week.
Need to cut loads of gussets & ribs this week as well as order some more box section.....sheesh.

Neil
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Post  nhazelwood on Sun Feb 05, 2012 7:13 pm

Just a quick update..

Only got 2 more tubes to cut & tack weld in, & the front chassis is getting close to being done. (Did some more welding in the dark, after i took these photos)

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Starting to look like a scamp again.

This week i'll mostly be gussetting........muhahaaaa....and some plating in too.

On a side note, i might see the light at the end of the insurance fiasco this week. Finally got a letter from finance house stating no financial interest Smile
Then got the battle with HPI to clear walle's records...

Neil
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Post  nhazelwood on Fri Feb 17, 2012 6:21 pm

Apart from the top tube that the bonnet sits on, all tubes are tack welded in place.

Battery box welded in place & ready to go.

Insurance cheque cleared yesterday, new arc & tig welder ordered yesterday, email this am to say welder has been dispatched. Trip to local BOC agent today to get new gauntlets & arm spats......waiting poised & ready to try & remember my old stick welding basics (been 20yrs).

Come on courier, please deliver tmrw.....
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Post  nhazelwood on Sat Mar 17, 2012 7:58 pm

Just a quick update,

Progress is being made...but v slowly.
Workng stupid hours at moment, end of financial year so we're running all over the country to get deliveries & installation done by April 1st.

Managed to get new front chassis sections & subframe fully seam welded...then new welder went 'pop' on sunday...having to use old mig welder to tack bits together, should get welder back this week.

Waiting for Corsa C power steering column to turn up this week...yeah i'm getting lazy Smile

Got lasercuts for new pedal box & bonnet hinges to pick up from fabricators.

Tomorrow i'll be starting to cut the new bulkhead & body panels.

Sorry Rob, no photo's, maybe tomorrow....

Neil
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Post  Mk3rob on Sat Mar 17, 2012 8:46 pm


If there's no bodged bits then the 3 line whip will be voting you out of the club Twisted Evil

Never mind, I'm a nit picking B******** i'll find something Wink
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Post  nhazelwood on Sun Mar 18, 2012 11:32 am

Hehe Rob, dont worry theres plenty of bodging going on.
Just dont trust my bodging when it comes to brakes !

And suprise suprise, its BLOODY RAINING AGAIN Sad
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Post  nhazelwood on Thu Apr 05, 2012 5:57 pm

Last week due to work restrictions managed about 4hrs work on walle Sad

After another 6hrs work on sunday, the pics below show the current progress...

Front sunframe is now fully welded up & reinforced, ready for cutting away to suit the engine.
Corsa C power steering column is 60% fitted, just need to add a uj to the mini rack & position the indicators.

[img]Neil's Incident - Page 3 2012-04-01191827[/img]

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Will post some more pics after my marathon 3 day extended weekend...(ordered the weather for friday, sunday & monday to be glorious sunshine.....watch it piss down now)

Neil
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Post  nhazelwood on Fri Apr 06, 2012 6:21 pm

Just a quick post.

Down to scrapyard this am, got corsa wiper & indicator stalks + loom & ignition switch + loom. Also picked up a polo radiator to offer up.

Indicators & wiper stalks fitted & top of column lined up level. Supports for top of column welded in & reinforced. Just need to get a speed controller to create the speed signal for the power steering, & get a uj & bodge it to the rack.

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Saturday is daddy day, so sunday i'll hopefully be starting the bulkhead & heater, with a bit of subframe cutting thrown in. (Screwfix opening times dependent !)

Neil
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Post  Mk3rob on Mon Apr 09, 2012 1:06 pm

Doh got it wrong again


Last edited by Mk3rob on Mon Apr 09, 2012 6:44 pm; edited 2 times in total (Reason for editing : Transferred to correct place)
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Post  Mk3rob on Mon Apr 09, 2012 6:33 pm


Why the heck did i put it on here Derrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrr
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Post  nhazelwood on Mon Apr 09, 2012 9:39 pm

Yesterday weather was great, today it hasn't stopped either raining or drizzling Sad
Still got a bit done this long w/end....

Cut out subframe sides to clear engine.
Mounted the subframe.
Stripped suspension off old subframe & fitted into new subframe.
Set hilos to very low & fitted front wheels.
Split engine & gearbox.
Offered gearbox into subframe & chocked it roughly in position.
Lifted engine in (no hoist Sad , used pure bloody mindedness instead).
Bolted engine & box together.
Chocked engine & box in position.
Made rough engine mount points in subframe.
Made rough front engine mounts.
And breath......

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Marked up some plates to replace over generous clearances in the subframe.
Split egine & box.
Removed engine & box from car.
Took wheels off & removed subframe with suspension still attached.
Welded plates back into sides of subframe.
Welded up front engine mounts.

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(Getting the hang of this Arc welding lark...Smile )

Reinforced engine mounts in subframe & fully welded up.
Carved extra clearance at rear of subframe to clear gear linkages.
With subframe on floor, put gearbox in.
Mauled the engine back into the subframe.
Spent 30mins trying to line up engine & box....swore alot....gave up...
Sat in Starbucks with coffee.....Smile

Just got a few simple bits to do after work this week...

Weld up holes for driveshafts in subframe, put engine & box back in.
Mark out positions of new driveshaft holes.
Cut plates for rear engine mounts & tack in place.
Remove engine & box again.
Fully weld up rear engine mount in subframe.
Cut driveshaft holes & reinforce as required.
Cut & weld some extra reinforcement plates for front of subframe.

Hopefully by weekend will have a finished subframe. Its going to be hammershited for the moment (time & finance restraints...)
Once the subframe is back in the car i should be able to push it up & down the drive, and clear all the scrap out from infront of the garage doors.

Roll on payday friday...

Sorry for the lack of photo's, its been raining too much today.

Wheres the bath and my bed...
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Neil's Incident - Page 3 Empty Red Bull

Post  Mk3rob on Mon Apr 09, 2012 9:53 pm


Great work

Love the Redbull stand Twisted Evil
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Post  nhazelwood on Tue Apr 10, 2012 10:03 am

The Other side usually has a Starbucks cup on it....till the cup gets down to about 1/3 full, & then the wind blows it off...
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Post  TRR Motorsport on Tue Apr 10, 2012 9:49 pm

Lookin' good Neil. I can't wait to see it in the flesh.
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Post  Adam on Mon Apr 16, 2012 6:21 am

You should be able to write off Hiluxs now let alone Yaris.

Maybe a silly question but where does Vauxhall end and mini begin? Have you used modified drive shafts?
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Post  nhazelwood on Mon Apr 16, 2012 3:32 pm

Hi Adam,

Engine & Box are bog standard Vauxhall.
The inner CV's are Vauxhall.
The outer CV's are Standard Mini.
The suspension is totally Standard Mini, apart from adjustable arms, tie rods & Hi-Los.
If i've got time front brakes will be Ford !
Engine Mounts are Landrover Gearbox mounts (Softer than the Landrover engine mounts).
The driveshafts were turned down to similar diameters & then a tight fitting tube hammered over. Once length was confirmed the bits were cross drilled & pinned, then welded up.

On a side note the exhaust downpipe is standard Astra, then cut & welded to match the exhaust.

After the blood sweat & tears of the last few months, i DONT WANT TO HIT ANYTHING, let alone a Hilux... Very Happy

A Quick Update....

Walle is now sat on all 4 wheels, with driveshafts & suspension fitted...Radiator & Fan Fitted, Hoses roughed out. Just got to get engine out, subframe out, cut & weld a few bits into the subframe & tidy all the welds up... Oh & work out where i'm going to mount the Dampers, (the one thing i forgot when i looked at the subframe)...Got new bits for suspension coming this week, so suspension bits & bobs need stripping repainting etc...etc...


Last edited by nhazelwood on Mon Apr 16, 2012 3:42 pm; edited 1 time in total
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Post  Mk3rob on Mon Apr 16, 2012 3:37 pm


You forgot the Caffeinne powered lunatic behind the wheel. Twisted Evil
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Post  nhazelwood on Sat Apr 21, 2012 9:37 pm

Just a quick update while my 4shot latte is cooling....

Corsa power steering column now connected to mini rack.

Take the last 1 1/2" of mini column & astra universal joint assembly...
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Add an angle grinder loaded with a cutting disc...
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Mix them all up, and melt together...Swap cutting disc for 80grit flap wheel...

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And voila, a scamp with power steering...(bodged enough for you Rob Smile)

Spent 2 hours piddling about with shiny lasercut pedal blanks...after much swearing, cutting, welding & hitting in the vice i've now got brake master cylinder mounted & a workng pedal (ish).
Tomorrow i'm hoping to make clutch pedal & cable mounted.
Got to swap alternator belt (wanted one slightly shorter, choice of 2 shorter ones...bought the one thats too short Sad) & should get alternator fitted.
Hoping to make bulkhead panel & mount wipers as well..

Decided to improve my workshop yesterday (only did 2hrs work this week after work due to rain)...
Neil's Incident - Page 3 2012-04-21141903

Coffee is now cold, time to crack open the Stella.

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Post  Mk3rob on Sat Apr 21, 2012 9:57 pm


Thats hi-tech bodging Neil

the dogs bits Twisted Evil

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Post  nhazelwood on Sun Apr 22, 2012 7:38 pm

Hasn't stopped raining all day, at least i've been dryish...

Didn't get my planned jobs done today...suprise suprise...

Clutch pedal is working, just needs a bit of bending to clear column, a bit more welding & a grind up.

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Then the welder went 'pop' again........bo##ocks...Sad

Started cutting the panels for the bulkhead & associated sealing areas.
Mounted the wiper driveboxes, just need to sort out location of motor & where tube passes thro bulkhead....which requires welding.....bo##ocks....
Was going to mount the washer jets, but too fed up.

Neil's Incident - Page 3 2012-04-22183730
Bulkhead at close of play....
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Post  wezgit daan saaf on Sun Apr 22, 2012 10:11 pm

Lookin' good Neil,I think you call the weather we are having "Stoneleigh Weather"!!
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Post  nhazelwood on Tue May 01, 2012 9:19 pm

Just a quick update, & some teaser pics for Rob..

70% of the bulkhead welded in.
Wiper driveboxes mounted.
Wipermotor bracket made & welded to bulkhead.

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Alternator mounting bracketd welded & painted.
Exhaust extended, downpipe modified & painted.
Exhaust manifold painted.
Inlet manifold painted.
Fan & cowling mountings made & painted.
Radiator mounts fully welded.
Radiator & fan bits painted.

Tomorrows jobs....
Modify gear linkage.
Remove engine, box & subframe.
Cut couple of bits out of subframe & weld a few bits back in.
Finish fettle, prime & paint engine mounts.
Fettle & paint subframe.
Grind bulkhead & chassis welds.
Fill & prime bulkhead.
Start making front panels.
Make & weld side panels in.
Hopefully red oxide front chassis !

Phew....going to lie down....

Neil

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Post  nhazelwood on Wed May 02, 2012 9:23 pm

Well the 'Neil' syndrome has kicked in...

Achieved NON of my planned jobs today...had a big setback...

WHICH IDIOT FORGOT ABOUT THE SHOCK ABSORBER MOUNTS WHEN THEY PLANNED, CUT & WELDED UP THE NEW FRONT END !!!!!!!!!!!!

AAAAAAARRRRRRRRGGGGGGHHHHHHHHH.

Engine back out....loads of cutting out.....more plate cutting.....more welding.....result.

6 flipping hours wasted..........still the mounts look as if they were meant to go there....hehe.

Tmrw, roof & windscreen off.....loads of grinding....

Uber depressed, where's the Stella.

Neil
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