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Author My Mates SWB Quattro - Build Thread
adam.d
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Registered: 7th Nov 07
Location: hartlepool Drives: corsa LET
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3rd Feb 08 at 19:44   View User's Profile U2U Member Reply With Quote

This will be a cracker when complete, well done
Daniel_Corsa
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Registered: 21st Apr 04
Location: Wigton, Cumbria
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10th Feb 08 at 19:49   View Garage View User's Profile U2U Member Reply With Quote

Mates been on with bending and welding the floor pieces this week....

The cardbord templates have turned into metal, and it now has a metal floor again!









Hopefully his Kevlar Cobra suzuka seats will turn up this week and get those mounted in, then the seams inside the car all need stitch welded, and after that its onto the cage!


April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
ainsley_brader
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Registered: 24th Mar 02
Location: Tattershall, Lincolnshire
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24th Feb 08 at 20:40   View User's Profile U2U Member Reply With Quote

need an update!
SVM 286
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Registered: 13th Feb 05
Location: pain
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24th Feb 08 at 20:52   View User's Profile U2U Member Reply With Quote

Lovely work.
mantamark
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Registered: 19th Jun 06
Location: Northumberland
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24th Feb 08 at 21:51   View User's Profile U2U Member Reply With Quote

Very nice bud.

How did you go about welding the roof up?

i was told it would buckle with the heat?

Any signs of this?

cheers.
Daniel_Corsa
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Registered: 21st Apr 04
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24th Feb 08 at 22:01   View Garage View User's Profile U2U Member Reply With Quote

He's done a good bit more doesn't look much from the pics but its finishing off the shell after it was cut to make it look like it wasn't thats taking the time!

so from this:



to this:



The inner skin has been welded up to put more strength back into the roof. Also the very inside piece of the roof rails have been silced and re-welded to make them line up. Its like paper the metal so a bit of a bitch to weld but its done in a fashion. He is planning to slice a piece off the roof section which was cut out to patch over the hole thats left and then thats the roof finished!

The floor is not far off being finsihed bar welding some pieces into the chasis rails so they look all part of the same section. He has also removed the firewall. He needed it out for the cage to go in, also the fact it was full of holes made it not the best firewall in the world! New one will be made up to go back in once the cage is finished.





Welded the sections under the windows



Done a bit of grinding in the engine bay, all brackets have come out, just need to finish taking the seam sealer off so it can be stitch welded.



Oh and the seats have arrived, Kevlar Cobra Suzuka beauties!







So thats it for now, cage to come next, 30 meters of tubing on its way inside it!


April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
mantamark
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Registered: 19th Jun 06
Location: Northumberland
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24th Feb 08 at 22:22   View User's Profile U2U Member Reply With Quote

So the roof is probs the same thickness as the corsa roof then.

Hmm, i need to sort the hole out from the sunroof in the corsa but was told it would buckle with the heat.

Good progress though, fuck me the blokes a loon!
Daniel_Corsa
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2nd Mar 08 at 21:08   View Garage View User's Profile U2U Member Reply With Quote

He's done a bit more today...

Had to cover this hole



So he cut a section out of the roof piece that was removed and bashed it around a bit untill it was a good fit and welded it in.

Adds a good bit more strength back to the roof rails as well.





They will look fine once they have had a proper grind up and a skim of filler.

Then he moved onto making the pieces to make the chasis rails appear more as one.





Looks like thats going to work now so will have both sides all finished off this week. Should end up looking much more factory.

Its not far off being a finished shell!


April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
sand-eel
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Registered: 15th Mar 07
Location: carluke/braidwood--IRNBRULAND
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3rd Mar 08 at 09:46   View User's Profile U2U Member Reply With Quote

BYRON
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Registered: 1st Jun 04
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3rd Mar 08 at 09:54   View User's Profile U2U Member Reply With Quote

Fuckin immense.
Marc
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Registered: 11th Aug 02
Location: York
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3rd Mar 08 at 18:53   View User's Profile U2U Member Reply With Quote

Whats it all going to weigh when its finished?
pow
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Registered: 11th Sep 06
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3rd Mar 08 at 21:52   View Garage View User's Profile U2U Member Reply With Quote

Hawt
Adam-D
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Registered: 11th May 02
Location: Cheshire
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3rd Mar 08 at 22:00   View User's Profile U2U Member Reply With Quote

very cool, impressive welding there
SVM 286
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Registered: 13th Feb 05
Location: pain
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3rd Mar 08 at 23:31   View User's Profile U2U Member Reply With Quote

My envy is growing.
markeyturbo
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Registered: 13th Aug 07
Location: bury st edmunds
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4th Mar 08 at 00:33   View User's Profile U2U Member Reply With Quote

thats fuckin cool.. got alot of time for projects like this.. bit like the sxoc s13 morris minor!
Daniel_Corsa
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Registered: 21st Apr 04
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10th Mar 08 at 19:43   View Garage View User's Profile U2U Member Reply With Quote

Just a little update.

The roll cage tubing is here, and the chasis rails are almost done!













So just a small bit to finish on them and then the shell shortening is completed!

There is the seam welding to finish inside, the seat rails to sort out and then its the climbing frame time!




April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
Daniel_Corsa
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16th Mar 08 at 20:34   View Garage View User's Profile U2U Member Reply With Quote

Managed a bit more! The chasis rails are now totally finished. He then cut some pieces of 3mm steel to make the mounting points for the cage. Then got them welded together, and finaly welded into the car. The seat rails are also cut and the plates welded into the car to take them.















Roof spars were also cut out as there was rust behind them





Pretending to be the roll cage......................





So there are a couple more plates to make for the rear struts. Then will make the main hoop and the A pillars as a template to get the shape right, then off to somebody with a mandrel bender to make them properly!

Its getting there...........


April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
SVM 286
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16th Mar 08 at 21:24   View User's Profile U2U Member Reply With Quote

SO impressive. The man's ability is quite astounding.
Robin
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Registered: 7th Jan 04
Location: Northants Drives: Clio 182 Cup
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16th Mar 08 at 21:25   View Garage View User's Profile U2U Member Reply With Quote

His welding rocks
Daniel_Corsa
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23rd Mar 08 at 21:34   View Garage View User's Profile U2U Member Reply With Quote

Roll cage time! Enough said really. Been making templates for the main hoop and a pillar bars this, extended, weekend so that these can then be taken to some dude with a mandrel bender to be replicated, hopefully getting them done right first time. Well, thatís the plan.

Photos anyways!























A random one of the rad in the boot




April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
little_duke
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Registered: 21st Aug 06
Location: Tamworth,staffordshire Drives: rover coupe
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23rd Mar 08 at 22:05   View User's Profile U2U Member Reply With Quote

joey736
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Registered: 11th Mar 07
Location: hexham, near newcastle drives: Aurora XE
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23rd Mar 08 at 22:05   View User's Profile U2U Member Reply With Quote

very, very cool
Graeme
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24th Mar 08 at 00:42   View Garage View User's Profile U2U Member Reply With Quote

that is just truley amazing, his welds are so gd i bet the car is much stronger than when it left the factory!
Marc
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Registered: 11th Aug 02
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24th Mar 08 at 11:23   View User's Profile U2U Member Reply With Quote

You guys are easily pleased with the welding aren't you!!!

Good progress
Daniel_Corsa
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11th Apr 08 at 18:10   View Garage View User's Profile U2U Member Reply With Quote

Done a little more!

The roll cage tubing was dropped off at Protection and Performace. What a place! Had to sign a disclaimer to say wouldn't take any pics to look around as they do work for Aston and Bentley

The bender they use is quater of a million! Computer controlled CNC jobbie, once its all programed in you just press start and it self feeds, it can also put large radius curves in the tube as well for things like windscreen bars so can curve it the wole way.

He said they are onto 2" pipe next week so should be able to pick it up sometime next week!

Today the seam welding was finished off in the footwells. Also cut a load more brackets off from the dash area that wont be needed.

Not even sure if will run a dash but will leave that option open at the min.







The seat rails seem to be taking an age to make! Finally have the nuts welded onto the back of them, just need to get the distance apart sorted out and then the triangle bits can be welded to bars. Then a lick of paint and weld them in!





This week has consisted of filling the underside of the roof and the roof rails to loose the join. Well that was the plan! Would have liked it to turn out better! Some of the bits are going to be impossible to get to once the cage is in, hence why did them rather than leave them to Dave. The bits that can be seen once the cage is in Dave can make look nice, the bits that cant then it doesn't matter









Today after suffering sanding down filler and being underneath all the dust all week he decided to do something more fun.....................................

















The fact the gromit was holding on for dear life was pretty funny, just incase i needed access into the hole to put some wax oil in...........................



So it was a fun day all round!

Picked up a 2 by 1 meter piece of 1.2mm steel to make various parts, one being a new boot floor and radiator cowling. Also to make some plates to weld over sections like where the heater used to live.

Phoned the roll cage lads today as well. They were just changing the tooling to move onto 2" tube. So the fella said it would be ready by the weekend or early next week! So will head down and pick it up next week to start the fitting next weekend!




April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car

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