Yoof's Turbo

[Yoof]

Finished the off-side sill mounts now, there's 3' difference total between them, and a 1.5mm height difference. Only noticeable on a perfectly flat surface (assuming I can make the sill stands exactly the same height!)

Anyway, first job was to panel wipe the parts and etch prime inside the sill:

Untitled by Peter Strange, on Flickr

I made a blank for the end of the female part, so no crud can get in:

Untitled by Peter Strange, on Flickr

Slot her in the hole:

Untitled by Peter Strange, on Flickr

Then weld it up:

Untitled by Peter Strange, on Flickr

And etch prime:

Untitled by Peter Strange, on Flickr

The interior section will be welded when I flip the car over:

Untitled by Peter Strange, on Flickr

And some measuring to check my handy work:

Untitled by Peter Strange, on Flickr

Height difference from sill face to underside of receiver is 1.5mm front to rear

Then check the car is level front to rear:

Untitled by Peter Strange, on Flickr

And with a piece of L-section sitting on the top of both sill receivers:

Untitled by Peter Strange, on Flickr

That'll do pig!

Untitled by Peter Strange, on Flickr

I've left them long currently, as I've not made the side skirts yet, I expect to chop 40mm or so off them.

Just got to do the other side now, and make sure the heights are consistent.

Cheers

Pete

[scully]

Any progress/updates soon?  I have another question about your gearbox modification. Have you also considered the Salzmann conversion? Since he offers ready to weld in panel parts with TUV approval. If you did, why did you decide against it? Also, did you do calculations to your custom work, or is it a case of making it strong enough?

[Yoof]

TuV not applicable in the UK - so why pay £1k+ for something I can make myself 

I also wanted to keep the original suspension mounting points, the Salzmann conversion does not.

Regarding calculations - experience and a best guess. My expertise doesn't lie in chassis FEA 

[scully]

TUV is not applicable in the Netherlands either, but it does mean that it should be a decent kit. Thanks for replying though, your thread has been really helpfull for me on deciding which way to go.

[Yoof]

So, sill receivers are all complete, taken a fair old while, but should make working on the car easier, I'll build the stands in due course.

Untitled by Peter Strange, on Flickr

Tubes capped off internally, and then etchprimed:

Untitled by Peter Strange, on Flickr

Then etch prime the inner sill, plate, and everything else:

Untitled by Peter Strange, on Flickr

Then time for welding:

Untitled by Peter Strange, on Flickr

Untitled by Peter Strange, on Flickr

Whilst working on the rear of the car, the grinder caught the arch... which I duly found out was actually filler. Long story short, I'd tacked the arches together before sending it to the bodyshop (post Oulton) and asked them to finish tubbing them off an tidy it up. That got interpreted to stick filler in all the gaps and paint it.

No pictures of that as it looked utter gash, suffice to say its a long old job, but if it's worth doing, DIY!

Offside rear:

Untitled by Peter Strange, on Flickr

Nearside rear before etch prime:

Untitled by Peter Strange, on Flickr

Untitled by Peter Strange, on Flickr

I finished off last night by removing some crusty sections of the sill, and straightening it out. As its going to have a false floor, I'll have to extend the jacking points through this so I don't have to take the floor off for jacks/ramps.

Untitled by Peter Strange, on Flickr

Also picked up a few bits for the update, EPAS column and some new rear brakes, nowt too exciting yet!

Untitled by Peter Strange, on Flickr

Cheers

Pete

[Etches]

Epas sounds like it would be a nice addition. Crackin!

[Yoof]

Underside now in primer

Untitled by Peter Strange, on Flickr

Untitled by Peter Strange, on Flickr

Cheers

Pete

[Yoof]

So, the last few weeks I've not spent much time on the car, but have now finished removing the old harness mounting points, and fitting new ones.

Why? Well the old harness pickup points, weren't in line with the new manufacturers instructions (Schroth), and I wanted to lower the passenger seat rails and generally tidy things up.

So, better to do it on it's side when access is easy!

First up some measuring, and drawing out what I could achieve with my current driving position:

Untitled by Peter Strange, on Flickr

Untitled by Peter Strange, on Flickr

I'm slightly out of Schroth's guidelines on the lap and crotch (by 2' and 3' respectively), but this is the best I can do with the space (short of cutting the tunnel up). My measurement error is probably that much anyway!

Ordered some ready made FIA spec plates 7/16th for the lap, ended up making my own for the crotch, as the floor is to thin, I made this plate larger than the sum of two individuals (6-point harness so 2 crotch points), also boxed the inner lap belt mounts in.

Usual process, bit of cardboard, cut the steel, tack together, etch prime the rear, weld it up, then paint:

Untitled by Peter Strange, on Flickr

Untitled by Peter Strange, on Flickr

Untitled by Peter Strange, on Flickr

Untitled by Peter Strange, on Flickr

Untitled by Peter Strange, on Flickr

Untitled by Peter Strange, on Flickr

Untitled by Peter Strange, on Flickr

Untitled by Peter Strange, on Flickr

And you can see all 8 points here:

Untitled by Peter Strange, on Flickr

That's about it for now, I've been tinkering with a few other bits, like getting some 2008 Seat Ibiza rear brakes to fit a 1991 Polo:

Untitled by Peter Strange, on Flickr

And the new fuel tank:

Untitled by Peter Strange, on Flickr

More on those, next time!

Cheers

Pete

[kwijibo_coupe]

Those rear brakes are they the 255mm ones?

[Yoof]

232mm, with a solid disc.

[Yoof]

Cut a hole for the ATL Cell, I'll add some steel angle to mount the aluminium box to, and then figure out the in-tank pump setup at a later date.

Untitled by Peter Strange, on Flickr

Untitled by Peter Strange, on Flickr

Onto the exhaust, handbrake cables, and under-body next 

Cheers

Pete

[pauloscooby]

hi
peter, already follow your project a long time I can tell you a lot of work but every time this best like to see, 5 stars, congratulations.

cheers
paulo

[Yoof]

Thanks Paulo!

[runforrestrun]

Everyone's favourite build thread

Jim

[physicsfool]

Attention to detail is spot on. Wish I could weld. Keep the updates coming