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RIR18 last won the day on June 4 2018

RIR18 had the most liked content!

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  1. Considering we actually now actually have something of the car to mount it to, we thought we'd better start making some stuff for the wheels to attach to! Rob has designed a new tubular/sheet steel front subframe and upright package from scratch, so it can be much lighter AND much stronger than the oe setup on the car, whilst still working with the standard steering rack/mounting points on the chassis, making it a 'bolt on' assembly.... at least it will do when we've made it all!! Lot's of parts to turn/mill, so here's the first parts of the upright - we're going to use a 4.5" x 5 bolt pattern, because it gives us a large choice of wheel sizes/offsets for sensible money, but if we want to go back to the oe 100mm x 4 pattern we can just make another couple of hubs 😎 https://imgur.com/a/Oaq6PjH
  2. More action from the manta welding endurance event! This episode - o/s floorpan/chassis leg...... We cut out all the bad stuff, and were pleasantly suprised that things were not as bad as the n/s! So we started as before by getting the new pan fitting nicely, drilling it ready for plug welding on the front overlap, and then tacking it evenly in place - closely followed by seam welding it all, then a lot of grinding back for that one piece as manufactured look: https://imgur.com/a/uyxcLe2 Then both parts of the chassis leg - made a big difference knowing how we were going to go about it, having done the other side - think it took us about half the time! https://imgur.com/a/GVyO8z2 And then all married back together, after some minor repairs to the front subframe mount area of the legs - at last, that's all the front end repairs done 😆 - really pleased with how it's come out! https://imgur.com/a/toAB87b
  3. Thanks chaps! We're trying to do the very best we can. In the midst of doing the o/s now, not quite as bad as the n/s thankfully!
  4. It's been a busy couple of months on the old 'home front' which has slowed progress on our manta somewhat, however that's not to say that things haven't been moving forward - we've just finished replacing the n/s/f floorpan, lower chassis leg outer, upper swan neck outer and inner chassis leg strengthening section - the later of which we made from scratch, allowing it to be a lot stronger than the original reinforcement piece is. Worth the effort in our opinion, even if it causes our lungs to fail in the process due to airborne metallic particles that are ever present when we work on the car Cutting out the old floor, the usual hidden (and not so hidden) rotten chassis leg reinforcement piece gladly removed! https://imgur.com/a/CvaEQfv Next we cut the new pan to shape and tack welded it at various points to keep it where it should be. At this point we trial fitted the outer leg repair sections, and soon realised there was a fair bit of fettling to be done! In the end we made the section joining the lower to the swan neck as it was the only way to get everything to fit the pan flush with no gaps - we also had to flatten the return flange on the lower, as it had curled up when it had made. See our high tech jig to prevent weld warpage during fabrication https://imgur.com/a/VzMjjBQ Then when we were happy with how it fitted, we used it as a jig to make the inner reinforcement section, ensuring it would fit snugly to both the floor and the inside of the leg. We formed the upper and lower sections first out of strip steel, then made the side sections to fit the profile. These were then seam welded at regular intervals to spread out the heat, again minimising warpage: https://imgur.com/a/JYFX3XG Finally the outer section was refitted (after copious amounts of zinc primer were sprayed on the reinforcment piece) using several m6 nuts and bolts through the holes we previous drilled in both the leg flange and the floorpan. Every other hole was left open, to allow us to plug weld the sections together, then those were removed to allow the rest of the holes to be plugged also. At this point the floorpan was fully welded, and the new front jacking point (which also required a lot of modding!) was fitted. All the welds were then dressed, and everything was given a healthy dose of acid etch primer https://imgur.com/a/1BIlh07
  5. drivers side scuttle panel repair - the lower corrosion hole says it all, looking like a screaming face - i know how it feels https://imgur.com/a/wQkpbPA
  6. passenger side forward section chassis leg and front chassis leg brace/lower radiator mount repairs, step 1 - take ages to remove front brace spot welds, as they are in reaaaly anoyying /places, then rejoice when it is finally free, only to reveal just how rotten it is in the corners https://imgur.com/a/gZWzGcY - but is in excellent condition in the main span, so well worth repairing.... https://imgur.com/a/al0Hty9 step 2, chassis leg repair - this had a historical repair hidden away inside, so was a good job done replacing it https://imgur.com/a/yyYclwq step 3 - reunion! https://imgur.com/a/FilKtnW it's taking time, but we'll get there! Just can't wait to get on with the exciting stuff...... Thank you sir! It's slow progress, but like most of us it's being done in our (formely) free time, but really helps being on here looking at what everyone else is up to!
  7. A post repair section now - amazing how localised the corrosion was on this part, with paper thin sections next to good healthy material - it's almost like it's been etch erroded with a template! But from reading through the forum here i can see it's a pretty common area - seems they all rot in the same areas fairly predictably so we templated it pretty extensively because of it's complex curve, which changes both angle and depth as it heads downwards, and after a first 'prototype' version (bin fodder ) we came up with this: https://imgur.com/a/LTd5yOe and after some gentle 'adjustment' and welding ...... https://imgur.com/a/ZxVvqxu really pleased with how it came out - also nice to fill up some structural holes!
  8. Next bit of the puzzle - the weird shaped infill piece between the washer tray/inner arch/brake servo mount. The old and newly made piece side by side: https://imgur.com/a/zXBvlp2 then all welded in, top and bottom views: https://imgur.com/a/SJCmO85
  9. Also some more design progress for the front subframe - a few detail changes for how the bottom arms will locate in the new frame, using laser cut plates that will jigsaw together for strength and better accuracy when fabricated. Also the addition of an upper shock absorber mount to allow us to fit coilover suspension, allowing greater choice of spring rates, which will be very important to us, given that our drive train will be a fair bit lighter than the oe CIH iron block/cylinder head! https://imgur.com/a/w6utDwy
  10. A little more progress over the last week or so, got the brake servo/washer tray repair section welded in https://imgur.com/a/pPwYgy3 Then moved on to the inner wheel arch repair section - found this a little tricky as what should have been there was long gone, so we didn't really have a point of reference to make repair sections - google images to the rescue!! So after much head scratching we realised there should be a return edge where the inner and outer panels join, forming a protruding lip - perfect work for the shrinker/stretcher machine! Started with a strip of metal for the inner, folded it 90 degrees, then stretched the edge to form the lip https://imgur.com/a/xNtbbB3 Then did did the same with the outer, except being a larger piece of metal when the edge was gradually stretched, it naturally tried to curve the flat part of the piece, so once happy with the stretched part of the curve a bit of reforming was required to get face flat again https://imgur.com/a/VuEfmcc Both parts tack welded together https://imgur.com/a/W2OfwaW Then fully welded https://imgur.com/a/T29p0qQ
  11. And the underseal is so thick! Took ages to clean the bits so far, using a combination of heat gun + scraper, knot brush and poly wheels - felt a little bit funny from a the fumes afterwards Thanks! It's going to take a while, but i know it'll be worth it - even if my lungs change colour during the process
  12. We did consider just making some tubular arms that were length adjustable, fitted to the standard subframe, but that would only have given static adjustability - it wouldn't have changed how the wheel angle moves dynamically during suspension movement (castor/camber gain is what we wanted to change) - and you can only do that by moving the inboard pickup points on the subframe, hence why we're going to make the whole package anew. We could cut the old frame about to acheive the same thing, but where's the fun in that?! Also being tubular it is stronger, lighter and better looking than the open 'u' channel as standard, so will stiffen up the front end nicely.
  13. Away from the restoration the manta needs to get it structurally sound again, we've also been giving the suspension package some thought - bearing in mind we have plans to make our old opel a match for much modern machinery of today, we're toying with the idea of making a new tubular front subframe and suspension arm package, incorparating much improved geometry that would not otherwise be possible with the standard parts - plus it will look cool . We very much want to make it a 'bolt on' upgrade piece using the four original mounting points in the car, which should keep the finished item as accurate as possible - that way we can make a jig to construct it off the car, making sure everything stays where it should when it gets welded together. Some autocad pics of what we've come up with so far - https://imgur.com/a/N9uO3ON
  14. Got some good progress in over the last couple of weeks, just been a bit busy to post it up! Tackling the drivers side front inner wing/washer bottle tray/a post area at the moment, plenty of historic repairs here going on which needed removing - also a lot of underseal! Some pics of cutting out to see what we're left with - https://imgur.com/a/URAf8cb Cutting out the washer bottle tray, used what was salvageable to make a cardboard template, to then fashion a nice new non rusty version - https://imgur.com/a/2hwEQLu final form of the tray, templated + made a small repair section that boxes the tray in, then welded in https://imgur.com/a/xmzTUuh outside view of inner arch repair section and some small repair sections going in around the brake servo mounting area. Also made a satisfyingly large repair piece to link the tray back into the servo mount, but ran out of time and didn't get to weld it in https://imgur.com/a/IAa80E8
  15. Got some more progress in this weekend, removed the front wings, doors (which took hours - very seized roll pins!), front suspension uprights/arms, steering rack and brake master cylinder/servo Found some 'interesting' previous repairs on the inner wings! Nothing too bad though, wing mounting rails need some repairs and the rest we will cut all that out and start again methinks.......
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