WelshMart's 2009 BDC Project Tramp Saph 24v - Page 2 - Drifting forum

robrs2 · 17-08-2008, 21:50

Ref: Cage. The 3 door and saff or 5 door have the same floor pan. So to feet of the cages are the same. The main hoop should be in the same place as there normaly positioned in relation to the drivers seat, although 4 door ones are sometimes further forward ? don't know why.
The main difference is the height of the cage due to the sunroof, but the sunroof runners can be cut off the roof to fit a non sunroof cage.
Some 3 door cages are hard to fit in a 4 door shell though if they have X bars in.

Mart, Nice work on the sound shit. Mine is still on.

WelshMart · 18-08-2008, 07:04

More stripping on Sunday, as I'm using all my old stuff I'm giving the front cross member and rear subframe back to Tom

So now everything is stripped it time to start rebuilding, first on the list is to break out the trusty welder, there's a patch on the passenger side of the transmition tunnel that needs patching and this inner sill to floor have atarted to go in a few places inside, I've also got a few unwanted holes in the bulk head that the BDC reg require me to block up....

WelshMart · 02-09-2008, 18:12

Sorry for the lack of updates recently but the weather has been crap in derby and progress has been slow.

Managed to get some stuff done most of last week involved cleaning the engine bay, btw cheap ass washing up liquid is great for cleaning off all the grime and oil in the engine bay, I also managed to prep the rusty areas, mainly by chopping out the big pieces and treating the smaller patches with rust treatment.

On the weekend I got the welder out:

Patched the inner sills where they had started to rust away

Also the passenger side rear outer seat mount needed some work

The transmittion tunnel on the passenger side had rusted through
I patched this underneath with 3mm plate where it had gone through the double skin and it was near the gearbox mount then dressed it inside. Debating if I should drill some hole anf plug weld them together, but doubt it'll really add strength.

Also cout out the old handbrake mount to make a nice flat section to mount the hydro, used 3mm plate again to make it nice and strong

As I'm not gonna be running heaters in the car I had some holes in the bulkhead to patch some fire cant get through them

Then I got bored of welding, I've decided to try and save weight at the front I'm gonna make a box section front end which will have a removeable part to aid installing and removing the engine and also have a radiator protector built in to save me from those nasty cones so I took the angle grinder to it.....

Weather was shit on Monday nite but I got home from work today and the sun was out so I set about making a rear firewall so that I can install a boot mounted fuel tank, I ended up with this before it poured down

Dont be too harsh with my welding skills I know they aint great but I still got my L plates and trust me the inner sills in the sierra are like paper, I'm getting better I think...

chunk · 02-09-2008, 18:27

Big hats off to you Mart. Your doing a top job dude.

I'll try to pop over and have a nosey on day soon

Silverfang · 02-09-2008, 18:30

That's not bad welding considering, Mine's not much better to be honest

But looks like you've got good penitration there (oo er!)

I found easing back on the wire helps avoid too much weld build up and if you 'swirl' the weld pool it knits the metal together rather well if you can get it going.

Sides that, looking really good there so far

WelshMart · 02-09-2008, 19:01

Cheers guys, it the first time I've let loose with the welder on my own so a lot of it was learning as I go. Its not too bad but certainly not upto pro standards, I'll get grinding a bit more to flat the welds back a bit and neaten them up a bit but I'm happy with them so far and I've learnt a lot.

Chunk pop over whenever you're free always welcome dude

rsturboboy · 02-09-2008, 23:30

Quote:

Originally Posted by WelshMart

Sorry for the lack of updates recently but the weather has been crap in derby and progress has been slow.

what u on with Mart the weather has been brill

........

WelshMart · 22-09-2008, 18:01

Right another update for you, things are still going slow what with the Derby weather recently and the need to use power tools outdoors but work is carrying on when I get chance out there.
In the last couple of weeks I have cut out the spare wheel well and welded in a sheet to cover the hole and give me somewhere to mount my new shiny fuel cell

I have sprayed the boot black, well most of it the rest I couldn't do without getting gassed

I have cut the structure out of the boot to save some more weight

and I have put bonnet pins on the boot to make it accessable without a key as the rules of BDC state

I have also fixed the drivers side electric window which had come off its runners and I have cut out the sunroof and replaced it with a sheet of metal

Tonight I started to construct the box section front end that i am making but rain stopped play after I had tacked the uprights in and the new headlamp suround on one side in so hopefully a drier night tomorrow for me to finish that.

NikDev · 22-09-2008, 21:50

Real nice construction work there!

But is spot welding enough? On both firewall and boot?

topi · 23-09-2008, 00:13

Quote:

Originally Posted by NikDev

Real nice construction work there!

But is spot welding enough? On both firewall and boot?

Yep!

WelshMart · 23-09-2008, 09:02

Neither the boot floor nor the firewall are structural so spot weldswill be fine

Jeek™ · 23-09-2008, 09:21

Nice work mart! you could have saved a bundle and just bought mines!

WelshMart · 23-09-2008, 10:10

I couldn't have got enough of the money back out of my old car to afford yours, plus I'm learning a lot whilst I build and applying things that i learnt last time and seeing them work so I'm finding it quite satisfying..

Quail · 23-09-2008, 10:25

This is a really nice build. Keep up the good work

WelshMart · 23-09-2008, 19:12

Finally I get a dry nite to break the welder out properly, so I set about making the box section front end

Some pictures of my welds, camera kept wanting to focus on other things though.

And here is the finished article

And doing what its made to do

Protecting the radiator which is in a fragile place, I'm happy with it and it looks pretty tidy too

Corey_XR4I · 23-09-2008, 19:59

Thats awsome m8, so erm.... when you doing mine?

WelshMart · 24-09-2008, 09:33

When you bring me your car, some metal and some money to pay for my skils, lol

Corey_XR4I · 24-09-2008, 18:46

Quote:

Originally Posted by WelshMart

When you bring me your car, some metal and some money to pay for my skils, lol

Ha, i ideally need two new inner and outer cills and one new rear arches off where i crashhhuuuu into garage door

doh!

a lad near mine is coming to do them cheap i believe so all is good, very impressed with your skills tho m8 very nice

WelshMart · 25-09-2008, 19:41

I've had another hard evenings work, the pull cables are mounted

the bonnet is pinned

and the big holes in the rear shelf are covered

Here's the trailer full of scrap metal that I have cut out of the shell

That means that most of the welding is done, leaving me now with some tidying up to do, painting the interior, painting the engine bay, refitting the loom and dash etc.

Hopefully in the next few weeks I should start seeing it all coming back together and looking less and less like a bare shell on my drive and more like a car again.

robrs2 · 25-09-2008, 23:00

Some extreme work there Mart. Are you going to tie the cage into the front inner wings?

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17-08-2008, 21:50	#21 (permalink)
robrs2 dorifto kingu! Join Date: May 2005 Location: Teesside Posts: 970	Ref: Cage. The 3 door and saff or 5 door have the same floor pan. So to feet of the cages are the same. The main hoop should be in the same place as there normaly positioned in relation to the drivers seat, although 4 door ones are sometimes further forward ? don't know why. The main difference is the height of the cage due to the sunroof, but the sunroof runners can be cut off the roof to fit a non sunroof cage. Some 3 door cages are hard to fit in a 4 door shell though if they have X bars in. Mart, Nice work on the sound shit. Mine is still on.

18-08-2008, 07:04	#22 (permalink)
WelshMart touge runner Join Date: Mar 2007 Posts: 217	More stripping on Sunday, as I'm using all my old stuff I'm giving the front cross member and rear subframe back to Tom So now everything is stripped it time to start rebuilding, first on the list is to break out the trusty welder, there's a patch on the passenger side of the transmition tunnel that needs patching and this inner sill to floor have atarted to go in a few places inside, I've also got a few unwanted holes in the bulk head that the BDC reg require me to block up....

02-09-2008, 18:12	#23 (permalink)
WelshMart touge runner Join Date: Mar 2007 Posts: 217	Sorry for the lack of updates recently but the weather has been crap in derby and progress has been slow. Managed to get some stuff done most of last week involved cleaning the engine bay, btw cheap ass washing up liquid is great for cleaning off all the grime and oil in the engine bay, I also managed to prep the rusty areas, mainly by chopping out the big pieces and treating the smaller patches with rust treatment. On the weekend I got the welder out: Patched the inner sills where they had started to rust away Also the passenger side rear outer seat mount needed some work The transmittion tunnel on the passenger side had rusted through I patched this underneath with 3mm plate where it had gone through the double skin and it was near the gearbox mount then dressed it inside. Debating if I should drill some hole anf plug weld them together, but doubt it'll really add strength. Also cout out the old handbrake mount to make a nice flat section to mount the hydro, used 3mm plate again to make it nice and strong As I'm not gonna be running heaters in the car I had some holes in the bulkhead to patch some fire cant get through them Then I got bored of welding, I've decided to try and save weight at the front I'm gonna make a box section front end which will have a removeable part to aid installing and removing the engine and also have a radiator protector built in to save me from those nasty cones so I took the angle grinder to it..... Weather was shit on Monday nite but I got home from work today and the sun was out so I set about making a rear firewall so that I can install a boot mounted fuel tank, I ended up with this before it poured down Dont be too harsh with my welding skills I know they aint great but I still got my L plates and trust me the inner sills in the sierra are like paper, I'm getting better I think...

02-09-2008, 18:27	#24 (permalink)
chunk sucks Join Date: Jun 2005 Location: Leicester Posts: 4,424	Big hats off to you Mart. Your doing a top job dude. I'll try to pop over and have a nosey on day soon

02-09-2008, 18:30	#25 (permalink)
Silverfang No longer K1 Join Date: Aug 2006 Location: UH's workshop / Milton Keynes Posts: 1,017	That's not bad welding considering, Mine's not much better to be honest But looks like you've got good penitration there (oo er!) I found easing back on the wire helps avoid too much weld build up and if you 'swirl' the weld pool it knits the metal together rather well if you can get it going. Sides that, looking really good there so far

02-09-2008, 19:01	#26 (permalink)
WelshMart touge runner Join Date: Mar 2007 Posts: 217	Cheers guys, it the first time I've let loose with the welder on my own so a lot of it was learning as I go. Its not too bad but certainly not upto pro standards, I'll get grinding a bit more to flat the welds back a bit and neaten them up a bit but I'm happy with them so far and I've learnt a lot. Chunk pop over whenever you're free always welcome dude

22-09-2008, 18:01	#28 (permalink)
WelshMart touge runner Join Date: Mar 2007 Posts: 217	Right another update for you, things are still going slow what with the Derby weather recently and the need to use power tools outdoors but work is carrying on when I get chance out there. In the last couple of weeks I have cut out the spare wheel well and welded in a sheet to cover the hole and give me somewhere to mount my new shiny fuel cell I have sprayed the boot black, well most of it the rest I couldn't do without getting gassed I have cut the structure out of the boot to save some more weight and I have put bonnet pins on the boot to make it accessable without a key as the rules of BDC state I have also fixed the drivers side electric window which had come off its runners and I have cut out the sunroof and replaced it with a sheet of metal Tonight I started to construct the box section front end that i am making but rain stopped play after I had tacked the uprights in and the new headlamp suround on one side in so hopefully a drier night tomorrow for me to finish that.

22-09-2008, 21:50	#29 (permalink)
NikDev Drifts a Swede Join Date: Oct 2006 Location: Norway Posts: 426	Real nice construction work there! But is spot welding enough? On both firewall and boot?

23-09-2008, 09:02	#31 (permalink)
WelshMart touge runner Join Date: Mar 2007 Posts: 217	Neither the boot floor nor the firewall are structural so spot weldswill be fine

23-09-2008, 09:21	#32 (permalink)
Jeek™ www.TrampDrift.com Join Date: Aug 2005 Posts: 1,313	Nice work mart! you could have saved a bundle and just bought mines!

23-09-2008, 10:10	#33 (permalink)
WelshMart touge runner Join Date: Mar 2007 Posts: 217	I couldn't have got enough of the money back out of my old car to afford yours, plus I'm learning a lot whilst I build and applying things that i learnt last time and seeing them work so I'm finding it quite satisfying..

23-09-2008, 10:25	#34 (permalink)
Quail Kouki Monster Join Date: Feb 2006 Location: Milton Keynes & Portsmouth Posts: 1,172	This is a really nice build. Keep up the good work

23-09-2008, 19:12	#35 (permalink)
WelshMart touge runner Join Date: Mar 2007 Posts: 217	Finally I get a dry nite to break the welder out properly, so I set about making the box section front end Some pictures of my welds, camera kept wanting to focus on other things though. And here is the finished article And doing what its made to do Protecting the radiator which is in a fragile place, I'm happy with it and it looks pretty tidy too

23-09-2008, 19:59	#36 (permalink)
Corey_XR4I XR4I 24V FTW Join Date: Aug 2007 Location: Sunderland NE UK Posts: 1,975	Thats awsome m8, so erm.... when you doing mine?

24-09-2008, 09:33	#37 (permalink)
WelshMart touge runner Join Date: Mar 2007 Posts: 217	When you bring me your car, some metal and some money to pay for my skils, lol

25-09-2008, 19:41	#39 (permalink)
WelshMart touge runner Join Date: Mar 2007 Posts: 217	I've had another hard evenings work, the pull cables are mounted the bonnet is pinned and the big holes in the rear shelf are covered Here's the trailer full of scrap metal that I have cut out of the shell That means that most of the welding is done, leaving me now with some tidying up to do, painting the interior, painting the engine bay, refitting the loom and dash etc. Hopefully in the next few weeks I should start seeing it all coming back together and looking less and less like a bare shell on my drive and more like a car again.

25-09-2008, 23:00	#40 (permalink)
robrs2 dorifto kingu! Join Date: May 2005 Location: Teesside Posts: 970	Some extreme work there Mart. Are you going to tie the cage into the front inner wings?