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MC2 Project - Chassis prep


DeLaSoul
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  • 3 months later...

What a fascinating build, when it was suggested that I check this out for inspiration for track mods, I wasn't expecting something quite so elaborate. Kudos to you Sir!

 

How is the engine coming on? What plans have you got in the exhaust department? I see you've got the manifold, but with the Powerflow system will it not be a little loud for track use?

 

Once again, a fantastic build. driving.gif

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What a fascinating build, when it was suggested that I check this out for inspiration for track mods, I wasn't expecting something quite so elaborate. Kudos to you Sir!

 

How is the engine coming on? What plans have you got in the exhaust department? I see you've got the manifold, but with the Powerflow system will it not be a little loud for track use?

 

Once again, a fantastic build. driving.gif

 

 

Cheers.  For the exhaust I was going to hand the car to Liquid Metal in Bicester and have them fabricate something on the car.  I've had a Powerflow system before and they can tune the noise to suit but they do get louder with more driving.  That will be one of the last things to go on the car!

 

any updates on this?

 

Sorry, been away a lot with work but some progress.  I'll try and summarise:

 

Bonnet catches - DONE

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Went for paint/bodywork quote.  Mild heart attack - more pennies to be saved :(

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Return, started the refit.  New deep dish steering wheel to bring the wheel closer to me to make it more comfortable

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Good but not perfect :(

 

Routing power and fuel lines down the tunnel plus working out where the mini heater will fit

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Fuel lines go through in the top right corner of the dash

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Fuel filter with dry break quick disconnect and safety locking system.  All made by a local hydraulics company

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Windscreen washer bottle - new left, stock right

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Should save room and weight :)

 

Sunroof plug mould - mounted on wooden panel and filled the underside

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Need to expand the mould by a few mm as the roof opening is 10mm bigger than the panel.  3.6mm ply sheet all around to give less of a gap to put the sealant into

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There is a gap under the lip of the roof panel where the rubber seal went so filled in the majority of it with wire, all that I had to hand!

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Made up the corners in sections as the wood will not bend enough in one piece

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Filler, sand, filler, sand, filler, sand, filler, sand........................

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Just needs filler primer and a final sanding and the plug is done!!!

 

Stock dash was becoming a nightmare to plug all the holes ready to take a mould from :(

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So went back to my own design.  Needed to be modified to take the centre vent (which gives access to the middle mounting screw), side plate angle in slightly to make it easier to remove from the mould tool and the top edge rounding off to match the curve of the screen

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Seen this trick done for speaker boxes, cover the frame in fleece material and apply resin to it.  It sets solid, and you can fibre glass the back of it to give it structure

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Hated it, all the ribs were on show and would require a ton of work to complete :(  Scrap the idea and switch to plan B, fill all the flats in with thin ply

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Cover the ends up

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Re check it fits.  Made sure it was easy to get in and out without going through the windscreen!!

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Now need to locate the steering wheel (new wheel, come to that in a bit)

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Align the centre console

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Onto the steering column, worked out where is went through the dash and cut the hole.  Refitted the column and refitted the dashboard and all the covers

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Wheel now sits exactly where I want it with a flat wheel and 60mm spacer.  

 

3 different wheels, original Momo I bought for the car from a DC2 that came with the correct boss to fit the civic, the deep dish wheel that I wanted to move it closer to me and the new wheel and spacer that is even closer that the deep dish

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Check where the instruments will end up and if the centre vent will fit

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So now that's all done I got on with the filling and sanding ready yo make a mould from the dash

Used expanding foam and tape to make up the gaps

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Once set this stuff cuts and sands so easily :)  Also plugged up the column hole.  Ready now for filler

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New and "old" dashboards

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Had to mod the centre console to fit.  I want to use the original part as a template, but it gets in the way of the brake bias lever.  I cut a section away and sanded all that dam rhino skin effect off! Took ages!

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Finally, got the wheels to clear the front brakes with spacers.  Hate spacers but these hub centric H&R ones are pretty cool.  Anodised black they also blend in to the wheel/brake bell

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Sorry - big post and I know I've missed a few things!  Must remember to keep this updated

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