bawward

iTrader: (3)

OK. Back to the project:

Where I left it

[img]https://i.imgur.com/bNVZG6o.jpg[/img]

Cut off some more:

[img]https://i.imgur.com/6bVVxnu.jpg[/img]

[img]https://i.imgur.com/Nb9cgoE.jpg[/img]

[img]https://i.imgur.com/QD4p3Qz.jpg[/img]

Main Hoop Diag and Horz harness bar:

[img]https://i.imgur.com/9nG9s6k.jpg[/img]

[img]https://i.imgur.com/SA0cJeP.jpg[/img]


My head / helmet would have hit those roof bars - despite being confident in my measurements - the real things just turned out to be too intrusive into the seating area. SO - redesign.

Threw a bend in the roof bars - see a post below showing the 45* gusset bars I added because of these roof bar bends

[img]https://i.imgur.com/YrcUHuf.jpg[/img]

Front strut tower reinforcement - cardboard templates

[img]https://i.imgur.com/VSU0VzV.jpg[/img]

bawward

iTrader: (3)

So - another normal day of bending, listening to some Wolfmother, when BAMM!!!

[img]https://i.imgur.com/8AGcOjB.jpg[/img]

Sounded like a grenade going off (20 ton jack running that die - 8 ton jack couldn't handle it)

Good news - Speedway Parts got me a replacement for half-cost - and I've been fine for the last several months. Scared the crap outta me though!

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iTrader: (3)

More Progress - I needed to move onto the front bumper - before I could, I needed the motor/trans back in the car (had a helper - who is now over 130lbs)

[img]https://i.imgur.com/Py9V5fs.jpg[/img]

Messing with some rough conduit templates - didn't like the look

[img]https://i.imgur.com/GjOipn8.jpg[/img]

[img]https://i.imgur.com/bCdX60V.jpg[/img]

[img]https://i.imgur.com/bSNl70m.jpg[/img]

(See that face? Neither did he)

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iTrader: (3)

So - deciding to ignore the front design for the moment, I moved onto finishing the rest of the cage itself:

'V' roof bars - (to be followed by Inverse-V' rear main-stay bars - as req'd per regs) - chose this style instead of the typical 'single-diag' or 'x' design - more room for my big head!

[img]https://i.imgur.com/nZB1rdz.jpg[/img]

[img]https://i.imgur.com/aN579rV.jpg[/img]

[img]https://i.imgur.com/kLLbP9K.jpg[/img]


Added - 'FIA' bars and the 45* gusset bars (at the intersection of the rear main hoop and bent roof bars)

bawward

iTrader: (3)

Welp - progress continues:

-Boxed out and reinforced the frame rails (boxed unibody - whatever) - with 1/8" plate.
-Bent up the main bar for the rear bumper
-Fit reinforcing bars that tie into the rear frame rails
-Created back-stays for the bumper bar (these will tie into the leg bases of the Rear Main Hoop - they're simply tacked in place for now)

[img]https://i.imgur.com/NK0I92t.jpg[/img]

[img]https://i.imgur.com/mFXdu0r.jpg[/img]

[img]https://i.imgur.com/QAwz0X1.jpg[/img]

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iTrader: (3)

Headlights (The WD-40 and PB Blaster cans taped together):

-Checking fitment of the considered units (Hella 90mm sealed projectors) - checking any possible conflict with bars / engine / radiator / tires, etc.

Not completely sold on these particular headlights yet - I don't want to look too similar to other Miata-Karts out there - not looking to steal anyone's aesthetic, I also want this to be a completely unique layout - I'm still considering the Hella 7" round units as well as something more rectilinear - however there aren't many street-legal options out there.

[img]https://i.imgur.com/kYosVjI.jpg[/img]

[img]https://i.imgur.com/I5CxBSu.jpg[/img]

[img]https://i.imgur.com/8udc5lw.jpg[/img]

bawward

iTrader: (3)

Moved on to finishing up the bars for the front bumper.

[img]https://i.imgur.com/g6ymzmd.jpg[/img]

The entire unit will be removable - difficult to see, but there are yellow dots marked on the 1/8" plate (where the bumper bars come into contact with the frame rails / strut tower) - this area was reinforced prior with this idea in mind (see photos above)

The reinforcing bars (far left and right - returning to the Front Main Hoop) will probably be a sleeve-style connection - Grade 8 hardware securing the connection - allowing me to completely remove the front bumper and surrounding bars when desired

[img]https://i.imgur.com/aMjittm.jpg[/img]

[img]https://i.imgur.com/oktJQXc.jpg[/img]

[img]https://i.imgur.com/eihQds3.jpg[/img]

[img]https://i.imgur.com/WKhHQbw.jpg[/img]


Radiator fits nicely - will sit about 9" off the ground (front lower bumper bar will sit 6" above ground - tub frame rails will have +/- 7" clearance)

[img]https://i.imgur.com/FZqCvE1.jpg[/img]

[img]https://i.imgur.com/IUMQqCS.jpg[/img]

[img]https://i.imgur.com/hAb7Z5R.jpg[/img]


All the major components roughly installed - all clearances and fitment looks good

New radiator position is now high enough (in a previous layout, it wasn't the highest point in the system - as to not allow air to be trapped at the cap, but rather somewhere in the cooling circuit - bad news)

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iTrader: (3)

Updates:

*Actually* finished the rear bumper - prior the 'backstay' bars for the bumper just sat on the Rear Main Hoop base plate - now they intersect the Rear Main Hoop (at the base) (Stock Muffler is just a placeholder)

[img]https://i.imgur.com/HxAqCWF.jpg[/img]

[img]https://i.imgur.com/hLIUHKe.jpg[/img]

[img]https://i.imgur.com/fLr22be.jpg[/img]

[img]https://i.imgur.com/YiCi6wA.jpg[/img]

bawward

iTrader: (3)

I continued messing around with the headlight layout - don't have anything that stands out to me yet - just more options (7" round , 90mm Hella's, 50mm Hella's, 2"x7" bar)

[img]https://i.imgur.com/zBNRdcl.jpg[/img]

[img]https://i.imgur.com/a94OaUm.jpg[/img]

[img]https://i.imgur.com/rCmFbJC.jpg[/img]

bawward

iTrader: (3)

Finished up the radiator support - used angle for the bottom rail - this will be a bolted connection - the top support will be fixed / non-removable (didn't want to see all the hardware - wanted a cleaner look)

[img]https://i.imgur.com/RVF1NDq.jpg[/img]

[img]https://i.imgur.com/DM9XdCz.jpg[/img]

[img]https://i.imgur.com/FsquiF0.jpg[/img]

[img]https://i.imgur.com/9vBL05M.jpg[/img]

[img]https://i.imgur.com/p14ZsXv.jpg[/img]

[img]https://i.imgur.com/OEtZbuw.jpg[/img]

[img]https://i.imgur.com/ZvFAGtW.jpg[/img]

[img]https://i.imgur.com/wq38ynm.jpg[/img]

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iTrader: (3)

Making some more progress - shifting my attention to the interior - getting burned out on the other stuff

Started planning out the dash - trying to figure out what support / structure I want to go with (something other than the Peet's K-Cup box... probably)

[img]https://i.imgur.com/nVi0eGu.jpg[/img]

Got the secondary dash bar in

[img]https://i.imgur.com/vYVadGV.jpg[/img]

Still can't really decide what the center console is going to look like... rather keep it 'light' and not too massive...

[img]https://i.imgur.com/sBCIiLG.jpg[/img]

The trick - I am going to daily drive this thing when it finally gets finished - 90% street, 10% track - so I need some secure storage - enter this pistol safe - is weather tight, lockable (key or keypad for entry - decided 'no' on the fingerprint scanner), and generally will be stout enough to handle being exposed to the elements.

[img]https://i.imgur.com/XtwqKcd.jpg[/img]

It's ALSO big enough to fit the Miata manual

[img]https://i.imgur.com/1XQve1N.jpg[/img]

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iTrader: (3)

deleted

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iTrader: (3)

Kept with the interior work - made a bracket for the pedal assembly (as it was removed during the 'gutting' process) - you can see the tabs that will be drilled for nut/bolt - should the bracket need to be removed in the future - everything is just tacked in for the time being

[img]https://i.imgur.com/H5tD3QG.jpg[/img]

Started working on the steering / gauges - had to figure out what kind of clearances I wanted (increased ease of existing the car) - ignition will be relocated to the dash

[img]https://i.imgur.com/tfURb9W.jpg[/img]

Angle was used for the column support

[img]https://i.imgur.com/v1d65ea.jpg[/img]

[img]https://i.imgur.com/cbQbDrb.jpg[/img]

Then added another bracket for the gauges to mount to - also in this photo, the basic frame work for the safe

[img]https://i.imgur.com/6YdaP8d.jpg[/img]

[img]https://i.imgur.com/yNWehpQ.jpg[/img]


I never noticed the offset on the gauge hood before - I'm assuming it matches the increased width on the right hand side of the steering column due to ignition switch assembly, etc? Just never noticed...

[img]https://i.imgur.com/z8ejJmN.jpg[/img]

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iTrader: (3)

Last night was GUSSET NIGHT - It actually feels good to be onto something different that bending tubes and grinding fishmouths!

I'm not going to go into the 'how to' of making gussets - there are several great videos on youtube out there if you need them - (recommend the videos by "Urchfab" or "The Fabricator Series")

Anyway, here we go:


Layed out on the 6" sheet metal strips - 6" was the standard 'hypotenuse' length I decided on for all the gussets (5.25" minimum (1.75" x 3) req'd per NASA Appendix B)

[img]https://i.imgur.com/hK7jD8t.jpg[/img]

Cut out with holes cut and beveled edges applied

[img]https://i.imgur.com/8p7B4oE.jpg[/img]

Bent up

[img]https://i.imgur.com/26eqAZG.jpg[/img]


Lined up (after some trimming)

[img]https://i.imgur.com/RlYOQj2.jpg[/img]

[img]https://i.imgur.com/9OlgtcF.jpg[/img]


Need (4) more to complete the intersections on the built cage so far - there will be (2) more added to each door bar when those get created.

At this point they're just friction-fit - I'll be trimming all the pointy corners back to visually expose the tube intersections for safety inspections.

bawward

iTrader: (3)

Weekend updates:

Rescued a 2002, 6spd, with 90k miles, FMII kit, 2.5", ARP head studs, 949 Re-route, 310cc injectors (with secondary fuel rail), FM Flywheel/Clutch Happy-Meal (10.3lbs flywheel), 3:90, big-brake kit, Koni yellows, piggyback (sadly - but good opportunity to learn Megasquirt!)

Owner was a nice guy - he had the car since 9,000 miles - he hit a tree - planning on doing a 'roller skate swap' to the kart, then part out the 2002 or throw the old roller skate under it and sell it for what I can get.

[img]https://i.imgur.com/Ehwi5zI.jpg[/img]


Roll Cage:
Decided to go ahead and do the 'final welding' on all the tubes I have assembled thus far - it was holding me up from finishing the dash/interior (along with all the other 'accessory' brackets that need to mount to the cage bars) - welding went fine, not the prettiest I've ever done but it'll pass inspection

Tail Lights:
I picked up a set of '2013 Polaris RZR 800 EFI' tail lights (the variant that have a back-up lens).

I liked their size and shape - shouldn't be too hard to wire in the new pigtails. I first attempted to use a set of NA tail lights and the proportions just didn't work. Most 'aftermarket' tail lights are for trailers/similar - eww. That's what got me turned onto the UTV market.


Tail light frame is 1/2" round - then 1/8" mounting plate insert

[img]https://i.imgur.com/XhT6l0h.jpg[/img]

[img]https://i.imgur.com/RulVQPM.jpg[/img]

[img]https://i.imgur.com/AEuwU6y.jpg[/img]

[img]https://i.imgur.com/JewBLlQ.jpg[/img]

afm

iTrader: (3)

for the homebuilt everything!

Do you live under the ocean or something? How does fresh steel plate rust that fast in a garage?

bawward

iTrader: (3)

Thanks for the cat!

Not so much - hard to find oceans up here in CO

All the surface rust visible on the sub-frames / unibody came courtesy of being an Illinois car all it's life.

The surface rust on the plate steel / roll cage bars are from the project being put on hold for nearly a year - (house, cars, trips, dogs, moves, etc - see posts above) - The car sat outside for a solid 5 months, got rained and snowed on - the tube is also too long to store in my garage, so it sits outside waiting to be used.

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iTrader: (3)

Made a bit more progress the other night -

Fuel Filler Bracket

[img]https://i.imgur.com/jJLsYx7.jpg[/img]

Headlights came in - did some double-checking of clearances - cool thing about these units, they're DOT approved (with paperwork), and the Halo can be wired to DRL (glowing white), and / or wired to the turn signals (glowing orange when activated) - saves me from having to mount a seperate turn signal (like you see on a lot of Caterham 7 kit cars)

[img]https://i.imgur.com/xnsTszg.jpg[/img]

[img]https://i.imgur.com/xh1iXuQ.jpg[/img]

[img]https://i.imgur.com/w9h9V5s.jpg[/img]

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iTrader: (3)

My primary focus has been the interior / dash / cowl / center console recently - the interior has to be buttoned up and done before creating / installing the door bars (ease of access)

I had a decent switch panel (Moroso 74131) that I'm planning to run all required switching through (4 loads - others will be blanks) - I was fairly happy with the panel construction (shown here):

[img]https://i.imgur.com/Ym0xmuc.jpg[/img]

[img]https://i.imgur.com/SiZO9a1.jpg[/img]


However I really, REALLY didn't like the blank space beneath the panel - just didn't look very proportional - so I ripped it off.


I also hadn't initially planned for the turbo-related gauges (I've got an A/F, Boost, Water Temp (might swap for oil temp), and EGT. I also wanted to incorporate my battery disconnect switch into the panel (will mount on the far left) - so I whipped this up.

[img]https://i.imgur.com/qAzjVnn.jpg[/img]

Nice tight fit

[img]https://i.imgur.com/Era0JoM.jpg[/img]

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iTrader: (3)

More items off the list:

I've designed the front bumper to be removable (it bolts to the reinforced front strut towers) - but the reinforcing arms (that run to the Main Hoop / Dash Bar) needed a removable connection - so I bought a set weld-in tube connectors (image below) and am pleased with the simplicity - much stronger than a 'slip' connection and visually simplistic.

[img]https://i.imgur.com/Pigmyyj.jpg[/img]

[img]https://i.imgur.com/Bd8auNJ.jpg[/img]

[img]https://i.imgur.com/achhsHt.jpg[/img]


Moved onto the front headlight mounting tabs - they're 3/8" plate and will double as gussets at the front bumper bar. I wanted them set back a bit and a bit 'hidden'