Posts Tagged ‘ATL’

Dash for Progress

Posted: 5th September 2012 by asteriskr in Rallye 16v, Welding
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About to become exceptinoally busy with work which will put a dampner on much progress in the coming month or so and as a result I am trying to make a bit of a push on the car. I suspect the biggest development is to finally decide the direction for the build, which is now intended for stage rallying. So with that in mind picked up a few more bits Peugeot Sport France (PSF) style sumpguard and mounting that will need to be welded onto the front of the car.

Sumpguard

Sumpguard

Wilwood hydraulic handbrake conversion kit was next. The current handbrake has now been drilled with a 2.5mm hole uinto which a locking pin (bit of stainless steel bicycle spoke) can be insterted to make it a fly-off lever by disabling the ratcheting mechanism and will now need a tab welding on so that the bracket that drives the piston can be attached. I need to have a look at leverage ratios to make sure I mount it properly.

Hydraulic Handbrake

Hydraulic Handbrake

My friend Stu who makes a good living out of welding day in day out kindly did the honours on my EPAS column:

Which has meant that I can reassemble the unit and get it back in the car. I just need to finish assembling it with the support bearing and tube that fits near to the boss. What a mission this has been.

EPAS

Welded in the rear mounts for the fuel cell container – the alloy for the retaining straps turned up today too. Looks a bit messy at the moment, but it will clean up nicely.

Fuel Cell Mounting

Fabrication Time

Posted: 29th August 2012 by asteriskr in Rallye 16v, Welding
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Well had a bit of time away and a chance to get perspective and decide what I wanted to do with the car. Came back with a bit more enthusiasm and then tonight managed to get a good few hours working on the car. Fabricated up some mounting points for the retaining straps that are going to hold the fuel cell in. These are going to be strong. Welded M8 nuts onto some 3mm plate and then welded that to some SWG16 sheet which I then folded and welded up. Might have played with the swager set in the process…

fabrication

fabrication

fabrication

These pair of bad boys will be welded in behind the fuel cell in the hollow where the rear seats used to be and will sit flush at the same level as the boot floor. Then just need to mount the other two plates onto the bulkhead and form up a template for the retaining strap out of some steel and then I’ll get some made up out of 5mm alloy.

Make it Stronger

Posted: 20th August 2012 by asteriskr in Rallye 16v, Welding
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additional bracing

The more I looked at how other builders had fabricated mountings for fuel cells the more I decided that mine wasn’t beefy enough so I have added in some additional sections to cross brace it with box section.

Update

Posted: 5th July 2012 by asteriskr in Rallye 16v
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Finished the Fuel Cell Framing last week and it’s now in a base coat of POR15. Since then I’ve been doing some tidying up elsewhere on the shell, such as removing the studs that had held on the fusebox. The heads of these are real rust traps in the wheel arches so there was some rot to cut out. All tidied up and in primer now.

I’ve also taken delivery of a pair of chassis rail gussets from 106parts. I fabricated what was neded for the repair on the 8v but the whole panel needs replacing on both sides so it was the only sensible thing to do as they’re not simple shapes. These are genuine Peugeot/Citroen panels rather than after market supplied ones and are the first repair panels I’ve purchased.

Chassis Rail Repair Panels

Chassis Rail Repair Panels

Spoke to the machine shop yesterday, they haven’t started on the column yet and are closed for two weeks from Monday on holiday so could be soe time before that’s ready to collect for welding.

In the mean time I’ve been amassing a selection of items to crack on with some wiring. This includes more Raychem DR-25 heatshrink and some inline butt slices. The challenge is a neat way of connecting and terminating the coiled lead that will connect the steering wheel controls to the loom. Due to the use of relays the wiring is all signal cables so very fine cable (SWG26) which doesn’t have much substance with which to work, but still needs to be connected up to the ITT Cannon Neptune connectors.

Fuel Cell Mounts In

Posted: 7th May 2012 by asteriskr in Rallye 16v, Welding
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Wanted to press on with things, so back at it again today. After load of measurements, I fabricated up these supports for the fuel cell container.

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Capped off the ends to give a nicer finish – you’ll never see it, but it’s all about satisfaction about knowing it’s been nicely done.

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Welded in the supports. Needs a bit of cleaning, but they’re solidly mounted now.

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Next job to do some more plating to fill holes. As well as this there are a good number to fill in the floor plan and on the bulkhead behind the seats.

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