Gingea1pom's Build Diary

[Bonzo]

The top of my stays are more or less in the same place



I have placed the bottom of the stay on the top of the rear panel hoop & will fabricate a brace to go from the bottom of the stays to tie into the rear diff mounting frame

[gingea1pom]

That’s still looking really RED Ronnie, thanks,

Gus, I see what you are saying, I have just realised I haven’t attached D12 and D13 yet. I think I will get them done tomorrow then decide if I am going to go to the outside edge of the rear end or butted up to D13 like yours.

Great isn’t it designing as we go, just fantastic.

Cheers Ginge

[HandyAndy]

Ginge,
the bottom of your back stays will be the same as mine but the top i am putting "in" the corner of the bend of the roll bar, don,t know why, just feels right.

chassis looking smart

got a good camera man there

andy

[gingea1pom]

16 Dec 09

Well it has been awhile since my last update. I have been in the garage almost every day, bar weekends, which is ‘family time apparently!’ I only manage an hour or two some days and then others I get six.

I stopped messing around with the roll bar and completed the rear end welding on D12 and CP7 was OK but as I have gone for constructing the rear end to accommodate the fibre glass rear tub D13 was at a different angle and length. I used CP9 for the bottom of the roll bar stays only in a different location.

[IMG][/IMG]

The roll bar cross member required the ends re-profiling as they were not in line with each other, then I had to drill the holes for the upper seat belt mounts, as purchased from 3GE. Now I should have really used a pillar drill but as I don’t have one or have access to one I set to by hand. First a small pilot hole right through the cross member so I could see how far of I was then opened up with an angry big drill then opened up a little more with a stepped drill then finally a grinding wheel on my dremmal. The final hole was almost an interference fit which made it easier to weld up.



I then welded the cross member to the roll bar. I tightened the roll bar to the suspension mounts and held the cross member with to ratchet straps, when I took the bolts out to remove the roll bar the hole do not line up any more. They are out by about 3mm, I can pull everything back in line for re-fitting but it is just a little annoying having ensured that the roll bar was tightened down to avoid this exact problem. Ho Hum.

Steering column support, steering rack mount and all the suspension mounts to go then the Sierra is coming into the garage, from work, for its strip down.

Cheers Ginge

[Bonzo]

Some good progress there Ginge

I am amazed at just how clean & bright your chassis still looks, You must be working in a dry enviroment .

Don't beat yourself up about the roll bar pulling a little when you welded it.

Unfortunately a weld of this type is going to pull ........... I would be more concerned if it didn't

If the mounting plates have pulled inwards by only a few mm it's nothing a small trolley jack & sturdy bit of timber wouldn't sort out.
Give it a gentle tweak, it'll not stress the weld too much.

If they have pulled outwards a sturdy ratchet strap will do the job.

Looking good mate

[adrianreeve]

That's how I've done my rollbar too ginge. When the chassis and suspension get back from the powdercoaters on monday (now that's what you call a good chrissie present from my wife!), I'll post some piccies. It's the same powdercoaters that Caterham use, so they know what they're up to.

Cheers

Adrian

[HandyAndy]

very smart Ginge
you,ll be finished in no time at all at this rate.

andy

[gingea1pom]

Adrian,

May I ask how much the powder coating was or is it a secret as it is a prezy

Cheers Ginge

[adrianreeve]

Ginge

Foe chassis, rollbar, wishbones, uprights, pedal box and pedals, engine mounts, engine pullies, all the little brackets from the engine, calliper brackets for all four corners and the cam cover - £200

Bargain!

Cheers

Adrian

[AshG]

ginge rather than putting a jack on the roll bar plates just drill the holes out 1mm bigger. it will give you just enough room to get all the bolts in