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Old March 1st, 2015, 11:45 AM   #51
moler
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Join Date: Aug 2010
Location: Lincolnshire, UK
Posts: 129
Default Re: Jet Rocket!!

New cross member section trimmed to fit around the steering column tube...


...and welded in, more welding to go on this later...


...section cut and drilled to fit onto the top of the beam...


...I was very tempted to blast all this in, but you can bet it'd be wrong so I'll wait to get the steering rack before proceeding.


I decided to have a go at straightening the bonnet, I've nothing to lose by trying, these are the main problem areas...




...the bottom of the nose is a little bashed about too, but this should be fairly easy to dolly out...


...I started with some light malleting either side of the centre, and I actually got some good results...


...I worked the other areas too and it looks like I might just be able to save it, so I bare metalled it, "so why the long face? :P"...


...Thursday evening is usually garage time, but I had to go and collect the steering rack and UJ's, 2 1/2 hour round trip, but well worth it...


...this mount needs to go...


...as does this shroud...


...new boots required too.


The rack is too wide and requires shortening, so I need to find the required width, to find that I need to build the front beam back up. The beam I had went to a mate as I don't want adjusters, the beam I have for mock up is shot...




...so I'll use it to figure out how much to cut'n'turn the new beam when I get one...


...this will help a little with the beams structure when I cut the front, and give me something to roll the tube against to keep it true(ish)...


...my nemesis, putting leave back in a beam, so I used my usual trick...




...guide marks for the turn...


...the trailing arms aren't parallel, that makes the suspension progressive as one set of leaves will tighten up before the other, doesn't it?...


...not sure this is low enough yet, but it'll do for now...


...so now I know the steering rack needs narrowing by 196mm. I don't have an M14 die, but I do have an M14 tap, so I'll cut the new track rod down and use the old track rod to sleeve over the top...


...first job, turn the new rod down so it'll go inside the old one...


...I cut a section off the old rod and tap a thread into it...


...I then welded it at the end, drilled and tapped an M6 hole, screwed a bolt through it as a dowel, cut the ends off and welded it in...






...one side done...


...the other side was done using the same process, and both have a right hand thread, no left hand thread required here...


...and I trimmed the shroud down...


:)

Last edited by moler; December 19th, 2016 at 11:19 AM. Reason: New pic url's
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Old March 2nd, 2015, 11:03 AM   #52
moler
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Join Date: Aug 2010
Location: Lincolnshire, UK
Posts: 129
Default Re: Jet Rocket!!

I had 45mins after work to quickly whip the bracket off the steering body and offer it up for a look at how it fits. After cutting the lumps off a rasp makes light work of alloy, and doesn't clog like a file...




...so here it is, slightly low, and slightly forward trying to replicate what I can see under the bonnet my UP! with regard to track rod position...






:)

Last edited by moler; December 19th, 2016 at 11:20 AM. Reason: New pic url's
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Old March 8th, 2015, 01:05 PM   #53
moler
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Join Date: Aug 2010
Location: Lincolnshire, UK
Posts: 129
Default Re: Jet Rocket!!

Budget update!!
Wow I actually remembered to include this finally...I've played my joker which was to sell the original 1200 engine ;) I have all the parts to build 1641 with twin 40's in the shed, and overall with various deals I've done in the past it's cost me nothing save for the engine case being line bored, and crank ground. So the spend currently sits at 866 :D (seeing as I'm making the rules I don't see this as cheating :lol: )
__________________________________________________ ___________________________
As I'd decided on the final position for the rack, I could get on with the front structure...








...I then needed some uprights for the rack to mount to...


...mocked up in the position I wanted, all seems good...


...you can just about see the depth of the mounting rubbers is 10mm...


...I guessed they must mount on to something on the Golf subframe, and I was right...


...so I needed to make those...








...happy with these I needed a nut of some kind in the top of the uprights...






...drilled and countersunk for countersunk bolts...






...freshly blasted steering rack clamps liberated from a MK2 Golf at my local scrapyard...


...when I initially saw that the rack wasn't going to be in the centre of the box section I was a little annoyed, but as I thought about it, it wasn't all that bad, for one with the bolts near the edge there's no need to include an inner sleeve to prevent crushing, and it made for easier attachment of the mounting lugs...


...all mounted up...




...I was just going to get it in there and repair the bulkhead once the body was off, but I thought I'd be easier to do now...


...repairs sections from original VW metal, NOS too...




...added side structure...












...I seem to have missed a few pics, oops, uprights welded in...


...I do need to stop the box section across the top from crushing, you can just see one already installed through the hole...


...and secured with a cheeky plug weld underneath...


...and that's the front structure almost done. On to the column...




...it doesn't extend as far as I thought...


...this is gonna in need a bush to centre column, and the collapsing section removing...


...this is short too!...


...no matter I need to put a spline on the bottom of the column to take the UJ anyway. I have this old notchy T25 bevel box that has some useful parts to liberate...


...inside...


...with no obvious way to get the shafts out I unceremoniously cut the box up, it did give the perfect piece for the bottom of the column though...


:)

Last edited by moler; December 19th, 2016 at 11:21 AM. Reason: New pic url's
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Old March 15th, 2015, 12:06 PM   #54
moler
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Join Date: Aug 2010
Location: Lincolnshire, UK
Posts: 129
Default Re: Jet Rocket!!

Short update due to a week of DIY emergencies!!

So next job was to make the splined bit fit in the end of the column shaft...




...I did that on the lathe, then welded it to then end, and plug welded both sides...


...unfortunately the steering shaft is too big for the lathe, so I had to fettle this with a grinder...


...next I needed a bush to hold the steering shaft in the middle of the sleeve...


...nylon would be ideal, but I have polypropylene, lets see how this works...


...I'll start the bush like this, coupon out of a holesaw...




...first one was too, small :lol:


...second time lucky...


...OD turned, and tapered to make installation easier, time for the bore...






...this'll do nicely I reckon, if I have any trouble with it I'll change it to nylon...


...next job was to connect the steering shaft to rack...


...no process pics, but I basically cut the UJ piece in half then shortened the centre shaft till they met up, I'll weld this up properly once it's out and on the bench...




...next I wanted to get all the small jobs done under the bonnet while access is easy, I started with covering in the handbrake mech...










...I don't want cover the mech without being able to access it from the top, so I created a hatch...


...rivnuts :D ...






...that's all folks :)

Last edited by moler; December 19th, 2016 at 11:21 AM. Reason: New pic url's
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Old March 22nd, 2015, 12:43 PM   #55
moler
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Join Date: Aug 2010
Location: Lincolnshire, UK
Posts: 129
Default Re: Jet Rocket!!

Continued over on the Cutting Board
http://volksrods.com/forum/showthrea...670#post580670

:)
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Old December 19th, 2016, 11:22 AM   #56
moler
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Join Date: Aug 2010
Location: Lincolnshire, UK
Posts: 129
Default Re: Jet Rocket!!

Should you have missed them, pic's now re-tagged
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