Going to build a race 1m

[Manic172]

Had a few hours after work so I had time to play cars... I bolted the front panel on and then bolted the wings loosely.
Fitted the bonnet and hinges. Gave it all a rough line up. It's all fibreglass so nothing is going to be perfect.
One problem I had is the edge of the bumper where it lines up to to the front wing it had a different twist and needs holding in position. Again being fibreglass nothing has any holes or brackets.
You can see the edge where the wheel is. It's not bad and then it just sticks out.

So in the wing I drilled a hole and put the a m6 bolts and then a washer and a tallish my lock nut too. Then drilled a hole in the bumper for it to locate in to

Moving forward I then drilled threw the bumper and the wing . 20mm in the bumper a

These are the things I found on eBay.. cost £5 for 4 of them.

The final result isn't to bad I think

Then press and it all comes away

and from a distance angina when the car is painted black I don't think you will see them

 

[Sparkie]

Push fit!!
That’s pretty freakin cool.


Badger5 Custom Map + TIP,
3”Custom exhaust, FMIC, Bosh 550’s, BC Coilovers, ARB’s +loads more.

 

[Manic172]

Evening all.
Another Saturday afternoon in the workshop playing.... put the parking sensor on the other side and the locating bolt... and remembered I had the o ring with cottern reel set up things I could use to hold up the rear of the bumper.

Also found the splitter sapports I had laying about the fitted them.

then started fitting the aero catches to the slam panel and cutting the bonnet. They are looking good.

Now just thinking on ideas of that to do for the grills next t o the head lights and the centre grill. Not sure wether to mesh the lot.. but don't wanna go to much of a Halfords hero style.. so might fit some originals .. or make some thing but not sure what.... please share your ideas and things you have done.

 

[Thai-wronghorse]

Does anyone else see this? haha

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[Manic172]

Got stuck at work in till about 2ish today so didn't get to long down the workshop..
Any way as I am rebuilding this thing I am trying to replace all the fixings with either ally or stainless steel. I did find some one who was selling stainless selftappers for the front wings but I decided to go for m6 x 10mm dome headed stainless bolts. So I had to make some threads in the inner wings.
There was a bit of talk about nutserts so I took pics and thought I would do a write up. Right here goes

This is a nut set.. (m6 this one is )

and this is one style of tool used to make them squash up and hold in a panel/hole

When squeezed up they look like this

As we know this being an m6 it's 6mm roughly on the out side of the thread of the bolt it's self. But we need to measure the out side size of the nut sert

yep batteries are flat... any way these are about 9mm. So wack a 9mm drill bit in your drill.and make a hole...

Befor

After

Put a bit of paint around the bare metal then wind a nut sert on to the tool and push in to the hole.. tighter bit the better so it has more material to hold on to. Squeeze tight then unwind the tool and you will be left with a thread now in your panel

Then a quick test fit.

I think they look better than the originals.. unless you making some thing look like how it left the factory.

once you get the hang of it it takes seconds.. with 5 along the top of the wing . 2at the front under the bumper..2 down the inner of the wheel arch and 2 at the bottom of the wing in the sill. So that's 10 per wing... 20 over all it took an hour or so. That was with me striping the front off it ( wasn't a lot there to start with )

 

[Manic172]

Then I started to make my brake cooling ducts.

I had two rings water jet cut some time ago.. now I gone for the bigger brake set up my old idea was now no good... So this was with a grinder and a lot of hopeing

I took the ring and cut a chunk of it or to a rough size I needed

Then cut some more off. I help it in position and looked where it was hitting on. It was the too ribs of the his so cut them out too.

I lined it up so it would bolt threw the 2 6mm holes where the abs sensor goes. But one of them sticks out a lot. So with trusty grinder in hand I cut that back and tapped it all the way threw. The lower hole sat back a bit so that is spaced with a couple of washers

A hold in place and Mark the back of it threw the holes to get a position and then drilled them.
Bolted in to position and checked for clearance and all seemed ok.

Next up is some 45mm carbon tube I cut to length

Then I realised I have my hole saws at work. So with a grinder I rounded off the edges and marked where I need the hole to be for the ducking to mount to.

So now at work on Monday I need to drill them and fit with some epoxy glue to hold the tube In to place...
Last week looked like a jump forward with every th8ng bolted on... But now it's 2 steof forward 10 back lol

Any way you gotta break and egg to make a cake so I can make a mess ....

 

[Manic172]

Still gotta drill the back plates for the brake ducts..... I can't find my hole saws so will be buying some tomorrow.
Right on to my mistake. I was gonna keep this quiet lol... but we all make mistakes now and again.... mine was building this car lol...
Right I wad fitting the aerocatches as seen

All looking good... So you would think. But where I put the eyelet catch threw the front panel. Marked in a circle and arrowed.....

. Then marked and drilled the bonnet. The cut big holes to fit the catch.
All good...till I tried to shut the bonnet. Where I had fitted threw the high point of the front panel. I can't get it Low enough for the bonnet to line up. So ?. After lots of bad bad words being shouted.. Then loads of head scratching. It was out with the grinder.

cut a shape. I could have just cut a chunk out and ran a plate under it and it would have done... but oh no..... I can't do it a simple way so I cut it so it ramped down.. went flat then back up and look a bit better... Then it was out with the scissors and cardboard and cutting shapes... I did forget to do pics threw the process ... I will on the other side.after about 2 hours a 5 coffees I have plates welded in. Just grind back the welds and it should be not too bad

It should look better then ground and just even primered ....

 

[Manic172]

Got the grinder out

If smear a bit of sealer around the edges it will be all good

 

[Connor H]

Love this thread and all the home engineering. They're my favorite builds seeing peoples creativity come out.

 

[Manic172]

Love this thread and all the home engineering. They're my favorite builds seeing peoples creativity come out.

Thanks for the kind words mate.. this car is being built by an idiot with a tool box and his son..... if it works and goes it will be a good achievement. Also I have to thank the people in here for the help and guidance too. I think I might have given up by now

 

[Connor H]

Thanks for the kind words mate.. this car is being built by an idiot with a tool box and his son..... if it works and goes it will be a good achievement. Also I have to thank the people in here for the help and guidance too. I think I might have given up by now

Rather this than a thread of bolt on mods any day, i learn stuff i didnt know existed from tyour posts haha

my eventual aim is to have a full blown project like this when i move and get a garage, albeit it'll be a rwd car for mad skids

 

[Manic172]

My next idea is to get a 4wd from Spain.... Then convert to rwd 500bhp toy .... a few years away I think.. but might try to rwd a toledo and do the full wide arch again lol

 

[Connor H]

My next idea is to get a 4wd from Spain.... Then convert to rwd 500bhp toy .... a few years away I think.. but might try to rwd a toledo and do the full wide arch again lol

a rwd toledo would be naughty!

 

[Manic172]

And the other side is now done...

As I done all this at work

I will tidy up Monday lol...

 

[Fozzy84]

Keep up the good work dude

 

[robertj]

My next idea is to get a 4wd from Spain.... Then convert to rwd 500bhp toy .... a few years away I think.. but might try to rwd a toledo and do the full wide arch again lol

I believe you can do the conversion with an Audi S3 floor pan and rear end.
Someone on here did it a few years ago


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[Thai-wronghorse]

This is true, you can also use the mk4 Golf 4motion and R32 rear floorpan but its a huge undertaking.
I've seen so many of these conversions abandoned over the years.
Personally I'd opt for shipping or driving one back from Germany and do a RHD conversion on it.

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[Manic172]

Made some brackets quickly just to mount the rear bumper.from some 59x50 1.5mm ally angle

I took off the old bracket and marked the holes to mount to the body then cut the corners to angles and fitted nut serts

Quick.test fit

I am going to remove the brackets and lighten them with holes and rou ding the corners more.
On to the rad. Well.i ordered this about 3 to 4 years ago when I was planning on a fast road car. But any way. The leon is ment to have like stumps on the side then you get rubber mounts to mount to the front panel. But as life goes on this build nothing, absolutely nothing is simple. This one has holes like it's ment to be bolted to the front panel. So some more ally brackets .

It's getting there . I have also had to order some m8 rubber mounts to hold the rad to the brackets

 

[Yellow fr]

Don’t forget todo some mounts for the bottom off the rear bumper too


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[Manic172]

Don’t forget todo some mounts for the bottom off the rear bumper too
I am designing some that go to the sides as it will have a carbonfibre defuser go on to it. I have to support that and line it up with the botton of the fuel tankard the rest of the flat floor set up too. Oh the joys of it

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