Grahams81-Leon 4wd, Big Turbo - Back in the saddle :-)

[grahams81]

No bracing?

I didn't bother in the end, found a dozen people done the conversion on golfs etc and nobody else bothered they didn't have any problems.
There is still quite a bit of strength left ever with the back cut out, i lifted the car up by hand to get the last brick in and i couldn't feel any flex in the shell, so i just propped the remaining panels at the back up using a standard scouse lift (bricks !!!) sorry couldn't resist

 

[Jacko_lcr]

looking spot on fella cant wait to see more up dates this is gunna be awesome....

in regards to your location i see your at county durham well im just down the road from you mate at middlesbrough. would be nice to see the car in the flesh once its finished as i know its gunna be a beast. should have a mooch to teesside park one wednesday when your up and running and show a few things up

 

[Deleted member 35176]

THis is shweeet!!!

All the best mate with the project!!

 

[sirjimalot]

Well didn't start grafting till lunch time but got some progress made on the Leon shell.

o.

Yeah and again on Sunday, that will be my fault for showing up and not gettinG any work done! Oh well at least the cats had fun climbing on the Beef!

I need to come round more often to watch you butcher it up.

I've been looking at using that k03s to get an exchange k04 K03 hybrid!!!!!

 

[INA]

No bracing?

i was about to say the same thing.

 

[tom t]

definatley looks a little mad without any bracing especially sat on them bricks lol.
keep up the work though.

 

[grahams81]

Yeah and again on Sunday, that will be my fault for showing up and not gettinG any work done! Oh well at least the cats had fun climbing on the Beef!

I need to come round more often to watch you butcher it up.

I've been looking at using that k03s to get an exchange k04 K03 hybrid!!!!!

No bother Jim, just pop round when you want the turbo mate, preferably sunday may need your massive guns for lifting the s3 back end in
cheers Beef.

 

[grahams81]

Bit of an update, i've been working on the car all day but not really got much to show for it.
Just been removing seam sealer and removing all the strips of metal from the joints where i just cut it to get the major lumps out. I knew it would be a boring day but plodded on anyhow.

When doing the conversion all the panels have been seperated where the original panels meet, apart from one which is a side rail that runs full length of the car, i had to cut this during the strip down.
I have marked the photo with a red line where i will cut the side rail in question -

I will measure the dimension for the cut from the front of the boot floor lip and cut the s3 floor in the same place. I have already removed a portion of the s3 frame rails to give access to reweld the side rail, picture showing the removed section of the s3 rails -

Once i have the floor in i will weld the side rails and then weld the parts of the frame rails back in.

So i've got a bit more trimming & cleaning to do tomorrow but hopefully gonna lift it in by end of play tomorrow. Thinking of dragging it under the car and then using my engine lift through the boot to lift it in.

I'll update again tomorrow night hopefully with some better pics and some good news.
So Long for now.

 

[Scott-o]

Awesome mate. You'll really have to bring it out to the local meets when it's done!

 

[Willie]

Graham, what are you using as a reference point for aligning the front and rear sections?
What are you using to measure to said reference point?
This is the bit that's holding me back from attempting this.
There's a local company doing a 4WD conversion on a MK2 Golf, this is where their struggling.

 

[grahams81]

Awesome mate. You'll really have to bring it out to the local meets when it's done!

I will do mate, looking forward to attending some meets / shows.

 

[grahams81]

Graham, what are you using as a reference point for aligning the front and rear sections?
What are you using to measure to said reference point?
This is the bit that's holding me back from attempting this.
There's a local company doing a 4WD conversion on a MK2 Golf, this is where their struggling.

Willie, i have took plenty of measurments and the s3 rear is dimensionally the same as the leon.
The front edge (panel above petrol tank with the fuel pump access holes) is not just flat it has different heights (steps) on both sides so it locates itself laterally in the shell.
So with the front section centered and the wheelarches sitting snug inbetween the outta arches the Rear s3 section should be quite nicely aligned. I will then line up the front edge of the front panel longitudinally with the original marks, then the wheel arches will be aligned with each other.

There is quite a bit of adjustment on the trailing arms for wheel alignment.

 

[traumapat]

Graham is there no way of avoiding cutting the side rails?

 

[Willie]

It's going to be hugely difficult to ensure everything is spot on and aligned to ensure the prop has no undue loads on it.
Looking forward to seeing how you tackle this.

 

[grahams81]

Well i thought i better update the thread, just finished today - i'm absolutely goosed.

Started off cleaning and trimming of inside the leon shell, here's a shot of the frame rails cut to size ready to accept the s3 part -

After much prying, wiggling, grunting and with the help of the missus managed to get the s3 part semi lifted in -

As you can see its gotta come up by a couple of inches so the wheel arches meet up and forward by about an inch.
The only snag is that the back panel doesn't fit, im gonna have to cut the lower part off it to allow the floor to come up to the right height (the floor height is now higher than the original)
All in all i'm quite happy the back is nearly in, cos my back is falling out !!! this is serious graft.
Anyway i've gotta drive 300 miles down to somerset now.... oh its gonna be a long night.
Next weekend i'll hopefully get it in its final position and start welding it up.

ZZZZZ So long.

 

[Danny@INA]

What I done when I got to where you are now is bolt the diff and everything back put the wheels on drop it back on the floor jump on it a bit lol to get it where u want it measure center nut to center nut to see if it's all lined up tac it up then take the running gear back off to fully weld it up

 

[worcesternaf]

Awesome

Awesome project mate, really looking forward to seeing some more progress.

 

[seatcupramad23]

coming along nicely graham

 

[betty_swollox]

After much prying, wiggling, grunting and with the help of the missus managed to get the s3 part semi lifted in -

Love how you dragged her into it hahah

 

[grahams81]

Thanks again for all the comments lads.

What I done when I got to where you are now is bolt the diff and everything back put the wheels on drop it back on the floor jump on it a bit lol to get it where u want it measure center nut to center nut to see if it's all lined up tac it up then take the running gear back off to fully weld it up

Cheers for the tips danny, hopefully this weekend i'm gonna take your advice and get the s3 back siting nice, give it a tack up then fit the diff & back wheels measure up axle to axle then fully weld it up once im happy....

Hopefully when i get back from work this week i will have my parcel i ordered up from ebay seller wayside adhesives.
I have ordered etching primer to cover up the bare steel, brushable seam sealer for the joints, and loads of textured rubberised stone chip gaurds / undersealer for the wheelarches and floor. Also ordered a couple of tins of sprayable cavity wax to spray into all the hidden parts of the chassis once i've finished welding to try and protect it from rust as the OEM stuff melted out during the cutting / welding.

Turbo wise i have been emailing everybody under the sun lately for prices on HTA3076's and GTX3076's, pricey with the two external Tial MVS's.

I've been toying with the Borg Warner EFR's there suppose to be very good, fast spool with really good flow rates, they also come with the option of Twin scroll T4 housings with built in wastegates - so although the turbo's are expensive they save money on 2 WG's and make a neater / easier install.

So i've got a good price for a EFR7670 - there is a bit of a waiting list on them but it'll be okay as i've got loads of work still to do to the shell.

The EFR7670 is rated as a 375 to 600bhp turbo able to flow 64lb/min probably a bit over the top but why not eh ???
here's a couple of piccys i borrowed off tinternet -

Price wise its a good bit cheaper than a GTX / HTA turbo if you add on the Wastegates etc.
So just finalising price with supplier then i'm gonna order it.

May aswell be first 4x4 Leon conversion in the U.K with the first EFR turbo too....