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Projects and Restorations Building a car from scratch, restoring your pride and joy, building a track car, or starting a long term project? This is your place to document it.

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Old 17-12-2015, 08:40 PM   #31
jas_racing
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Quote:
Originally Posted by Forsh View Post
Nice mechanicals!

Loving the neat brake lines - did you use a pipe bender?

Thanks & yes I used a mini pipe bender.
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Old 17-12-2015, 09:48 PM   #32
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Update time

The rear caliper mounting plates also hold the ABS sensors, and were looking pretty grotty. I wanted to remove the ABS sensors to allow me to clean & paint the plates but they didn't look too keen on coming off:



New sensors are no longer available and used ones are pricey so I decided to approach the removal of the existing ones slowly and carefully. First up was to slice off the heads of the retainings bolts as there was zero chance of them unscrewing. I then used some cobalt drill bits to drill out the remains of the bolts, and with these out plus plenty of WD40 I was thankfully able to grip the base of the sensor, rotate it a fraction back and forth bit by bit then eventually wiggle it all the way out. I was rather relieved!


This allowed me to clean up the plates:


A few brackets needed the same treatment, here they are as they came off the car: (exhaust hangers, fuel filter bracket, handbrake cable guide, etc)


The whole lot POR-15'd:


Caliper bracket back on the swing arm:


Dust shield refitted:


Onto the rear wheel bearings - I've always sworn by SKF bearings but UK prices for Coupé rears are sky-high...so I tracked some down in Germany for a third of the price:


As always though they come unpainted so were treated to a few coats of Hammerite silver aerosol along with a few other bits, including the bases of the ABS sensors:



I decided to clean up and re-use the discs that were on the car as they were barely worn, hadn't been on the car very long when I took it off the road. Cleaned up:


Onto the rear calipers - as they have very fiddling internals I decided to send them away to be refurbed. As they came back:


They were then treated to 3 coats of Ferrari red caliper paint (applied by brush):


With their carriers and all ready to fit, with high-tensile stainless steel bolts:


So Sunday afternoon just gone I refitted the bearings, caps, brake discs, caliper carriers, and calipers, plus connected the hydraulic lines:




That's all for now

Last edited by jas_racing; 05-05-2016 at 10:10 PM. Reason: Fixed pic link
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Old 17-12-2015, 10:23 PM   #33
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Thats some dedication for you there.

Brilliant work - great attention to detail.
Subscribed ready for more updates
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Old 17-12-2015, 10:45 PM   #34
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Brilliant Thanks for taking the time to post the update
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Old 17-12-2015, 11:01 PM   #35
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Brill thread, subscribed. Great work btw!
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Old 18-12-2015, 10:32 AM   #36
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Wow, great work and amazing attention to detail! Keep it up
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Old 14-01-2016, 02:14 PM   #37
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Another great thread, subscribed
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Old 02-05-2016, 08:18 PM   #38
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Just realised that I'm long overdue an update on this project! LOTS done in the last 2 or 3 months so here goes...

With the rear-end rebuilt and refitted I could put the car back on her rear wheels:



With that done I turned my attentions to the front end. OSF wheel removed to see what I was tackling:




A bit of poking & scraping to see what the corrosion situation was:

Not too bad, I've seen worse on a Coupé.

Treating the rust:



Getting cracking on stripping down the front end running gear, subframe off after a couple of hours work:




Front hubs:


Driveshafts, shocks, etc, removed:





Stripping down the front end:



New front dampers ready to go after a couple of coats of additional satin black paint:


New top mounts painted (for extra protection) & ready to fit:


All ready to assemble with new springs, bearings, etc:




PAS pipes were covered in 16 year's worth of gunk (no pics, sorry) but cleaned up well ready for painting:



Masked up:


Painted:




PAS rack needed sprucing up too...before:



Masked up for painting:


Etch primed:



Cleaned up:




New front wishbones:


Front hubs stripped and ready for shot-blasting:



Front slam panel ready for shot-blasting:


Subframe & transmission tunnel support also ready for shot-blasting:


Parts back from shot-blasting:




Front subframe after shot-blasting & galvanising:


And the slam-panel:


Slam-panel after powder-coating:


Subframe after powder-coating:



Partial assembly with new wishbones & ARB:



Front hubs POR'd and fitted with new SKF bearings:


Front ABS sensors tarted up (these were VERY difficult to remove from the hubs on one piece!):


Various brackets after shot-blasting & POR-ing:


After MANY hours of rubbing-down & grinding, the front end was stripped down and masked for a spot of primer (and no I'm not making a political statement with my choice of newspaper headline!):



Primed:


Front subframe & shock back on the car:


Front hub on:



PAS rack back on:


Front left gearbox mount made to look a lot nicer & ready to fit:


At this point I was able to refit the front wheels and drop her off the axle-stands so she's mobile again. Moving onto the minor details:

Lots of brackets & clips cleaned/rubbed-down & ready for painting:


A few painted:





ABS pump bracket in zinc-primer:


And painted in satin black:


The driveshafts are currently being worked on but essentially I am now waiting for the Coupé specialist (FCSS) to confirm when they can take the car in for the remaining welding and set about the bodywork/respray. The last estimate was "end May/early June" so I've got time yet but when I get the thumbs-up the car is ready to winch onto a trailer and take it down there so until then I can concentrate on the peripheries.

That's all for now

Last edited by jas_racing; 05-05-2016 at 10:08 PM.
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Old 03-05-2016, 05:06 PM   #39
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Nice update, fantastic work
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Old 03-05-2016, 06:58 PM   #40
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Awesome update!

Are you planning on leaving the inner wings as they are?
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