Andyrews Progress Thread, 1/16/22 A Trip to The Red Barn - Lets fab a Firewall! Options

[Andyrew]

And my next challenge is moving the air box I made back a couple inches.

[Andyrew]

I opened up the firewall a bit more on the bottom and removed the old mounting system I built for the ac/heater box. I built a cage for the box just like I did for the guage cluster but I haven't mounted it. I'll work on that later, I just wanted to make sure I could get it all to work at a later date.



I designed a layout for how the dash pieces will work and it's very similar to the original dash. I'm making everything out of steel as I can work with it much easier.


I mounted up the ignition switch and decided to put it on the left side just for fun.


Working on the dash face I started with thin guage steel but thought against it and decided to go with thick guage steel to build a strong base for the dash. I'll go to thinner guage for the dash top and bottom.

[Andyrew]

And from the last photo to here was 4 hrs of fiddling....


Figured out how I was going to be able to remove the intercooler fan controller

Adjust fit some items, lots of metal needed some massaging over the knee to get lined up like I wanted.

Cut in the hole for the AFR guage, and did a silly amount of trimming on the dash to get everything how I wanted. Also had to redo the mount. Dumb me thinks I can weld aluminum with steel....


Little things take a lot more time when a toddler is asleep....



Oh and in case your wondering... The holes on the bottom of the intercooler fan controller are for adjusting the temp the fan goes in. I wanted to be able to adjust it but knew I would rarely do so, so I added a small hole to be able to do so. I'll transfer the holes to the fabric when time comes.

[sixnotfour]

grinding noise was a lullaby for me.....dads home..

nice dash (IMG:style_emoticons/default/welder.gif)

[tygaboy]

Andrew - Don't mean to hijack but:
If you'd like, bring the dash with you on the 18th and we (you!) can maybe give a go to measuring it out. We could translate that into a .dxf and we could cut you a face plate on the plasma table. I have some .050 aluminum and some 18 and 20 ga steel. Add some beading or a strategically placed break for some add'l strength?

I'd be happy to walk you through the process so you'd be making it.

Here's an example of some panels I did for the Lotus 7 replica.

Just a thought... (IMG:style_emoticons/default/idea.gif)

[Andyrew]

I'll take you up on that offer for the center console Chris. The dash is pretty much doneand I don't need any additional features to it for my design concept.

The center console on the other hand could definitely use some design characteristics as right now it'll just be flat panels.

[Andyrew]

Progress on the dash.

Drilled the cutout for the ignition.


Dropped the relay box as the dash was resting on it.


Added the rest of the dash face.





Figured out wire arrangements a bit and so far am pretty happy how things are laying out.


Next on the list is getting back to mechanical. I'll need to bleed the clutch to see if I just accidentally got air in the lines or why my clutch is to the floor.

[tygaboy]

(IMG:style_emoticons/default/smash.gif) (IMG:style_emoticons/default/welder.gif)

Isn't it "fun" as you try and bring to life the vision in your head?
It's so interesting for me to watch someone else go through this. Seeing the "first I tried X, then realized Y so redid things because of Z."

You're making great progress.

I may have missed it but are you planning to paint or upholster the dash face?

[Andyrew]

Chris, these kind of moments when things work are what makes it all worthwhile.

For the dash face, when I learned that 914rubber had built a hot press that they used with vinyl for recreating the 914 basketweve I asked if they could press some fabric of mine. Some money exchanged hands (wasn't cheep) and I got my hands on enough material in my color to do the dash face and door panels.


I always wanted brown leather interior on a car so here we are... A couple posts up I updated my drawing of my dash concept. The brown is this material.

[tygaboy]

I dub thee: "Factory over covered Custom"

Awesome! (IMG:style_emoticons/default/aktion035.gif)

[76-914]

If you were going to leave it as is I would have dubbed thee "Mad Max". (IMG:style_emoticons/default/biggrin.gif)

[Andyrew]

List is getting shorter (IMG:style_emoticons/default/smile.gif)


914 to do list

**Mandatory total: 15hrs
Non mandatory total: 207hrs

Suspension: 26
Replace front shocks 3
Fabricate front sway bar arms 20
Install and adjust 2
Test 1


Brakes:3
*Bleed brakes 3

Engine:30
Replumb fuel system for cleaner look 10
Look for source of oil leak. 2
Fix oil leak 10
* Dyno tune with tuner 8

Transmission: 2
*Reinstall slave cylinder and bleed clutch with power bleeder 2

Body: 75
Fabricate trunk firewall 20
Fabricate and install roll cage 30
Fix targa top knicks 5
Repaint bumpers 5
Clean up front trunk for new paint 10
Clean up rear Trunk and paint 5

Interior:87
Design and build center console 20
*Tighten all steering components 1
*Mount water pump controller 1
*Clean And mount wires 1
Install new seats 4
Finalize Dashboard 20
Design and build rear firewall 20
Design and build door cards 20



Send dash, Seats, Door cards, Center console, and Rear firewall to upholster for finalizing. (My tests revealed I don't have the skill to do this…)


Spares for WCR:
Trans
Axle
Clutch Disk
Serpentine belt
Shift Cables
Relays
Fuses
Fuel Pump filter
Fuel pump
Oil
Plugs
Coil packs

[dan10101]

You're a lot more realistic setting hours for repairs.
I was so far off I gave up putting times on mine.

Glad it's a shorter list...

[914 Ranch]

When my list is that long I just go do something. You just made a huge elephant that's going to take fourever to eat. If I thought that far ahead I would never get started. I have no plan or direction, I just turn wrenches.



But that's just me.

[76-914]

Are you using the new plastic back pad from 914rubber or using the OEM cardboard. If the plastic one, what were you quoted? This info will help me decide if I want to be an upholsterer or not. (IMG:style_emoticons/default/biggrin.gif)

[Andyrew]

Are you using the new plastic back pad from 914rubber or using the OEM cardboard. If the plastic one, what were you quoted? This info will help me decide if I want to be an upholsterer or not. (IMG:style_emoticons/default/biggrin.gif)

I havent bought/tried anything yet. I have a feeling Im going to make something out of fiberglass as I'll need to make some considerations. Not sure. I'll probably do that next year (IMG:style_emoticons/default/smile.gif)

[Andyrew]

Progress!

Drove it yesterday! If your at all interested in a 5 min video of the sky and 11minutea of me looking around and diagnosing stuff your welcome to watch (IMG:style_emoticons/default/smile.gif)


https://www.youtube.com/watch?v=U2FqsUZ5pW4


In short.

The good:
The new trans shifts like a boxster, buttery and amazing.
The steering system feels fantastic.
The engine runs just like it always has.
Chassis feels much stiffer with the steering system improved. Feedback is much better.
Dash has a very usable layout.

The bad:
First gear was difficult, I didn't have enough throw in the shifter to engage it. A little 20second shifter adjustment and I think that's taken care of.
AFR guage needs calibration
Intercooler fan controller isn't working for some reason.

The Ugly:
I warmed it all the way up and tried restarting. No avail even with my modulating or full throttle work around. I let it cool down some and took some video of it struggling to start and what I was doing with the throttle to coax it to start. Myself, my dad and my tuner think it needs more fuel. My tuner says it has two fuel maps, one for enrichment and one for normal operation. He says we can add fuel to make it right. I'm going to get some starter fluid and see if adding starter fluid helps the hot starts. If it does we finally know what the problem is and can correct it.


I have a Dyno day I'm working on scheduling before WCR so I can get a bit more torque and clean up the map just to make sure I have my basis covered.

[Krieger]

Congratulations! (IMG:style_emoticons/default/piratenanner.gif) (IMG:style_emoticons/default/piratenanner.gif)

[tygaboy]

Progress, indeed! Happy to hear you're getting it there!

[dan10101]

Awesome progress!

(IMG:style_emoticons/default/piratenanner.gif) Stacking um up and knocking them down! (IMG:style_emoticons/default/piratenanner.gif)

(IMG:style_emoticons/default/driving.gif) (IMG:style_emoticons/default/aktion035.gif)