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Discussion Starter · #161 · (Edited)
Thank you for you comments! @Them Witches - I'm coming up on 60 next month, and have been fortunate health-wise. Most of my issues have been results of the many accidents I subjected myself to - surgeries for broken bones, multiple digit surgeries, lower back & neck injuries... However I am now getting arthritis in my wrist, which sucks. My children are adults in their 30's, so I don't have to do that anymore, which gives me time after work most days to chip away at projects.

Today I got a fair bit done on the bracing - added captive nuts, boxed the horizontal support
welds came out clean on this - forgot to photo before primed
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installed that, so I could figure out the center plate
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5 M6 sems screws in the plate - the trunk support ties into that, so I need to make sure it's not going anywhere
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came out nice & level with outer panels. I need to figure out a lip seal on the vertical section to keep water out of the trunk. Maybe a flange underneath then thin closed-cell foam.
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added back the vertical support for the trunk stay
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they have to stay separate since the panels must be independently removeable
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where I left off - had to prime & top coat so I'm not looking at all those obvious bolts. I'll paint it properly before I'm done
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Discussion Starter · #162 ·
Handwriting Rectangle Schematic Font Parallel


cardboard full panel

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after that, I decided I could add the boxed section to the panel I had in place previously, then cut out the backside & add some bits to either upper side as needed

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Discussion Starter · #163 · (Edited)
worked on the cover panel a little yesterday

Textile Sleeve Handwriting Font Material property


have to add to the left & right to fill gaps between panels

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Today I worked on the 4-2-1 V-band feed into the flex coupler & cat. Took some time to get the pipe angles right so the cat sits parallel to the crossmember. I'm not doing great with my SS welds at the moment. Had some distortion of the flange. Anyway, shouldn't be enough to be a leakage issue, I used lipped V-bands for this.

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I can play with the height of the cat to some extent. I think where I have it currently will work, and it should be a cooler setup than the previous

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Did some more sketching to figure out how to close off the access panel junctions, and a seal between the two braces.

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worked on the cover panel a little yesterday

View attachment 106355

have to add to the left & right to fill gaps between panels

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View attachment 106359

Today I worked on the 4-2-1 V-band feed into the flex coupler & cat. Took some time to get the pipe angles right so the cat sits parallel to the crossmember. I'm not doing great with my SS welds at the moment. Had some distortion of the flange. Anyway, shouldn't be enough to be a leakage issue, I used lipped V-bands for this.

View attachment 106360

I can play with the height of the cat to some extent. I think where I have it currently will work, and it should be a cooler setup than the previous

View attachment 106363

View attachment 106361

View attachment 106362

Did some more sketching to figure out how to close off the access panel junctions, and a seal between the two braces.

View attachment 106372
wow !!! just wow !!!

Awesome sketches, engineer talent at play with the production fabrication skills of sure craftsman. I really enjoy this thread you are good at what you do and it is a pleasure to watch history unfold.

your sketches look just like my dad's. respect
 

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In Germany they would withdraw street approval for this build faster than you can say "but". Any modifications are great pain in the arse to get approval for. Think of california emissions issues and modifications but covering the entire car down to the tires you mount. You mostly free to choose the color of the paint or wrap. Obviously no cop car paint job or reflective gold or chrome.
 

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Discussion Starter · #166 · (Edited)
wow !!! just wow !!!

Awesome sketches, engineer talent at play with the production fabrication skills of sure craftsman. I really enjoy this thread you are good at what you do and it is a pleasure to watch history unfold.

your sketches look just like my dad's. respect
Thank you. I usually draw out my ideas, to work out the details as I go along. I'm no engineer though - math was NEVER my strong suit. I'm a public high school Art teacher :)

Was able to get back to the exhaust today, got the right side "U" figured out after several attempts, along with the muffler placement & started figuring out the tailpipe & hanger placement. VBands all over to make setup & component removal easier. I'd like to pin the VBands after, to make installation more precise, not sure how to successfully achieve that.

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Discussion Starter · #167 ·
In Germany they would withdraw street approval for this build faster than you can say "but". Any modifications are great pain in the arse to get approval for. Think of california emissions issues and modifications but covering the entire car down to the tires you mount. You mostly free to choose the color of the paint or wrap. Obviously no cop car paint job or reflective gold or chrome.
I can't imagine having to work around that. NY is not as loose as many states in terms of requirements, as we have to have annual safety & emissions testing, however, as long as the car 'looks' structurally sound, they are not going to question the type of mods I have made at all, especially if it looks much as it should in terms of layout.
 

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Thank you. I usually draw out my ideas, to work out the details as I go along. I'm no engineer though - math was NEVER my strong suit. I'm a public high school Art teacher :)

Was able to get back to the exhaust today, got the right side "U" figured out after several attempts, along with the muffler placement & started figuring out the tailpipe & hanger placement. VBands all over to make setup & component removal easier. I'd like to pin the VBands after, to make installation more precise, not sure how to successfully achieve that.

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Art teachers are the coolest cats in the whole school 100% best times I ever had were in that class 😂
 

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KBuilt is right Indeed art teachers were the best teachers and everyone remembers them throughout their entire life. I still remember my technical engineering and architectural drawing teacher too of four years. I learned all of it before turbo cad came into play and thankful.
 

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Discussion Starter · #171 · (Edited)
Finished up (for the most part) the trunk access / exhaust cover panel

tested my new toy on some scraps of the two gauges SS I used for the panel

Motor vehicle Wood Bumper Automotive exterior Gas


worked from cardboard templates

Wood Gas Tool Scrap Auto part


test fitting the sections

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all welded

Automotive exterior Bumper Motor vehicle Gas Composite material


Some minor additions needed to wrap it up

Rectangle Handwriting Font Parallel Pattern


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drilled the top lip & tapped cross bar for M5 sems screws in the center, and M6 on the outer tabs

Motor vehicle Trunk Automotive lighting Hood Automotive exterior


welded the ears for the right hangers. Can't go any further, the muffler they sent me is the wrong model, I have to wait for the correct one

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Discussion Starter · #172 ·
got a few little bits done during the week

SS plate to seal off cross braces

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Motor vehicle Wood Automotive exterior Bumper Gas


worked on the exhaust hanger setup & VBands for the new muffler & tail section

Hood Automotive lighting Motor vehicle Bumper Automotive exterior


Hood Automotive lighting Motor vehicle Vehicle Bumper


Automotive tire Motor vehicle Bumper Automotive exterior Musical instrument


Automotive tire Hood Motor vehicle Tire Automotive lighting


Automotive tire Motor vehicle Bumper Automotive exhaust Automotive exterior


elbow outlet ready to attach new Vibrant 1792 resonator - only about 9" - so it will work in place of my Volvo one that is too long to fit

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got a few little bits done during the week

SS plate to seal off cross braces

View attachment 106524

View attachment 106525

worked on the exhaust hanger setup & VBands for the new muffler & tail section

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elbow outlet ready to attach new Vibrant 1792 resonator - only about 9" - so it will work in place of my Volvo one that is too long to fit

View attachment 106531

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Very nice fab work. 👍 the header and exhaust look great.
 

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Discussion Starter · #174 ·
Welded the trunk brace support tab to the upper brace

Wood Automotive tire Motor vehicle Gas Bumper


After I pulled the cylinder head off my friend's V50,

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I worked on the resonator / tail section. Finally getting close to done!

test fitting - leveled off the tailpipe a touch after I took this pic

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had to use 3 cut sections of a mandrel bend to get the right angle out the resonator to the tailpipe. Cut most of the straight sections off the resonator, about 1.5" each end

Motor vehicle Automotive tire Automotive design Wood Gas


Still have to seam weld the tailpipe to the resonator - the tip has three welds, that's enough

Automotive tire Bicycle frame Bicycle tire Bicycle fork Motor vehicle


Textile Motor vehicle Public space Automotive design Market


Motor vehicle Automotive tire Red Automotive exterior Auto part


Have to add a hanger to the upper left - either off the resonator/tail pipe, or off the forward edge of the muffler

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Discussion Starter · #175 ·
Braces & cover panel complete, just need heat shield material


Finally done with all welding on the exhaust & hangers. Only thing left is a firmer compound upper right hanger, I have several versions & the one I used is a little too soft.

left rear hanger done

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Automotive tire Light Hood Motor vehicle Automotive design


plenty of clearance - and no interference for the control arm bolts

Wheel Tire Automotive tire Tread Vehicle

It's close to the 4-2 collector, but not touching. About 1/2" or so, about the same off the rear cross brace

Automotive tire Motor vehicle Automotive exhaust Automotive design Automotive exterior


Definitely happy with the layout. Hopefully it sounds & performs as good as it looks 😁

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Discussion Starter · #178 · (Edited)
worked on the trunk floor panel and the cross brace cover sealing

adding a second frame to give some area for heat dissipation

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Wood Bumper Gas Automotive exterior Metalworking hand tool


Wood Flooring Gas Mesh Automotive exterior


Automotive lighting Hood Motor vehicle Grille Red

SS cover panel
Bumper Motor vehicle Automotive exterior Red Trunk

1/8" foam
Brown Product Wood Textile Luggage and bags

then carpet. Enlarged original mount holes & used torx screws set into lower frame. No reason to remove this. Closed cell foam beneath.
Vehicle Motor vehicle Automotive exterior Gas Car

Finally figured out how to address the flange for the center cross brace cover. Spot welder did the trick - until I realized I could do it this way, I couldn't see a practical way to join the flange to the original panels without a mess.

Double wall is still thin enough for trunk seal to fit properly here
Hood Motor vehicle Wood Bumper Automotive exterior


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I'll use the thinnest closed cell foam I can get away with on the overlap flange - so I'll try 1/16" first
Motor vehicle Hood Wood Bumper Automotive exterior
 

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Discussion Starter · #179 ·
heat shield



foam on flanges





Took the exhaust back off today so I could weld up the factory cross brace ends

Header can be removed without removing the brace insert or top cap, just the trunk cross brace has to come out

Automotive lighting Automotive tire Hood Grille Motor vehicle


rights side cap welded & primed

Motor vehicle Automotive exterior Wood Vehicle Bag


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drivers side partial cap. The inner frame here has multiple reinforcements, so I just added a cap to prevent the inner skin from flexing where the bolts are

Motor vehicle Wood Hood Bumper Automotive exterior


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painted

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Motor vehicle Automotive exterior Wood Red Gas
 
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