Matt Seabrook Posted February 6, 2011 Share Posted February 6, 2011 ....... just tell me if this has been done to death. Right before I start I dont plan on going to the lengths Windy has on his fantastic Escort build or Mick's builds but will update as things happen. I will start with an almost bear chassis and go from there. The alloy panels had to be removed as this is to be a rebuild to a new car standard. Once the panels had been removed the chassis could be ground ready to weld the rivet holes up. Mark grinding the chassis Then the welding started. Once all the rivet holes where welded up the welds had to be ground back. I have also removed a dodgy gearbox mount as someone had converted the chassis from four to five speed gearbox and the welding was not the best. Next was to fit a floor mounted pedal box. I opted for an OBP pedal set but the better set up which needs some chassis mods to make it fit. The pedal set need spacing up to get it to clear the chassis rail at the bulk head. So a new peace of chassis was welded in. I did not want the pedal box bolts coming through the floor so I turned up some round dowels which I threaded. The new part of the chassis was drilled 8mm though the top of the chassis and 13mm on the under side. The dowel was held in place and the botop of the chassis was welded up underneath and ground back flate ready for the floor. I am fitting working on this project around other work the comes in to my workshop so things may not flow that logicically as working on the chassis is not always convenient. So now was one of those times. So I made use of my spare time by starting work on the rear brakes. I am going to fit disc brakes to the rear.. TBC Quote Link to comment Share on other sites More sharing options...
cidersurfer Posted February 6, 2011 Share Posted February 6, 2011 I'm going to enjoy this... Quote Link to comment Share on other sites More sharing options...
Matt Seabrook Posted February 6, 2011 Author Share Posted February 6, 2011 Thanks mate. ....... not wanting to add weight I thought long and hard about rear brakes and thought I can add lightness be fitting discs if I am careful. So I started off checking the brake drums 8" for weight and found that they are 3.5kg next I thought I would check a disc. as you can see they are just under 3.2kg so I thought I would set about removing weight from the disc on the lathe and pillar drill. This is the end result Just under 2kg so a result in that the disc and Wilwood caliper will come in at about the same as the brake drum. Looking good so far. Quote Link to comment Share on other sites More sharing options...
Dave Eastwood (Gadgetman) - Club Chairman Posted February 6, 2011 Share Posted February 6, 2011 ....... just tell me if this has been done to death. Not possible Absolutely love good build threads, especially with plenty of pics. Quote Link to comment Share on other sites More sharing options...
Nic Chase (NICO) - Shropshire & Mid-Wales AO Posted February 6, 2011 Share Posted February 6, 2011 You can never have too many good build threads. Passes the long winter nights. Love those discs.... Quote Link to comment Share on other sites More sharing options...
Matt Seabrook Posted February 6, 2011 Author Share Posted February 6, 2011 Thanks folks I will keep this going and not delete the thread then. Quote Link to comment Share on other sites More sharing options...
chazpowerslide Posted February 6, 2011 Share Posted February 6, 2011 This is begining to bring back memories (or nightmares) good luck with the build Matt. Chaz. Quote Link to comment Share on other sites More sharing options...
Cleggy the Spyder Man Posted February 6, 2011 Share Posted February 6, 2011 thirded - I only bother getting involved in build threads these days looks like a very good start - tell me about the the lathe with the discs - was the lathe used just for refacing the braking area? or did you cut the bigger holes in the hub area with it as well? some pics of how you did this would be good - always keen to learn :-) Quote Link to comment Share on other sites More sharing options...
Matt Seabrook Posted February 6, 2011 Author Share Posted February 6, 2011 Thanks Ian I just hope it turns out as well as your car did. Cleggy the disc was faced up on the lathe and taken down a few mm. The face where the wheel bolts up to was also taken down 3mm to 5mm. The holes have all been done on the pillar drill. The holes in the disc face have all been counter sunk. Quote Link to comment Share on other sites More sharing options...
Matt Seabrook Posted February 6, 2011 Author Share Posted February 6, 2011 I did manage to get the discs within 2g's of each other after drilling and turning which I was very please with. Quote Link to comment Share on other sites More sharing options...
pistonbroke Posted February 6, 2011 Share Posted February 6, 2011 eagerly awaiting the next episode Quote Link to comment Share on other sites More sharing options...
Martin Keene Posted February 6, 2011 Share Posted February 6, 2011 Matt Looking good, will follow with interest. Quote Link to comment Share on other sites More sharing options...
Cleggy the Spyder Man Posted February 6, 2011 Share Posted February 6, 2011 Thanks Ian I just hope it turns out as well as your car did. Cleggy the disc was faced up on the lathe and taken down a few mm. The face where the wheel bolts up to was also taken down 3mm to 5mm. The holes have all been done on the pillar drill. The holes in the disc face have all been counter sunk. Understood - what did you use to make the big holes - big drill piece or other? Quote Link to comment Share on other sites More sharing options...
Matt Seabrook Posted February 6, 2011 Author Share Posted February 6, 2011 25mm hole cutter and a slow cutting speed. Quote Link to comment Share on other sites More sharing options...
Hammy Posted February 7, 2011 Share Posted February 7, 2011 yes keep it up - love armchair re-builds. Quote Link to comment Share on other sites More sharing options...
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