Josh's Build Thread
03-31-12, 05:45 AM
#80
Well it's been 3 months since I last posted in this thread. The project is not dead!
Around mid January Jack Frost decided to show up and that means I had to switch to a 6 day work week until mid February. At the end of February the weather relented and I was able to switch back to a normal work week. It also started to warm up enough I could start work on the car.
So I've been working on the car, every day I can, since the very end of February. As the car currently sits, it is up on my rotisserie and I started the welding phase of the chassis prep. I plan to be finished with the welding this weekend and then I'll be ready for paint. I'll be doing the transmission rebuild soon and getting the motor cleaned and painted. Also, I have lots of parts ordering to do over the next couple weeks.
Over all, I'm having lots of fun, working as much as I can without burning myself out. Pics coming in the next few posts.
Current man-hour total is around 60-65 hours.
Around mid January Jack Frost decided to show up and that means I had to switch to a 6 day work week until mid February. At the end of February the weather relented and I was able to switch back to a normal work week. It also started to warm up enough I could start work on the car.
So I've been working on the car, every day I can, since the very end of February. As the car currently sits, it is up on my rotisserie and I started the welding phase of the chassis prep. I plan to be finished with the welding this weekend and then I'll be ready for paint. I'll be doing the transmission rebuild soon and getting the motor cleaned and painted. Also, I have lots of parts ordering to do over the next couple weeks.
Over all, I'm having lots of fun, working as much as I can without burning myself out. Pics coming in the next few posts.
Current man-hour total is around 60-65 hours.
03-31-12, 06:27 AM
#81
Day 1: 70% of the interior removed.
Day 2: Dash removed.
Day 3: Carpet and heater removed.
Day 4: Engine and transmission out.
Day 5: Major body assemblies removed.
Day 7: Gas tank out.
Day 8: Rear subframe assembly out.
Day 9: Front subframe assembly out.
Day 10: Started wiring harness removal.
Day 11: Wiring harness out and rest of crap in engine bay.
Day 12: Rotisserie test fit.
Day 2: Dash removed.
Day 3: Carpet and heater removed.
Day 4: Engine and transmission out.
Day 5: Major body assemblies removed.
Day 7: Gas tank out.
Day 8: Rear subframe assembly out.
Day 9: Front subframe assembly out.
Day 10: Started wiring harness removal.
Day 11: Wiring harness out and rest of crap in engine bay.
Day 12: Rotisserie test fit.
03-31-12, 06:28 AM
#82
Day 13: First rotation.
Day 15: Second cleaning and seam sealer removal.
Day 16: Started seam welding prep.
Day 17: More prep and rear speaker tower metal removal.
Day 18: More prep and cut out rocker panel rust areas.
Day 19: Started seam welding, 25% done.
Day 15: Second cleaning and seam sealer removal.
Day 16: Started seam welding prep.
Day 17: More prep and rear speaker tower metal removal.
Day 18: More prep and cut out rocker panel rust areas.
Day 19: Started seam welding, 25% done.
03-31-12, 01:19 PM
#83
Day 20 (Today): I got all my welding prep done. I completed 50% of the chassis welding before I ran out of gas. Unfortunately that means I'm done for the weekend cause everything is closed on Sunday. So I'll be working on breaking down the transmission so I can order the rebuild kit.
04-04-12, 02:25 PM
#90
Day 21: I have completed about 85% of the welding. I went through an entire bottle of gas (just 1L bottles). My dry ice didn't come today for some reason. Here's hoping I have better luck tomorrow. Should only need one more bottle of gas to finish it all. This weekend I should have the transmission apart enough to get the rebuild kit on order.
04-06-12, 04:32 AM
#92
Day 22: My dry ice finally arrived yesterday and I was able to remove the tar sound deadening material. Luckily I had read another member's thread and caught a tip. Put the dry ice in a trash bag (I used a black force flex bag) so you can move it around; makes it easier to handle and also less of a hazard. The bag also makes the ice last longer and doesn't seem to degrade it's performance in loosening the tar. I used a hammer to loosen and start to break it up, then a putty knife to get it all up. This kept the dings in the metal to a minimum. The whole process took about 2 hours. Here's the pics (before and after):
04-06-12, 11:00 AM
#94
On a separate, but related note: I ordered 20kg of dry ice and I'm fairly certain I ended up only using about 7kg. Another site I read estimated 10kg, but the trash bag seems to help increase working time...I never had to refill the bag, I used the same bag full of ice the whole time. Unfortunately, the best deal was for 20kg...fortunately another friend is doing a build on his Corrado and is buying the other half of the ice from me (it was 68 euro!).
04-09-12, 12:41 PM
#99
Day 23: Took me a few days to get back out to the garage, but I managed to get out there tonight. I should easily be able to finish all the welding tomorrow night. Today I welded the interior portions that were uncovered by the removal of the tar sound deadening material. Then once I get the rocker panels repaired the body will be done till I'm ready to paint. I can move on to the mechanicals while I wait to do paint. No pic, cause there wasn't much of a visual change.
