Cavalier Trackcar Project

[TurboDan]

More welding done today.

Fixed the hole in the corner of the drivers footwell/chassis leg end. It turned out to be allot worse once the sealer was all scraped off so I cut the bad bits out and welded new in, in a few places its 3 skins thick and so I had to weld in about 6 plates to get it all right, like a jigsaw puzzle. Its all solid now which was the plan. Some random pics:





All cut out:


All welded:


Also welded up the heater matrix/aircon/auto gearbox wiring holes:



All welded and primed both sides:



Only got a couple more bits in the bay to weld up then that bits done. Any critiscm/comments/arguments always welcome on my thread lol

[gsi pie]

your welding looks like its coming on nicely dan

[TurboDan]

I can weld fine, its the welder/settings that are a pain to get right on mine. Its a big welder and not meant for thin car panels really but once you've got it set right its great. Today was one of them welding days where I just picked it up and welded no problems, worked perfect all day and for anyone that welds often they will understand how nice that is! lol

[btcctroy]

Yep nothing worse than wanting to smash your welder and your car up, after a welder misbehaving. The thing I find with your welder is that you don't have much of a setting window. Either to Much or not enough, I think a change co2 gas would be a blessing in disguise. Having said that it's a great welder and the user is a natural. People don't realise how hard it's to weld in nooks and crannies.
Good work pal

[TurboDan]

Yeah next time I'm definitely goin for the other gas. I'm glad them bits on the bulkhead are done now though as they were arkward!

[TurboDan]

Done the 2 other bits in the bay today.

Heater blower motor hole welded up:


Bit of rust on the bulkhead lip cut out and new piece welded in:


Primered:

[Chip Pan Dan]

weld porn!

[Cavalier342]

That is a really neat job!

[James McGrath]

Looks great. Should feel really nice to drive once it's finished.

Only problem being if you take it out on a cold day you'll have nothing to warm yourself up with or keep the windows clear from mist.

[TurboDan]

I'm going to use something like this to clear the window, its a Rear window heater for a bmw e36 convertible:



Quite a few people have used these before in track cars and they work well. cheap too.

[Gray16v]

Good work, what colour is it going to be and what engine ?

[Brett]

I really like the project, if I can add one thing though. Like you've done with the steering rack mount already, I would also stitch weld the suspension turrets to the inner wings and also the chassis legs all the way along the seams. You are putting a lot of extra stress through the turrets in particular and I wouldn't expect the standard welds to like it for too long:)

Ive had the engine bay on my Astra GTE fully stitch welded even though its not a track car, it makes so much difference. Can get a picture if you like.

[TurboDan]

Yeah i was tempted to do that whilst i'm here as it easy whilst at this stage anyway. Put some pics up of your bay if you can.


Gray16v - Not sure on the coulor yet, either blue or white i think. The engine is troys old C20xe, he has a new one for his so i have bought his old one.

[TurboDan]

More welding..........


Although thats the last of it for the engine bay (unless i weld up all the seams).

Done the last support for steering rack mounts. Welded then primed and also welded 2 plates to the other supports to tie them into the front archs.










I did bolt the brake servo back in before i welded the tube in to make sure it fitted and it did, just!

[iangsi]

A lot of the mk2 astra boys strengthen the bulkhead & steering rack mounts by running box section between them.

[Brett]

This is the only picture I have, I only got the car on Saturday. Ive highlighted all thew stitch welds you can see in the rather poor photo but they basically go all the way round the turrets, and all the way along the top and bottom seams of the chassis legs. Also done all the way round both steering rack mounts.

hope this helps!


unedited

[TurboDan]

Yeah i see what you mean, i'll do it tommorow i think, shudnt take long.

What brake setup does yours have on it?

[joe cavalier sri]

whats the red bar ?

[btcctroy]

Well it's a tube with red paint lol

[Brett]

its a lower strut brace, Mk2 Astra's dont have a subframe like a Mk3 Cavalier so that helps stiffen the front up instead. It sits to close to the road for road use I think so its coming off!

[iangsi]

Here's a pic of what someone has done

http://s1119.photobucket.com/user/bemon ... 5.jpg.html

[btcctroy]

Here's a pic of what someone has done

http://s1119.photobucket.com/user/bemon ... 5.jpg.html

I don't really see the purpose of that

[planetc]

I don't really see the purpose of that

Maybe it's for warming up marshmallows? Next photo will probably be a toasting fork.

[TurboDan]

Its to add strength to the steering rack mounts. Its abit more stealth than the way ive done it

[joe cavalier sri]

i thought all cavs had a front subframe how come this cav hasn't got one ?