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Thread: The STI 5 project that i got in trouble for when i turned it into a project......

  1. #221
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    I finally got back around to tinkering after six weeks recovering from an op, trying to get as much done as I can before the next one....


    So been playing with a few aero bits, did the wheels at last and have really started to get into the interior bits.... well what's left og it at least


    So, I wanted to make a larger under tray that goes just beyond the bell housing and under the engine completely. Lets nip the first thing in the bud quickly. I have used marine ply for this at the moment for a couple of reasons. firstly it great for a template, easy to work and can take a bit of a beating.... secondly, I haven't the budget for a huge carbon item that could turn out to be useless for my needs, get crack, smashed and wrecked in uk roads.... so as a test bed the ply will do just fine...


    A frame work was also make using simple square bar with tabs here and there for suppose and fixings. I haven't made the rose joints etc yet but all the bits are on route... some pics:







    The next bit was to finally ditch that nasty chrome look on the wheels. The wheels needed a small bit of repair but noting major; so on with the repair and silver base coat. That was followed by a few coats of a Xerallic purple mix and then a few coats of clear...







    following the new wheel look and front floor section I turned back too looking at a little more aero for the front. Canards. There was literally nothing I could buy off the shelf to suit what I kind of wanted so out with the fibre glass...



    Quick test fit and eye ball:







    They both still need a bit of trimming and adjusting oh and painting but this gives you an idea and to be fair I was pretty happy with them at this stage...

    while they where being finished off:
    Last edited by seventune; 11th May 2017 at 19:56.

  2. #222
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    The pesky interior.... lots to do here. The S6 I have isn't a plug and play. I didn't want too use the stock loom as it has issue so a full new engine loom is required and I shall do that bit soon. The aim here again along with the seat swap is too loose weight and make it all simple....

    A vast strip back of the stock loom saved a huge 13kgs.... these is leaving the lights, wiper systems, front electric windows, steering rack controls and indicators. pretty much everything else has gone.... including the bulky air con unit and heater unit.... The heater is being replaced with a smaller much lighter unit....


    so that's those gone:



    all this seemed very unnecessary:





    And this is what is left:



    with the heater/air con/wiring an over all saving of just under 21 kgs.... that'll do for now....

  3. #223
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    I might have just bought a dash!!


  4. #224
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    Not a problem.... to be honest if this wasn't the kind of thing I did for a living it would be a very different car...

    A curious black box turned up this morning....



    What's inside???





    The comes the question... near or far.... have to say I think it's close for me.... means the dash moves with the height adjustment on the steering colum.....



    Near:


  5. #225
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    Not had much time at all to get anything done on this for a while due to health issues.... though there are a few bits underway and not much left to do before i can get an eye in for getting the old girl fired up.... well in a few months

    big things:
    Exhaust
    wiring
    fuel tank needs to be made an put in the boot
    P/S pump and lines

    Could do with some paint at the end of it all!!!

    the dash is now mounted, 3D printed bracket so it fits nicely inside the steeling wheel in clear viewing poistion:









    With the exhaust i have decided to go with side exits, one either side and use big silencers position under where the rear seats used to be. This area i hve modded to get more a good deal more space by lifting the floor height....





    just waiting on some more sheet metal to finish this off....

  6. #226
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    As for the exhaust i need to mount the diff properly before i can make that so i have can see how how much room i have to get the pipes in the right place and the mufflers tucked up.... but i made the tip quickly yesterday just to get an idea of position and how it will look....







    coming to gether slowly but a big push over the new few months should see me in the home stretch

  7. #227
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    I'm liking the splitter. Many people use ply so don't feel bad. Great fabing work too.

  8. #228
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    I've had no time to play the old girl for ages!!! Just been silly busy with? Well I'm sure what other than work!!!

    Anyway managed to get a few more bits done.... Diff mount is almost finished (T45 box section before you ask ). There are a few more braces to weld in just to aid with the twisting motion from the drivechain but you get the idea. The brace that holds the diff is also tied into the floor support and exhaust mount points that are part of the rear floor section.

    I have also spent a while re working the rear arches a little and modding the rear bumper with cuts aways. These will have addition sections added in which I'm hoping i might get done tomorrow. There is some fiber glass work to do on the bumper too which i will have to do before paint.... some pics:

    The almost finished diff brace:



    The new rear floor section which has been mad to house the two side exit silencers:



    As for the arches, you can't really tell from a pic the changes as they look pretty similar but evidence to show the working and also the cut away sections which, with any luck, will look better in the next few days:







    Doesn't look like much has been done but there is a "few" hours in there the last couple of days!!! Once these bits are done i will be making the battery tray, mounting the ECU and Injector driver. Then onto the the PS reservoir, header tank and air intake tube.... my tube roller is busted so for now I will use 4" ally tube for that and will build the Ti one at the later date once i have rolled the tube.... The onto the Exhaust and wiring!!!

    Oh yeah and the fuel system!... I forgot about the fuel system!!! Quite important that bit! but anyway there isn't a huge amount left to do which has given me a 2nd wind

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