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 Post subject: Re: Back in the game! Project "Monster"
PostPosted: Fri Feb 12, 2016 11:10 am 
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Well as usual it would seem I have kinda made some progress but not as I've hit a snag on things with the flywheel bolts now!

As mentioned I purchased some ARP flywheel bolts from the info in this thread...http://www.redlinegti.com/forum/viewtopic.php?f=4&t=52483&p=507356#p507356

and from talking to others who had used them only to find the same issues as others in getting bolts that are too long to use :(

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The stock bolt is 19mm UHL (Under Head Length) but the ARP ones are 26.7mm UHL so far too long... which is always nice to find at 1am! If anyone can point me to the right bolts (not just a part number) that would be awesome!

On a brighter note, I weighed the stock flywheel compared to the lightened one and I've gone from 7.5kg down to just 4.5 so happy with that :)

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 Post subject: Re: Back in the game! Project "Monster"
PostPosted: Sat Feb 13, 2016 11:10 pm 
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Okay so despite the flywheel bolt issues Buzz and I had a crack at a few things last night. Well mostly Buzz as my kids were anti sleep.. but hey... :P

Anyway, we got the woring issues in the dash sorted, put some new white led bulbs in the dash, got the shifter setup removed for an upgrade ;) , wired up the water temp sensor and got all the things we could sorted without being able to bolt the flywheel in. I have planned out the intake setup and air feed from the cf fog light insert and also how to mount the oil temp sensor (sump plug).

On that front i am having the bolts that should be perfect... should be... for the flywheel being sent Monday and we will see how they go.

So kicking some goals even if they aren't the ones i had hoped :)

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 Post subject: Re: Back in the game! Project "Monster"
PostPosted: Wed Mar 16, 2016 11:07 pm 
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Well it has been over a month now since my last post. Partly as i have been busy, partly i have been procrastinating and also waiting on parts! The flywheel bolts special ordered from the US took longer to arrive than expected and the upgraded shifter setup is taking longer than expected to come back. But that's custom car parts for you.

The flywheel and clutch are now in. With the flywheel secured in place using M16A flywheel bolts from ARP hooked up to the 4 puk clutch. Hopefully Friday night Buzz and i will be free and both have a good crack at getting the drivetrain back in place and the car back on all 4 wheels ready for the shifter setup to arrive hopefully before Easter.

Then over the Easter break the plan will be to do all i cam to get it running again. After that its just $ needed for the crossmember to be made to clear the dump pipe, suspension setup and decent tune and it'll be ready to hit the track so long as there are no more dramas!

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 Post subject: Re: Back in the game! Project "Monster"
PostPosted: Mon Mar 21, 2016 9:08 am 
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More progress :) Friday night Buzz and I had a late one and got the gearbox in... well mostly... as well as 2/3 90 Duro Poly Engine mounts. The gearbox (with pg lsd) went in and was bolted up in about 30 minutes other than the rear mount which we left off to do the poly mount swap.

Once the mounts were swapped (and many attempts to get the bolts for the mount into the firewall - if you haven't done this, do it with the engine out or not at all :P ) we spent a lot of time trying to get the rear mount setup to line up to the box and block with out luck. Due to the lack of visibility because the engine, wires and intake are in the way we didn't notice that the bolts for the mount itself were slightly fouling on the case of the box, causing it to move out of alignment just enough to be a pain and not bolt up :(

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We inspected the 2 other 1300AWD boxes that I have and sure enough both have the section that was snagging ground out of the way, the one bolted to the engine did not :( not having a working Dremel meant that was game over for the night but it should be an easy fix when I get in there with the new Dremel sometime this week. You can see in the pic above the raised section getting in the way, it's not massive so some gently massaging from the Dremel should sort it easily enough and mean I don't have to pull the box off again!

So once again I'm a little closer and slightly snagged :P But progress is progress so I'm happy with that!

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 Post subject: Re: Back in the game! Project "Monster"
PostPosted: Tue Mar 22, 2016 7:25 pm 
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Pic of the engine mounts for those that want to see them fitted


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 Post subject: Re: Back in the game! Project "Monster"
PostPosted: Tue Apr 05, 2016 10:03 am 
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Decided last night I should get stuck into fixing the issue with the gearbox casing. So the plan was first fit up the cheeky little mod I got from Bwitched - SX4 Washer Nozzles...

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Less than 5 minutes later and all done, so I was in a winning mood :)

I undid the gearbox mount at the front of the engine and dropped the box onto the waiting jack - still connected to the engine - had a quick look at things and had a brain wave... with the front mount off again I could almost line up the rear mount to the box... after about 45 minutes of laying under the car trying to line up the box and mount using the jack, some choice words, a little help from the Mrs, and some stuffing about to find the right bolts I got the first bolt in and was loving life! :D

I jumped up to the top of the car again to see how it was looking and sure enough it was snagged at the same point... I worked out I could probably get the bolt from the mount that was hitting the case over the lip and I'd be home, so some stuffing about with my "gentle persuasion tool" and it was clear... but still snagged! I had completely forgotten the it is the mounting bracket that snags, not only the bolt! :evil:

As I had moved most things from around the rear of the engine/box I had a pretty good view of where I needed to cut the casing, I spent a few minutes working out how to get the Dremel in there and found I could, just, and began to cut... it worked but it wasn't long before the cutting wheel was too low to get through the section I needed to remove so it's now looking like this...

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If I can find a slightly larger cutting wheel for the Dremel I might be able to cut out the section I need t remove without the hassle of removing and refitting the box. But at this point... after 3 hours of stuffing about. I'd say it would have been faster and easier to remove the box, hit it with the grinder and refit!

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 Post subject: Re: Back in the game! Project "Monster"
PostPosted: Wed Apr 06, 2016 6:06 pm 
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I think it will still be quicker to remove the box,there is a fair amount of material that has to be removed

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 Post subject: Re: Back in the game! Project "Monster"
PostPosted: Wed Apr 06, 2016 7:33 pm 
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Thanks Dave,

totally agree. Seeing it and having some time to mull it over it'll have to come out. It's annoying but you have to do these things. Hopefully nice and straight forward for a change. I just need to find the time now. Time like this I wish I had an engine crane to help with the box.

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 Post subject: Re: Back in the game! Project "Monster"
PostPosted: Tue May 17, 2016 11:48 am 
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Some small, yet significant, progress last night. It took some time and wrangling but I think I have the casing adjusted to properly fit the rear mount now without it fouling. I didn't manage to get it 100 bolted up to the firewall but the bolts are in the rear of the block as well as the bottom of the gearbox and it'll just take some manoeuvring to get the box lined up 100% for the engine mount bolt and the bolt in the top of the box. I gave up trying last night as the combination of wet shed floor (leaky roof) and a thunder storm over head was not appealing.

If you look at the photo above you can see what I've taken out now in the progress pics below.

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 Post subject: Re: Back in the game! Project "Monster"
PostPosted: Wed May 18, 2016 2:37 pm 
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Make sure none of the filings have gotten in the box they will tear the bearings and seals apart. :shock:

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 Post subject: Re: Back in the game! Project "Monster"
PostPosted: Thu May 19, 2016 4:04 pm 
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Thanks for the tip, lucky it was shut up tight and will get vac'd and i will be flushing the gearbox before use too :)

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 Post subject: Re: Back in the game! Project "Monster"
PostPosted: Mon May 30, 2016 11:31 am 
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So i made some progress Friday night with the supervision of a tame mechanic and now the gearbox and engine are fully connected and 2 oit of 3 poly miunts are in. I ran out of time to finish getting the drivers side done as they are a bloody tight fit.

I will be out of action on this for a couple of weeks after some minor surgery but hopefully i will get one last crack at it before the end of June so i can have it on all 4's again before I live at work for the following 3 months

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 Post subject: Re: Back in the game! Project "Monster"
PostPosted: Tue Jun 14, 2016 12:18 pm 
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As I've had a lot of people asking lately here is a simple update, following the progress made at the end of May I have had a nasty complication to a eye op I had 2 weeks earlier which has meant I have been off work and unable to use my left eye. It's slowly on the mend but at this stage the build is going no where unless I get some volunteers to do it for me as I won't be able to work on the car anytime soon :(

it seems like there's always something but I'm not giving up on this build as I'm achingly close!

Just praying for things to go my way for long enough to get this at least track ready! [-o<

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 Post subject: Re: Back in the game! Project "Monster"
PostPosted: Fri Jul 01, 2016 8:39 pm 
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So today marks the 4th anniversary of my purchase of this car from Squirt... I'm still amazed at what the car is becoming but progress is slower than I ever dreamed it would be! But that is car building on a budget I guess. Anyway...

Some progress yesterday for the car, I'm back using 2 eyes after 5 weeks not being able to use the left one because of an operation followed by staph infection and now am on day 1 of living at work season. But Buzz let himself into the shed yesterday and managed to get the last engine mount in properly so the engine and gearbox are now 100% BOLTED in! :D

Starter motor is bolted back in, along with one of the driveshafts as well. While there is still a ways to go it's slowly getting there. Hopefully I can get to it again after September when work has settled again.

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 Post subject: Re: Back in the game! Project "Monster"
PostPosted: Wed Aug 03, 2016 9:42 am 
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So word on the street is this project is inching closer to being on all 4 wheels... reports have reached me that the car now has all 4 wheels properly attached, engine and driveline installed, all while I have been punching out 90 hour work weeks and without the car leaving the shed...
it still needs a few things doing to be running and rolling but it's inching closer... keep tuned in for more details once i actually get the chance to get out to the shed and see for myself or Buzz takes some pics of what he's been working on while I've been busy! :wink:

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 Post subject: Re: Back in the game! Project "Monster"
PostPosted: Sun Aug 21, 2016 10:23 am 
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Just a quick photo update as i have had a lot of guys asking me privately for some pics

Here is how the Swift Sport shifter (about 25% shorter throw than a 1600awd shifter) setup looks with the stock trim, it fits very nicely, i need to get the small inner trim piece back on the cover but this was just a quick test so i will do that later.

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And look front wheels are back on!

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At this stage i can't see much getting done by me at least until the end of September as i am still working 6 day weeks amd need to see my family for at least 1 day a week. It is inching closer though, the list to get sorted before it needs a pro is short, but i need a good day working on it with someone like Buzz to achieve that.

seeing all the views tick up on here does give me motivation even if the comments don't :wink:

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 Post subject: Re: Back in the game! Project "Monster"
PostPosted: Sun Aug 21, 2016 10:45 pm 
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Popping in a comment. Watching with interest and enthusiasm! Just about to start getting back into working on my car in next fortnight or so. Keep it up, you are getting there.

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 Post subject: Re: Back in the game! Project "Monster"
PostPosted: Mon Aug 22, 2016 12:04 pm 
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Cheers mate, encouragement always helps, hopefully things go smoothly from here - even if they are slow, small steps! :)

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 Post subject: Re: Back in the game! Project "Monster"
PostPosted: Wed Sep 21, 2016 12:49 pm 
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Just a small update, Iv'e been busy working etc but have started putting together a few little bits needed for an up coming weekend of work on the car with Buzz

The to do list for the weekend seems pretty straight forward so here's hoping it is! [-o<

Job list

- Shifter setup
 - Fit short shifter
 - Fit rubber grommet to firewall for cables to pass through
 - Install shifter linkages into gearbox
 - Fit cables
 - Install gear knob, leather boot & trim
- Flush & fill Gearbox
- Fit wire for water temp sensor
- Adjust plumbing for oil lines from catch can to cooler and re-wrap with heat wrap.
- Install oil temp sensor into sump
- Install oil drain from turbo to sump
- Heat wrap cooler piping past battery
- Plumb air filter to turbo and cold air feed to filter & heat wrap
- Dummy Fit under body brace and check clearances
- Fit new plugs
- New fluids and oil filter
- Fit “Monster” items
- Rough wheel alignment
- Install "rear washer" intercooler spray setup
- Refit battery etc
- Paint muffler
- Check turbo for oil leaks when running
- Clean inside and out

If time
- Install sub under passenger seat
- Install spare 6x9’s
- Check fitment of front bar and clearance of CF lip
- Check eyebrow height
- Stickers

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 Post subject: Re: Back in the game! Project "Monster"
PostPosted: Tue Oct 04, 2016 9:52 am 
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So the weekend started like this...

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Buzz and I spent a couple of hours sorting a few little things out, we swapped the selector over to the Swift Sport setup and then called it a night.

The following day we had a few errands to run to grab some parts needed, but ran out of luck with no one local having a 3" to 2.75" silicone reducer to make the K&N Apollo setup work so I just made it work so it can run in the shed etc with a decent filter on it.

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After stuffing about with that and getting the oil lines freshly heat wrapped, we hooked up the shifter cables and found we had installed the selector the wrong way around and the car wouldn't shift #-o

The sealant we used was great and took us ages to break the seal on, we played around with things and got it lined up as we thought it should. But when we tested the shift I didn't realise the selector pins had not been screwed in and the box is not stuck between gears #-o we tried for hours to get it to come loose before running out of time and patience with it. I'll get back to it over the next week or so to keep at it and get it to come back out of gear etc.

having not a lot else to do as it all hinged on the gearbox being ready to roll there was only one small job left for me to do, paint the exhaust tip. I've been wanting to make it a little less obvious that there's a 3" dumpy back there so I did this and think it looks the goods.

First Coat

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Finished Look

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Still so close yet so far :x

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Back in the game! Now building something mental... Will I ever finish? I hope so! When? No idea.


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