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> Bringing out the dead
Jeff Hail
post Feb 23 2011, 11:21 PM
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Installed some new metal on the left side of the tunnel where the flange/ floor meet.

Trim, trim, trim and drill a bazillion spot welds. The left side floor crossmember has twice as many resistance welds as the passenger side. Some rust under the crossmember flange actually "rust welded" the floor together.

I might make new crossmember overlays if it doesnt come apart at the flanges easily. An air chisel will tear the flanges up and a hand spot weld buster is already doing that.



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krazykonrad
post Feb 24 2011, 10:48 AM
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QUOTE(Jeff Hail @ Feb 23 2011, 09:21 PM) *

"rust welded"



Don't cut out the rust welds. Those are original from the factory! (IMG:style_emoticons/default/blink.gif)

Konrad
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Jeff Hail
post Mar 7 2011, 05:03 PM
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A few more modifications to the early firewall. Closed off the heater cable tube holes and airtube exits from the inside.

Early/ Late lower firewall:
The brake presure regulator and brake line exit sits farther to the left on the early firewall. I think I will leave them where the early panel locates them. Not sure if the later location will interfere with the 3.2 but I don't want to find out later.

Lower firewall final fit up done. Held with Cleco's. Inner reinforcement (AA) halves welded together to create a single panel...easier to assemble.









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Jeff Hail
post Mar 7 2011, 05:06 PM
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Next I will fit the floor and trim as needed. Take it all apart and punch the holes for the plugs.
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Jeff Hail
post Mar 7 2011, 05:08 PM
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QUOTE(krazykonrad @ Feb 24 2011, 08:48 AM) *

QUOTE(Jeff Hail @ Feb 23 2011, 09:21 PM) *

"rust welded"



Don't cut out the rust welds. Those are original from the factory! (IMG:style_emoticons/default/blink.gif)

Konrad


I missed that Konrad. You're a funny guy! I wonder if "Rustone" was a factory color code option?
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Jeff Hail
post Mar 21 2011, 11:55 PM
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Bunch of little things to tidy up, fabricate... before I button the floor up....

1)FABRICATE THE PASSENGER SIDE TUNNEL REPAIR PART.

Fabrication is easy. Doing it twice with opposites is a challenge. Even know the parts are dimensionally symetrical they are not the same. ( Cutouts, notches etc)

Came out a beautiful piece of metal !!!


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Jeff Hail
post Mar 21 2011, 11:56 PM
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Now thats a SHIFT knob !!

Whatcha think?



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KELTY360
post Mar 22 2011, 12:13 AM
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QUOTE(Jeff Hail @ Mar 21 2011, 09:56 PM) *

Now thats a SHIFT knob !!

Whatcha think?


I can get behind that.
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Hontec
post Mar 25 2011, 12:26 PM
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I just read your topic and maybe I read over it, but the lower part of the firewall on the engine side, who makes that panel? AA or restoration design or did you manage to get an original one?

Thanks and I love the way you're doing this, extremely nice work!!!
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914outlaw
post Mar 26 2011, 09:33 AM
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QUOTE(Jeff Hail @ Mar 22 2011, 01:55 AM) *

Bunch of little things to tidy up, fabricate... before I button the floor up....

1)FABRICATE THE PASSENGER SIDE TUNNEL REPAIR PART.

Fabrication is easy. Doing it twice with opposites is a challenge. Even know the parts are dimensionally symetrical they are not the same. ( Cutouts, notches etc)

Came out a beautiful piece of metal !!!



Nice work Jeff. What gauge steel did you use by the way?
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Jeff Hail
post Apr 6 2011, 08:58 AM
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QUOTE(Hontec @ Mar 25 2011, 11:26 AM) *

I just read your topic and maybe I read over it, but the lower part of the firewall on the engine side, who makes that panel? AA or restoration design or did you manage to get an original one?

Thanks and I love the way you're doing this, extremely nice work!!!


The lower outer firewall is a New Old Stock panel for an early car.
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Jeff Hail
post Apr 6 2011, 08:59 AM
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QUOTE(dpires914 @ Mar 26 2011, 08:33 AM) *

QUOTE(Jeff Hail @ Mar 22 2011, 01:55 AM) *

Bunch of little things to tidy up, fabricate... before I button the floor up....

1)FABRICATE THE PASSENGER SIDE TUNNEL REPAIR PART.

Fabrication is easy. Doing it twice with opposites is a challenge. Even know the parts are dimensionally symetrical they are not the same. ( Cutouts, notches etc)

Came out a beautiful piece of metal !!!



Nice work Jeff. What gauge steel did you use by the way?



16 guage
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obscurity
post Apr 6 2011, 09:34 AM
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QUOTE(Jeff Hail @ Apr 6 2011, 10:58 AM) *

QUOTE(Hontec @ Mar 25 2011, 11:26 AM) *

I just read your topic and maybe I read over it, but the lower part of the firewall on the engine side, who makes that panel? AA or restoration design or did you manage to get an original one?

Thanks and I love the way you're doing this, extremely nice work!!!


The lower outer firewall is a New Old Stock panel for an early car.


Where did you find the part? Was it pricey?
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krazykonrad
post Apr 8 2011, 09:05 PM
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Jeff-

Your level of craftsmanship is incredible! Every time i see this thread, I'm just amazed.

Konrad
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Jeff Hail
post May 7 2011, 12:05 AM
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A bit of a hiatus after two back to back surgeries. Nothing major just time away for healing.


I have never been a fan of articulated headlamps. Loss of form when raised and aerodynamically handicapped. Added weight etc, etc, etc. I have been on the hunt for three years for a viable compact alternative to the original.

Hella offers a solution but not econonical at $1400 a pair including ballast. F that!

I have seen flush mounted lamps that frankly look and are cheap substitutes for a functional alternative to the original.

CRITERIA:
1) A more powerful lighting solution.
2) Improved illumination with less power draw on high beam than the original sealed beams
3) Cost effective and easy to fabricate/modify.
4) Able to fit into the original lamp bucket without cutting original material away (in case I ever want to revert back to the pop ups)
5) Somewhat plug and play.

Enter Bi-Xenon lamps: ake Daimlers "Xenarc" projector headlamp
A compact and short Bi-Xenon projector assembly

Both the 2010 SL55 and E class use the same Xenon projector assembly. The lamp assemblies are completly different as the SL55 has adaptive (pan, tilt) servos BUT the actual projector inside the lamp is the same identical unit. A friend at a Benz shop has damaged assemblies all day long BUT the projector is always OK.

I take a few junk damaged headlamp assemblies home and start destroying them for the guts. The high end cars have about 180 individual pieces that make up ONE headlamp assembly. I am only after the projector with the shutter actuator. Bi-Xenon lamps do not have a low and high beam. The lamp is always on. What differentiates high and low beams is a shutter or brow that blocks off a partial amount of light like a camera lens shutter or iris.

These are light weight, short and compact. I only need to fabricate a housing like the 944 flush headlamps and lens. Make sure it is servicable and sealed.

If Lamborghini could get away with using 92 Nissan 300ZX headlamps on the Diablo I can do this easily. (bet you never knew that)


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Loser_Cruiser
post May 21 2011, 08:58 PM
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any updates? (IMG:style_emoticons/default/smile.gif)
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Jeff Hail
post May 21 2011, 10:39 PM
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QUOTE(Loser_Cruiser @ May 21 2011, 07:58 PM) *

any updates? (IMG:style_emoticons/default/smile.gif)


Nope... busy elsewhere.
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saigon71
post May 23 2011, 02:38 PM
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Awesome work Jeff! I have learned a lot from this thread. (IMG:style_emoticons/default/welder.gif)
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Jeff Hail
post May 25 2011, 11:18 PM
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A little time to play last night. Been busy everywhere else.

The rear portion of the tunnel is done and welded. Spent a lot of time fitting the floor to the tunnel flanges and lower rear firewall. Lots of trimming here and there, leveling and self tapping screws for positioning. Then take it all apart again for the last time before I weld everything up.

1)Still need to weld in the mid bracing for both the clutch and throttle cable tubes rom the underside. Need to pickup some copper rod to shove inside the tubes so I dont blow holes.

2) Contemplating moving the shifter tower back a couple of inches.

3) Need to media blast the inside of the tunnel to remove the last of any scale.



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speed metal army
post May 25 2011, 11:52 PM
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QUOTE(Jeff Hail @ Mar 21 2011, 10:56 PM) *

Now thats a SHIFT knob !!

Whatcha think?

I think youre on the right track.Fu**in A! (IMG:style_emoticons/default/aktion035.gif) (IMG:style_emoticons/default/aktion035.gif)
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