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Carried on with the (w)underbar today – mostly just measuring and mocking up the first cross beam and making sure it’s all level. It needs a little adjustment but only once the cross beam is attached so it all stays lined up. It’s gradually taking shape though 🙂
This was first time out with the new chop saw and whilst it seems to have some limitations (mostly due to some disc “wobble”) the cuts are noticably better than freehanding everything with the angle grinder. It got dark before I could get much further but the fit of this cross beam looked a LOT closer than any of the previous joins.
Hopefully pics tomorrow if it’s not chucking it down…
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ah bugger I was messing about with the SSL stuff yesterday after getting scary warnigns from google about “insecure pages”, will see how I managed to break it.
EDIT: Actually the pics on the first page of this post are showing up for me. Are they the ones you mean?
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the same topic on here should be here: https://forum.vwsyncro.co.uk/forums/topic/brake-upgrades/
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yep it has an angle vice thing..though at this point even straight cuts would be an improvement 😉
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I like your rotisserie btw, is it made or bought?
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just bought a mitre/chop saw which should make all this pipework stuff a lot simpler. Finally some actually square cuts \o/ (with a bit of luck)
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Pics of the (w)underbar in progress. It’s only tacked together at this point and the front “prongs” won’t protrude beyond the cross beam as they do now, and there will be a couple of cross beams to strengthen it but hopefully you get the idea from these. It mounts/locates onto the front wishbone bolts and will hook onto the subframe so that in the event of a hard impact the two bolts don’t bear the full brunt of it (or you’d be walking home!). The bottom half should be hardly visible under the regular big bumper skin (tho it has the lowest bit removed for clearance)
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welcome back! – nothing done?? looks like you’ve done loads. That’s some fairly major work you’ve done 🙂
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Much to my surprise the “(w)underbar” is coming together nicely. Bit fiddly to make but actually should end up a lot simpler and stronger than I initially thought and should be almost invisible under the front bumper when all finished.
There’s two main beams which run either side of the engine, made form 30x30x2.5mm box section steel which will have a main cross-brace from the same, and some additional cross braces from L-section. So far clearance round the left side by the PAS pump, sump etc seems pretty good with about 1.5″ all around.
It was dark by the time I’d finished yesterday so no chance for pics but will take some today hopefully. It doesn’t remove any ground clearance and should provide pretty decent sump protection. I just need to find a couple of slightly longer bolts for the front wishbones as the wunderbar mounts onto those to fit flush with the subframe and that doesn’t seem like somewhere I’d want to lose 5mm off the thread depth.
I’m waiting on more cutting discs before I can do much more on that front.
Annoyingly though, my downpipe appears to be leaking where it bolts up to the 16v manifold so am thinking I’ll have to either cut a new manifold mating plate out of thicker steel or possibly slice the original plate off a 16v dowpipe..though that looks like it might be cast so not sure how weldable that’ll be (assuming I want it to stay intact).
It might be time to break out the plasma cutter on some 6/8mm sheet which is fine, except it will mean unwrapping the heat wrap which is kinda annoying…but c’est la vie I guess, it needs to not leak. If I’m having to re-do that part of the downpipe I might see if I also can make a nicer twin-pipe version which would mean longer, smoother secondaries which should be better for power than merging just after the stock 16v manifold as it does currently. I’ve got a little pipe flaring tool so hopefully should be able to hack up a couple of 16v downpipes to make little sections which fit over each other and mean I can mock the pipe up in situ before TIG welding it up. It is *very* tight in there though.
pics to follow..
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that seems pretty cheap actually..not sure what they cost normally but I guess that’s if you can even get a pair here.
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towbar for the front has been shortened and adapted to fit to the front, actually looking like it should fit nicely inside the existing bumper. So far it’s just tack welded in place with the mig and will stay that way till I’ve got all the underside/sump protection mocked up too, then will take it all off and tig weld it up properly.
The underside bit looks like it will be a bit of a challenge but should be doable. Need to get a few more bits of metal first though.
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towbar for the front has been obtained, seems like the chassis legs on the front are a little bit closer together than the back so will need to chop and re-weld it a bit but that’s lots better than if they’d been wider. It’ll need the actual towar bit chopping off too. Time to test out the plasma cutter I think 😉
the towbar is a bit on the heavy side so might see if i can fab up some sort of more lightweight reinforcement for the bumper instead but don’t currently know how possible that is. I’m still trying to figure out the lower half before hacking anything up.
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