RHD BEAMS Progression/Build Thread, Finally Getting to Finish Options

[enderswift]

celicas, celicas everywhere

[ricochet1490]

[ricochet1490]

Bolting the firewall in through the holes created by the spot welds




This locates the firewall in there, welding soon.

I'm not putting it in there exactly lie the factory did. The firewall from the factory was put in there in layers. It was sandwhiched between a layer for the floor pan, and the layer for the wheel well.... and then it changes sides and is in the engine bay in the middle.... very complicated, so it's getting welded back in on the inside of everything. I've hammered the inside layers to the outside, and that's why I'm bolting it in through the holes, to pull it up tight and to weld it in there. If it's anything but where it should be, It might be the thickness of the firewall toward to indside..... 0.8mm lol

[ricochet1490]

Took the firewall back out and cleaned up the old seam sealer so welding would be possible.... then I put it back in, drew it up tight, hammered everything flush with some good old tin work.....

The results:









Welding tomorrow!

[kurt95gt]

Looking good buddy

[richee3]

Nicely done! I can't wait to see it all welded up and finished. What's next? Interior reassembly?

[ricochet1490]

Nicely done! I can't wait to see it all welded up and finished. What's next? Interior reassembly?

seam sealer, engine bay wiring, brake/ac/fuel lines, mount parts on firewall, then start dash install with hvac stuff and remaning dash hookup wiring.... mount airbag sensors, radiator, condensor, cram subframe under car, bolt and hook up and attempt to start before totally buttoning the front end back up....

Oh and somewhere in there drill out the RHD hole for the wipers to mount.

[richee3]

Picked up the clip today in cincinatti....
1) finish finals, week of Thanksgiving (Nov 2_th)
2) weekend after deer season begin tear down of shell, complete gutting, interior, carpet, dash, everything (complete by end of first weekend in december)
3) firewall of shell cut out either that weekend or shortly thereafter. Saving all cables for trunk pop/gas etc. - setting aside all usdm parts for later install into my DD, sale on 6gc, give back to Richee3 because of all of his previous kindness.
4) drop motor from clip out of the bottom ( I have a forklift etc.) and begin clip tear down (noting and saving all bolts and wiring locations) Drop motor by christmas.... have clip torn down and parts organized by Jan 15 2012
**Classes start back up and progress will drastically slow so I need to do as MUCH as I possibly can before Jan 3. **
5) reweld clip firewall into shell and begin running chassis wiring. Have wiring run and dash parts more or less installed by Feb7 (my birthday)
6) install interior with EXTRA sound deadening everywhere with legit RHD center console ( from FORGMANN, he's the man) Complete by Feb 22
7) Install engine bay parts and tie up odds and ends like wiper bulkhead. Matching spray paint color to car - paint firewall- Complete by March 12.
8)Install engine subframe into shell by installing from bottom. Hello forklift - Hook up all engine electronics/fluids/fuel etc - Complete and have running by March 26 (end of spring break)
9) Install exterior parts/pieces tails, jdm fenders, bumpers etc. - finish by april 15
10) bleed brakes - bolt on wheels - drive to buereau of motor vehicles and get registered and liscensed - May 5th
11) Run the piss out of the car for a weekend, park it and begin all remaining body work that MIGHT need to be done if I haven't gotten to it yet. - Send to paint and have painted the color she was.... sleight blue gray.
12 Project complete for my College graduation.. Present to myself.

Ahem...... By my count, you're six months behind. No more excuses! I'm tempted to get the ban hammer out. But I decided that's not enough motivation. So I'm jumping straight to... THE BAN WHIP!!!



This post has been edited by richee3: Aug 2, 2012 - 11:09 AM

[kurt95gt]

Ouch breaking out the ban whip

[rave2n]

[ricochet1490]

welding didn't go as planned. wrong setup on the welder for sheet metal. .045 wire on a 220V machine, not good for firewall. Had some success, but limited.
Trying again tomorrow with a different machine that we ahve set up with .025 wire. Just have to move the gas bottle over as the one currently attached is pure argon instead of the 75/25 argon c02 mix.

Also gotta find some brass or something to help prevent burn through lol

[richee3]

Any luck on the welds yet?

This post has been edited by richee3: Aug 3, 2012 - 4:32 PM

[ricochet1490]

They freaking suck.....

It's just too dirty with paint primer, and remnants of seam sealer. I thought I had it pretty clean...

[ricochet1490]

My usual skill.... Not bad



What this firewall is looking like


I'm gonna turn the heat up and slow the wire feed and go back over them I think

This post has been edited by ricochet1490: Aug 3, 2012 - 7:44 PM

[kurt95gt]

Not lookin so good lol
Keep tryin man you'll get it

[ricochet1490]

It's just too dirty. I'm just welding the sure **** out of it now to make sure it sticks....
They are looking better after I turned the heat up, but I burn through now if I'm not careful

This post has been edited by ricochet1490: Aug 3, 2012 - 8:23 PM

[ricochet1490]

Welded it up some more, ground it down, welded it up....
Welded the inside with "tabs" of weld if that makes sense. A bunch of big tack welds basically after I tried doing what I could to seam weld everything together on the inside as well.


Just some pics. I'm sure it's not coming out anytime soon lol









word of advice if ANYONE else decides to do this..... take off all the paint and primer in the area. Even if you think it'll be fine, that was my biggest problem. I had to put those crappy welds in there to get the paint to burn off and give me more metal to flow too. That's all I did for nearly 6 hours was try to weld this thing in..... and the welds suck! but they'll be hidden so no biggie I guess.


Taking out bolts tomorrow and applying seam sealer VERY HEAVILY to cover all holes, cracks, nooks, crannys, and then gotta paint the engine bay cause I dinged it more than once during spot weld removal.

Got a job and start work officially on wednesday, so I gotta hustle lol

This post has been edited by ricochet1490: Aug 3, 2012 - 11:08 PM

[enderswift]

are you doing MIG or TIG?

[ricochet1490]

Given that I referenced wire feed, def MIG welding.

[ricochet1490]

If the surfaces were pristine, either welding would work. But it's got more than enough on there. If you knew how hard it was to get out....

It continues