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5 GT Turbo 11 years later silver bullet comes home

Which battery tray option

  • Leave as is with battery tray sections

    Votes: 0 0.0%
  • Fully remove all spot welds and battery tray sections

    Votes: 1 100.0%
  • Leave battery tray in and trim/cut out sections not required to tidy

    Votes: 0 0.0%

  • Total voters
    1
  • Poll closed .
Well to honour my new 'mad' staus...thanks @andybond 😄 here is how today went

Got in my office at 6 a solid 3hrs early lol, lunch break ran to Tesco for mini shop, finished at 3, ran around with the boys for an couple of hrs, 2 of their friends staying for 2 nights (5 boys bouncing around) yeaaa, fed the lot of them including us, washed up, and the words fell out my mouth....just going to pop round garage to do an hr 😀 got the look, fired up hot tub threw kids in and ran leaving my wife with them again 🤫

2hrs later managed to get the below done and used ever last drop of gas (take the boy out of Cov and all that) but the low flow def made the last welds a bit trickier...refill here tomorrow. Back home and kids all my mine to look after for rest of night as reward 🌙😴

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Ok got a decent few hours in on Saturday, straightened up and cleaned original cut of rear outer sill, bit more prep or rear arch section which needs a new bit making, same up front....made decision to retain oem overlaps and butt weld it in outer sill....sill does seem pressed to want to naturally sit on top but nothing a bit of time and slight play will not sort.

Had a bit of oil canning on top section of the inner sill where clearly bit too much heat and left a clamp off in area was the cause. While almost certainly would have caused no real issues with outer sill clamped and joined.....it was bothering me too much, so cut slit, clamped welded and all back to straight :) and back to happy state.

Spured on with that then decided to cut outer sill ready to warm upto actually fitting....measured 3 times scored & cut, only decided in my eternal wisdom while cutting last min to leave a bit extra of meat only I had the sill upside down and actually cut shorter grrrr queue toys out of pram, went home drank beer lol.

Lesson learned with my short bursts of time to slow down a bit at times and accept not always getting what I want done 🙃

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Great progress Mr G! You are right about the slowing down and accepting that you may not always feel like your achieving your targets, but as you say, progress is progress! It’s coming on great now and your attention to detail will pay off in the end!!
 
Great progress. A couple of spare hours here and there keeps it moving, can even be more productive than a full day if your all set to go with materials ready, compared to a full day thats wasted due to missing or running out of something essential.
 
So got 2hrs tonight.....not going to get bk in until next week 😞

Got plasma cutter out to play and cut too big on purpose 😉 lol. Plenty of measuring, grinding, measuring, grinding and bit of hammer and be ready to treat and get welded on woop woop

Made end piece needed but needs welding

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Well very little progress over August with work commitments, 2 week family staycation and repairing roof over recent B/H weekend (2 full days of hard labour 🥵)

Anyway got back in tonight to get back moving again, prior to that was a few hours stolen to get my spot welder working and a play....thanks to @Mark_L for the advice 👍

Spot welder is up there with plasma cutter fun although while clearly working my paranoid android mode means some stitch, plug, seam weld will be added for completeness

Sooo cut a small section to fill the inner sill, prob not needed so of course I did lol. While spot welder doing its nugget magic dropped a few plug welds in and then seam welded...not coming off anytime soon

Had a blast of primer but still need to dress a few bits before primer and get outer sill on

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2hrs sweating butt off in garage only to find front jacking point about 25% fit.....gave up after 30mins of cutting and tweaking before it got cut in half and thrown in the pit! Reached out to @Chris74# to what joy he had and feel slightly better in that he had to cut and reweld the whole thing and not just me lol 😆

Tbf rear jacking point also needed plenty of tweaking and mixture of spot weld, plug weld and few solid tacks done...frustrating but still a tiny step forward 👍

Beer time 🍺

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2hrs in garage just, my youngest (7) came to help......which felt like I was recording a YouTube episode and never stopped asking questions, telling how I should it and wanting to do jobs the whole time 🤯

But cool he wanted to help 👌

So with ear defenders, goggles and full safety geared up (do as dad says not what I do lol)

Happy it fits and ready to stick....top section next to 1/4 panel needs a bit of work as the top bit does not follow the contours right but think I will weld from the bottom and work it as needed and play by how much the weld pulls it in etc

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That line of weld where you stitched panel back together might cause you some differing gauge issues when you weld the join, I'd thin it back as much as you can, it'll soak more heat as it stands on that side, blow on thinner original panel, you've got more adjustability on your R tech than I've got on my shit box SIP, think I'd struggle with that joint big time.
 
Thanks for flagging and good point @Turbell 👍

Teach me for not cutting right 1st time round

Will spend some time tarting it up, going to pratice with old metal cut out and off cuts of sill also to fine tune welder as it has the potential to be real fun so prep prep prep and hope for ok 😉
 
That line of weld where you stitched panel back together might cause you some differing gauge issues when you weld the join, I'd thin it back as much as you can, it'll soak more heat as it stands on that side, blow on thinner original panel, you've got more adjustability on your R tech than I've got on my shit box SIP, think I'd struggle with that joint big time.
You articulated what I was going to say, better than i was going to say it :)
 
Few pics of last few hr sessions

On real postive changing to type c rcb for 16amp feed has given spot welder full power/timer and fully happy it is joining 1+1mm 'spot on' 👌👍 in fact able to give too much now so turned down 😉

Note to self....don't weld upwards when crouching down and in shorts....especially you have a rottiserie lol 😆 while rear mount never coming off def harder to control and fair play to @Turbell doing this fun without one...

Filling small holes in floor a joy, think tiny patches might have been less hassle but most of the way there and finish off tomorrow. Quick pratice on the bench building upto sill section, bit more pratice but should be fine

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