5 GT Turbo 11 years later silver bullet comes home

[DaveL485]

Looking forward to seeing the process of making the wafer thin back end of this french cream cracker strong enough to handle that lump!

 

[Duncan Grier]

Solution = full spaceframe for wishbones/suspension and engine mounting and tied into full bad boy cage by @Mark_L

 

[Duncan Grier]

So after hours of frustration at times getting the 1st frame made and was close to having to go far wider than wanted and or going manual gearbox......



....but happy to report I have been able to meet mm perfect pickups, fits in 5 well lining upto oem torsion mounting section and while super close fits 5 pot and DSG - anyone would think I planned this lol

I need to relocate wishbone bracebars to get engine/box perfect and have retained offset to give more even L/R weight distribution.

Sacrifices atm is A/C see how it sits after making the rest of the spaceframe before getting creative....remember final version will be in tube giving a few mm more anyway not take that many pics but some below

 

[Duncan Grier]

Few hours back in tonight and decided to go 40mm longer to give a bit more clearance and ease of access longer term to oil filter etc.

Anyway usual boring pics

 

[Big Steve - Raider]

Welds looking great sir!

 

[Duncan Grier]

Thanks @Big Steve - Raider bit rusty tbh having not done much as of late but it is straight and not moving

Forgot how much I enjoy it, sooo much work on it atm with very little to show but getting it right now will avoid all sorts of challenges later on

 

[andybond]

Far from boring. 40mm sounds like a good idea.

 

[Duncan Grier]

Well seems after closer inspection while mm as correct, somehow used the wrong measurment and the front pickup which needed to be 4mm wider...doh! You can just see it by eye in 1st pic.

Considered cutting box and widening and weld back up but knew what was coming.

Picked up an old draper (1980) big pillar drill early Saturday, need to make a small stand for it but happy with it......do need to give it a bit of a refresh as there is a bit of float on chuck but ok for now and nothing terrible

So 3hrs to fix a 10min error, always takes longer to rectify your mistakes but got bolted together and measurments bang on, sorted a few things in garage and raised into position.....pics don't show it well but fits as planned and feeling minor victory.....can get on with making top pickups now and think about mounting to the 5.

Moral of the story while measure 5 times cut once is all great.....just make sure you know your target measurment 1st

 

[Duncan Grier]

And the drill

 

[Spooky]

Awesome work, love the progression in the welding too

 

[gordini stu]

Top stuff Dunc
I reckon you will need some arches on there too

 

[Duncan Grier]

Cheers @gordini stu have few options that could be reworked and some more out there plans of my own, but that is def one I can't decide on until on 4 wheels and know final body dimensions.....

 

[Duncan Grier]

Quick 90mins just, generally playing with postion measuring, more measuring

Cut a quick letterbox for top wishbone and more measuring, old school plumb line, spirit level and right angle and you guessed it more measuring lol

As a total win my quest for 300mm clearance from bottom of sill line and new wishbone pickup is bang on and butts upto oem rear torsion bar ready to make a decent mounting bracket....so while everything is mega slow the measuring and planning is coming good

Wheel looks to sit about right but need to brace the boot area before taking too much out just to be sure and just keep going

 

[Duncan Grier]

Well more hours of you know what

Got on with working out the top mounting as you can see in the pics a decent angle to get right. Got tabs welded on and will get in position and joining box next session but again hopefully you can see how that will work from pic . Should then have one side done ready for final sign off or scrap

 

[Duncan Grier]

Ok so D-Day for 5 rear end as in a nut shell it dont fit after much trying and lots more measuring

So while in a mood with myself and choice words in garage got thinking harder

Ended up with 3.5 options

1. Sack it off and sell bits and by a normal sports car

2. Increase width of pick up 50mm and loose aircon along with limit engine left/right placement

3. Increase width by 100mm and retain aircon and some space to balance left/right a bit better

3.5. Look at 6 speed manual..........nahhhh

Pinged a few friends for feedback, got head out of butt and starting measuring changes up and impact to placement in car etc.

50mm looks to be the best option and easier to absorb and have some extra wheelbase I can use for the % change....load of random pics for Sunday up and down adventure

 

[Big Steve - Raider]

You DARE sack it off!!!

 

[Woznaldo]

Hi DG, it's been a while since I've been on here but, your project caught my eye! Firstly for the rust repairs (your welding has improved imensely since the start) but, now for the whole RWD setup. Your current dilemma is not uncommon with this type of conversion. Are you set on the upper and lower wishbones you have? You could tweak the lengths and the pickup points of to get similar geometry?

 

[Duncan Grier]

Thanks @Woznaldo

I considered custom wishbones but trying to reuse oem items where possible to reduce any tolerance I might introduce and also future replacement needs. Also save time which is always a premium

Nothing is set in stone mind and constantly reviewing how I am achieve the end result

Having spent some time reviewing measurements 50mm will be added to the rear, and build out from there as my reference point, but plan increasing wheelbase by % of rear width added and review front after.

 

[Woznaldo]

I invested in Paul Fickers' Suspension software (DynatuneXL). It's Excel based (hence the name) and a fraction of the cost of more commercial solutions (Optimum-G or Adams Car). I plan on using it to model my 5 and will validate it against data I will be collecting via a whole heap of sensors. I'll start my own thread once I'm up and running again.

I'd be happy to throw in the coordinates of your setup if you'd like? I'm still very new with the software but, getting better.

DYNATUNE-XL

HOME PAGE OF DYNATUNE-XL SOFTWARE

www.dynatune-xl.com

 

[Duncan Grier]

That would be brilliant I will drop you a message