5 GT Turbo R5 GT Turbo - Complete strip down and re-build #1

[DaveL485]

So, I called the engine builder again today to try and get my engine back, he has had it for over a year now! He keeps fobbing me off with the waiting for parts excuse, it'll be next week and so on! I think Im just going to have to go down there and take the engine back in whatever condition it is currently in. If people have no intention of doing the work, why take it on????

Sadly, seems to be the norm for...well...most things in the motor trade beyond the normal daily servicing and maintenance.

I got all the parts together for my C1J in under a month so if a professional can't do it in a year i'd be taking my business elsewhere.

 

[gordini stu]

Some cracking work going on here.
Are you building your engine to a high spec or fairly standard ? There’s some lads on here that would build a standard engine in their sleep .

 

[DaveL485]

Some cracking work going on here.
Are you building your engine to a high spec or fairly standard ? There’s some lads on here that would build a standard engine in their sleep .

If I didnt do my own I would ask @Brigsy or @sparkie to do it,

 

[Chris74#]

Some cracking work going on here.
Are you building your engine to a high spec or fairly standard ? There’s some lads on here that would build a standard engine in their sleep .

I am looking to go standard with it. @Big Steve - Raider fid mention @sparkie earlier, I am only up the toad from Brum too

 

[Chris74#]

Some cracking work going on here.
Are you building your engine to a high spec or fairly standard ? There’s some lads on here that would build a standard engine in their sleep .

Thanks Stu. I am going standard with the engine.

 

[sparkie]

Hi, I'm assuming you want everything nice and shiny on the standard rebuild - if so that's unfortunate as I like covering things in greasy hand prints.

 

[Chris74#]

So as advised by the forum (@Big Steve - Raider & @DaveL485 ), I tackled the rust in the n/s rear outrigger!


Once the spot weld drill bits turned up I carried on getting the spot welds out, and then removed the two add-on pieces.


Quite a bit of crusty rust under there. I then cut the outrigger out! rust gone!



I then got the wire brush on the exposed underside of the boot floor.


Once I got the piece off I realised that the metal used on these is thicker than the other metal that I have been using! shite!

I then slapped some rust converter on the shell and headed off down to the scrapyard to have a mooch!


Got some metal from the scrapyard, so much cheaper than buying it new!! Then got busy with the hammer and grinder!!



I tried the fit just to make sure my measurements are correct...

Looks good, so I sprayed some etch primer on to the shell, whilst I got on with forming the holes in the new outrigger section.


I formed these holes with a cone drill and square file!

I then drilled the plug weld holes in the section...and gave the inside a lick of etch primer.


I then got the what I think is the towing eye and maybe exhaust hanger?? and got the wire brush on them to clean them up a bit.

The exhaust hanger was looking pretty sorry for itself with a hole in it, so I cleaned it up and dropped some weld onto it.


I then painted everything with etch primer and tried the pieces on.I then welded them back on to the new section.



I then got to work connecting this piece back to the car.


I then ground the welds back and got some etch primer on it.






I then reconnected the car to the rotisserie feeling pretty happy with myself!!

Thanks for reading guys!

 

[Big Steve - Raider]

Great work @Chris74#

 

[Chris74#]

Great work @Chris74#

Thanks @Big Steve - Raider - There is great satisfaction when you make something out of nothing and it goes well..

 

[Adey]

There's some awesome fab work going on here on turborenault.co.uk. Inspirational, keep it up

 

[Chris74#]

I'm looking for some advice on how to tackle this one!

Its right at the junction of two other members! Can I cut the other members back, then cut the rust out replace and then weld the pieces I cut off back on?
Help!!! @DaveL485 @Big Steve - Raider anyone else that can advise?
Thanks in advance!

 

[Big Steve - Raider]

I'm looking for some advice on how to tackle this one!View attachment 155249
View attachment 155251
Its right at the junction of two other members! Can I cut the other members back, then cut the rust out replace and then weld the pieces I cut off back on?
Help!!! @DaveL485 @Big Steve - Raider anyone else that can advise?
Thanks in advance!

Faced with that, I would just cut round the red line I drew, pull the rotten bit out, and rust-proof the inside of that box section, then weld a nice new bit of plate in.

Interested to read what the other boys say..?

 

[Duncan Grier]

If the sides are okay I would be tempted to remove small sections of the layers on top of effected area and replace the rotten section underneath as you mention and build bk up. This will keep the originality you crave just more work

Guess you are not going to know until open but hopefully caught it and treat inside

Other option as Steve mentions cut rectangle out clean and weld, add some extra sheet to retain strength

 

[MOS]

Great work!
I did this section on mine also, it's documented in my thread.
Remember to test fit your doors and plastic parts in the process, or before paint at least.

 

[Chris74#]

Great work!
I did this section on mine also, it's documented in my thread.
Remember to test fit your doors and plastic parts in the process, or before paint at least.

Thanks MOS, I have just checked your post, it will be a great help, your 5 is looking great! Loving the paint booth!!

 

[DaveL485]

Depends how OE look you want it. I'd chop out the whole segment as per Steve's pic and seam weld a bit of 2mm in there in one bit, however if you want to keep it original look you will need to remove the 'flaps' first, cut out the chassis member, weld a bit in there and then remake the flap bits you cut off.

 

[Turbell]

Up to you how far you go, look at my Campus thread, pic above to closer to front of car where beam mounts, my guess is most are like this.
Your choice, but my tact is if I suspect, I in pick it apart and search.

 

[Chris74#]

I took the forum advice and got cracking with the other rear outrigger! Same drill as the passenger side, I flipped the car up on its side and removed it from the jig, with the help of a ratchet strap, bottle jack and set of steps!
I then marked out the areas that I was going to cut out, drilled out the spot welds and cut the first piece out.

While doing this, I noticed that the rear plate had also rotted away.
I got the piece out and set about making a replacement.

But noticed that the rear valance is pretty rotten also, so I made a piece for this first.







I then welded it in.

I then ground it down and sprayed some etch primer on it.

I should have waited until I had made the outrigger piece before painting it.

 

[Chris74#]

Cracked on with the outrigger piece! Took some measurements and marked the metal.

Cut and bent an oversize piece.


I trimmed it down to suit and notched out the holes as per the original piece.

I then welded it in place after giving the area a good wire brush and coat of etch primer.

I then cut ou the second rust patch that I had marked and made a new piece for it!


I then clamped it in and welded it in position!


Once this was done, I had a look at that rotted rear plate! Marked out why I was going to cut out and then removed it and made a replacement piece.



I then got that welded in and ground down!

Thanks for reading guys!

 

[Big Steve - Raider]

Bugger me, you’re getting very proficient with that metal joiner sir!!