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post #331 of 386 (permalink) Old 01-24-2018, 12:23 PM
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One trick Iíve seen is to stretch felt over the area, apply some resin/hardener, and let it set up. Done!

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Gen 2 Type 65 Coupe: Gen 2 Coyote, TKO-600, T-bird IRS with 3.55 Torsen diff.

This year's RNA event supports Camp Sunshine whose mission is to provide respite for families of children with life threatening illnesses. See "Team Limer" on FB for info. Thanks!
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post #332 of 386 (permalink) Old 01-24-2018, 04:09 PM
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Agree with Glenn, lots of speaker enclosures etc are built like that.

John

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Building when I can, sigh....


Coupe #386,17" Team III 245 FR 315 RR, 3-link, T5, 4 wheel disk, power brakes/steering. Fast EZ EFI
First start Sept. 18 2013
First go kart Sept 19 2013


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post #333 of 386 (permalink) Old 01-24-2018, 09:23 PM Thread Starter
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Thanks gents... not heard of that, sounds like a great solution for all the curves and shapes as well as weight.. checked it out on youtube. Basically make some of the defined shapes with ply, cover in a felt then impregnate with resin, prime and paint.. Could overlay with fibreglass cloth for a stronger smooth finish..

Pics to follow if it works out..

Appreciate the lead..

Chris

Coupe 65 #646

Ordered - 28 May, 2014.
Delivery, Sydney - 18 August.
Fabrication and recoating complete - 25 October
Assembly commenced -27 October
Engine installed - 18 December 2014
Engine running - October 2015
First gokart - December 2015

TR6060, LS3 motor, IRS, Willwood brake upgrade, three channel ABS, 17'' replica rims, sat nav / stereo, Motec PDM and keypad, AC, adjustable steering column,
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Last edited by northshore2014; 01-24-2018 at 09:37 PM.
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post #334 of 386 (permalink) Old 02-12-2018, 11:28 PM Thread Starter
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Update.. not forgotten or abandoned, but am having to take a bit of time out to settle the inflammation in my lower back which has required AI's for the past couple of months to be able to sleep at all. I stopped exercising regularly when I started the build, and its unfortunately showing in more ways than one.

Have the felt and resin for the inner doors as well as a few pieces to tack in place.. will look forward to picking it up and closing this part of the build out, then finish the dash shell before sending it to the trimmer..

Cheers

Chris

Coupe 65 #646

Ordered - 28 May, 2014.
Delivery, Sydney - 18 August.
Fabrication and recoating complete - 25 October
Assembly commenced -27 October
Engine installed - 18 December 2014
Engine running - October 2015
First gokart - December 2015

TR6060, LS3 motor, IRS, Willwood brake upgrade, three channel ABS, 17'' replica rims, sat nav / stereo, Motec PDM and keypad, AC, adjustable steering column,
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post #335 of 386 (permalink) Old 02-14-2018, 03:45 PM
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sorry to hear that Chris. Lower back pain is a bummer. Hope you feel better soon.

Jim

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Eaton Super Charged 306 SBF, T5 G-Force, IRS.
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post #336 of 386 (permalink) Old 02-14-2018, 04:35 PM
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Been there, done that, sucks!
Hope you get to it soon. Like to see what the felt trick does for your door panels.

John

Building when I can, sigh....


Coupe #386,17" Team III 245 FR 315 RR, 3-link, T5, 4 wheel disk, power brakes/steering. Fast EZ EFI
First start Sept. 18 2013
First go kart Sept 19 2013


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post #337 of 386 (permalink) Old 02-14-2018, 07:50 PM
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A bad back can really mess up your life. Take your time to get it taken care of.

I'm Glenn. Find me at "Team Limer" on Facebook

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Gen 2 Type 65 Coupe: Gen 2 Coyote, TKO-600, T-bird IRS with 3.55 Torsen diff.

This year's RNA event supports Camp Sunshine whose mission is to provide respite for families of children with life threatening illnesses. See "Team Limer" on FB for info. Thanks!
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post #338 of 386 (permalink) Old 02-16-2018, 04:34 AM Thread Starter
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thanks gents..

Coupe 65 #646

Ordered - 28 May, 2014.
Delivery, Sydney - 18 August.
Fabrication and recoating complete - 25 October
Assembly commenced -27 October
Engine installed - 18 December 2014
Engine running - October 2015
First gokart - December 2015

TR6060, LS3 motor, IRS, Willwood brake upgrade, three channel ABS, 17'' replica rims, sat nav / stereo, Motec PDM and keypad, AC, adjustable steering column,
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post #339 of 386 (permalink) Old 06-08-2018, 06:57 AM Thread Starter
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Update from the injury ward... the anti inflammation drugs I was taking for my back were masking a tear in the rear deltoid and rotator cuff on the RHS and a 30% tear in the medial ligament in my right knee.

Knee is progressing (this one I knew about, and was putting off), am walking a straight line with little pain at the mo.. shoulder remains weak, but is steadily getting there.

I continue to talk to the Coupe most days and lay out parts and templates to start on progressively. I fear I will end up remaking the dash I have after lowering the floor some time ago now, it just sits too far into the eye line. But with Jim S' good work and generosity posting his updates, I am at least clearer on how I can get it done.

Enjoying watching the progress at you guys are making, some in leaps and bounds, constantly.. !! Look forward to getting over these little hurdles and finishing of the last 20%.. .

Cheers

Chris

Coupe 65 #646

Ordered - 28 May, 2014.
Delivery, Sydney - 18 August.
Fabrication and recoating complete - 25 October
Assembly commenced -27 October
Engine installed - 18 December 2014
Engine running - October 2015
First gokart - December 2015

TR6060, LS3 motor, IRS, Willwood brake upgrade, three channel ABS, 17'' replica rims, sat nav / stereo, Motec PDM and keypad, AC, adjustable steering column,
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post #340 of 386 (permalink) Old 06-08-2018, 10:04 AM
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Best of luck with your recovery. Hopefully you'll be back soon and can finish up and drive your coupe.

-Matt


FFR#629CP
Kit picked up: 1/4/2014
First start & Go Kart: 9/13/2015
Finished: 5/8/2017

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post #341 of 386 (permalink) Old 06-11-2018, 10:30 AM
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Chris,

I 2nd what Matt said " Best of luck on a speedy recovery", that's a real set back.

I just finished up the steel and lights in my paint booth so I'm getting ready to get back to the coupe.

Jim

FFR Coupe # 487
Eaton Super Charged 306 SBF, T5 G-Force, IRS.
JimS Custom made headers, Mufflers, SC Intake, Power Windows, Dash board, ETC... :-)
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post #342 of 386 (permalink) Old 06-12-2018, 04:44 AM Thread Starter
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Thanks guys, you are too kind... the list of joint failures is long but the progress is steady..(exercise must be over rated... all the athletes I know have no knees and or shoulders too.. !).

Started on some sheetmetal work over the weekend... as long as I limit the time I spend I can get a few things done..

Coupe 65 #646

Ordered - 28 May, 2014.
Delivery, Sydney - 18 August.
Fabrication and recoating complete - 25 October
Assembly commenced -27 October
Engine installed - 18 December 2014
Engine running - October 2015
First gokart - December 2015

TR6060, LS3 motor, IRS, Willwood brake upgrade, three channel ABS, 17'' replica rims, sat nav / stereo, Motec PDM and keypad, AC, adjustable steering column,
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post #343 of 386 (permalink) Old 07-01-2018, 08:13 AM Thread Starter
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Finally made some progress.. shifted the gear lever back 2" with a simple bolt through section in 1/4" plate connected to the Hurst short shifter. Shortened the lever 1/2" as well as the extra leverage accentuates the angle of movement.

Used the felt and fiberglass resin technique suggested earlier to make a new hood for the instrument cluster. Used the same process with the help of a little spray adhesive over a wire mesh frame to take the first steps for an internal door skin..... after considerable procrastinating on this one.

Pics included.. have now impregnated the cloth with resin. If I can get this stable enough will lift the felt off the door then add a couple more layers of mat before seeing if I can figure a way to seal the front of the door around the hinge in a way that's removable and also makes a decent seal.

Best to all..

Chris
Attached Images
File Type: jpg IMG_E1130.JPG (158.0 KB, 55 views)
File Type: jpg IMG_1133.JPG (131.5 KB, 53 views)
File Type: jpg IMG_1132.JPG (120.5 KB, 55 views)

Coupe 65 #646

Ordered - 28 May, 2014.
Delivery, Sydney - 18 August.
Fabrication and recoating complete - 25 October
Assembly commenced -27 October
Engine installed - 18 December 2014
Engine running - October 2015
First gokart - December 2015

TR6060, LS3 motor, IRS, Willwood brake upgrade, three channel ABS, 17'' replica rims, sat nav / stereo, Motec PDM and keypad, AC, adjustable steering column,
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Last edited by northshore2014; 07-01-2018 at 11:38 AM.
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post #344 of 386 (permalink) Old 07-01-2018, 03:19 PM
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Chris,

Think you are on to something here. Shelby was a chicken farmer, your using chicken mesh.......
Looks good and nice to see your back at it. Must mean your feeling better.
Tell us more about the side pipes. Donít remember seeing those yet.

John

Building when I can, sigh....


Coupe #386,17" Team III 245 FR 315 RR, 3-link, T5, 4 wheel disk, power brakes/steering. Fast EZ EFI
First start Sept. 18 2013
First go kart Sept 19 2013


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post #345 of 386 (permalink) Old 07-02-2018, 10:20 AM
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Closing up the front of the door was one of the more challenging parts of the project. Especially the transition from the door to the window frame.

I'm Glenn. Find me at "Team Limer" on Facebook

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Gen 2 Type 65 Coupe: Gen 2 Coyote, TKO-600, T-bird IRS with 3.55 Torsen diff.

This year's RNA event supports Camp Sunshine whose mission is to provide respite for families of children with life threatening illnesses. See "Team Limer" on FB for info. Thanks!
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post #346 of 386 (permalink) Old 07-03-2018, 08:55 PM
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Quote:
Originally Posted by northshore2014 View Post
hi Glen,

The duct was intended as the primary air intake for the engine...
IMHO, you should figure out a way to use the area around your fog lights for engine intake.... high pressure, cooler, etc. and duct it back to the air box. Your NACA duct is in a low-pressure area with hot air, I don't think it will accomplish much... maybe even put a vacuum on the air box.
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post #347 of 386 (permalink) Old 07-06-2018, 08:31 AM Thread Starter
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Quote:
Originally Posted by Tom Sharpe View Post
IMHO, you should figure out a way to use the area around your fog lights for engine intake.... high pressure, cooler, etc. and duct it back to the air box. Your NACA duct is in a low-pressure area with hot air, I don't think it will accomplish much... maybe even put a vacuum on the air box.
hey Tom.. not sure what happened there with that response.. have an intake for the engine at the bottom of the screen.. at the end of the day it may cost 20hp in 500+... its not a pure race car.. I expect it will work ok.. .

Coupe 65 #646

Ordered - 28 May, 2014.
Delivery, Sydney - 18 August.
Fabrication and recoating complete - 25 October
Assembly commenced -27 October
Engine installed - 18 December 2014
Engine running - October 2015
First gokart - December 2015

TR6060, LS3 motor, IRS, Willwood brake upgrade, three channel ABS, 17'' replica rims, sat nav / stereo, Motec PDM and keypad, AC, adjustable steering column,
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post #348 of 386 (permalink) Old 07-06-2018, 08:41 AM Thread Starter
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thanks Gents.. yes, stabilised the shoulder somewhat... getting there... Am not a wreck.. just not jumping out of my skin.. .

The side pipes.. found a pic or two for you John... custom headers to high volume cats and 4:1. Side pipes are 4" OD with 1/2" lining... my need to add a switchable or vac activated baffle or alternately increase the thickness of the lining, as it seems like it will exceed the track noise limit of 98db at 15 feet.

Door skin coated and set.. need to trim and smooth the issue I had near the front of the door, where the spray adhesive let go at just the wrong time, then cover in a couple of layers of glass over the weekend.. .

Cheers

Chris
Attached Images
File Type: jpg IMG_0026.JPG (147.4 KB, 57 views)
File Type: jpg IMG_1147.JPG (184.2 KB, 56 views)
File Type: jpg IMG_0129.JPG (162.3 KB, 57 views)
File Type: jpg IMG_9911.JPG (199.0 KB, 53 views)

Coupe 65 #646

Ordered - 28 May, 2014.
Delivery, Sydney - 18 August.
Fabrication and recoating complete - 25 October
Assembly commenced -27 October
Engine installed - 18 December 2014
Engine running - October 2015
First gokart - December 2015

TR6060, LS3 motor, IRS, Willwood brake upgrade, three channel ABS, 17'' replica rims, sat nav / stereo, Motec PDM and keypad, AC, adjustable steering column,
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post #349 of 386 (permalink) Old 07-08-2018, 11:11 PM
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I was reading old posts trying to catch up w/ your build. I was grousing about your NACA duct. Your current duct/airbox looks much better. Great build. Thanks for the reply.
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post #350 of 386 (permalink) Old 07-10-2018, 09:24 AM Thread Starter
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Cheers Tom... ended up re-purposing the NACA duct for my sons open wheeler... used the ebay sourced hood to clear the air cleaner as well..
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Coupe 65 #646

Ordered - 28 May, 2014.
Delivery, Sydney - 18 August.
Fabrication and recoating complete - 25 October
Assembly commenced -27 October
Engine installed - 18 December 2014
Engine running - October 2015
First gokart - December 2015

TR6060, LS3 motor, IRS, Willwood brake upgrade, three channel ABS, 17'' replica rims, sat nav / stereo, Motec PDM and keypad, AC, adjustable steering column,
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post #351 of 386 (permalink) Old 10-22-2018, 06:28 AM Thread Starter
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Question:

So who was silly enough to buy a complete running race car for their son AND think that it..

1. Wouldn't need any work and
2. That said purchaser could actually leave it alone.. give up...

Answer... that would be ME..

Added a 32/26 carbie (up from a 24/28) to the 1.8L boxer engine, full flow fuel filter, 2:1 steering quickner (and learnt lots about alignment of rotating parts before getting a 3/4" DD uni), anti roll bars and repainted it... ummm again... has been a 10 month detour overall.. but my boy is happy and keen to learn.. so thats priceless..

Now the open wheeler is back on the car trailer (after scaring a limited number of small children during a test run) I have room to 'unpack' the rest of the garage and get back onto the door trims.. !!

Have fitted the inner door release handles, need to fashion a grab handle from foam and fibreglass matting then do a final trim. The rest of the dash is done, will do a final assembly and test before pulling it apart once more. The mech and elec systems have been commissioned and dyno tuned was done some months ago now.

Have had a heavy international schedule of travel.. which is not abating, making it hard to get a clear space to work on the Coupe. If I can find a trimmer to take it before Christmas then well and good.. if not will be a new year project.. then paint and the road worthy..

Best to all..

Chris

Coupe 65 #646

Ordered - 28 May, 2014.
Delivery, Sydney - 18 August.
Fabrication and recoating complete - 25 October
Assembly commenced -27 October
Engine installed - 18 December 2014
Engine running - October 2015
First gokart - December 2015

TR6060, LS3 motor, IRS, Willwood brake upgrade, three channel ABS, 17'' replica rims, sat nav / stereo, Motec PDM and keypad, AC, adjustable steering column,
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post #352 of 386 (permalink) Old 11-17-2018, 06:41 AM Thread Starter
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Well that was a surprise.. I thought someone may have chipped in to agree with me..

So back onto the Coupe... am fitting the door skins and anchor points. While the glass was drying I went back through a few basics on the brakes, driveline and engine. Connected the battery and started her up. Sounds glorious.. !!

Engaged first gear with the intent of cycling a little heat into the brakes and running through a couple of gears to exercise the transmission ever so gently..

As I released the clutch, RHS hub began to oscillate in a vertical path as the disc rotated.. !!

Disconnected the UCA and pushed the disk back and forth a couple of times to check if the drive shaft had dropped out when I removed the lower control arm to modify the fixing point for the QA1 shocks. It seemed to slide home and back out easily and was retained by the circlip on the axle stub inserted into the diff. Video loaded here https://youtu.be/OIF7C5FNn8E

Is it possible the wheel hub end of the drive shaft has fallen out..??

Look forward to some input please gents.

Cheers

Chris

Coupe 65 #646

Ordered - 28 May, 2014.
Delivery, Sydney - 18 August.
Fabrication and recoating complete - 25 October
Assembly commenced -27 October
Engine installed - 18 December 2014
Engine running - October 2015
First gokart - December 2015

TR6060, LS3 motor, IRS, Willwood brake upgrade, three channel ABS, 17'' replica rims, sat nav / stereo, Motec PDM and keypad, AC, adjustable steering column,
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Last edited by northshore2014; 11-17-2018 at 09:27 PM.
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post #353 of 386 (permalink) Old 11-18-2018, 03:35 AM
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I have three boys and din't by them a race car but when the second one got his drivers license I bought a 68 Bronco for them to share. They blew up the transmission once and the rear end twice. Never crashed the Bronco all three crashed my Nissan pickup at least once.

I watched the video...that does not look good. A little hard to see. Is it an independent rear end?

Chris

If it's too LOUD....you're too OLD!!

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Complete Coupe kit, IRS, T-5, 392ci 351W, Webers, Jeff Miller Paint

Delivered 4/29/09
First Start 3/28/11
Licensed 10/1/12
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post #354 of 386 (permalink) Old 11-18-2018, 04:10 AM Thread Starter
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thanks CJ... I utterly trashed my mums prized Volvo, which was finally written off after a ram raid (stolen..!!) with Police in pursuit .. so kids will be kids for sure..

Yes... its an independent rear end.. the diff retainer and shaft appear straight and ok.. the LHS is fine.. can only think that the shaft has dropped off the spline at the hub end.. causing the eccentricity.. about to undo the U and LCA bolts to see if there is anything there..

UPDATE...

Removed the control arm bolts and the brakes.. need to grab a socket to undo the centre nut on the drive shaft (seems to be 1 7/16").

Question.. is the process of removing the drive shaft from the diff to basically hammer the hub away from the centre line of the car to release the retaining circlip, or do you need to remove the rear diff casing and compress the clip from inside the diff housing..??

Cheers

Chris

Coupe 65 #646

Ordered - 28 May, 2014.
Delivery, Sydney - 18 August.
Fabrication and recoating complete - 25 October
Assembly commenced -27 October
Engine installed - 18 December 2014
Engine running - October 2015
First gokart - December 2015

TR6060, LS3 motor, IRS, Willwood brake upgrade, three channel ABS, 17'' replica rims, sat nav / stereo, Motec PDM and keypad, AC, adjustable steering column,
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Last edited by northshore2014; 11-18-2018 at 05:33 AM.
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post #355 of 386 (permalink) Old 11-18-2018, 12:57 PM
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Chris,

Thatís quite the sacrifice on coupe time.
How about some pics of the race car?
Canít help with your cobble stone rear end unfortunately as I have a 3 link, but that does not seem like itís a good thing.
Hope you figure it out.

John

Building when I can, sigh....


Coupe #386,17" Team III 245 FR 315 RR, 3-link, T5, 4 wheel disk, power brakes/steering. Fast EZ EFI
First start Sept. 18 2013
First go kart Sept 19 2013


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post #356 of 386 (permalink) Old 11-23-2018, 09:41 PM Thread Starter
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Thanks John... will upload a couple (before and after the rebuild).. its a very basic thing, a good learners car, has an 1800cc Subaru motor..

Re the Coupe.. inspected the boot adjacent the wheel hub.. appears fine.. noticed that when I did so the diff end of the shaft was only being held in by the boot.

Will undo the SS ties and see whats happening there.. hopefully it just needs to be reinserted in some form.

Has anyone had to remove a half shaft.. any clarification on the process..??

Cheers

Chris

UPDATE... checked out the diff end of the shaft.. is fine... back to the wheel hub.. need to get a deep socket to separate the hub and half shaft... can only be something broken in the CV joint at the wheel..
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Coupe 65 #646

Ordered - 28 May, 2014.
Delivery, Sydney - 18 August.
Fabrication and recoating complete - 25 October
Assembly commenced -27 October
Engine installed - 18 December 2014
Engine running - October 2015
First gokart - December 2015

TR6060, LS3 motor, IRS, Willwood brake upgrade, three channel ABS, 17'' replica rims, sat nav / stereo, Motec PDM and keypad, AC, adjustable steering column,
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Last edited by northshore2014; 11-24-2018 at 02:44 AM.
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post #357 of 386 (permalink) Old 11-24-2018, 02:21 PM
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Wow thatís a lotus super seven like engine on wheels. Gotta be fun to drive.
Now tell us a little more about that red car in the background....


John

Building when I can, sigh....


Coupe #386,17" Team III 245 FR 315 RR, 3-link, T5, 4 wheel disk, power brakes/steering. Fast EZ EFI
First start Sept. 18 2013
First go kart Sept 19 2013


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John Dol is offline  
post #358 of 386 (permalink) Old 11-25-2018, 01:20 AM Thread Starter
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Join Date: Apr 2014
Location: Sydney
Posts: 885
hi John...

Well you can see how a car trailer and two cars fills a garage..

Took the RH half shaft out.. had my son very slowly release the clutch.. the RHS half shaft end rotated cleanly.. the issue with the RHS had transferred to the LHS.. with the wheel hub 'hopping' as the shaft rotated.

Conclusion is the issue must be in the diff..! Its a Levy 3.55 Torsen unit, has done about 6km on a dyno, and another 15 - 20 km going in and out of the garage or on the blocks.

RHS hub hopping.. https://youtu.be/OIF7C5FNn8E

First though is to remove the other half shaft and then the diff as it appears to be something in the worm drive mechanism..???????

Clueless beyond that.. still look forward to some thoughts..

Cheers

Chris

Coupe 65 #646

Ordered - 28 May, 2014.
Delivery, Sydney - 18 August.
Fabrication and recoating complete - 25 October
Assembly commenced -27 October
Engine installed - 18 December 2014
Engine running - October 2015
First gokart - December 2015

TR6060, LS3 motor, IRS, Willwood brake upgrade, three channel ABS, 17'' replica rims, sat nav / stereo, Motec PDM and keypad, AC, adjustable steering column,
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post #359 of 386 (permalink) Old 11-28-2018, 12:41 AM Thread Starter
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Posts: 885
Unhappy

Separate thread started with a response from Gordon Levy..

The remedy..

The hub was hopping because I effectively increased the shock length by moving the LCA mounting point to fit the QA1 double adjustable units. The extra travel, although only 3/4" took the half shafts beyond the working range for the CV joint.. which then caused the hub to 'hop' as it bottomed out on the CV joint lobes when it was rotating.

All back together and running fine.. but thats another three weeks of head scratching.. not building..

Coupe 65 #646

Ordered - 28 May, 2014.
Delivery, Sydney - 18 August.
Fabrication and recoating complete - 25 October
Assembly commenced -27 October
Engine installed - 18 December 2014
Engine running - October 2015
First gokart - December 2015

TR6060, LS3 motor, IRS, Willwood brake upgrade, three channel ABS, 17'' replica rims, sat nav / stereo, Motec PDM and keypad, AC, adjustable steering column,
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northshore2014 is offline  
post #360 of 386 (permalink) Old 11-28-2018, 01:40 PM
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Join Date: Jul 2008
Location: Gorham, ME
Posts: 3,453
There's three weeks you'll never get back!
Glad you where able to figure it out though.


John

Building when I can, sigh....


Coupe #386,17" Team III 245 FR 315 RR, 3-link, T5, 4 wheel disk, power brakes/steering. Fast EZ EFI
First start Sept. 18 2013
First go kart Sept 19 2013


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