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post #361 of 386 (permalink) Old 12-02-2018, 05:04 AM Thread Starter
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Gordon 'figured' it.. lol.. Im just the grateful vessel of knowledge.. ! lol

Organising a stainless tether to limit the travel.. just need to make a couple of tabs to connect it to.. ... then back to securing the doors and fitting the dash..


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 #362 of 386 (permalink) Old 12-03-2018, 12:56 PM
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Originally Posted by northshore2014 View Post
Gordon 'figured' it.. lol.. Im just the grateful vessel of knowledge.. ! lol

Organizing a stainless tether to limit the travel.. just need to make a couple of tabs to connect it to.. ... then back to securing the doors and fitting the dash..
Here is one I added on a Solstice. I thought about cable or chain, but these were easy and quiet. They are available on Amazon.

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post #363 of 386 (permalink) Old 01-02-2019, 06:40 PM Thread Starter
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thanks Tom.. is clearly the most common and best solution...


Have had a few unproductive days on the Coupe over the break going over what I have done to make sure its good to progress.

  1. Battery failed after 4 yrs.. the replacement was slightly larger and had different terminal locations, so remade the battery tray and hold down bracket and re-route the wiring.
  2. Am unable to bleed all of the air from the cooling system.. have read the recent 'overheating' post/s and will YouTube a few videos to see where I am going wrong.
  3. The leak in the line or the slave cylinder for the clutch has got to the point where the gear box will need to come out to fix it.
  4. The cut off switch in the console is playing up.. either a loose connection or the contacts themselves have failed, so remove the console to see whats happening there.

So after three days working on the car I actually have more to do than when I started... it really does seem to be fighting me every step of the way.

Have ordered the travel limit straps for the rear suspension... should arrive shortly... then I can get back onto the doors, which have slightly warped as they have cured (used the impregnated felt under fiberglass sheet technique).

HNY to all ..

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 #364 of 386 (permalink) Old 01-02-2019, 10:23 PM
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Never easy Chris!
HNY

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 #365 of 386 (permalink) Old 01-02-2019, 11:29 PM
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I've had days like that ... more than I can count. Gotta just keep pushing!

Happy New Year!

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post #366 of 386 (permalink) Old 01-03-2019, 12:43 PM
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Yes, that's pretty much how most of my build has gone. I think it's just the nature of the beast. Especially when you veer as far as I have from what FFR sent you and intended it to be built like. I've caused a lot of my own headaches because I wanted things to be different than FFR set it up to be. That said there are definitely days that you just end up pretty discouraged and when that happens sometimes I walk away for a day or just bare down and power through it.

I wish I had better advice other than stick with it. The other thing is the car isn't going anywhere so don't put unrealistic dead lines on yourself and then be pissed off or discouraged when you don't meet them.

I took delivery of my car in 2010 so I've been working on it, on and off for 8 years, but when I get done, it will be what I wanted and there won't be another one like it.

Take Care.

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post #367 of 386 (permalink) Old 01-03-2019, 09:36 PM Thread Starter
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Thanks guys... it is appreciated.. was a crap couple of days at the end of my holiday break.

To state the obvious.. am struggling to make progress despite the effort.. is embarrassing in a lot of ways... I've certainly deviated from the blueprint and learnt a lot along the way.. and yes.. every action does have a consequence, unfortunately... but having to do things over and over is the hard part... The realisation with something as simple as bleeding the radiator is that Im a capable engineer... not a builder or mechanic by trade.

If there was a 'travelling builder' equivalent in Aus i reckon two weeks would basically get it to a ready to a rub down and trim state...

When I started the project I took the chassis design and over about 2 weeks knocked up a space frame version of it, retaining part of the original chassis rail sections as anchor points for the front a rear suspension. I had included a slightly higher roof line and wider body, which the existing shell could be modified to suit. When the Type III came out the FFR design was different in two areas only... the A pillar to front X brace V section and the bracing on the windscreen / shield. How hard could it be.. ! lol

I thought I could knock the build off in a year or so... but then got a local builder do the key mods on the RHD conversion and engine mounts / steering rack set up. Fair to say his attention to detail was poor.... which then led to 4 - 5 months of rework to get the parts he'd been supplied to actually fit and prob 18 months to complete the chassis mods overall.

All of that said..

Have ordered a radiator fill kit (US $25 turns into $70AU once its shipped), found the loose ground connection for the isolator and bled the clutch pending removal of the gearbox when I can get some help as well as changed the connector type for the positive terminal lead so the battery cant short on the retainer bracket. The door skins are clamped on the bench to take the twist out... one day at a time..

Best to all.. and thanks again.. 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 #368 of 386 (permalink) Old 01-04-2019, 01:38 AM
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Iím sure Mark would be willing to come over.....

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 #369 of 386 (permalink) Old 01-04-2019, 04:24 AM Thread Starter
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I offered Matt free accommodation last year... but he preferred snow to sunshine and the beach... is hard to help some people..! lol

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; 01-07-2019 at 08:43 AM.
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post #370 of 386 (permalink) Old 01-04-2019, 04:14 PM
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Quote:
Originally Posted by northshore2014 View Post
I thought I could knock the build off in a year or so...



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 #371 of 386 (permalink) Old 01-07-2019, 08:42 AM Thread Starter
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genuinely laughing out loud.. !!! cheers John...

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 #372 of 386 (permalink) Old 03-17-2019, 02:04 AM Thread Starter
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Been getting only a few hrs a week the past few months... still going on the doors... have finished fitting the internal skins, not sure whether they need to be sanded down before they are trimmed. Need to realign the drivers door and outer skin.. like a lot of the jobs at the moment is 20 min process with 2 ppl and several hrs of stuffing around with just moi..!

Before I go any further on the interior the transmission needs to come out to fix a leak somewhere in the slave cylinder or the pipework.... not sure how feasible that will be to do with just one person with the car on jack stands.

Best to all from a very wet Sydney..

Cheers

Chris
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File Type: jpg IMG_2250.JPG (201.3 KB, 49 views)
File Type: jpg IMG_2251.JPG (191.5 KB, 47 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 #373 of 386 (permalink) Old 03-17-2019, 04:52 PM
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Chris,

I had to take the transmission out too, and did it on jack stands by myself.
I have a T5 not sure what you have in yours but it was tight with the T5.
Had to jack up the rear end of the engine to create enough clearance for the trans to come out.
Oh by the way you have to disconnect the drive shaft too....

Door skins look great btw.

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 #374 of 386 (permalink) Old 03-18-2019, 10:52 PM Thread Starter
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thanks John... I did get a set of instructions when the leak first arose... has failed completely now.. will let you know how I go..

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 #375 of 386 (permalink) Old 03-19-2019, 10:44 AM
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Looking good Chris. Sorry about the trans. That stinks, one step forward 2 steps back. It seems like these projects go like that.

Can't wait to see the door panels finished. I like the storage area.
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post #376 of 386 (permalink) Old 03-24-2019, 01:08 AM Thread Starter
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thanks Jim...


Started undoing brackets and removing the tail shaft in order to remove the gearbox...

Question... @John Dol or anyone that may be able to confirm... do you leave the bell housing attached to the rear of the engine, or remove the gearbox with the bell housing..?

Signed... Mr Basic..

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 #377 of 386 (permalink) Old 03-24-2019, 10:13 PM
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@John dol here, yes the bell housing stays attached to the engine. Just disconnect the trans from the bell housing.

Slide it backwards and turn it on itís side far enough to get out of the bellhousing.
Then drop it out forwards.

HTH,

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 #378 of 386 (permalink) Old 03-26-2019, 10:27 AM Thread Starter
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thanks John.. have everything set up to go.. Just one bolt holding the bell housing to the gearbox together at the moment.

Have the engine hoist with the balance bar attached to the back of the block and a jack underneath... Seems the driveline only needs to be tilted a few degrees to get enough clearance..?

Will prob wait till the weekend to take the last step, when my son is here, will be able to check underneath as well as have a second pair of hands to manage the gearbox.


Second consideration..

Re the few hrs work around the gearbox and engine to get this far.... has anyone thought of or aware of a solution to create a removable rear cross member... cut and cap the existing cross member with a 6mm disc then insert and weld a piece of 6mm (1/4") bar to create a spigot. Slot and cap the now separated ends of the cross member.

Hold the assembly in place with a bolted hoop clamp that may even secure with tapped holes into the spigot / cross member.

This way you undo the new retaining hoops and the cross member drops out, allowing the gearbox to be removed without any work in the engine bay or the read gearbox mount allowing removal in a simpler and more controlled fashion than having to rotate and lower the box on a jack.

Any considerations re structural integrity, loss of torsional rigidity...?

Look forward to any thoughts on this one.

With thanks

Chris
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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; 03-26-2019 at 11:07 AM.
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post #379 of 386 (permalink) Old 03-26-2019, 04:20 PM
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It would make life much easier if you had to do it again. Once you get the trans out that would be the time to tackle it. I thought about it...Ö. but that's all I did.

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 #380 of 386 (permalink) Old 03-27-2019, 01:07 AM
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Just a thought ...

Rather than compromising that cross member, add a new cross member made of the same size tubing positioned a bit farther rearward. Then remove the original cross member and add a removable transmission mount extending between the main tubes of the ladder 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 #381 of 386 (permalink) Old 03-27-2019, 05:14 AM Thread Starter
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thanks Gents..

Beck.. from what I recall, moving the cross brace rearwards would extend the longest unsupported section in the chassis as well as foul the output adapter ring for the tail shaft connection.

Best

Chris

UPDATE - Friday:

Box rotated to 30 degrees before a lug on the gearbox casing fouled on one of the braces for the trans tunnel.

Very cleverly, at the early part of my build, I narrowed this part of the chassis to create just a little more interior room for a pair of seats I eventually wasn't able to use... will shave the lug on the gearbox with a grinder (less than 1/4") and should then be able to complete the 90' rotation required.

Had a second look at the bracket at idea of creating a drop section in the cross member. The easier solution would be to make the bracket for the rear gearbox mount removable. Will have a think about this once the box is out.

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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Last edited by northshore2014; 03-29-2019 at 07:30 AM.
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post #382 of 386 (permalink) Old 03-31-2019, 10:02 AM Thread Starter
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Gearbox now out after around 8 hrs work.. ended up cutting the cross braces in the trans tunnel to get enough clearance, this was because I also added structural cages around the footwells that narrowed the front of the trans tunnel to the extent that the box would never rotate through the 90 degrees required.

Will need to make up some sort of removable cross brace as per the previous post (minus 2) in order to be able to repeat this process again. I still have some of the RHS I used to create the drop section in the flooring (100x50x6mm). The local steel shop thankfully has precut 4 and 6mm thick discs that I can use to plug the ends.

Will post again when I have some good news.. and it looks like it was all very easy and took just an hour or two to make everything right again..

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 #383 of 386 (permalink) Old 04-01-2019, 11:25 AM
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Chris,

I would do this on your cross member trans mount. I sent you step files of this. This would use 12mm bolts. There is enough clearance in the counter bores for a 18mm socket. The through holes are 12.1mm giving just a little clearance to slip the bolts through. The slot is 0.1mm bigger than the tongue of the male part to give a slip fit there too. The only thing that needs to be adjusted is the size of the OD that slips inside the pipe. I wasn't sure exactly what the ID of the 4" tube was.
I feel that if you don't do this the cross member strength will be extremely weak. You would assemble this, then weld these male and female plugs into the tubes, once welded you should be able to remove the bolts and the cross member should drop right down.
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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 #384 of 386 (permalink) Old 04-16-2019, 12:06 AM Thread Starter
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hi Jim,

Many thanks again..

Have used a single piece of 12mm x 80 mm flat bar in one piece through the centre section of the cross member (mainly because I really dont have the equipment to be able to machine up the female piece in your model), then welded matching 12mm plate to the stubs of the cross member before capping all of the open faces with 5mm thick steel discs. Also plug welded the 12mm plate to the new centre section tube.

Spent some time fitting the pieces on the chassis rails so I could weld to the stub section of the cross rail on all 4 contact points plus the vertical face of the tube. Will load pics later today..


HT 12mm cap head bolts and nyloc nuts to connect the parts.


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; 04-16-2019 at 12:23 AM.
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post #385 of 386 (permalink) Old 08-02-2019, 07:31 AM Thread Starter
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Well neither gone, nor forgotten... may have been slightly distracted with another build that has progressed, while I work my way around the Coupe. Have the parts I need to finish the rear suspension tethers and the gearbox mount.. my kids are with me this weekend.. will make a start and update shortly... he says.. !! fingers crossed..
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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 #386 of 386 (permalink) Old 08-02-2019, 06:35 PM
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Looks fun! Is that along the lines of a Formula SAE car for a college build?

Gen 3 Type 65 Coupe builder
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