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Saloon number 2

Gareth

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Finally all the skirt fixings are done. Now to get the rear lower sections finished off. Little bit of trimming and filling. They will be able to be removed to access the sill for maintenance. I will be making the lower halfs one piece again due to the joint been in the wrong place. Might put a "Fake" joint line were the 2 doors meet. I don't know yet. But hopefully get them painted along with my bonnet and rear bumper by the end of the month or fist weekend in July. IMG20220622211341.jpgIMG20220623201157.jpg
I will be putting some kind of barrier between the sill and skirt to prevent water ingress.
 

Gareth

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Damn Gareth you been a busy boy! Love what you've been doing lately.
Cheers Andy. I'm just annoyed it won't make VBOA but never mind il still be there..
 

Gareth

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Got alot more done this last week tbh I haven't really stopped. Despite miss haps and stuff. Hopefully il have the correct radiator this week.. as you can see from the pics, the rads massive was ment to be 50mm but the Tape measured 60mm :lol: new one is 40mm so il be able to move the condenser back and the CC rad back.. but anyways cracked on and mocked up the rad packs. Made numerous stainless steel brackets, drilled, rivnut and bolted on the lower cross member. Had to relocate the AC drier/receiver behind the Drivers light. Had a AC pipe off a Saab and after a couple tweeks it for perfect for the job :cool:. IMG20220626190222.jpgIMG20220626191821.jpgIMG20220702124216.jpgIMG20220702092025.jpg

After making a massive BOO BOO of hitting the condenser with the drill and a 8mm bit. I've had it repaired and pressure tested. Costly mistake il not do again.
So moving wile waiting for parts arriving to move forward I fitted my wastegate pipe out the bonnet as there's no space down the front to run a 38mm pipe. Plus I need to leave access to the AC valves.IMG20220703191235.jpgIMG20220712201827.jpg

But I can say everything fits were it should. I do have my Oil cooler mounted now behind the Drivers foglight,
Couple extra pics as we stand IMG20220709182549.jpgIMG20220703191247.jpg
Still need the CC pipes routed but that's no issue. I checked the pump was working hence the coolant in the pipework..
IMG20220629212717.jpg
And a big thanks to Dan for the boot badge :)
 

DavebGsi

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Awesome progress mate, will be quality to have working AC on the car! Impressive u can fit it in there aswell, not much room for anything on a mk3! Have u had to chop the bumper at all?
 

Gareth

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Awesome progress mate, will be quality to have working AC on the car! Impressive u can fit it in there aswell, not much room for anything on a mk3! Have u had to chop the bumper at all?
Yes it will be great, the bumper is trimmed on the inside mainly the remainder of the crash bar, but not on the actual mouth which I'm glad about. I've absolutely no space for anything in the front :lol:. I've still gotta get 2 fans on the AC condenser yet which will result in a trim probbly in the back of the grill fins. But il cross that bridge once I get to it.
 

joycey

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Looking great! That charge cooler setup is very cool!
 

Gareth

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So after been to VBOA without my car due to delays on getting my radiator. Plus the car wasn't finished bodywork wise. I've had a week off from it. But got back on it yesterday. Previous alloy rads were ment to be 50mm however they were more like 60mm. And wrongly cored. New Rad is Alloy and 40mm :) that's a 20mm space saving. So as I had all my extra brackets made for the old rads I've had to cut and re-drill the mountings for the AC and Charge Rad..

So firstly with the rad been for a Sierra RS500 I had to cut the original mountings off. I'd made brackets to secure it to the slam panel in the original holes.. as you can see it's ridiculously big :lol:
IMG20220730144249.jpg

Second mod top rad outlet needing changed due to my turbo position. So out with the multi tool, tape and a straight line, cut the outlet off. I'd bought a 180 degree pipe and cut it in half to get the tightest possible bend. Result will be spot on. Looks tight but thats just the turbo jacket.
IMG20220730143946.jpg

Third mod expansion return outlet as the Sierra don't have them and vauxhalls do I had to put one in. I could of just had a bit of 8 or 10mm take off pipe put in but I wanted it to look better #becauseRaceCar so I got a AN6 weld in take off and a barb fitting with new pipe mad with one piece with no joins.
IMG20220730145640.jpgIMG20220730150345.jpg

Fourth mod is it needs a second Rad fan switch fitting so I have a M22 weld in bung to go in just above the lower rad outlet il need a step drill to drill it out. Once that's done il get it took to my friend and have the mods welded in :)

And lastly with the AC condenser in how far the brackets had to be moved back IMG20220730154709.jpg
Nice and flush with the edge of the lower cross member too. I'm happy. Everything's going to get a fresh coat of paint too :)
 

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