TubaMagna8
Club Member
You know I’m always up for giving a hand if I can, lighter nights etc
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Saloon number 2
- Thread starter Gareth
- Start date
Gareth
Club Member
So as I sed I was gonna get cracked on wile off work this week. So here's a update so far. Rather productive day. First on the list was to modify the Morrette's. Inner lamp delete changed to cold air feed ports..
Started by cutting some perspex sheet into discs
Removed one of the films so I could find the centre with the Air ducts.. drew round one of the ducts, needed a 76mm centre so grabbed a 76mm exhaust piece and drew round it. End result was a good one
The perspex disc will be painted either black from the back or body colour from the front. 3" feed pipe screws through the inner backing hole lovely
So that's the lamps near enough done just need to get them painted and finally fitted.
Next job today was change the pvc clear hoses I fitted to the charge cooler system as they had hardened over time and kinked. Not a good look and certainly not fit for purpose. So I ordered the Braided clear hose, by far a better fit and no kinks
Ned to spend more money as the other 2 hoses need to exit the bay down to the charge radiator so plan is to buy some AN-10 Bulkhead fittings and couplings and drill holes Infront of were the battery tray was. The twin horns are under their so need to be precise
Third job was the lower rad inlet with the AC pump right in the way the only was was up so out with the grinder cut off the straight outlet and made a tight 90
I've a new silicone 90 hose to fit the water pump and lower hose.
hoping my friend can alloy tig it this week then I can get final assembly done and button the water system up.
Thats all for now
Started by cutting some perspex sheet into discs
Removed one of the films so I could find the centre with the Air ducts.. drew round one of the ducts, needed a 76mm centre so grabbed a 76mm exhaust piece and drew round it. End result was a good one
The perspex disc will be painted either black from the back or body colour from the front. 3" feed pipe screws through the inner backing hole lovely
So that's the lamps near enough done just need to get them painted and finally fitted.
Next job today was change the pvc clear hoses I fitted to the charge cooler system as they had hardened over time and kinked. Not a good look and certainly not fit for purpose. So I ordered the Braided clear hose, by far a better fit and no kinks
Ned to spend more money as the other 2 hoses need to exit the bay down to the charge radiator so plan is to buy some AN-10 Bulkhead fittings and couplings and drill holes Infront of were the battery tray was. The twin horns are under their so need to be precise
Third job was the lower rad inlet with the AC pump right in the way the only was was up so out with the grinder cut off the straight outlet and made a tight 90
I've a new silicone 90 hose to fit the water pump and lower hose.
hoping my friend can alloy tig it this week then I can get final assembly done and button the water system up.
Thats all for now
Last edited:
Gareth
Club Member
Another Day more jobs ticked off the list.
First job this morning I took my radiator so get the Outlet welded on. Wile that's away I thought I'd fit the AC fans and carry out any adjustments needed to the Charge cooler as it was fouling the bumper. Managed to push it back 15mm that shall do. Trial fitted the AC fans they only 7" each from Spal hopefully it's enough to cool the AC abit.
Centre grill locators had to go so out came the multi tool and zipped them off.
Fitted the Morrette grill and I've about 5-10mm clearance
Clear is Clear "right"
Just need to solder the plug on to plug into the Original AC fan plug and they are done. Il do that once I've got the radiator back in etc. Okh and I've ordered my AN-10 fittings to sort the Charge cooler radiator water hoses out.
Another job was to swap out the Turbo cold housing for a one I fitted a Vacuum feed for the Boost controller.
That's all for now till the radiator is back.
First job this morning I took my radiator so get the Outlet welded on. Wile that's away I thought I'd fit the AC fans and carry out any adjustments needed to the Charge cooler as it was fouling the bumper. Managed to push it back 15mm
that shall do. Trial fitted the AC fans they only 7" each from Spal hopefully it's enough to cool the AC abit. Centre grill locators had to go so out came the multi tool and zipped them off.
Fitted the Morrette grill and I've about 5-10mm clearance
Clear is Clear "right"
Just need to solder the plug on to plug into the Original AC fan plug and they are done. Il do that once I've got the radiator back in etc. Okh and I've ordered my AN-10 fittings to sort the Charge cooler radiator water hoses out.
Another job was to swap out the Turbo cold housing for a one I fitted a Vacuum feed for the Boost controller.
That's all for now till the radiator is back.
Gareth
Club Member
Massive milestone achieved over the week I've had off. Engine bay is 99% complete now and I couldn't be happier
AN fittings arrived Saturday for me to do the charge cooler hoses to the heat exchanger, changed all the hoses to braided instead of PVC stuff that I had previously fitted..
Need some clips on the hoses but Its there now. I've a battery on charge ready for testing. Borrowing the Nitrogen tester from work today to check my AC system tonight for leaks and test light the compressor to see if it turns on from the switch in the car update again later on this evening.
AN fittings arrived Saturday for me to do the charge cooler hoses to the heat exchanger, changed all the hoses to braided instead of PVC stuff that I had previously fitted..
Need some clips on the hoses but Its there now. I've a battery on charge ready for testing. Borrowing the Nitrogen tester from work today to check my AC system tonight for leaks and test light the compressor to see if it turns on from the switch in the car
update again later on this evening.
Todd100
Club Member
Looking sweet mate, love how the turbo sits, ready to suck in everything it can!
Gareth
Club Member
The position of the turbo is the only way I could go to squeeze everything in at the front. Millimetres clearance everywhere
Gareth
Club Member
Little update and a set back 
the update is the charge cooler system now contains water/coolant mix and is flowing rather well. Pressure tested the AC system at 10bar / 150psi couple of leaks from the Schrader valves so I replaced them. Think I need new sensors so il replace them both as I seem to have nothing at the compressor live wire with the system pressurised. I've had the engine turning over she sounds healthy the thumping out the downpipe ooosh I had a s*x wee ano its going to be loud .
Set back is I filled my radiator and theirs a pin hole in the last weld I had done so il have to take it apart again and take it to be spotted, it was a **** to weld due to the angle. It's no biggy but it's not what I wanted. Soon be sorted
the update is the charge cooler system now contains water/coolant mix and is flowing rather well. Pressure tested the AC system at 10bar / 150psi couple of leaks from the Schrader valves so I replaced them. Think I need new sensors so il replace them both as I seem to have nothing at the compressor live wire with the system pressurised. I've had the engine turning over she sounds healthy the thumping out the downpipe ooosh I had a s*x wee ano its going to be loud . Set back is I filled my radiator and theirs a pin hole in the last weld I had done so il have to take it apart again and take it to be spotted, it was a **** to weld due to the angle. It's no biggy but it's not what I wanted. Soon be sorted
Wow quite the update there Gaz. Looking epic! Can't wait to see it in person, it's been a while since you had a mk3 on the road 
Mega update gaz!! looking awesome. It's seriously easy to leave a pin hole in a tig weld, sometimes invisible to the eye aswell! easily sorted but a pain when you have put all the coolant in!
Should make vboa without an issue?
Should make vboa without an issue?
Gareth
Club Member
So continued on I got the Radiator done and back within 24hrs and refitted back in the car.. got the AC back in with the Fans etc etc. Wile I was on I wrapped the top coolant hose with gold reflecting tape as this runs over the top of the Turbo collector
Wanted the car to look evil from the front with the Morrette's in so give the lamps and indicators a light tint 
Still plenty of light through them so John law can't be a C#*T
And finally last weekend I had the car running as per our group chat I was over the moon she runs so drove it out the garage for a bath
Next up on my list is to finish the body kit so set to and got on with the skirts as I wanted them removable instead of blended into the shuts etc. This was much easier to achieve with the skirts actually clipped onto the body this time round. Plenty card, mesh and good old fibreglass and fillers built a leading edge. Now with them been 3dr skirts on a 5dr the joint line is totally out of place so last night I marked them up put some temporary screws into hold them wile the bonding set in the joint and fibre glassed the joint over. Now to sand them flat and prep them for paint
oh and how many layers of paint
On a plus note I shall be at VBOA fingers crossed the replacement log book arrives
Wanted the car to look evil from the front with the Morrette's in so give the lamps and indicators a light tint
Still plenty of light through them so John law can't be a C#*T
And finally last weekend I had the car running as per our group chat I was over the moon she runs so drove it out the garage for a bath
Next up on my list is to finish the body kit so set to and got on with the skirts as I wanted them removable instead of blended into the shuts etc. This was much easier to achieve with the skirts actually clipped onto the body this time round. Plenty card, mesh and good old fibreglass and fillers built a leading edge. Now with them been 3dr skirts on a 5dr the joint line is totally out of place so last night I marked them up put some temporary screws into hold them wile the bonding set in the joint and fibre glassed the joint over. Now to sand them flat and prep them for paint
oh and how many layers of paint On a plus note I shall be at VBOA fingers crossed the replacement log book arrives
Looking good, can't wait for a proper poke around at VBOA
Yes looking forward to seeing this at vboa now
Gareth
Club Member
Looking good, can't wait for a proper poke around at VBOA
More than welcome too. The doors are unlocked, the bonnet is open.
Spending 3 hours a day ruffly to get it done
What did you use to tint the lights btw? Looks really good
Gareth
Club Member
Continuing on tonight with the skirts, got the second one fibre glassed wile that was setting, I sanded the first one back and give it a skim of Dolphin Glaze filler if you haven't heard of it, it's a self levelling filler ideal for the job I'm doing 
And I've set about the finer details like the jacking point recesses removing the multiple layers of paints and primers done the same on the cover edges
Still plenty to get out :/
And I've set about the finer details like the jacking point recesses removing the multiple layers of paints and primers done the same on the cover edges
Still plenty to get out :/
Gareth
Club Member
I bought a roll of light smoke headlight tint off eBay about £7 2m long by 30cm wide. No prep required other than a clean. Stick it, heat it and stretch it
Gareth
Club Member
Little bit more done on the skirts. Trying to knock back as many layers of paint as I can must be about 7 :lol the black is the original plastic
On the flip side tho my blended join is pretty seamless now.
That will be alright once it's been wet flatted then 2k primer'd flatted and painted then cleared.. never ends but should be flat as Texas
On the flip side tho my blended join is pretty seamless now.
That will be alright once it's been wet flatted then 2k primer'd flatted and painted then cleared.. never ends but should be flat as Texas
Top work badger
Gareth
Club Member
Update today this week I've been spending 2.5hrs a night after work to get the rest of the body kit prepared and ready to be fitted this weekend. I'm not gonna lie it's a nightmare prepping such large parts off the car than it is on. Anyways battled on Tuesday the skirts were finished and Wednesday I got the majority of the bumper done and finished it off this morning before work 
. Baring in mind I built this bumper some 13yr ago so couple of repairs were needed, used the plastic welder sunk in a few bridging pins, fibre strands and resin and a skim over afterwards. 
Tonight I've managed to get all the bits into primer
Door trims
Morrette's
Bumper
I soaked the garage floor and walls in water. God bles tomorrow when the top coat goes on after I've flatted them all back off.
More tomorrow and Saturday.. Sunday il have a day off
. Baring in mind I built this bumper some 13yr ago so couple of repairs were needed, used the plastic welder sunk in a few bridging pins, fibre strands and resin and a skim over afterwards. Tonight I've managed to get all the bits into primer
Door trims
Morrette's
Bumper
I soaked the garage floor and walls in water. God bles tomorrow when the top coat goes on after I've flatted them all back off.
More tomorrow and Saturday.. Sunday il have a day off
Gareth
Club Member
Well I've been flat out as I sed Thursday, Friday in the garage spent painting parts ready to fit Today (Saturday) lack of pictures during as I was against the clock. Made a mess on the rear bumper so had to flat that back this morning and get it painted. Wile that was in the garage Baking I set to and started re assembling the Morrette's and fitting the skirts.
Bumper re done this morning
So put the skirts on the now one piece lower sections ingot myself some 6mm push rivet fixings to secure the underside of the skirts. So drilled the sills, painted the holes and fitted the clips
Fitted one in the rear of the dogleg section. As theirs nothing holding this section on as they original 3dr skirts
Now it's dry and Dan Wilde came over to lend a hand we put the bumper on
Fitted my LED numberplate lamps least they won't yellow as quick like the halogen bulbs do.
Added gold reflecting tape to the underside of the exhaust cut out
Bumper re done this morning
So put the skirts on the now one piece lower sections ingot myself some 6mm push rivet fixings to secure the underside of the skirts. So drilled the sills, painted the holes and fitted the clips
Fitted one in the rear of the dogleg section. As theirs nothing holding this section on as they original 3dr skirts
Now it's dry and Dan Wilde came over to lend a hand we put the bumper on
Fitted my LED numberplate lamps least they won't yellow as quick like the halogen bulbs do.
Added gold reflecting tape to the underside of the exhaust cut out