AE86 booter

[Mylesmck]

(08-03-2020 09:23 PM)banpei Wrote:  

(08-02-2020 02:09 PM)Mylesmck Wrote:  I had already measured the diagonals across the two door openings and found they were out by roughly a centimeter

You mean the roofline is skewed to one end?

Possibly, requires more investigation, but with the door is on there is a slight perceptable step up when I run my hand over where the top of the door meets the roof near the screen (if that makes any sense lol). It could have something to do with the hole in the floor and the outrigger... My theory is that if the a-pillar moves rearwards where it meets the bulkhead, it will cause the top of it to rise

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[Mylesmck]

...making up an alignment frame; got it square, used some 40x80mm box as it won't be used for chassis adjustment, just to keep things in place when welding, and to give reference points when replacing the chassis leg. Also, the H-beam was surprisingly flexible....pound for pound the box should be more rigid torsionally. I'll probably add some gussets to add lateral strength.
This is the basic frame, I'll connect to the outer suspension mounts on the rear, chassis rails at 2 points each side, and the front subframe to chassis rail bolt holes

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... it's a slow process, not helped by the time taken to bore holes

[Mylesmck]

New lower offside door hinge.... Bolts are on back order, found one and stuck it in and it's pulled the door up slightly. I'm hoping that the door will be flush with the roof with the correct bolts as they 'step up' in thickness after the thread ends...

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[Mylesmck]

Some more progress on the frame

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[Mylesmck]

Braced the doors, the nearside gap is about 5mm longer than the driver's side, so adding the correct length brace to both sides leaves the doors closing perfect

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...and some more work on the frame...the first pic shows points Q,q,R and r mapped out onto perfectly flat jig for attachment to the frame (points from underside diagram in tech info/manuals in this site)

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[banpei]

Nice work!

[Mylesmck]

So in-between doing other more pressing things, I had a go at polishing up this kouki grill using Meguires plastic polishing compound.... Came up ok-ish, looks like there's remnants of either clear lacquer, or more likely thinner damage... Id always preferred the zenki grill tho

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.... something is missing...

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Test fitting the chassis rail/apron, it still needs a small bit of work before fitting, cleaning up drilled out spotwelds & making good some torn metal. The rad support has been removed and the two "gussets" drilled off of it, not sure whether to save them or replace with something sturdier

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[Ivan141]

Wow, serious work going into this.
Stay awesome!

[Mylesmck]

(09-25-2020 01:47 PM)Ivan141 Wrote:  Wow, serious work going into this.
Stay awesome!

Thanks

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[banpei]

(09-25-2020 01:47 PM)Ivan141 Wrote:  Wow, serious work going into this.
Stay awesome!

I can't agree more with you!