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Old 22nd May 2017, 12:03 PM   #41
Mashmoreuk
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I nearly bought the Alcons on FB just before you did - almost glad I hadn't now!
it's what to expect when buying second hand brakes really, there are many people who over look servicing their callipers, people just expect to buy them and they last years and years as there's no prescribed "service interval"

Got stung a little by these Front aps I bought though, they were sold as working but need a new set of brackets, and im probably expecting pistons also!

Hey ho, not that im bitter about it...
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Old 22nd May 2017, 01:03 PM   #42
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Hello mate how did you manage to remove the pistons?
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Old 22nd May 2017, 03:05 PM   #43
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Hello mate how did you manage to remove the pistons?
Hi mate, 2 ways really...

Air line, block of wood to bring the pistons out evenly - if they're ****ty to get out = blow torch, expect to be replacing seals though.

or wrap the calliper up in some old t shirts and bang it against the ground/wood/carpet on concrete ... piston facing down and obviously repeat the other side...
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Old 23rd May 2017, 04:58 PM   #44
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Well that's one side of the underseal removed....



Flip her over, and now onto the other side



Lets start with the arches shall we... pried the lip back as they're going to be rolled anyway so I could view it better... and yeah we got rust, but not as bad as the other side that's for sure... we might even get away without cutting it out.. but I'm not sure yet...



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Old 24th May 2017, 07:34 PM   #45
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The envy for your workspace is strong... Looking forward to updates on this one, keep 'em coming!
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Old 24th May 2017, 09:34 PM   #46
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The envy for your workspace is strong... Looking forward to updates on this one, keep 'em coming!
Not as good as it looks unfortunately shared space, so space is minimal - but overall space is good if that make sense...

Thanks bud,
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Old 13th June 2017, 01:06 PM   #47
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Been a few weeks since I've updated last but other things have got in the way... holiday/work etc etc

So had a push last night on got on with a few bits...

the underside is pretty much stripped now, just awaiting delivery of some tulip head wire brush's so I can get in the gaps/crevasses. I have also started the process of stich welding the shell...



looks quite dull due to the zinc residue...

in addition to this ive also started trying to patch the inner rear arch, I bought some replacement outer arches and with a bit of fettling they have seem to go in quite nicely













still not welded in yet, but still playing with settings first as new welder and all and have very little experience welding body panels thickness...

but yeah quite happy that they kinda fit, well much better than me making patches to fit anyway.
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Old 16th June 2017, 08:16 AM   #48
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Its seam welding time! Bit of a learning curve, especially with a new welder and very little experience on panel thickness metal, but its not looking to bad at all!













Been struggling quite a bit to find the sweet spot between blowing holes and finding the right penetration... giggedy





Not all of the welds look like that, unfortunately I spent a lot of time practicing on just 0.9mm sheet but not a lot of actually body panel which was totally different, nothing that a grinder can sort though ey..

and one from the weekend at Silvetone BritishGT,

lol

Anyway, over half way there now with the seam welding, next job is to finish that off, cut the boot floor out then give the car a light dusting of etch primer before it can be raptored!
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Old 19th June 2017, 01:00 PM   #49
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never ending these e46 seems.....







no problems with penetration... well in some parts I did tbf haha



Hopefully have all the underside seems done tonight, think its just the arches to go, and probably a few bits I've missed in the boot floor.

Speaking of boot floor, I'm yet to cut that out anyway, some more photos tonight I'm sure in the sweat box!
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Old 19th June 2017, 02:33 PM   #50
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Great work fella!! Love the build can not wait to see more
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Old 19th June 2017, 02:58 PM   #51
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Great work fella!! Love the build can not wait to see more
thanks mate, appreciate the comments!
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Old 19th June 2017, 04:25 PM   #52
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thanks mate, appreciate the comments!

Most welcome my friend!

Thanks for sharing this build. Really is a credit to you.
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Old 19th June 2017, 07:00 PM   #53
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unit temp was about 33degrees, and along with welding it was just over the what I could tolerate, rear arch stitched though so not a wasted journey! some welds could do with getting grinding back though, reacted quite badly with some pesky hidden seam sealer!
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Old 19th June 2017, 08:15 PM   #54
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wooow after you can do mine mate . Folowing
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Old 19th June 2017, 08:17 PM   #55
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wooow after you can do mine mate . Folowing
No problem mate, send her over!
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Old 21st June 2017, 07:55 PM   #56
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bit of a sweat box tonight! I say bit, must of lost weight lol

Finished the underneath seam welding tonight, wasnt to happy with quite a lot of the appearance of the welds but going to put that down to seam sealer between panels and experience...

last arch that was needed doing...



this with the main seam meant job done...

Next job was to work on the engine bay, since the car will run full motorsport loom the original fuse box area and metal work wasn't needed and will make a handy space for a catch tank or similar...





anddd she's gone...



unfortunately didn't take many other photos as just wanted to get job done and outa there, but that's kinda the progress for this week.

I'm at Thurxton tomorrow, then have gotta prep a mates 205gti Friday for Castle Combe on Saturday - if anyones doing that on here?

more progress ont weekend!
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Old 27th June 2017, 09:15 AM   #57
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Time to flip the shell over again to work on the other side of the engine bay, to remove all the panels that hide the servo.



Some pretty poor photos, but hey you get the idea...







Loads of room for activities in there now! few small bits to cut of still, as I left them as you have to get creative with the drill and angle grinder to reach them...

Tonights job,
- finish of the engine bay spot welds, clean it up, stich weld it, light dusting of etch primer
- Finish interior spot welds """"""""""" light dusting of etch primer
- Start making some patches for all the small original holes and holes I've made, plus all bulkhead holes that aren't going to be used.

Cheers all
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Old 27th June 2017, 10:04 AM   #58
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This is one to watch
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Old 27th June 2017, 04:11 PM   #59
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This is one to watch
bit of a scrapper currently haha
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Old 27th June 2017, 06:00 PM   #60
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Really enjoying the updates on this, much bigger task than I would undertake!
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