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 mk2 track car build

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nevw

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Male Number of posts : 31
Age : 36
Location : Newmarket
Drives : MK2 16V MK4 GTTDI150
Registration date : 2010-03-17

PostSubject: mk2 track car build   Fri Apr 02 2010, 20:31

Just thought I would try to show some pics of my car I have been building over the past year. Hope it works as am not very good at this computer stuff.

Its a mk2 gti 16v, which will have weld in cage, abf engine on jenvey throttle bodies, cable change gearbox, and lightened as much as possible.

All comments welcome, but don't expect much feedback, due to my lack of computer skills.

ht[URL=http://s1016.photobucket.com/albums/af290/nevw_123/
all under seal removed now time to start seam welding


Some


good heat penetration
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CaddyRage
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Male Number of posts : 6348
Age : 36
Location : Ellington, near Huntingdon, cambs
Drives : T4 2.5tdi daily, 83 mk1 golf gti 16v, 92 mk1 Caddy project
Registration date : 2007-12-29

PostSubject: Re: mk2 track car build   Sat Apr 03 2010, 09:45

Nice, i look forward to seeing progress on this mate

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ianb



Male Number of posts : 37
Age : 31
Location : hockwold norfolk
Drives : mk1 caddy, mk2 20v project
Registration date : 2010-03-01

PostSubject: Re: mk2 track car build   Sat Apr 03 2010, 17:49

sounds like a cool biuld! look forward to the next update
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nevw

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Male Number of posts : 31
Age : 36
Location : Newmarket
Drives : MK2 16V MK4 GTTDI150
Registration date : 2010-03-17

PostSubject: Re: mk2 track car build   Mon Apr 05 2010, 17:40

Cheers for your comments. As you can tell, this build is not very fast going, as we only really work on it 1 night a week, then to the pub.

Car at the moment has had all the under seal removed (which took forever), also interior sound deadening. All studs and brackets cut off underneath, inside and engine bay, and removed rain tray/bulkhead in the engine bay. The chassis number has been relocated to fill the heater pipe hole. Front top mounts have been modified to take adjustable solid top mounts.

Next we removed the roof as my model came with a sunroof and it was too heavy for what I was looking for. I have a fibreglass one ready and waiting to go back on.

Here are some pics, which hopefully should explain what I am going on about.







We have also had to modify the bulkhead for clutch master cylinder as will be using a hydraulic clutch

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MarkGTX

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Male Number of posts : 2925
Age : 30
Location : fens!
Drives : Rocco and Passat
Registration date : 2008-01-19

PostSubject: Re: mk2 track car build   Mon Apr 05 2010, 20:19

looking good so far, good to see your going all out
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Jimbo

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Age : 27
Location : Thetford, RAF Marham
Drives : B7 Audi A4
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PostSubject: Re: mk2 track car build   Mon Apr 05 2010, 21:27

gonna be awsome mate
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RM2WAS



Male Number of posts : 256
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Location : dicking about everywhere
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Registration date : 2008-02-28

PostSubject: Re: mk2 track car build   Tue Apr 06 2010, 20:15

wardy!! who's doing all the typing for you?

looking like Ben's doing a lovely job for you there
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nevw

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Male Number of posts : 31
Age : 36
Location : Newmarket
Drives : MK2 16V MK4 GTTDI150
Registration date : 2010-03-17

PostSubject: Re: mk2 track car build   Tue Apr 06 2010, 20:35

RM2WAS wrote:
wardy!! who's doing all the typing for you?

looking like Ben's doing a lovely job for you there


cheeky

but yes emma is typing for me as its faster and spelling is correct

ben does have some amazing fabrication and welding skills
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nevw

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Male Number of posts : 31
Age : 36
Location : Newmarket
Drives : MK2 16V MK4 GTTDI150
Registration date : 2010-03-17

PostSubject: Re: mk2 track car build   Fri Apr 16 2010, 21:10

We actually managed to get a whole weekend on the car, which meant we could get the cage in. This is the pile of bits we started with. We took it to Ben's workshop as he wanted to use his own welder.




First job was to tack in the platforms for the main hoop



Then tacked in the main hoop





We then offered up the front legs, we found them to be obstructed by the lower dash bracket and bulkhead. So we had to remove/notch



With legs fitting nice and close to the roof line and A Pillar, it was time to profile the end to fit neatly round the main hoop. This job was made easier with a notching tool



Front leg platforms were tacked into place





Main hoop has also been tagged to the B Pillars
Screen bar was profiled and tacked in place



Both rear legs and cross brace were profiled, cut and tacked in





Door bars, dash bar and main hoop brace were also tacked in place. Once we were happy with the fit, it was all welded up and we then had a nice cup of tea (which gave me something to do)

Once it was all in, it was close enough to tag the cage to the roof in 4 places







A big thanks to Ben, as always
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jim-uk16

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Location : Germany baby!!
Drives : 83 MK1, Octavia Workhorse and general chum's carrier pigeon
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PostSubject: Re: mk2 track car build   Fri Apr 16 2010, 21:36

this is gonna be good to follow me thinks.

how was it taking the roof off? i ask as i wanna do the same to mine in the future but need to find someone happy to do it.
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nevw

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Male Number of posts : 31
Age : 36
Location : Newmarket
Drives : MK2 16V MK4 GTTDI150
Registration date : 2010-03-17

PostSubject: Re: mk2 track car build   Mon Apr 19 2010, 20:02

It was relatively straight forward. Let us know when you are ready to do yours, and we might be able to help you out?
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nevw

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Male Number of posts : 31
Age : 36
Location : Newmarket
Drives : MK2 16V MK4 GTTDI150
Registration date : 2010-03-17

PostSubject: Re: mk2 track car build   Fri May 14 2010, 20:22

Not really done a lot recently. Just been collecting some bits. I tried cutting the frame out of my original bonnet to try to save some weight, but it made it very flimsy and was still quite heavy, so decided to order a Fibreglass boot and bonnet





I thought I would attack the doors with a grinder to see what weight I can save with them.

Before



After



Just thought I would show you a pic of my Bias pedal box which replaces the servo



If anyone can see where I can save some weight, feel free to let me know
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Ian83

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Male Number of posts : 493
Age : 34
Location : Cambridge
Drives : Mk4 GTi
Registration date : 2008-12-01

PostSubject: Re: mk2 track car build   Fri May 14 2010, 20:42

Going to keep an eye on this. Never seen a build thread were someone has taken the roof off to fit a cage yet! Shocked
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whittle

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Age : 27
Location : Secret Base
Drives : along the pavement
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PostSubject: Re: mk2 track car build   Fri May 14 2010, 20:49

looks awsome

how much did all the crap that came out of the door weigh?

are you going to weld the original roof back on? have you thought of getting a carbon one made?
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nevw

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Male Number of posts : 31
Age : 36
Location : Newmarket
Drives : MK2 16V MK4 GTTDI150
Registration date : 2010-03-17

PostSubject: Re: mk2 track car build   Fri May 14 2010, 21:06

I haven't weighed it yet, but will try to and let you know. I have already got a fibreglass roof to go on and will post a pic soon. Cheers for your comments
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millfischk69

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Male Number of posts : 997
Drives : MK1 Golf GX 1457cc, 53 plate MK4 R32 in DPB, Kawasaki Ninja J1
Registration date : 2009-11-07

PostSubject: Re: mk2 track car build   Fri May 14 2010, 21:43

Looking to be good build and them welds on the cage looks super.

Does your friend like doing welding on the side for other people as i might need some welding doing soonish Wink
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nevw

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Male Number of posts : 31
Age : 36
Location : Newmarket
Drives : MK2 16V MK4 GTTDI150
Registration date : 2010-03-17

PostSubject: Re: mk2 track car build   Sun May 16 2010, 19:42

thermal wrote:
looks awsome

how much did all the crap that came out of the door weigh?

are you going to weld the original roof back on? have you thought of getting a carbon one made?


I weighed the metal frame that came out of the door, it was 1.6kg.

Found a pic of my roof thats going on, but its not that great as its from my phone

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nevw

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Male Number of posts : 31
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Location : Newmarket
Drives : MK2 16V MK4 GTTDI150
Registration date : 2010-03-17

PostSubject: Re: mk2 track car build   Wed Oct 27 2010, 20:43

Not done a lot recently, what with holidays and stuff going on.

Got my doors finished off, seat bars and harness bar are now welded in. The pictures are probably better at doing the talking, hope you can understand what they are of.















I tacked the 2 skins of the door together to give it some extra strength, where I had cut the inner frame out







Made a frame up to hold the seat side mounts so we could see where the seat would be, without it in









Repaired the rusty fuel filler neck supporting bracket





Harness bar in with some rings to stop the harnesses sliding across when cornering

Thats it for now!
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RM2WAS



Male Number of posts : 256
Age : 36
Location : dicking about everywhere
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Registration date : 2008-02-28

PostSubject: Re: mk2 track car build   Thu Oct 28 2010, 19:02

Workmanship is looking as tidy as ever, well done gents.

How many beers per weld do you think you are getting through?
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curtis_caddy

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Age : 26
Location : duxford
Drives : mk2 driver
Registration date : 2008-02-03

PostSubject: Re: mk2 track car build   Thu Oct 28 2010, 20:17

very tidy fella looks awsome!
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nevw

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Male Number of posts : 31
Age : 36
Location : Newmarket
Drives : MK2 16V MK4 GTTDI150
Registration date : 2010-03-17

PostSubject: Re: mk2 track car build   Fri Oct 29 2010, 17:24

RM2WAS wrote:
Workmanship is looking as tidy as ever, well done gents.

How many beers per weld do you think you are getting through?

one or two

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RM2WAS



Male Number of posts : 256
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PostSubject: Re: mk2 track car build   Fri Oct 29 2010, 19:33

nevw wrote:
RM2WAS wrote:
Workmanship is looking as tidy as ever, well done gents.

How many beers per weld do you think you are getting through?

one or two


I just showed Clare that picture and said guess who's garage that is.

without pause for thought she said NEV!! lol!
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nevw

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Male Number of posts : 31
Age : 36
Location : Newmarket
Drives : MK2 16V MK4 GTTDI150
Registration date : 2010-03-17

PostSubject: Re: mk2 track car build   Tue Nov 23 2010, 21:06

Just a quick update. Have got all 4 bonnet pins fitted and the bonnet drilled, then spent the day at my mates sand blasting a few bits.



Had to make a bracket to attach the rear bonnet pins as the bonnet will be removeable, not hinged.



Started off with this



Like this after shot blasting





Then a quick coat of etch primer







Not sure what to do the top coat with. Any ideas?

Shot blasting was done in my mates very professional looking homemade tank



This is one of the little goodies I have treated myself to as an early Christmas present

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MK1G60
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Drives : MK1 ABF Bike Carbd, MK1 G60/20vt Project, MK1 Caddy 1.6D
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PostSubject: Re: mk2 track car build   Wed Nov 24 2010, 11:09

Good work, keep it coming...

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nevw

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Male Number of posts : 31
Age : 36
Location : Newmarket
Drives : MK2 16V MK4 GTTDI150
Registration date : 2010-03-17

PostSubject: Re: mk2 track car build   Tue Feb 15 2011, 20:19

Just a couple more pictures to show you the latest update

Got my hubs painted



We have got most of the custom fabrication on the shell done, so just need to address the rust issues now - starting with the rear panel



Started off by drilling out the spot welds, then cut the majority of it off with an air saw



Once we had got most of it out, it was easier to remove the trickier bits from the edge



Trial fitted the new panel. Once we had it in the correct place, secured with self tapping screws so when it came to refitting, it would be in the correct place



Then removed the panel and cleaned all the areas which needed to be welded, then etched primed





Then refitted the panel, using the previously positioned screws and spot welded



This is what it looks like at the moment



Thats it for now, but currently working on front strut brace and radiator mounts
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