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Thursday 12/10/2006 - pt2
With my suspension pretty much sorted, I continued work on my boot project.
Heres some pics of the boot with the new housing sikaflexed in place -
http://img.photobucket.com/albums/v1...DSCF0004-2.jpg
http://img.photobucket.com/albums/v1...DSCF0018-1.jpg
Sikaflex is a marine adhesive - incredibly tough and best of all water resistant so makes a perfect bolnding material.
The next task was to fill the edges with filler. Before doing this I cleaned off the excess sikaflex from the edges and degreased with panel wipe to ensure a strong bond. I then re-insterted the badge after applying 3 layers of masking tape round the edge so I could take the filler right up to the edge.
This image shows the filler after a light sanding -
http://img.photobucket.com/albums/v1...DSCF0019-1.jpg
The next task was to layer up some resin and fibreglass to cover the metal insert. I started by making the lower section of the boot totally horizontal. Resin like water will sit flat if on a level surface. I measuring up a fibreglass insert -
http://img.photobucket.com/albums/v1...a/DSCF0020.jpg
and to ensure this would be thoroughly soaked, I split the sheet into 3 sections (fibreglass is layered - split it up and you get 3 thinneer sheets). This will ensure a tight air free bond.
I started by applying a layer of resin right up and over the edges. I then added the 2st layer and srtippled it in place. This was followed up by more resin and another sheet and so on up to the 3rd. I then applied the rest of the resin and stippled away until all 3 sheets had been absorbed.
The final boot lid was then left to settle and set -
http://img.photobucket.com/albums/v1...a/DSCF0023.jpg
http://img.photobucket.com/albums/v1...DSCF0025-1.jpg
http://img.photobucket.com/albums/v1...a/DSCF0026.jpg
This is the 1st stage. Tere will obviously be ripples and divets in the surface and it will need a skim of filler and then sealing. The boot will cure over the weekend (I'm going away for a few days) and when I return I will sand back to a level surface (its slightly higher in some places), skim it and see what it looks like from there.
I then need to rebuild the small area cut away from the inside, backfill the entire thing with expanding foam to prevent water ingress and secure the boot mechanism.
Looks really good though
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Nice ade.
Its good to see your thinking outside the box with this one.
I wish I'd fitted poly bushes when I did my suspension.
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Excellent job Ade. It's the first time i've had a look at how this is going for several months.
I can't believe the amount of work you're putting into it, the wife must be breathing fire at you by now, not to mention the neighbours!
The ingenuity you've displayed with sheets of cardboard to create templates for pretty much everything on the car that needs to be custom made, from scratch is amazing. The headlight mounts, combined with the radiator mounting in particular i thing is an amazing job.
I'm holding back judgement on the smoothed tailgate until its finished, still lots of room for it all to horribly wrong yet :D
PS. I wont say keep up the good work, because... well, why would you suddenly start doing a shoddy job of it? lol
PPS. Bring back the expletives monitor to each report that was included in Ade's garage version 1. Don't try telling me you're doing all this without swearing, i don't believe you.
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well ****ing done mate, this is looking mental, cant wait to see it in the flesh some time. keep us posted on further development, as iam sure you will matey.
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wow jus gone through this thread and your a god mate with some top vision the lights are a real nice touch and then the boot jus tops it off,top work mate keep us posted.
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chers guys will do!
Andy - lol re the swear section of the original ades garage. Found the wife very accomodating - seeing as how shes currently 200 miles up north in Elgin during the week! Means I can come in and just get on with it.
The neighbours are excellent too! Always popping in and seeing how its going - went away this weekend and for some unknown reason left my garage door wide open, lights on with all the tools out on display! Realised what I'd done on the motorway 1/2 way up to see the wife and couldnt do owt about it.
Got to wifes at about 10.30pm, told wife - she tutted (as they do) called her sister to see if she could help who just happened to have our next door neighbours telephone number who wass called and advised us that she'd seen me drive off and when she took dogs for a walk noticed garage open and went round and closed it all for us!
Will defo have to buy her a bottle of something!
:D
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what a nice neighbour!
boots starting to take shape now, you figurd out how to wire it up yet? going to use the standard locking mech from the VW or create your own>
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not too sure. I'll use a universal solenoid obviously but need to wire in some kind of relay so that you cant just walk up and open it.
Hoping to get an alarm with a remote boot release...
Anyone else got any suggestions?
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Monday 16/10/2006
Not been too well today - woke up and was completely deaf in my left ear and my balance was all over the shop! Felt like I was p1ssed!
Went to the docs and He gave me some drops for ears and some sea sick tablets! An hour later I felt well enough to take the day in the garage. I just shoved some ear plugs in my head all day so the drops wouldnt fall out!
Started off by sealing up the engine bay and light housings with seam sealer. I used Greystripe brushable seam sealer - used it before and its very good -
http://img.photobucket.com/albums/v1...a/enginea5.jpg
http://img.photobucket.com/albums/v1...a/enginea4.jpg
http://img.photobucket.com/albums/v1...a/enginea1.jpg
http://img.photobucket.com/albums/v1...a/enginea3.jpg
http://img.photobucket.com/albums/v1...a/enginea2.jpg
Whilst this was curing I did a bit more on my boot - the resin had cured fully and it was very tough. I needed to sand it down though as it was too high. This too absolutely ages! Once down, I skimmed with a layer of filler to try and level if off (there were some low points) -
http://img.photobucket.com/albums/v13/danga/boota1.jpg
http://img.photobucket.com/albums/v13/danga/boota2.jpg
Whilst this cured, I started to paint my engine bay and under my wheel arches. I'm giving it a few coats of black no rust paint. I'm not too fussed about the finish at this stage as long as it looks relatively smooth - most of it's going to be hidden beneath the engine anyway. The type of paint I;m using is actually really good at self levelling anyway. The main focus is to try and reduce future rust problems for as long as possible.
I've applied the 1st coat but it needs at least one more (you can still see some of the original paint in places). I also need to treat the new light housings to a few coats of special metals primer too - galvanised steel needs primed 1st.
Once this cures fully I'll lightly smooth the visible areas and spray over it with some standard primer.
Once I'd finished painting my engine bay and surrounding bits, I sanded back the 1st layer of filler on the boot and then repeated the process.
Heres the 2nd payer curing -
http://img.photobucket.com/albums/v13/danga/boota3.jpg
http://img.photobucket.com/albums/v13/danga/boota4.jpg
http://img.photobucket.com/albums/v13/danga/boota5.jpg
this is already looking much smoother and the hole where the lock will go really adds a great big detail to the back end! I was never keen on smoothed boots - too much metal but breaking it up slightly should really make a big difference. Theres still a fair way to go - perhaps another layer or two before its ready for a light prime and then further rub downs...
Plans for Tuesday (its my day off conveniently!) -
- pick up my front hubs from local engineering firm after they've had new front bearings fitted as well as steering rack which theyre slackening tie rod mounts off of so I can fit new ones.
- paint another layer of paint on the engine bay/arches.
- paint light housings with special metals primer
- fit new CV boot to drive shaft
- continue smoothing boot
- look at applying rocker shutz sound deadening material to the arches...
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How about using an immobiliser working on a bullet system in the boot, so that when your opening the boot with the key in your pocket it flips the relay and then alows the solenoid to activate?
I may be missing what your getting at though.
Good work matey, keep it up.
