Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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So some people will know that Hamish has picked up another shell to start another build. He was given the shell by a very generous man called Andrew Chew who offered it to him when he needed a roof.
The car is a coupe quattro which he had for 7 years sat outsdie his house under a cover. Hamish picked the car up in April and has had it stored until this weekend and its now ready to go upstairs to the chop shop!
Stripped it down today and its quite solid. Few bits of rot but nothing too difficult to put right, probably in better shape than the last one started off as.
The plan is to make this into an S1 E2 which was the evolution version of his with the even bigger arches and rear wing. It will have the proper screen angle this time donated from an Audi 90, and all carbon panels. Going to be having more of a spaceframed cage this time with it holding the rear diff, along the lines of a modern wrc cage to all the pick up points. When the shell is done he will use the engine and running gear from the current car as its nicely developed now.
How it had been sitting for 7 years.
Got it back to mine yesterday.
Spent today stripping it to a total bare shell for its move.
So hopefully it will end up something like this!
April '06' Corsasport Feature Car  | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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Nath
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Registered: 3rd Apr 02
Location: MK
User status: Offline
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This will be mega!
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BeetleGav
Member
Registered: 27th Jun 10
Location: lancashire, nelson
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Exciting! Can't wait to see how this goes!
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bigron1988
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Registered: 29th Aug 09
Location: Southport, Merseyside
User status: Offline
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quote:
Originally posted by Nath
This will be mega!
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Marc
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Registered: 11th Aug 02
Location: York
User status: Offline
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Be ace to see them both lined up when finished.
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M Sutton
Member
Registered: 11th Jan 03
Location: Northamptonshire
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Insane!!
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Chris F
Show Staff
Organiser: East Anglia
Premium Member
Registered: 26th Dec 05
Location: Newmarket Drives: Escort Van 1.8
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There pics/vids of the last one crahsing?
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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Yeah, and then being fixed and used again.
April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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SteveoBC
Premium Member
Registered: 22nd Feb 07
Location: Bucks
User status: Offline
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New quattro build thread
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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Got the last bits striped off the car today and put it upstairs. Started the horrible job of cleaning up the underside so he can get a jig sorted to bolt onto the suspension pick ups.
April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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Robin
Premium Member
Registered: 7th Jan 04
Location: Northants Drives: Clio 182 Cup
User status: Offline
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quote:
Originally posted by SteveoBC
New quattro build thread
Exactly this.
I'm so anal about things that the screen angle on the last one bugged me. This will be amazing 
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SteveoBC
Premium Member
Registered: 22nd Feb 07
Location: Bucks
User status: Offline
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that upstairs garage ramp is soo cool
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Steve X16XE
Member
Registered: 31st Dec 06
Location: Barnsley, South Yorkshire
User status: Offline
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Sweet!
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daymoon
Premium Member
Registered: 1st Aug 08
Location: Selby, North Yorkshire
User status: Offline
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 He is insane!
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Christopher
Member
Registered: 14th Oct 10
Location: Eastbourne
User status: Offline
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That garage is soooo cool I can see this project is
Going to be absolutely crazy
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Graeme
Premium Member
Registered: 26th Jul 04
Location: Northampton
User status: Offline
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This is gona be good to watch. Nice set off bbs e50's there aswell.
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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quote:
Originally posted by Graeme
Nice set off bbs e50's there aswell.
Make that 2 sets:
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Graeme
Premium Member
Registered: 26th Jul 04
Location: Northampton
User status: Offline
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Nice. I've got 2 10.5" x 17" ones I'm using at mine as small tables.
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Matt L
Member
Registered: 17th Apr 06
User status: Offline
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looking forward to seeing this one finished, does he have a date to aim for?
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Darryl H
Organiser: South Central
Premium Member
Registered: 19th Nov 09
Location: Camberley Drives: Porsche 944
User status: Offline
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This will be awesome!
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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Hamish has been getting on with cleaning the shell up so the grinding and welding can begin!
All the underseal off the floor pan. Weighed it because he's sad and there was 10kg
Its already made its own cut for shortening!
2 full bags of underseal!
Next he moved onto the inside and managed to get another 10kg from the sound deadening. Ontop of that he started removing all the brackets and metal work. Lots more to get chopped out but want it on the jig first.
Another 2 full bags!
Got a nasty bit of rust to sort on the A pillars. Apart from that the shell is solid. The floor area where its rusty will get chopped out when its shortened.
Managed to get himself a roof from an Audi 90. 4 door obviously but, going to use some composite B pillars to sort that. Also got the doors off the 90 to make sure the new roof goes on right.
Chopped the roof right down will use the new roof to repair the tops of the current A pillars.
Next job is to get the chassis jig made up so it can all be held square for being chopped to bits. Should be getting on with that this week.
April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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random dav
Premium Member
Registered: 7th Jan 04
Location: NSW
User status: Offline
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Awesome, looking forward to the updates.
WRLFC !
Project cars
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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Hamish had a nice delivery from Andy Krinks, some carbon/ kevlar B pillars which is the first part of the puzzle for the body work. Roof is next on the list then the cage can begin!
Next part of the puzzle which has held things up has been the chassis jig. Had worked out he wanted 80mm hole spacings on the jig as that means going forwards 4 holes gives the magic 320mm to shorten it. That meant using an I beam with at least a 100mm top plate. Ended up with 178 x 102 beam, 19kg per meter which was the lightest with a 102 top plate. Went with 4 meter lengths so its long enough to bolt to all the vital points. The width is set by the subframe mounting points. 196 holes drilled in total down its length so anything can be added including cross beams to increase the width for getting into the strut tops etc.
So once that was done it was time to get it up on the loft with the shell.
First job was to get the shell over on its side out of the way to drop the floor down.
Loaded the jig into the back of the van and drove it around to the garage as its bloody heavy!
Jig pushed up the ramp with 6 sheets of 3/4" ply to go down on the floor. Wanting to spread the weight of the jig/ shell and seal up the floor so no debris gets onto the car below.
Boards down to seal it up for what could be quite some time!
Tomorrows task is to make the pillars to bolt to the subframe mounts and then the cutting and shortening can begin!
Been working on the jig these past couple of days and managed to get the car mounted up on the jig. Big thanks to Jamie (Squib) for the help with the jig and lifting of the car couldn't have got the job done without his help!
Slowly getting his eye back in with the welder.
He has got some 100 x 50mm box to bolt across the jig to increase its width to go up into the turrets and front chassis. Will get the front chassis tied into the jig and then get it chopped and shortened over the weekend. Its moving along very nicely now!
Hamish cracked on with some more work today. Got the front chassis legs tied into the jig. Very happy that it all measures up straight as often they have had a little bump! Ignore the lower panel being damaged it was folded up when i used a jack under it.
That meant the front end could be chopped out giving a lot more space to work around it.
Finally he tied the A and B pillars together to keep them true when the roof comes off.
Hopefully having the shell tied down will mean nothing moves too far!
Set about the car today. The roof was first in the firing line for the chop!
Off she came!
Behold the open top quattro!
Next he set about the B pillar and floor area ready to get it shortened. Bear in mind the idea with this shell is to be as light as possible and it will be more of a spaceframe with a bit of shell left to keep the water out!
Outer arch chopped out:
Bit of strengthening removed:
B pillar was 3 skins:
They got the chop as he only wanted the door shut left it will be tied into the main hoop of the cage.
Rear chassis member cut out as it wont be needed.
Quite a pile of bits cut out!
New B pillars look like they will work nicely:
Cracked on with the shell work, cut the same out of the opposite side first thing:
Cut the last bits holding the 2 halves together:
Sat happily on its legs:
Brought back in and welded under the windows to hold the door shuts. Have left the floor for now until the main hoop is in place then he knows where wants the floor to go. Plan is to have the main hoop intersecting the 2 halves of the sill.
Screwed the B pillars in place to get an idea of where they are going to go:
Got over 25kg of metal cut out during shortening:
Finally chopped the dash panel out and opened up the A pillars to get a look at the damage!
How it stands tonight got a good bit more space to walk around it now with the 320mm cut out!
Next job is to get the roof on and sort the rust in the A pillars. Hes very happy with how its progressing!
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SteveoBC
Premium Member
Registered: 22nd Feb 07
Location: Bucks
User status: Offline
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jesus christ hes chopped the fuck out of that
be great to see the final product,looks mental getting a chassis jig up there lol
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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Hamish has been working away on the car over the past couple of weekends. First job was to look at the A pillars and decide what to do with them. He opened them up cutting out the strengthening pieces for the hinges. They were in a bad state as usual for these cars with sunroofs.
Could have repaired them but he decided to get new ones from Audi tradition. So it was out with the old:
And in with the new. Welded up the outer holes in them before going in. Also removed all the inner frame work to get them as light as possible:
They were plug welded back on in the factory positions. Also seam welded them onto the front arch as they are being left open so it looks tidier:
Ground off, they need a little more tidying:
Same done on the other side:
Looking much better now! They were parted from the upper sections at the join as per factory, so the 80 roof sits over to the scribed line ensuring it goes on in the right place.
The next job on the list was to tie the rear turrets into the jig before all hell was let loose with the grinder on the back of the car. Started off with some 60mm steel billets and he machined them in the lathe to bolt up into the turrets:
Welded onto an upright:
In place:
And locked off with a top plate:
All bolted to the jig and shell:
Having the turrets tied down enabled this to happen!
So now it was onto the roof. He attacked the 80 roof to take as much weight out of it as possible. So the A pillars have been opened up and the inner rails have been chopped out as you can see. This will also enable the cage to sit very tightly to the shell and it will be welded to the pillar all the way up to tie it in.
Then it was on with the Carbon/ Kevlar roof courtesy of Tonks!
Big thanks to squib for his help today! It was an awful messy day with grinding metal and Carbon/ Kevlar! Here he is looking happy with the progress!
So very happy to see it with a roof roughly back in place. Obviously the roof is just a quick trial fit so he can get an idea for roll cage templates. Will work on the roof fitment next and also going to get a carbon rear panel as the current one has had a smack at some point so isn't in the best of shape. Very happy with the recent progress, feels like he has turned the corner and starting to add bits back!
April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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