adam.d
Member
Registered: 7th Nov 07
Location: hartlepool Drives: corsa LET
User status: Offline
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This will be a cracker when complete, well done
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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Mates been on with bending and welding the floor pieces this week....
The cardbord templates have turned into metal, and it now has a metal floor again!
Hopefully his Kevlar Cobra suzuka seats will turn up this week and get those mounted in, then the seams inside the car all need stitch welded, and after that its onto the cage!
April '06' Corsasport Feature Car  | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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ainsley_brader
Member
Registered: 24th Mar 02
Location: Tattershall, Lincolnshire
User status: Offline
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need an update!
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SVM 286
Member
Registered: 13th Feb 05
Location: pain
User status: Offline
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Lovely work. 
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mantamark
Member
Registered: 19th Jun 06
Location: Northumberland
User status: Offline
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Very nice bud.
How did you go about welding the roof up?
i was told it would buckle with the heat?
Any signs of this?
cheers.
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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He's done a good bit more doesn't look much from the pics but its finishing off the shell after it was cut to make it look like it wasn't thats taking the time!
so from this:
to this:
The inner skin has been welded up to put more strength back into the roof. Also the very inside piece of the roof rails have been silced and re-welded to make them line up. Its like paper the metal so a bit of a bitch to weld but its done in a fashion. He is planning to slice a piece off the roof section which was cut out to patch over the hole thats left and then thats the roof finished!
The floor is not far off being finsihed bar welding some pieces into the chasis rails so they look all part of the same section. He has also removed the firewall. He needed it out for the cage to go in, also the fact it was full of holes made it not the best firewall in the world! New one will be made up to go back in once the cage is finished.
Welded the sections under the windows
Done a bit of grinding in the engine bay, all brackets have come out, just need to finish taking the seam sealer off so it can be stitch welded.
Oh and the seats have arrived, Kevlar Cobra Suzuka beauties!
So thats it for now, cage to come next, 30 meters of tubing on its way inside it!
April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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mantamark
Member
Registered: 19th Jun 06
Location: Northumberland
User status: Offline
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So the roof is probs the same thickness as the corsa roof then.
Hmm, i need to sort the hole out from the sunroof in the corsa but was told it would buckle with the heat.
Good progress though, fuck me the blokes a loon!
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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He's done a bit more today...
Had to cover this hole
So he cut a section out of the roof piece that was removed and bashed it around a bit untill it was a good fit and welded it in.
Adds a good bit more strength back to the roof rails as well.
They will look fine once they have had a proper grind up and a skim of filler.
Then he moved onto making the pieces to make the chasis rails appear more as one.
Looks like thats going to work now so will have both sides all finished off this week. Should end up looking much more factory.
Its not far off being a finished shell!
April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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sand-eel
Member
Registered: 15th Mar 07
Location: carluke/braidwood--IRNBRULAND
User status: Offline
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BYRON
Member
Registered: 1st Jun 04
User status: Offline
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Fuckin immense.
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Marc
Member
Registered: 11th Aug 02
Location: York
User status: Offline
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Whats it all going to weigh when its finished?
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pow
Premium Member
Registered: 11th Sep 06
Location: Hazlemere, Buckinghamshire
User status: Offline
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Hawt
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Adam-D
Member
Registered: 11th May 02
Location: Cheshire
User status: Offline
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very cool, impressive welding there
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SVM 286
Member
Registered: 13th Feb 05
Location: pain
User status: Offline
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My envy is growing. 
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markeyturbo
Member
Registered: 13th Aug 07
Location: bury st edmunds
User status: Offline
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thats fuckin cool.. got alot of time for projects like this.. bit like the sxoc s13 morris minor!
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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Just a little update.
The roll cage tubing is here, and the chasis rails are almost done!
So just a small bit to finish on them and then the shell shortening is completed!
There is the seam welding to finish inside, the seat rails to sort out and then its the climbing frame time!
April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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Managed a bit more! The chasis rails are now totally finished. He then cut some pieces of 3mm steel to make the mounting points for the cage. Then got them welded together, and finaly welded into the car. The seat rails are also cut and the plates welded into the car to take them.
Roof spars were also cut out as there was rust behind them
Pretending to be the roll cage......................
So there are a couple more plates to make for the rear struts. Then will make the main hoop and the A pillars as a template to get the shape right, then off to somebody with a mandrel bender to make them properly!
Its getting there...........
April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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SVM 286
Member
Registered: 13th Feb 05
Location: pain
User status: Offline
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SO impressive. The man's ability is quite astounding.
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Robin
Premium Member
Registered: 7th Jan 04
Location: Northants Drives: Clio 182 Cup
User status: Offline
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His welding rocks
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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Roll cage time! Enough said really. Been making templates for the main hoop and a pillar bars this, extended, weekend so that these can then be taken to some dude with a mandrel bender to be replicated, hopefully getting them done right first time. Well, that’s the plan.
Photos anyways!
A random one of the rad in the boot
April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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little_duke
Member
Registered: 21st Aug 06
Location: Tamworth,staffordshire Drives: rover coupe
User status: Offline
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joey736
Member
Registered: 11th Mar 07
Location: hexham, near newcastle drives: Aurora XE
User status: Offline
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very, very cool
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Graeme
Premium Member
Registered: 26th Jul 04
Location: Northampton
User status: Offline
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that is just truley amazing, his welds are so gd i bet the car is much stronger than when it left the factory!
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Marc
Member
Registered: 11th Aug 02
Location: York
User status: Offline
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You guys are easily pleased with the welding aren't you!!!
Good progress 
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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Done a little more!
The roll cage tubing was dropped off at Protection and Performace. What a place! Had to sign a disclaimer to say wouldn't take any pics to look around as they do work for Aston and Bentley
The bender they use is quater of a million! Computer controlled CNC jobbie, once its all programed in you just press start and it self feeds, it can also put large radius curves in the tube as well for things like windscreen bars so can curve it the wole way.
He said they are onto 2" pipe next week so should be able to pick it up sometime next week!
Today the seam welding was finished off in the footwells. Also cut a load more brackets off from the dash area that wont be needed.
Not even sure if will run a dash but will leave that option open at the min.
The seat rails seem to be taking an age to make! Finally have the nuts welded onto the back of them, just need to get the distance apart sorted out and then the triangle bits can be welded to bars. Then a lick of paint and weld them in!
This week has consisted of filling the underside of the roof and the roof rails to loose the join. Well that was the plan! Would have liked it to turn out better! Some of the bits are going to be impossible to get to once the cage is in, hence why did them rather than leave them to Dave. The bits that can be seen once the cage is in Dave can make look nice, the bits that cant then it doesn't matter
Today after suffering sanding down filler and being underneath all the dust all week he decided to do something more fun.....................................
The fact the gromit was holding on for dear life was pretty funny, just incase i needed access into the hole to put some wax oil in........................... 
So it was a fun day all round!
Picked up a 2 by 1 meter piece of 1.2mm steel to make various parts, one being a new boot floor and radiator cowling. Also to make some plates to weld over sections like where the heater used to live.
Phoned the roll cage lads today as well. They were just changing the tooling to move onto 2" tube. So the fella said it would be ready by the weekend or early next week! So will head down and pick it up next week to start the fitting next weekend!
April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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