Golfyste's road legal mk4 "project track car"

[golfyste]

Hmmm I think I will definitely have a look at doin it that way cheers 

[golfyste]

Ok time for another update 

Had a few deliveries lately 

New turbo intake pipe arrived as Even though next year I will be going bigger turbo I want to make sure I'm getting the most out f the setup I already have so got this as apparently they flow a little better the the Cm one.



It's great quality and very sturdy but I'm not sure if its genuine 

Is the forge writing supposed to be a sticker?




The silicone is strong and good quality and I wasn't even thinking of questioning it until I saw the sticker


 

Also two febi Cupra r ball joints 




And these arrived 
 Wishbone bushes, small dogbone mount bush, steering rack bush and main dogbone bush.



Gone for the powerflex black series throughout apart from some superpro caster rear wishbone bushes.
I also have some black series top mounts coming but he Messaged me sayin they are low on stock but should be sent in the next week or so 

30mm wishbone bush with the 45-30mm inserts I had made





The superpro bushes...
For some reason I have different ones to what everyone else seems to have 
I don't know the difference of if one are better then the other





Another pair of seat mounts




The lot 



Ok onto some work.
Started welding the n/s foot in place
Pretty awkward with the floor only being 1mm thick so I was running a small weld on the floor and then welding to the weld 1.5inch at a time to prevent overheating of the metal.

 


Also drilled the mounting plates for the shifter.
Have also cut out 8 other pieces of plate that will e welded as braces to stiffen the platform up.
Around where it will be welded in place....




I then got around to fitting the wishbone sleeves and bushes










And the bush fitted






That was it for today I had to stop welding as I started running out of gas again so need I refill it....again 

[golfyste]

Ok so a little update from yesterday

Spent half the day putting the bike back together so didn't get too much done on the car.

Basically I'm going to get it on the road with the standard engine aiming for the end of July and all that has to be done is the seats cage, shifter and also gonna try and get the suspension changed.
So I'm concentrating on these areas as everything else ( rebuilding the spare engine and brakes etc) can be done when I'm driving it and then put on over a single day or long weekend etc so I'm going that way with it.

Did some work on te shifter frame yesterday.
Had just enough gas left in the welder to do he work on it.

Tacked and welded the shifter in place.



Started tacking the brace bars in place








Then with all the braces tacks I removed it from the car and welded it all up.



Then cleaned it up and give it some primer (excuse the crap picture)



And a lick of paint 




I then moved on to the passenger seat
I got the front bar located and tacked in and then the rear bar is where it wants to be but I have well and truly run out of has for te welder so it's going to have to wait 

[golfyste]

Ok so another little update

Cleaned up the quick rack and fitted the uprated bush.



I didn't get many pictures of the progress but I spent a while Fabing a metal sheet to go on the top of the shifter platform
Also planning on making some side plates but can do then at a later date.

After bending and cutting



Approximately how it sits.




Some primer



And had to touch up frame from where I scratched it




I have also got the gas refilled so tomorrow I will be getting some welding done 

[golfyste]

I also noticed why my caster bushes looked different.....was because I had ordered them for a golf and not a Cupra r/s3/r32 ...... DOH 

Never mind new bushes have been ordered 

[golfyste]

Ok so another little update.

Got the passenger seat bars tacked in.




Got the front feet for the cage completely finished 






Made a plate for the original shifter hole and welded it in place then gave it a lock of primer




Welded up the door bar pin



One door bar done 



Other one won't take long and have ordered a 1400mm length tube to make a harness bar out of.


Also did a little bit of painting...

The shifter platform top plate




The shifter platform




And the standard shifter tower.

I have also ordered a b&m replica shifter off of eBay 


That's it for today.....more tomorrow!.....I do like my days off   

[golfyste]

Ok so another update 
(your going to have to excuse some of the photos as my camera is playing up  )

Welded in the passenger seat bars




Also finished welding the rear feet so thats all the feet on the cage finished all that is left to do is weld the door bar brackets in place (which i have marked up) and weld the harness bar in place (which i have ordered some more length of tube for  ).





I cut the the door bar to length and welded the end pin in place and then cleaned up the tubes and gave them a layer of primer to stop any surface rust.




Cleaned up all the feet and seat bars and then Threw some primer on to stop any further surface rust etc.






Also the new set of superpro caster bushes i ordered arrived!! Very quick delivery from PSI tuning.




I fitted the seats into position and placed the belt in place to figure out what to do with the anchor locations




Am i right in thinking you can use the original seat belt mount (the on the the RHS if in drivers seat) for the lap belt as the angle looks pretty good.
Also is this too close for the seat to be from the cage??
I may have to do some messing with position and angle etc once the car is on all 4 wheels




A Rough guide of how the shifter platform will look 




I then moved onto the caster bushes
Started by marking them up...




and in place




all together 




One for DH...
Does this look of for the crotch straps to mount to??
I was thinkg of bolting to the floor with reinforcement plates underneath but the floor is uneven and on the drivers side the fuel pipe run underneath just where the bolts want to go.
So with this welded to the seat bars would it be a good option??








Also welded on top, with one side under or both?




Another update tomorrow 

[Diamond Hell]

We used a single eye for the two straps of the crutch strap, with the correct spec plate welded on the underside of the floorpan. 

These straps shouldn't be taking a massive load - that's the two sides and the shoulder straps.  These are to stop the harness being adjusted up too far and to stop you sliding out under the top straps in an impact.

I would definitely go for the plate being welded in under the floor vs what you're proposing there.  Why are you using that box section instead of a proper seat-mounting kit with CDS from a motorsport supplier?  I'm especially not loving the holes drilled through the box section to take the bolts - that's going to weaken the box significantly - as a minimum you should really sleeve the holes and weld the sleeve in... although it's a bit late for that now  .

For the hip straps the outer mounts should be good, then the inners you want the correct plates welded into the tunnel, with the nuts on the outside of the plates.  Lots of uncomfortable welding, but necessary.

[golfyste]

Hmmm 

I was going off of omp supply as a weld in seat mounting kit like this one....



It classes as fia approved and is made of box with the holes drilled in it.


I was wanting to go through the floor with the crutch strap mount but the fuel lines are in the and as sai they aren't load bearing so have used the plate welded to the seat mount which I'm sure should be ok.

I have been trying to follow the blue book but couldn't find anything about the crutch straps or seat mount apart from then ring adequately secure. And having 40 sqcm of mounting area and be made of 3mm steel so figured it would be good 

[golfyste]

A small lunch time update as too whats been done today.

Routed the gear linkage cables ready for the modified shifter tower



Did the Crutch strap mounts




And welded the door bar brackets in place










Any Advice DH? will the mounts be ok or do i need to look at reinforcing them?
cheers dude

I also had some "roll cage tube" arrive....which turned out not to be seamless 
So not going to be able to do the harness bar today as planned as i need to send it back and reorder some CDS.

DH...Do you how much surfaces area the harness bar has to cover when welded to the wheel wells?

Cant find anything about it.

any comments or advice welcome