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Peter Nitschke
Junk Filterer South Australia UZZ30 UZZ31
Posts: 12750 Reg: 11-2004
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Ben Lipman wrote on Saturday, December 13, 2014 - 06:53 am:I just wish I had of given it a more imaginable thread title.
I can edit the title for you Ben, just keep it short. |
Ben Lipman
Goo Roo SA Soarer TT manual, plus TT track car, plus a spare shell
Posts: 3868 Reg: 04-2006
| Drivers interior door update. So the past few days have been busy. I added a frame to the Drivers outer mould and then flipped it over to prep the inner door plug. The flange of the outer mould will make the flange for the inner mould. This should make storing moulds easier as they will ‘clam shell.’
I started by making up a frame to support some white faced MDF panels, and formed a nice curve to meet the window glass from some pine. I then used the white faced MDF to make the door card, with a second layer over the top to create the recess for the door card to sit in. I don’t run a door card, but may choose to so I made provision for a nice flush fitting.
I then started the very long process of filling and smoothing all the various rebates, bumps, and holes in the door. There are a lot. This process took two days of filling and sanding, filling and sanding. It is not ‘perfect’ but I reckon it looks much better than the factory inner door skeleton.
Unfortunately, I ran out of all types of chopped strand matt (CSM) as I was laying up the mould. I think it is way too thin. I tried using some woven cloth, but it conformed poorly to the contours and would not consolidate well. I will order another roll of 300gsm CSM cloth, some more PVA, and more of the tooling Gelcoat. (I am loving the red colour!) Trojan Fibreglass online sales is proving to be a godsend as local pricing here in Canberra is criminal. Too far away from the ocean for there to be any real competition. |
Ben Lipman
Goo Roo SA Soarer TT manual, plus TT track car, plus a spare shell
Posts: 3869 Reg: 04-2006
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Peter Nitschke wrote on Wednesday, December 17, 2014 - 09:29 pm: I can edit the title for you Ben, just keep it short
Hmmmm. Will this fit? "Ben's Time Attack Soarer" Lines it up with the facebook and youtube stuff. No problems if it doesn't. It is such a small item in the scheme of things. I also managed to score a pair of Volk GTN 18x9.5 rims. I wasn't actively looking to buy, just keeping an eye out. These popped up for $200 the pair so I grabbed them. At 9.6kg they are a little on the heavy side. I was in a position to buy a full set of 18x9.5 Work Emotion CR Kai for $800, but am so glad I did not as the restock of fibreglass etc is going to hit the pocket a bit. |
James Johnson
DieHard Auckland 95 UZZ31 with R154
Posts: 632 Reg: 03-2009
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Ben Lipman wrote on Wednesday, December 17, 2014 - 09:46 pm: I was in a position to buy a full set of 18x9.5 Work Emotion CR Kai for $800
At that price it is a steal. I just sold a set of 4 but in 17x8 for 1K NZD, no tyres but in a fresh white powder coat, I should of put the price up but meh, I got the money now for a stand alone ECU.... |
Ben Lipman
Goo Roo SA Soarer TT manual, plus TT track car, plus a spare shell
Posts: 3870 Reg: 04-2006
| They have a fair bit of gutter rash, but yes it is a very good price. If they were a lighter rim, it would be a no brainer, but at 9.5 - 10kg they aren't light/cheap enough for me to commit. He is here local, but at this stage I would rather get these doors underway, and need some cash for a set of rubber next year. There were a set of SE37K I missed out on for $700. They are a bloody light rim, but for some reason not as popular as the TE37. No hurry for 18s, as they are only to fit the control tyre if I ever decide to run WTAC. I shall just keep an eye out. Never know I might find a pair of 10 or 10,5 inch rims to match the Volk GTN. They look very similar to the CE28N, and a number of other 10 spoke rims. |
Ben Lipman
Goo Roo SA Soarer TT manual, plus TT track car, plus a spare shell
Posts: 3871 Reg: 04-2006
| I reckon I saved the mould today. I hitched up my skirt, tucked in my big girls blouse and got out in the shed again. I gave the whole mould a rough sand, steel wire brush, and wipe down with acetone to promote 'keying' of the new resin. I then cut up 40 or so pieces of the heavy woven fabric in various shapes to get around the profile of the door. I also made up the beginnings of a frame to support the mould. I spent a couple of hours slowly adding the woven cloth to the mould and carefully consolidating with rollers and brushes. It looks like the hard work has paid off and the mould looks a lot more substantial and sturdy today. The wooden frame in the pictures is the start of a stand so that the inner mould can be set on a table or the floor. I need to make some legs and extend the frame up to brace the top edge of the door. The hard part now will be resisting the temptation to crack the mould tomorrow. The longer it cures over the plug the better it is. I also placed the order for new CSM and a few other things with Trojan Fibreglass today. It is unlikely that the order will be delivered until some time in the new year, so I guess both me and the shoulder get some enforced rest for a couple of weeks.
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Clayton Carlyle
TryHard NSW v8 soarer twin turbo
Posts: 347 Reg: 04-2009
| Holy Jesus, we should start paying you for these tutorials. This is some serious research, time & effort put into this. Your a freak Ben, I really hope this works out for you, any chance of putting in an order?? I am very close to getting down to Wakefield to put another time on the list. Probably have to learn to drive first. Any idea how much your car weighs now? It's nearly a full out sports sedan by now!! |
Ben Lipman
Goo Roo SA Soarer TT manual, plus TT track car, plus a spare shell
Posts: 3872 Reg: 04-2006
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Clayton Carlyle wrote on Thursday, December 18, 2014 - 11:01 pm:any chance of putting in an order??
I still have the entire passenger side door to prep and mould yet, but I intend to make my set initially and then additional sets for others. It really depends on my actual work load next year, but once the moulds are finished making the actual doors should be less work. Andrew and Aaron are the first priority as we have all been helping each other along the way. (not to mention I am currently using Andrew's fibreglass and resin) Let us know when you plan to head to Wakefield. I might be able to come up and help out. The car currently weighs 1351kg. Still 76kg over the minimum weight for Time Attack. |
Ben Lipman
Goo Roo SA Soarer TT manual, plus TT track car, plus a spare shell
Posts: 3873 Reg: 04-2006
| I trimmed the moulds today (just using a 1mm cutting disc on a grinder), and decided to make a stand for the inside mould. This should help it keep it's shape better and make it easier to work with down the track.
That should have been that, but I couldn't help myself.... I cracked the mould off the outside of the door. This was the one with no PVA, only mould release wax so I was a bit nervous. A couple of satisfying cracks and she popped right off. Not the hardest mould I have ever parted. If I had not of just ordered 4L of PVA, I might consider never using it again. The surface of the mould is an exact copy of the surface of the door. No 'water marks' from the PVA. I think a quick polish with the orbital buffer and then a few coats of wax and she will be ready to go. There are some minor imperfections that need some attention but they are in non critical areas that have no real cosmetic impact. I May sand down some of the sharper ridges for a nicer carbon part too.
I am loving that red colour! |
Andrew McKellar
DieHard NSW V8 Soarer Sports Sedan
Posts: 770 Reg: 06-2008
| Great work mate. Rehab is obviously going well. |
Aaron Casey
Goo Roo NSW '94 2jz JZZ30 gttl, '93 UZZ31 track, VT, 2x Leyland Mini's
Posts: 3737 Reg: 08-2005
| As soon as all the carbon panels are on looks like they will be painted red! Haha Clayton let both of us know. If its a weekend chances are I can help out also. Im only 10 mins away haha |
Peter Nitschke
Junk Filterer South Australia UZZ30 UZZ31
Posts: 12751 Reg: 11-2004
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Ben Lipman wrote on Wednesday, December 17, 2014 - 09:46 pm:Ben's Time Attack Soarer
Done! |
Andrew McKellar
DieHard NSW V8 Soarer Sports Sedan
Posts: 771 Reg: 06-2008
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Peter Nitschke wrote on Friday, December 19, 2014 - 06:49 pm:Ben Lipman wrote on Wednesday, December 17, 2014 - 09:46 pm:Ben's Time Attack Soarer Done!
Can I change mine too? Would like to shorten it to Sports Sedan Soarer. |
Andrew McKellar
DieHard NSW V8 Soarer Sports Sedan
Posts: 772 Reg: 06-2008
| Or maybe Toymax Sports Sedan Soarer. |
Ben Lipman
Goo Roo SA Soarer TT manual, plus TT track car, plus a spare shell
Posts: 3874 Reg: 04-2006
| Thanks Peter! |
Peter Nitschke
Junk Filterer South Australia UZZ30 UZZ31
Posts: 12752 Reg: 11-2004
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Andrew McKellar wrote on Friday, December 19, 2014 - 06:59 pm:Toymax Sports Sedan Soarer
Also done. |
Clayton Carlyle
TryHard NSW v8 soarer twin turbo
Posts: 348 Reg: 04-2009
| Guys thanks for the offers, I will need a lot of advice to get me started. I've just had a set back tho, my rebuilt p/steering pump is leaking badly after I welded a speedflow fitting to it. I'm toying with the idea of putting a Mazda 3 electric pump in as I truly HATE the stupid P/S pump. Also just bought a Xmas present for my supra, a 2jzgte, so now I'm looking at mid Feb. got a helmet the other day & looking for a race seat now. I can't wait to see these doors. I see Seibon does them for over 3k. Ben are you running 265's front & rear? I sure would like to see what your car would look like with some fat 10.5 rims on the back, but I understand it's not practical. |
Aaron Casey
Goo Roo NSW '94 2jz JZZ30 gttl, '93 UZZ31 track, VT, 2x Leyland Mini's
Posts: 3742 Reg: 08-2005
| I think he is running 9.5 front 10.5 rear now? hahaha always the way Clayton! but let us know how you are travelling! at that time Ill probably be still trying to set some decent na 1uz times haha so give you something to smash haha |
Ben Lipman
Goo Roo SA Soarer TT manual, plus TT track car, plus a spare shell
Posts: 3875 Reg: 04-2006
| Hey guys. Yes currently running 10.5(275) rears with a 38 offset. I head back to Australia in a couple if days and work will commence on the other side. I basically have a week to get it done before going back to work. |
Ben Lipman
Goo Roo SA Soarer TT manual, plus TT track car, plus a spare shell
Posts: 3876 Reg: 04-2006
| Passenger side (outer) is all prepped. I laid down the gel coat this morning, and I am waiting for that to go off before commencing the layup. Need to get it done before 1130 as I am taking the boys to watch the summernats cruise route in town at 1200. |
Blake Gloyn
Goo Roo manawatu soarer JZZ30 TT
Posts: 1227 Reg: 02-2006
| i just weighed a passenger door, 43kg! plus hinge is 5.6kg I think Ben said, so 48-49kg! HEAVY! |
Scott Vim
Goo Roo Vic Soarer (1uz) Chaser (1jz)
Posts: 1300 Reg: 12-2010
| What about the v8 leather seats with electric and seat warmer? Especially the drivers side is very heavy. When I went to lift it I got a shock and I was expecting it to be heavy. |
Ben Lipman
Goo Roo SA Soarer TT manual, plus TT track car, plus a spare shell
Posts: 3879 Reg: 04-2006
| All the moulds are done. I am sure there will be some gel coat repairs needed as there always is when making moulds, but all the major works are done. The freshly finished passenger moulds will sit over the door plug for at least a week to ensure they cure in the correct shape. I still need to give the moulds a trim, and sand the sharp bits off the back of them. The moulds need to be waxed thoroughly before the first parts can be made. Before anyone asks, that will be some time down the track as I am back at work this week, and therefore back to a couple of hours after dinner, weekends etc.
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Aaron Casey
Goo Roo NSW '94 2jz JZZ30 gttl, '93 UZZ31 track, VT, 2x Leyland Mini's
Posts: 3750 Reg: 08-2005
| Scott I measured an electric leather passenger seat and weighed in at 28.1kg, my scale max's out at 30kg so couldnt do the drivers one. So alot of saving to be had there! Cant wait to see one of these bad boys all laid up with carbon! |
Clayton Carlyle
TryHard NSW v8 soarer twin turbo
Posts: 352 Reg: 04-2009
| Ditto. |