My 2002's resurrection - 56k go die

[Justin B]

Got the forward inside plates boxed in. Definitely not the prettiest welds I've done, but it's all well penetrated and solid. I hate welding vertically, especially in small spaces. The patch panel went in nicely too, and the drain plug fits well. I'm working on the outside rear plates right now the, passenger side went in quickly so the driver side one should be a piece of cake too. The inside rear ones will definitely need to be boxed as well, so my goal is to get all the plates welded in by quitting time tonight. The actual seat rails will go in tomorrow, then drilled for the sliding brackets and seats test fitted.

Pics later.

[Justin B]

Alright. Done welding for today, and what a relief. I was getting tired, and tired of welding. The beads aren't anything to write home about, but they're good enough. The plates are way overbuilt.

Anyway, pictures! Lots of em!

Holding in the patch panel with some small magnets.

Done, ...

... looks good enough underneath too ...

... and the drain plug fits :roll:


On to the landing plate welding nightmare.

Boxed in the inside forward plates, this is the passenger side one. I did the same for the driver side as well obviously.

Passenger side rear outside plate -

This is how I had to angle the gun so I could partially see wtf I was doing, meanwhile laying on my side across the transmission tunnel in front of where the rear seat would be. This is where I started to get a little irritated. You also may note that there's a fat bump in my floor board there that shouldn't be, limiting how low I can get the MIG gun. I might try to bash it down a little with a mallet but its really not going to be in the way of anything anymore, and I'll never get it perfect so I'll probably just leave it as is.

Like this.

The bottom weld probably came out nicer overall than the one on the left side of this picture anyway.

The basic plates for the pass side inside rear plate before I slaughtered it with welds.

Done.

Same thing, other side.

Done.



This is one of the next projects, body wise,

along with welding shut the original fuse box hole. I also need to get on fabricating my dual brake master cylinder set up on my pedal box. That'll be trick.

[jakeb]

excellent, looking really nice!! Makes me want a project in the worst/best way.

I need to get to that SC for my m42ed 02. Maybe this weekend I will pull the intake manifold from my spare m42 on a stand.... hmmm yeah

[Justin B]

Late-mid day update. I got a really late start today since I slept in a few hours but I've got the passenger side seat rail welded in. It took forever to get the angles right on the rails that go side to side to get it to sit in the right spot, but it came out nicely. I measured the stock 2002 rail "bump" on the transmission tunnel, and it seems to be angled back 5 degrees in relation to the rest of the floor, so I put these in at a slight angle as well, but at 3 degrees instead. I welded all the way around the angle iron to the plates as well, not just the top and insides.

And the obligatory couple of pictures before I go out and try to get the driver side one done before quitting time -

[Justin B]

Got the driver side one in, it went in faster but didn't fit quite as good. Ended up saying fuck it and welding it in once I got it at the right angle and flat side to side the first time. It's about 1/4" or a smidge more aft than the passenger side. Ends up that works out fine though since between all the measuring, and estimating guesswork, I somehow managed to weld the inside rear driver side plate a little back too. If I had managed to get both EXACTLY straight across from each other, then the angle iron would have hit the plate right on the edge instead of somewhere closer to the middle...

Whatever, they will work.


Picture looks weird across the back here, like the pieces aren't square, they are.

[Justin B]

K. I figured out the best place for the seats, and they barely fit in the car as it is. I also painted the whole floor area with some more of my ZeroRust paint (similar to POR15), and am currently letting it dry/set up. It really stinks, so if its not dry in a couple of hours, and it probably wont be, I'll leave the rest of the work I had planned for today for tomorrow.

On another front, I also just bought my two brake master cylinders. Tilton 75 series, .75" bore (R) and .625" bore (F). According to the guy who responded to my bore size request, my front brakes are slightly undersized but it isn't a big problem. Usually they shoot for a lock up pressure at ~90 lbs pedal force, but with how I'm putting mine together, it should end up at about 105 according to them.

I'm eyeing my e21 LSD I've pulled apart and have currently sitting neatly together in a plastic bin next to where my driver door should be. Once I'm done posting here I'll be looking for all the bearings, gaskets, seals, friction plates, etc I need to rebuild it. I was going to use a franken-axle set up with a 2002 outer CV and E21 inner CV, but for some reason a long time ago when I did this, the e21's splines were a touch too long and wouldn't allow the half shaft circlip to go back on. I'm going to just forgo that set up and take the easy way out by buying redrilled output flanges and spacers from Dave Varco/Aardvarc Racing at www.2002parts.com .

So, the holes are drilled -


Seat position, it's at a pretty good height -

A little difficult to tell from this picture, but there's about 1/2-3/4 of an inch between the edge of the shoulder bolster to where I figure the door will close to. I ran a string between the A and B pillar on the inside and it cleared by about that much . I'm glad theyre not any wider because theyre in as far as they'll go, and between the shoulder bolsters on the inside, it'll have about 2-3" clearance between the seats. Plenty of room down below though for the ebrake and such. -

Rough driving position, of course these are adjustable by reclining and on sliders -

Painted the floor all over again. Once it's dry enough, I'll touch up the spots I missed with a 1" paint brush I found in the back seat area, and probably roll on a little more behind the passenger seat -

I also had a little bit extra in the pie tin, and saw a little bit of brownish discoloration but not quite surface rust so I rolled some onto the roof as well just to be safe...

[Justin B]

Again had a little bit of a late start today and I had to help get the race car trailer actually into the yard today. Got that done and decided what I'd end up doing today. I wanted to weld up the fuse box hole but decided against doing that right away. Instead I cleaned all the dirt and junk out, and painted inside that with more ZeroRust. I didn't have a whole day to deal with working on the car, so I figured I might as well do paint stuff that I'd need to let sit anyway and leave a good full day for another time. I had a couple ounces of paint, so I did that up with a brush, and went inside the car to touch up the seat rails and random spots where the paint was thin or missing. I also tore out the rear seat sheet metal divider thing so I have free reign of the floor to clean it up, paint, and soon rebuild something in its place, but better. No rear seat will be put back in this car, so the purpose will be different.

Dirty

Clean

Painted

Gone

[Justin B]

Just got back home, and I'm tired but these pictures are self explanatory.

[atan88]

Hi Justin this is Alvin. Im a friend of Cary. Pls pm me your phone number I need to ask you some questions. Im currently restoring 2 2002 turbo cars.

[Justin B]

So, I've been on the phone, or just waiting for a call most of the day looking for a job, and that put a slow down on any real true progress today. However, I did pull the nuts off the struts I have in the 02 right now and stole the spacers and a couple washers to put my "new" struts together.

Tada.



I think I'm gonna be going back out tonight, otherwise I'd put the bearings, rotor, caliper, and all that stuff on but that might be tomorrow.

[clavinZERO]

fucking beautiful.

[Justin B]

Another self explanatory one...

This is the non-tii strut Volvo BBK, '77 320i vented rotors, and Volvo 240 Girling calipers.



Packed the bearings, packed the hub between the outer races, popped in the inner dust seal, and slammed these together pretty quick. I did however discover that the 2002 dust caps are too shallow to cover up the spindle tip, so I think I need to find the deeper e21 ones(? .. or just pound out my stock ones a little). I also need to purchase some thread in wheel studs.

The patch for the fuse box hole is cut, and one side (bottom) was painted with ZeroRust, so that's drying tonight before I can weld it on.

[e30nub]

Solid progress man! Hope to see it rolling soon. I'm in RP by the way.

[Justin B]

That's the plan! Every day there should be at least some little thing done to it enough to post here.

[Justin B]

Washed the E30 today so it doesn't look like a dirt ball when I go down to Novato tomorrow to check out some place I might be getting a job at. Also decided I'd just modify my 2002 dust caps, and paint them for the E21 hubs, so I did that, filled them a little with grease and put them on. The paint was dry on my little patch panel, so I also welded that over the fuse box hole.

Contemplating whether I should put a coat of Evercoat over my patch now, or later. Probably now, and try to make it somewhat flat, so i can sand it later huh.