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Underbody braces, turbos and more!

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PostPosted: Mon Feb 12, 2007 2:41 pm 
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Location: portland oregon
Monday report


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removed the back wheel and suspension.
added ring to hold back end up, and rotate it.


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Look Ma no floor


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floor welded in, from bottom

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floor welded in, from top


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seat and batteries trial fit


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cut the frame, serial # on top


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just the seat


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divider/re-enforcement


Last edited by johnsn on Fri Nov 23, 2012 3:15 pm, edited 4 times in total.

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PostPosted: Tue Feb 13, 2007 12:04 pm 
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Hi guys, had a good night last night. that little bit of stiffening in the backbone made a big difference. I need to remount the dash, make the seat mounting, and get a heater before I can finish the backbone.
Also I will fill the hole in the floor.

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more re-enforcements to keep it from bending in the middle.


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the start of running the backbone up to the front crosmember. took the hump out. now I need to patch the hole.


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frame caped off.


Last edited by johnsn on Fri Nov 23, 2012 3:17 pm, edited 2 times in total.

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PostPosted: Tue Feb 13, 2007 4:30 pm 
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you're working really fast man, hurry up, I wanna see the finished product ^^ ;)

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PostPosted: Wed Feb 14, 2007 11:23 am 
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It's going to start slowing down soon. When I start doing mechanical work.
Thanks for the encouragement.
john :D


Last edited by johnsn on Wed Mar 21, 2007 4:31 pm, edited 1 time in total.

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PostPosted: Tue Feb 20, 2007 1:39 pm 
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Location: portland oregon
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Removed the old paint, cut the welds on the drivers side floor. The floor had a big wow in it. Etch primer makes it look much better. :D

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Look on the right side of the picture (left floor) small wow. It was a big wow. Took several hours to fix.

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Cut out the fire wall through the cross member Also patched the hump hole.

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Made a stiffener.

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welded the stiffener in. Now the backbone is connected to the crosmember.
Also sanded the paint off in preparation of putting toe board to sub-frame stiffener. :cheers: :D :D


Last edited by johnsn on Sat Jul 21, 2012 11:02 am, edited 2 times in total.

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PostPosted: Thu Feb 22, 2007 12:30 pm 
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Took it off the rotisserie last night. Need to finish welding the engine side of the firewall. Dropped the subframe out. Almost hit my foot. :shock:
Tonight I'll see if I can finish welding, and strip the paint off the firewall.
john :D


Last edited by johnsn on Wed Mar 21, 2007 4:33 pm, edited 1 time in total.

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PostPosted: Fri Feb 23, 2007 12:08 pm 
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Finished welding the stiffener. started cleaning off the paint.
That paint stripper is nasty. But effective.


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took it off the rotisserie, and removed the subframe


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unfinished welding


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welding done, paint stripped off


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I can't get back far enough to get all of it in


Last edited by johnsn on Fri Nov 23, 2012 2:41 pm, edited 3 times in total.

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PostPosted: Mon Feb 26, 2007 11:44 am 
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Stripping paint and priming, The worst is over. :D


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used up one wire wheel

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All sanded and ready to prime.

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Pretty

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Etch primer, and hanging from the rafters.

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Turned upside down. Fuzzy view of the toe-board.

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Still need to clean under the cowl.

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Inside firewall upside down.

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This is how it pivots at the back.

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All cleaned up and etch primed. The primer is still wet.

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Doesn't that look better?

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Still need to clean under the dash.

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Toe-board cleaned and primed.

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Flipped it over. Now it's time to strip and prime the rest. :0P

I'm getting tired. I feel like I'll never get done!
john


Last edited by johnsn on Fri Nov 23, 2012 2:46 pm, edited 3 times in total.

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PostPosted: Mon Feb 26, 2007 1:07 pm 
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Location: Bend, Oregon
John,

That's a really cool project. I've thought of doing something similar but easier like using an existing Metro, removing the rear suspension, and installing a motorcycle wheel in the rear. It would end up being an enclosed legal motorcycle in the state of Oregon.

Q (Bend)


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PostPosted: Mon Feb 26, 2007 1:11 pm 
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Q wrote:
John,

That's a really cool project. I've thought of doing something similar but easier like using an existing Metro, removing the rear suspension, and installing a motorcycle wheel in the rear. It would end up being an enclosed legal motorcycle in the state of Oregon.

Q (Bend)


id think that whould be kinda tippy unless you were going oto cut the car inhalf


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PostPosted: Mon Feb 26, 2007 5:25 pm 
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geopat wrote:
Q wrote:
John,

That's a really cool project. I've thought of doing something similar but easier like using an existing Metro, removing the rear suspension, and installing a motorcycle wheel in the rear. It would end up being an enclosed legal motorcycle in the state of Oregon.

Q (Bend)


id think that whould be kinda tippy unless you were going oto cut the car inhalf


What do you mean cut the car in half? Which way?
john :D


Last edited by johnsn on Wed Mar 21, 2007 4:37 pm, edited 1 time in total.

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PostPosted: Mon Feb 26, 2007 7:53 pm 
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Wow. Cool project.

When I looked at the CAD drawings with the batteries, the first thing that came to mind was: will the suspension support them all?

What kind of range & speed are you aiming for in the EV version?

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PostPosted: Mon Feb 26, 2007 8:16 pm 
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geometro wrote:
Wow. Cool project.

When I looked at the CAD drawings with the batteries, the first thing that came to mind was: will the suspension support them all?

What kind of range & speed are you aiming for in the EV version?


Thanks,
The suspension will need to be beefed up a lot.
It's looking like I can't fit as many batteries as I would like to. :censor:
The original design was 60 mph, and 60 miles.
I live 30 miles from work.
Maybe when you get done with your cardboard batteries you can ship them to me. :rollin:
john :D


Last edited by johnsn on Tue Apr 03, 2007 3:14 pm, edited 2 times in total.

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PostPosted: Mon Feb 26, 2007 8:21 pm 
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johnsn wrote:
Maybe when you get done with your cardboard batteries you can ship them to me. :rollin:


Sure thing!

I noticed you even drew the 3 cell caps on top like I did. Nice touch ;)

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PostPosted: Tue Feb 27, 2007 11:14 am 
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geometro wrote:
johnsn wrote:
Maybe when you get done with your cardboard batteries you can ship them to me. :rollin:


Sure thing!

I noticed you even drew the 3 cell caps on top like I did. Nice touch ;)


I copied you. :ez_tongue:
john :D


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 Post subject:
PostPosted: Wed Feb 28, 2007 6:42 pm 
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Q wrote:
John,

That's a really cool project. I've thought of doing something similar but easier like using an existing Metro, removing the rear suspension, and installing a motorcycle wheel in the rear. It would end up being an enclosed legal motorcycle in the state of Oregon.

Q (Bend)


Thanks for the encouragement.
Check out this car.
http://www.3wheelers.com/projgal3.html
john :D


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 Post subject:
PostPosted: Fri Mar 02, 2007 12:34 pm 
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Location: portland oregon
Image]
all cleaned up and etch primed. Subframe supports welded in and drilled.

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Rear floor trimmed to fit.set up with 150 watt lites to heat the metal. The paint stripper won't work at low temps.

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Warm!

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Paint stripping. Stinky!

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Stripped and weld through primer.

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All primed up.
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Rear floor part welded.

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Rear floor part welded from bottom.

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Rear floor part welded from bottom.

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Rear floor part welded from bottom.


Last edited by johnsn on Fri Nov 23, 2012 2:50 pm, edited 2 times in total.

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 Post subject:
PostPosted: Mon Mar 05, 2007 11:03 am 
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More stripping, welding, and priming.

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A length of angle iron to get the floor straight, then weld the sides.

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paint striped off the floor.

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Etch primer

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Inner sill striped easily.

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Welded in inner sill.

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Welded in inner sill.

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:D
Etch primer,Looks nice.


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:D
Etch primer,Looks nice.


Last edited by johnsn on Fri Nov 23, 2012 2:53 pm, edited 3 times in total.

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 Post subject:
PostPosted: Tue Mar 06, 2007 11:32 am 
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How do you spell moc-up?

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There is no clearance under the engine. I'll have to put a hatch in the floor. :-P

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Maybe I should put a Sprint engine there. :D


Last edited by johnsn on Fri Nov 23, 2012 2:55 pm, edited 2 times in total.

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PostPosted: Tue Mar 06, 2007 11:55 am 
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johnsn wrote:
How do you spell moc-up?



to answer your question, its mock-up :ez_tongue:

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1993 Geo Metro Only mods so far are a Honda short shifter, Glowshift tach and a 3a Racing ricer muffler (freebie)
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 Post subject:
PostPosted: Tue Mar 06, 2007 12:07 pm 
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Thanks Matt.
john :D


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PostPosted: Fri Mar 09, 2007 11:02 am 
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Well I cut a hole in my new floor. :shock:
I used 1/2" square tubing around the opening to stiffen the floor.
I also seamed sealed the firewall and sprayed sealer primer on it.
I think it looked better without the seam sealer.
But rust never sleeps. :furious:
That's all for now.
john :D


Last edited by johnsn on Wed Mar 21, 2007 4:41 pm, edited 1 time in total.

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 Post subject:
PostPosted: Tue Mar 13, 2007 4:13 pm 
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Didn't get much done this weekend. Had to work on the house. I'm putting in hardwood floors.

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This picture was hard to take, I had the body tipped up and away from me. So I had to hold the camera up over the edge of the floor and click. Came out OK. This shows the mock-up Honda with more parts on it. It also shows the hole and the 1/2" square tubing.

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Here s the bottom view of the hole , the tubing and the Honda.


Last edited by johnsn on Fri Nov 23, 2012 2:57 pm, edited 2 times in total.

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 Post subject:
PostPosted: Tue Mar 20, 2007 2:08 pm 
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I need to put a Swift engine in the front. to do this I have to modify the subframe to clear the transmission.
I have a sub-frame that is a little bent. So I will see if it will work.

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The rear flanges didn't line up, so I cut them off.
See how short the rear flange is.


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I thought I'd use 1" tubing to mount the subframe to the body.


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This gap is wrong. It's too much at the bottom on this side.

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So I cut it up.

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And welded the seams. Image]

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And trimmed, and welded a heavy walled tube on .......
The wrong way :shock: :furious: :censor: :thwack:
I'll fix it.
john :D :D


Last edited by johnsn on Fri Nov 23, 2012 3:05 pm, edited 5 times in total.

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 Post subject:
PostPosted: Mon Mar 26, 2007 11:13 am 
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Location: portland oregon
Well I cut the top off the tube, and I'm starting to weld the subframe back together.

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I won a spare bevel drive on eBay, and the guy I won it from lives really close to me. So when I went to get the part I also got a rear wheel with a good tire, and a Honda Silver-wing frame with the rear mono shock.
I cut the frame up and transferd the shock mounts to the cx500 frame.

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here is the swing arm and a bucket of parts I cut off the Silverwing frame.

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This is the shock mounts cut off the frame.

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The shock mounts held in the correct relationship with scrap bits.

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The shock mounts welded in. These pictures may look odd because when I took them the car was hanging upside down. So I flipped the pictures.

Now I have to put the swing arm back in and re-enfource the frame.
john :D :D


Last edited by johnsn on Fri Nov 23, 2012 3:11 pm, edited 3 times in total.

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