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clubstylus - View topic - New Stylus RT owner! Let the fun begin!
It is currently Wed Nov 14, 2018 10:29 am




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 New Stylus RT owner! Let the fun begin! 
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Joined: Mon Jun 08, 2009 10:51 pm
Posts: 75
Location: Camberley
Post Re: New Stylus RT owner! Let the fun begin!
File comment: 1. This is the standard diff mount which I thought is quite heavy & makes removing/ installing the diff a pain in the back side!
2010-02-23 23.36.47.jpg
2010-02-23 23.36.47.jpg [ 399.5 KiB | Viewed 2346 times ]


File comment: 2. I cut a couple of lengths of angle to length & tacked them into place, Also Notched the ends of the angle so they fitted
2010-04-11 15.20.22.jpg
2010-04-11 15.20.22.jpg [ 450.96 KiB | Viewed 2344 times ]


File comment: 3. I then marked on the angle where to cut in order to clear the petrol tank
2010-04-11 15.20.47.jpg
2010-04-11 15.20.47.jpg [ 496.64 KiB | Viewed 2344 times ]


File comment: 4. Angles cut down
2010-04-11 15.57.11.jpg
2010-04-11 15.57.11.jpg [ 434.9 KiB | Viewed 2344 times ]


File comment: 5. I then sanded all the paint off to give a nice clean surface to weld to
2010-04-11 16.20.19.jpg
2010-04-11 16.20.19.jpg [ 421.26 KiB | Viewed 2344 times ]


File comment: 6. Here they are ready for welding on
2010-04-11 16.21.16.jpg
2010-04-11 16.21.16.jpg [ 357.6 KiB | Viewed 2344 times ]


File comment: 7. Here they are welded into place.
2010-04-11 18.39.12.jpg
2010-04-11 18.39.12.jpg [ 458.57 KiB | Viewed 2345 times ]


File comment: 8. Diff being test fitted
2010-04-11 18.39.31.jpg
2010-04-11 18.39.31.jpg [ 405.01 KiB | Viewed 2345 times ]


File comment: 9. When I was confidient that this was the way to go I cut the existing mounts off the car either side
2010-04-11 19.35.32.jpg
2010-04-11 19.35.32.jpg [ 438.04 KiB | Viewed 2347 times ]


File comment: 10. Sanded it all smooth so theres no evidience of the old mounting arrangment
2010-04-11 21.15.51.jpg
2010-04-11 21.15.51.jpg [ 440.2 KiB | Viewed 2346 times ]


Fri Jul 23, 2010 2:13 am
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Joined: Mon Jun 08, 2009 10:51 pm
Posts: 75
Location: Camberley
Post Re: New Stylus RT owner! Let the fun begin!
File comment: 1. Nice an smooth... All evidience of old mounts gone!
2010-04-11 21.16.04.jpg
2010-04-11 21.16.04.jpg [ 362.09 KiB | Viewed 2344 times ]


File comment: 2. After deciding on the position of the diff i drilled the first hole then made a template, transfered it to ther other side & drilled the hole in the other side.
2010-04-11 21.30.33.jpg
2010-04-11 21.30.33.jpg [ 430.11 KiB | Viewed 2344 times ]


File comment: 3. Diff in place with bolt through top fixing hole.
2010-04-11 22.25.05.jpg
2010-04-11 22.25.05.jpg [ 407.32 KiB | Viewed 2344 times ]


File comment: 4. To project where the bottom hole needed to be drilled i bolted a plate to the diff, positioned the point in the center of the hole
2010-04-12 18.27.33.jpg
2010-04-12 18.27.33.jpg [ 454.56 KiB | Viewed 2344 times ]


File comment: 5. Then I lowered the diff into place & marked where the point was
2010-04-12 18.28.27.jpg
2010-04-12 18.28.27.jpg [ 464.02 KiB | Viewed 2344 times ]


File comment: 6. Close up of point, This is the center of the hole for the bottom mounting
2010-04-12 18.28.37.jpg
2010-04-12 18.28.37.jpg [ 405.63 KiB | Viewed 2344 times ]


File comment: 7. After i drilled that hole, I then done exactly the same for the other side. Also had to cut a small notch out of the angle to clear one of the ribs of the diff
2010-04-12 22.33.07.jpg
2010-04-12 22.33.07.jpg [ 425.99 KiB | Viewed 2345 times ]


File comment: 8. I then had to weld a small tab for where the copper brake pipes join the flexy pipe
2010-04-15 23.26.29.jpg
2010-04-15 23.26.29.jpg [ 397.87 KiB | Viewed 2346 times ]


File comment: 9. New diff mount finished :D ... I also fitted the 2 new copper fuel pipes, Both 10mm pipes.... more better than the previous fuel pipe which was less than 4mm inside diameter :)
2010-04-18 20.28.50.jpg
2010-04-18 20.28.50.jpg [ 390.29 KiB | Viewed 2349 times ]


File comment: 10. The drive shafts were looking very tatty and 3 of the 4 cv's were split
2010-03-23 22.08.50.jpg
2010-03-23 22.08.50.jpg [ 442.17 KiB | Viewed 2344 times ]


Fri Jul 23, 2010 2:31 am
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Joined: Mon Jun 08, 2009 10:51 pm
Posts: 75
Location: Camberley
Post Re: New Stylus RT owner! Let the fun begin!
File comment: 1. Rubber boots cut off
2010-07-14 12.14.48.jpg
2010-07-14 12.14.48.jpg [ 1.03 MiB | Viewed 2345 times ]


File comment: 2. CV joints removed
2010-07-14 12.15.47.jpg
2010-07-14 12.15.47.jpg [ 935.35 KiB | Viewed 2344 times ]


File comment: 3. CV joint dismantled, Not looking very pretty!
2010-07-14 12.27.16.jpg
2010-07-14 12.27.16.jpg [ 959.98 KiB | Viewed 2344 times ]


File comment: 4. Yuck!
2010-07-14 12.36.51.jpg
2010-07-14 12.36.51.jpg [ 1.01 MiB | Viewed 2344 times ]


File comment: 5. Much better
2010-07-14 12.36.47.jpg
2010-07-14 12.36.47.jpg [ 776.86 KiB | Viewed 2345 times ]


File comment: 6.
2010-07-14 12.36.58.jpg
2010-07-14 12.36.58.jpg [ 1.01 MiB | Viewed 2344 times ]


File comment: 7. All the bit ready for assembly
2010-07-14 12.58.18.jpg
2010-07-14 12.58.18.jpg [ 1.06 MiB | Viewed 2344 times ]


File comment: 8.
2010-07-14 13.04.48.jpg
2010-07-14 13.04.48.jpg [ 985.61 KiB | Viewed 2344 times ]


File comment: 9. After a few thin coats of anti-corrosion paint & 4 new rubber boots
2010-07-14 15.35.08.jpg
2010-07-14 15.35.08.jpg [ 891.42 KiB | Viewed 2344 times ]


File comment: 10. Packed full of grease
2010-07-14 15.35.16.jpg
2010-07-14 15.35.16.jpg [ 846.22 KiB | Viewed 2344 times ]


Fri Jul 23, 2010 2:45 am
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Joined: Mon Jun 08, 2009 10:51 pm
Posts: 75
Location: Camberley
Post Re: New Stylus RT owner! Let the fun begin!
File comment: 1. New fuel tank being made
2010-06-02 18.13.17.jpg
2010-06-02 18.13.17.jpg [ 1.04 MiB | Viewed 2345 times ]


File comment: 2. This is the swirl pot
2010-06-02 18.14.06.jpg
2010-06-02 18.14.06.jpg [ 1.05 MiB | Viewed 2344 times ]


File comment: 3.
2010-06-10 17.24.50.jpg
2010-06-10 17.24.50.jpg [ 909.12 KiB | Viewed 2348 times ]


File comment: 4. Finished tank!
2010-07-13 18.45.43.jpg
2010-07-13 18.45.43.jpg [ 927.73 KiB | Viewed 2344 times ]


File comment: 5. Complete with pirtec fuel fittings
2010-07-13 18.46.13.jpg
2010-07-13 18.46.13.jpg [ 1.05 MiB | Viewed 2347 times ]


File comment: 6. Packed full of foam blocks which stop the petrol sloshing around
2010-07-13 17.44.07.jpg
2010-07-13 17.44.07.jpg [ 1.01 MiB | Viewed 2344 times ]


File comment: 7. Modified watts link arms to clear the tank
2010-07-03 19.47.22.jpg
2010-07-03 19.47.22.jpg [ 760.43 KiB | Viewed 2346 times ]


File comment: 8. Rear suspension- stripped all the paint off this too...
2010-07-03 19.49.42.jpg
2010-07-03 19.49.42.jpg [ 682.77 KiB | Viewed 2347 times ]


File comment: 9.
2010-07-03 19.49.48.jpg
2010-07-03 19.49.48.jpg [ 648.12 KiB | Viewed 2345 times ]


File comment: 10. Rear beam also stripped down to bare metal.
2010-07-03 19.49.53.jpg
2010-07-03 19.49.53.jpg [ 881.87 KiB | Viewed 2346 times ]


Fri Jul 23, 2010 3:08 am
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Joined: Mon Jun 08, 2009 10:51 pm
Posts: 75
Location: Camberley
Post Re: New Stylus RT owner! Let the fun begin!
File comment: 1. Painted rear suspension parts
2010-07-03 21.15.28.jpg
2010-07-03 21.15.28.jpg [ 1.04 MiB | Viewed 2345 times ]


File comment: 2.
2010-07-03 20.42.23.jpg
2010-07-03 20.42.23.jpg [ 891.04 KiB | Viewed 2344 times ]


File comment: 3. Much better!!
2010-07-03 21.15.35.jpg
2010-07-03 21.15.35.jpg [ 812.56 KiB | Viewed 2344 times ]


File comment: 4. Re-installing rear suspension!
2010-07-14 18.04.34.jpg
2010-07-14 18.04.34.jpg [ 917.07 KiB | Viewed 2348 times ]


File comment: 5. Rear suspension & fuel tank fitted
2010-07-15 17.01.23.jpg
2010-07-15 17.01.23.jpg [ 921.46 KiB | Viewed 2350 times ]


File comment: 6. Diff cleaned nicely after a quick go with the sand blaster :)
2010-07-15 17.01.33.jpg
2010-07-15 17.01.33.jpg [ 990.92 KiB | Viewed 2347 times ]


File comment: 7. New gearbox mount
2010-04-18 20.21.38.jpg
2010-04-18 20.21.38.jpg [ 401.79 KiB | Viewed 2344 times ]


File comment: 8. Flipping Car back over! Scary stuff...
2010-07-15 17.49.15.jpg
2010-07-15 17.49.15.jpg [ 903.85 KiB | Viewed 2346 times ]


File comment: 9.
2010-07-15 18.25.13.jpg
2010-07-15 18.25.13.jpg [ 941.88 KiB | Viewed 2347 times ]


File comment: 10.
2010-07-16 21.53.27.jpg
2010-07-16 21.53.27.jpg [ 966.62 KiB | Viewed 2347 times ]


Fri Jul 23, 2010 3:29 am
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Stylus owner

Joined: Fri Mar 10, 2006 8:49 pm
Posts: 3750
Location: ASTON CLINTON BUCKS
Post Re: New Stylus RT owner! Let the fun begin!
Very well done Ross :!: very thorough . Can't see sorting the front end , we talked about , giving you any problems. I'll measure up my suspension and total body width today ok :wink:

_________________
I just love the Stylus but she keeps swallowing £££ !
[b]Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.


Fri Jul 23, 2010 8:55 am
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Joined: Wed Jan 30, 2008 2:09 pm
Posts: 232
Location: Suffolk
Post Re: New Stylus RT owner! Let the fun begin!
Just had a re-read through this thread - thanks for the detail Ross, you are doing a very thorough job.
Giving me some good inspirational ideas for my Stylus project which is arriving this week... think I've got alot of work ahead of me!

DH2


Tue Oct 19, 2010 11:28 am
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Joined: Mon Jun 08, 2009 10:51 pm
Posts: 75
Location: Camberley
Post The Stylus' New heart!
Time for an update!

Cylinder head pics:
File comment: Cylinder head back from machinests
2010-04-07 10.00.21.jpg
2010-04-07 10.00.21.jpg [ 581.2 KiB | Viewed 2344 times ]

2010-04-07 10.00.51.jpg
2010-04-07 10.00.51.jpg [ 533.42 KiB | Viewed 2344 times ]

File comment: Further work to the cylinder head
2010-06-14 17.27.05.jpg
2010-06-14 17.27.05.jpg [ 936.15 KiB | Viewed 2346 times ]

File comment: Port
2009-12-06 20.01.19.jpg
2009-12-06 20.01.19.jpg [ 445.48 KiB | Viewed 2346 times ]

File comment: Valves in place
2010-06-22 18.12.39.jpg
2010-06-22 18.12.39.jpg [ 875.43 KiB | Viewed 2346 times ]

File comment: 16x Rebuilt lifters
2010-06-22 21.15.20.jpg
2010-06-22 21.15.20.jpg [ 1018.82 KiB | Viewed 2345 times ]

File comment: Lifters in place
2010-06-22 22.40.38.jpg
2010-06-22 22.40.38.jpg [ 976.27 KiB | Viewed 2344 times ]

File comment: Cams in!
2010-06-22 23.58.05.jpg
2010-06-22 23.58.05.jpg [ 795.43 KiB | Viewed 2344 times ]


Attachments:
File comment: Valve springs installed
2010-06-22 22.25.39.jpg
2010-06-22 22.25.39.jpg [ 778.09 KiB | Viewed 2344 times ]
Tue Nov 30, 2010 10:45 am
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Joined: Mon Jun 08, 2009 10:51 pm
Posts: 75
Location: Camberley
Post Re: New Stylus RT owner! Let the fun begin!
File comment: Engine block cleaned ready for painting
IMG_20100818_230024.jpg
IMG_20100818_230024.jpg [ 952.2 KiB | Viewed 2345 times ]

File comment: Painted block
IMG_20100821_142355.jpg
IMG_20100821_142355.jpg [ 167.6 KiB | Viewed 2345 times ]

File comment: Pistons & rods
IMG_20100821_173431.jpg
IMG_20100821_173431.jpg [ 934.04 KiB | Viewed 2345 times ]

File comment: Pistons in!
IMG_20100821_201521.jpg
IMG_20100821_201521.jpg [ 890.56 KiB | Viewed 2344 times ]

File comment: Bearings
IMG_20100821_212758.jpg
IMG_20100821_212758.jpg [ 903.78 KiB | Viewed 2344 times ]

File comment: fitted & as usual smothered in assembly lube
IMG_20100821_225836.jpg
IMG_20100821_225836.jpg [ 984.76 KiB | Viewed 2344 times ]

File comment: Crank in place
IMG_20100821_225941.jpg
IMG_20100821_225941.jpg [ 980.6 KiB | Viewed 2344 times ]

File comment: End caps and crank gurdle fitted
IMG_20100822_153245.jpg
IMG_20100822_153245.jpg [ 942.4 KiB | Viewed 2344 times ]

File comment: Water pump fitted
IMG_20100822_153316.jpg
IMG_20100822_153316.jpg [ 1022.77 KiB | Viewed 2344 times ]

File comment: Up the other way, fitted ARP head studs
IMG_20100822_155840.jpg
IMG_20100822_155840.jpg [ 1.08 MiB | Viewed 2344 times ]


Tue Nov 30, 2010 10:59 am
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Joined: Mon Jun 08, 2009 10:51 pm
Posts: 75
Location: Camberley
Post Re: New Stylus RT owner! Let the fun begin!
File comment: almost there!
IMG_20100822_161815.jpg
IMG_20100822_161815.jpg [ 988.01 KiB | Viewed 2345 times ]
File comment: Cylinder head & timing belt fitted!
IMG_20100822_183644.jpg
IMG_20100822_183644.jpg [ 1.15 MiB | Viewed 2345 times ]
File comment: Ready for the cam covers
IMG_20100827_001044.jpg
IMG_20100827_001044.jpg [ 1.13 MiB | Viewed 2344 times ]
File comment: Cam covers fitted!
IMG_20100827_002722.jpg
IMG_20100827_002722.jpg [ 987.52 KiB | Viewed 2345 times ]
File comment: Getting ready to be fitted
IMG_20100828_211413.jpg
IMG_20100828_211413.jpg [ 995.99 KiB | Viewed 2348 times ]
File comment: One off Intake manifold
photo.jpg
photo.jpg [ 117.26 KiB | Viewed 2344 times ]
File comment: Finished!
DSC00047.jpg
DSC00047.jpg [ 98.59 KiB | Viewed 2344 times ]
File comment: Trumpets inside the plenum
DSC00045.jpg
DSC00045.jpg [ 75.97 KiB | Viewed 2345 times ]
File comment: Engine fitted!
IMG_20100903_225428.jpg
IMG_20100903_225428.jpg [ 1.12 MiB | Viewed 2344 times ]
File comment: Oops! new intake in path of steering colum!
IMG_20100903_191952.jpg
IMG_20100903_191952.jpg [ 970.64 KiB | Viewed 2344 times ]


Tue Nov 30, 2010 11:09 am
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Joined: Mon Jun 08, 2009 10:51 pm
Posts: 75
Location: Camberley
Post Re: New Stylus RT owner! Let the fun begin!
File comment: Modification to intake manifold
IMG_20100913_124215.jpg
IMG_20100913_124215.jpg [ 913.4 KiB | Viewed 2344 times ]

File comment: Front suspension parts
IMG_20100908_195908.jpg
IMG_20100908_195908.jpg [ 1.12 MiB | Viewed 2346 times ]

File comment: Assembly
1.jpg
1.jpg [ 131.46 KiB | Viewed 2346 times ]

File comment: And again
2.jpg
2.jpg [ 103.15 KiB | Viewed 2345 times ]

File comment: Wilwood's
IMG_20100909_212801.jpg
IMG_20100909_212801.jpg [ 928.41 KiB | Viewed 2345 times ]

File comment: Engine & gearbox had to come out as id forgot to fit the little spring to the release bearing
2.jpg
2.jpg [ 86.18 KiB | Viewed 2345 times ]

File comment: The evil spring!
IMAG0281.jpg
IMAG0281.jpg [ 1.72 MiB | Viewed 2344 times ]

File comment: Engine back in!
3.jpg
3.jpg [ 105.19 KiB | Viewed 2345 times ]

File comment: New wishbones & other bits being painted
1.jpg
1.jpg [ 82.21 KiB | Viewed 2347 times ]

File comment: New front suspension fitted!
4.jpg
4.jpg [ 112.85 KiB | Viewed 2347 times ]


Tue Nov 30, 2010 11:40 am
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Joined: Mon Jun 08, 2009 10:51 pm
Posts: 75
Location: Camberley
Post Re: New Stylus RT owner! Let the fun begin!
File comment: Front suspension again
2.jpg
2.jpg [ 109.57 KiB | Viewed 2347 times ]

File comment: And again
5.jpg
5.jpg [ 99.07 KiB | Viewed 2346 times ]

File comment: Modified manifold & front suspension again
6.jpg
6.jpg [ 93.37 KiB | Viewed 2346 times ]

File comment: Intake manifold again & steering colum fitted
7.jpg
7.jpg [ 113.72 KiB | Viewed 2344 times ]

File comment: Extended bonnet shut
IMG_20100906_225005.jpg
IMG_20100906_225005.jpg [ 907.67 KiB | Viewed 2346 times ]

File comment: Extended ledge forward so bonnet doesnt catch go behind (as it used to)
IMG_20100906_225705.jpg
IMG_20100906_225705.jpg [ 1.11 MiB | Viewed 2345 times ]

File comment: (inside boot) re reinforcing joint between fibreglass body and the aluminium panel and sides
IMG_20100724_103139.jpg
IMG_20100724_103139.jpg [ 918.04 KiB | Viewed 2345 times ]

File comment: Boot flowcoated
IMG_20100810_215715.jpg
IMG_20100810_215715.jpg [ 1.06 MiB | Viewed 2346 times ]

File comment: And again (couldnt decide where to fit fuel pump)
IMG_20100810_214736.jpg
IMG_20100810_214736.jpg [ 974.83 KiB | Viewed 2347 times ]


Tue Nov 30, 2010 12:07 pm
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Joined: Mon Jun 08, 2009 10:51 pm
Posts: 75
Location: Camberley
Post Re: New Stylus RT owner! Let the fun begin!
Making manifold
File comment: 10mm laser cut flanges
IMG_20100919_105442.jpg
IMG_20100919_105442.jpg [ 856.88 KiB | Viewed 2344 times ]

File comment: Fitted to the block
IMG_20100919_110408.jpg
IMG_20100919_110408.jpg [ 946.69 KiB | Viewed 2344 times ]

File comment: Joining ports 1 & 4
IMG_20100919_141606.jpg
IMG_20100919_141606.jpg [ 1.02 MiB | Viewed 2347 times ]

File comment: Joining ports 1 & 4
IMG_20100919_141606.jpg
IMG_20100919_141606.jpg [ 1.02 MiB | Viewed 2347 times ]

File comment: port matched
IMG_20100919_222032.jpg
IMG_20100919_222032.jpg [ 202.75 KiB | Viewed 2344 times ]

File comment: Branch to join 2 & 3 complete
IMG_20100922_221141.jpg
IMG_20100922_221141.jpg [ 1011.83 KiB | Viewed 2343 times ]

File comment: Another pic
IMG_20100922_221158.jpg
IMG_20100922_221158.jpg [ 1.02 MiB | Viewed 2344 times ]

File comment: Modifying engine mount to clear turbo
8.jpg
8.jpg [ 107.99 KiB | Viewed 2344 times ]

9.jpg
9.jpg [ 129.74 KiB | Viewed 2348 times ]


Tue Nov 30, 2010 12:27 pm
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Joined: Mon Jun 08, 2009 10:51 pm
Posts: 75
Location: Camberley
Post Tidying up the interior
File comment: tidied up & reinforced (This is the area where the door hinges bolt to the chassis)
IMG_20100724_103118.jpg
IMG_20100724_103118.jpg [ 950.54 KiB | Viewed 2344 times ]
File comment: Glue residue from the carpet, paint & surface rust all cleaned up
IMG_20100723_165726.jpg
IMG_20100723_165726.jpg [ 876.46 KiB | Viewed 2344 times ]
File comment: Front cleaned up too
IMG_20100723_165822.jpg
IMG_20100723_165822.jpg [ 779.57 KiB | Viewed 2344 times ]
File comment: Metal painted & fibreglass flowcoated
IMG_20100906_225649.jpg
IMG_20100906_225649.jpg [ 1.02 MiB | Viewed 2344 times ]

IMG_20100814_091315.jpg
IMG_20100814_091315.jpg [ 826.57 KiB | Viewed 2344 times ]
File comment: Seats in
IMG_20100814_091205.jpg
IMG_20100814_091205.jpg [ 1.13 MiB | Viewed 2343 times ]
File comment: Dashboard rested in place
IMG_20100814_091159.jpg
IMG_20100814_091159.jpg [ 1.19 MiB | Viewed 2345 times ]


Tue Nov 30, 2010 12:39 pm
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Joined: Mon Jun 08, 2009 10:51 pm
Posts: 75
Location: Camberley
Post Re: New Stylus RT owner! Let the fun begin!
File comment: This is the original frame which the radiator sat- pretty ugly contraption
IMG_20100912_165915.jpg
IMG_20100912_165915.jpg [ 1.26 MiB | Viewed 2346 times ]
File comment: And this is the replacement
2.jpg
2.jpg [ 114.04 KiB | Viewed 2344 times ]
3.jpg
3.jpg [ 85.11 KiB | Viewed 2345 times ]


Tue Nov 30, 2010 1:15 pm
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