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Re: New Stylus RT owner! Let the fun begin!

Posted: Fri Jul 23, 2010 2:13 am
by PuppiesBalls
1. This is the standard diff mount which I thought is quite heavy & makes removing/ installing the diff a pain in the back side!
1. This is the standard diff mount which I thought is quite heavy & makes removing/ installing the diff a pain in the back side!
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
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
3. I then marked on the angle where to cut in order to clear the petrol tank
3. I then marked on the angle where to cut in order to clear the petrol tank
4. Angles cut down
4. Angles cut down
5. I then sanded all the paint off to give a nice clean surface to weld to
5. I then sanded all the paint off to give a nice clean surface to weld to
6. Here they are ready for welding on
6. Here they are ready for welding on
7. Here they are welded into place.
7. Here they are welded into place.
8. Diff being test fitted
8. Diff being test fitted
9. When I was confidient that this was the way to go I cut the existing mounts off the car either side
9. When I was confidient that this was the way to go I cut the existing mounts off the car either side
10. Sanded it all smooth so theres no evidience of the old mounting arrangment
10. Sanded it all smooth so theres no evidience of the old mounting arrangment

Re: New Stylus RT owner! Let the fun begin!

Posted: Fri Jul 23, 2010 2:31 am
by PuppiesBalls
1. Nice an smooth... All evidience of old mounts gone!
1. Nice an smooth... All evidience of old mounts gone!
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.
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.
3. Diff in place with bolt through top fixing hole.
3. Diff in place with bolt through top fixing hole.
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
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
5. Then I lowered the diff into place & marked where the point was
5. Then I lowered the diff into place & marked where the point was
6. Close up of point, This is the center of the hole for the bottom mounting
6. Close up of point, This is the center of the hole for the bottom mounting
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
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
8. I then had to weld a small tab for where the copper brake pipes join the flexy pipe
8. I then had to weld a small tab for where the copper brake pipes join the flexy pipe
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 :)
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 :)
10. The drive shafts were looking very tatty and 3 of the 4 cv's were split
10. The drive shafts were looking very tatty and 3 of the 4 cv's were split

Re: New Stylus RT owner! Let the fun begin!

Posted: Fri Jul 23, 2010 2:45 am
by PuppiesBalls
1. Rubber boots cut off
1. Rubber boots cut off
2. CV joints removed
2. CV joints removed
3. CV joint dismantled, Not looking very pretty!
3. CV joint dismantled, Not looking very pretty!
4. Yuck!
4. Yuck!
5. Much better
5. Much better
6.
6.
7. All the bit ready for assembly
7. All the bit ready for assembly
8.
8.
9. After a few thin coats of anti-corrosion paint & 4 new rubber boots
9. After a few thin coats of anti-corrosion paint & 4 new rubber boots
10. Packed full of grease
10. Packed full of grease

Re: New Stylus RT owner! Let the fun begin!

Posted: Fri Jul 23, 2010 3:08 am
by PuppiesBalls
1. New fuel tank being made
1. New fuel tank being made
2. This is the swirl pot
2. This is the swirl pot
3.
3.
4. Finished tank!
4. Finished tank!
5. Complete with pirtec fuel fittings
5. Complete with pirtec fuel fittings
6. Packed full of foam blocks which stop the petrol sloshing around
6. Packed full of foam blocks which stop the petrol sloshing around
7. Modified watts link arms to clear the tank
7. Modified watts link arms to clear the tank
8. Rear suspension- stripped all the paint off this too...
8. Rear suspension- stripped all the paint off this too...
9.
9.
10. Rear beam also stripped down to bare metal.
10. Rear beam also stripped down to bare metal.

Re: New Stylus RT owner! Let the fun begin!

Posted: Fri Jul 23, 2010 3:29 am
by PuppiesBalls
1. Painted rear suspension parts
1. Painted rear suspension parts
2.
2.
3. Much better!!
3. Much better!!
4. Re-installing rear suspension!
4. Re-installing rear suspension!
5. Rear suspension & fuel tank fitted
5. Rear suspension & fuel tank fitted
6. Diff cleaned nicely after a quick go with the sand blaster :)
6. Diff cleaned nicely after a quick go with the sand blaster :)
7. New gearbox mount
7. New gearbox mount
8. Flipping Car back over! Scary stuff...
8. Flipping Car back over! Scary stuff...
9.
9.
10.
10.

Re: New Stylus RT owner! Let the fun begin!

Posted: Fri Jul 23, 2010 8:55 am
by stylussprinter
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:

Re: New Stylus RT owner! Let the fun begin!

Posted: Tue Oct 19, 2010 11:28 am
by DH2
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

The Stylus' New heart!

Posted: Tue Nov 30, 2010 10:45 am
by PuppiesBalls
Time for an update!

Cylinder head pics:
Cylinder head back from machinests
Cylinder head back from machinests
2010-04-07 10.00.51.jpg
Further work to the cylinder head
Further work to the cylinder head
Port
Port
Valves in place
Valves in place
16x Rebuilt lifters
16x Rebuilt lifters
Lifters in place
Lifters in place
Cams in!
Cams in!

Re: New Stylus RT owner! Let the fun begin!

Posted: Tue Nov 30, 2010 10:59 am
by PuppiesBalls
Engine block cleaned ready for painting
Engine block cleaned ready for painting
Painted block
Painted block
Pistons & rods
Pistons & rods
Pistons in!
Pistons in!
Bearings
Bearings
fitted & as usual smothered in assembly lube
fitted & as usual smothered in assembly lube
Crank in place
Crank in place
End caps and crank gurdle fitted
End caps and crank gurdle fitted
Water pump fitted
Water pump fitted
Up the other way, fitted ARP head studs
Up the other way, fitted ARP head studs

Re: New Stylus RT owner! Let the fun begin!

Posted: Tue Nov 30, 2010 11:09 am
by PuppiesBalls
almost there!
almost there!
Cylinder head & timing belt fitted!
Cylinder head & timing belt fitted!
Ready for the cam covers
Ready for the cam covers
Cam covers fitted!
Cam covers fitted!
Getting ready to be fitted
Getting ready to be fitted
One off Intake manifold
One off Intake manifold
Finished!
Finished!
Trumpets inside the plenum
Trumpets inside the plenum
Engine fitted!
Engine fitted!
Oops! new intake in path of steering colum!
Oops! new intake in path of steering colum!

Re: New Stylus RT owner! Let the fun begin!

Posted: Tue Nov 30, 2010 11:40 am
by PuppiesBalls
Modification to intake manifold
Modification to intake manifold
Front suspension parts
Front suspension parts
Assembly
Assembly
And again
And again
Wilwood's
Wilwood's
Engine & gearbox had to come out as id forgot to fit the little spring to the release bearing
Engine & gearbox had to come out as id forgot to fit the little spring to the release bearing
The evil spring!
The evil spring!
Engine back in!
Engine back in!
New wishbones & other bits being painted
New wishbones & other bits being painted
New front suspension fitted!
New front suspension fitted!

Re: New Stylus RT owner! Let the fun begin!

Posted: Tue Nov 30, 2010 12:07 pm
by PuppiesBalls
Front suspension again
Front suspension again
And again
And again
Modified manifold & front suspension again
Modified manifold & front suspension again
Intake manifold again & steering colum fitted
Intake manifold again & steering colum fitted
Extended bonnet shut
Extended bonnet shut
Extended ledge forward so bonnet doesnt catch go behind (as it used to)
Extended ledge forward so bonnet doesnt catch go behind (as it used to)
(inside boot) re reinforcing joint between fibreglass body and the aluminium panel and sides
(inside boot) re reinforcing joint between fibreglass body and the aluminium panel and sides
Boot flowcoated
Boot flowcoated
And again (couldnt decide where to fit fuel pump)
And again (couldnt decide where to fit fuel pump)

Re: New Stylus RT owner! Let the fun begin!

Posted: Tue Nov 30, 2010 12:27 pm
by PuppiesBalls
Making manifold
10mm laser cut flanges
10mm laser cut flanges
Fitted to the block
Fitted to the block
Joining ports 1 & 4
Joining ports 1 & 4
Joining ports 1 & 4
Joining ports 1 & 4
port matched
port matched
Branch to join 2 & 3 complete
Branch to join 2 & 3 complete
Another pic
Another pic
Modifying engine mount to clear turbo
Modifying engine mount to clear turbo
9.jpg

Tidying up the interior

Posted: Tue Nov 30, 2010 12:39 pm
by PuppiesBalls
tidied up & reinforced (This is the area where the door hinges bolt to the chassis)
tidied up & reinforced (This is the area where the door hinges bolt to the chassis)
Glue residue from the carpet, paint & surface rust all cleaned up
Glue residue from the carpet, paint & surface rust all cleaned up
Front cleaned up too
Front cleaned up too
Metal painted & fibreglass flowcoated
Metal painted & fibreglass flowcoated
IMG_20100814_091315.jpg
Seats in
Seats in
Dashboard rested in place
Dashboard rested in place

Re: New Stylus RT owner! Let the fun begin!

Posted: Tue Nov 30, 2010 1:15 pm
by PuppiesBalls
This is the original frame which the radiator sat- pretty ugly contraption
This is the original frame which the radiator sat- pretty ugly contraption
And this is the replacement
And this is the replacement
3.jpg