clubstylus

Posted: **Fri Jul 23, 2010 2:13 am**

: 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

: 3. I then marked on the angle where to cut in order to clear the petrol tank

: 4. Angles cut down

: 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

: 7. Here they are welded into place.

: 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

: 10. Sanded it all smooth so theres no evidience of the old mounting arrangment

Posted: **Fri Jul 23, 2010 2:31 am**

: 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.

: 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

: 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

: 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

: 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

Posted: **Fri Jul 23, 2010 2:45 am**

: 1. Rubber boots cut off

: 2. CV joints removed

: 3. CV joint dismantled, Not looking very pretty!

: 4. Yuck!

: 5. Much better

: 6.

: 7. All the bit ready for assembly

: 8.

: 9. After a few thin coats of anti-corrosion paint & 4 new rubber boots

: 10. Packed full of grease

Posted: **Fri Jul 23, 2010 3:08 am**

: 1. New fuel tank being made

: 2. This is the swirl pot

: 3.

: 4. Finished tank!

: 5. Complete with pirtec fuel fittings

: 6. Packed full of foam blocks which stop the petrol sloshing around

: 7. Modified watts link arms to clear the tank

: 8. Rear suspension- stripped all the paint off this too...

: 9.

: 10. Rear beam also stripped down to bare metal.

Posted: **Fri Jul 23, 2010 3:29 am**

: 1. Painted rear suspension parts

: 2.

: 3. Much better!!

: 4. Re-installing rear suspension!

: 5. Rear suspension & fuel tank fitted

: 6. Diff cleaned nicely after a quick go with the sand blaster :)

: 7. New gearbox mount

: 8. Flipping Car back over! Scary stuff...

: 9.

: 10.

Posted: **Fri Jul 23, 2010 8:55 am**

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

Posted: **Tue Oct 19, 2010 11:28 am**

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