A purists nightmare - E46 drift build

[Tkuhn]

Update.

Revised the front cage box design, measurements only so not much to show there.

Also revised and finished the rear cage boxes.

Then we cut, bent and did ALOT of trimming to get the rear boxes to fit as snug as possible.

Still might need a little more trimming but pretty happy with it.

The cage will most likely be mig welded just because we dont have the torch time to do tig. I have never learned to tig, and I'm ok at mig.

Moved on to starting to clean up the body work from the dent being pulled.

Layed down some filler.

And then sanded.

ALOT more detailed filler work and sanding is ahead but it's a start!

[Tkuhn]

Not a whole lot of progress this weekend but got something done that I've been meaning to do since I first built the car.

Before I scrapped the stock bumper and bumper supports I cut off the tow hook threads, finally got around to welding them to the bash bars.

Here's the front. I welded the threaded chunk into a piece of tube then to the bar. Worked out really well.

The rear was alot simpler since I had added the jack point last spring. Lined up perfect so all i had to do was burn the piece right to the bar.

little thing that wont be noticed really but it felt good to get it done. Both just need some paint and are complete.

I also made some "CAD" templates for the rear door panels once the cage is in. I wont be able to fit the stock panels with how we are doing the cage so I'll be cutting them out of the same ABS that I made the bulkhead out of and then using nutzerts and some nice hardware to secure them.

[B C]

CAD = Cardboard And Duct tape?

[Tkuhn]

B C said:

CAD = Cardboard And Duct tape?

Cardboard aided design hahah but that's a good one too!

[patsbimmer1]

I like this every time it's updated

[Tkuhn]

patsbimmer1 said:

I like this every time it's updated

I do my best! Honestly alot of the reason I update even on the littlest things is for myself. When I built my civic over the 8 years I had it I barely updated the build thread I did have, which was so much work. And sometimes the little stuff is informational and might help someone else too!

[Tkuhn]

So I've wanted to change my orientation of the handbrake for awhile now. I've seen a few people run the pull back style on the left of the shifter and use/make the window switch slot larger to accommodate for the throw of the handle.

Now that chase bays makes a pull back reverse mount handbrake I thought it was time to make it happen. Still need to order the brake but we have begun planning. 

My biggest issue with what I want to do is most people just let the window switches hang. Which I'm not cool with lmao.

Of course this project began with some Cardboard Aided Design, I didnt take any photos of that.

But then @Sam_Holzmann went full design boi on it for me.

The window switches are both being relocated to where the cup holder/slider thing normally is in the center console. And then a small cubby added. Mostly because it would be dumb to not have anything else there.

Actual computer design.

And the first print. Which took 44 hours.

As of now he is going to make some tweaks for the hopeful final print. I'm super hyped for this one off piece! I cannot thank Sam enough for this one, it will be so much nicer than anything I could have made out of an ABS sheet.

[Jdesign]

Tkuhn said:

So I've wanted to change my orientation of the handbrake for awhile now. I've seen a few people run the pull back style on the left of the shifter and use/make the window switch slot larger to accommodate for the throw of the handle.

Now that chase bays makes a pull back reverse mount handbrake I thought it was time to make it happen. Still need to order the brake but we have begun planning. 

The window switches are both being relocated to where the cup holder/slider thing normally is in the center console. And then a small cubby added. Mostly because it would be dumb to not have anything else there.

Actual computer design.

That looks great!

Any pictures of the handbrake set up that you are referring to? Is it like this?

[Tkuhn]

Jdesign said:

That looks great!

Any pictures of the handbrake set up that you are referring to? Is it like this?

Yes! Except the master is reverse so it faces forward.

[Tkuhn]

UPDATE!

Exciting weekend at the shop.

We started on the cage. So thankful for the help that Sam has given me already. 

Main hoop fits nice and tight thanks to the added ability of Sam with solidworks to be as precise as possible.

And then we were able to get the cross bar with the harness bars situated in the right spots for harness angle.

Then the downbars for the rear. Kinda hard to see with the straps holding the main hoop up.

Super excited to continue the process of getting this thing done!

Oh and on a side note I also bought some new windshield washer sprayers for my tire sprayer set up to keep the tires cool after each run, the spray pattern gets the whole tire now instead of only 2 spots.

Here's a pic of the spray pattern.

[Tkuhn]

Update.

Been busy with some personal stuff but finally got some time to get to the shop.

Pulled out the main hoop and got it completely welded. 

Which was a daunting task for me leading up to it. I can weld and do fab work but when it came to something this permanent I got nervous about my welding skills.

But it went well so confidence re-instilled.

Then I cleaned up all the seam sealer under where the rear box plated for the main hoop will be and re-tacked them in. Forgot to take a pic but it wasnt much of anything exciting.

Before putting the main hoop back in we "clearanced" the rear seat area with the good ole attitude adjuster. Aka hammer. The idea was to make room for the chassis harness to slide back down next to the bottom of the main hoop. Really excited on how that little detail turned out.

Next we threw in the main hoop and tacked it in place again, then I got the rear down bars properly aligned and squared up and did a final weld on them to the main hoop.

Hoping to make more progress next weekend!

[YoungCR]

Fitment looks perfect

[B C]

Very nice fab work

[Tkuhn]

YoungCR said:

Fitment looks perfect

B C said:

Very nice fab work

 Thanks guys! Cant take all the credit for myself but we definitely are striving for getting as tight a fit as we can.

[Jdesign]

Looks damn good. are you just making a 4 point or are you planning on taking it further?

[Tkuhn]

Jdesign said:

Looks damn good. are you just making a 4 point or are you planning on taking it further?

Thanks! And it's going to be a 6 point with door bars. So yes much further haha

[Tkuhn]

UPDATE!

Got some really rewarding progress done this weekend

Had the windshield removed during the week.

Then moved on go making my CAD rocker boxes a reality.

Next was the A pillar bars. Notching them was a real trial and error process but again super grateful to Sam for the help on these as well.

They fit really well and I'm happy with them.

Then I moved on to the door bars on the passenger side. Which turned out exactly how I envisioned them! Theres pleanty of ways to do a door bar but from day one this was what I wanted and I couldnt be happier.

Just need to add the verticals for more support.

And to further my excitement the door closes and fits perfectly with the seat and door panel!

Things are moving along so hopefully the other door bars go smoothly then final welding can commence.

[Tkuhn]

UPDATE

Started the weekend off with running down to a buddies in Waukegan to pick up a set of DonMusk M3 over fenders. Which I have wanted for a long time and timing worked out plus I saved huge not having to ship from Poland.

going to take some work to get them fitted right, more so on the end of opening up my wheel wells. The overs themselves fit great.

Then I moved onto passenger side door bars.

 And after that was getting the gussets in for the door bars on both sides.

With the gussets being completed that was the final touches of the true fab work. 

Then on to final welding!

Only pic I really took of final welds. Turned out ok.

The next step to finish final welding was to remove all 4 rocker boxes and drop the cage down to get to the tops.

That was about it for the weekend. Next weekend I am hoping to get the cage back up and in place, then weld the boxes to the car and the cage to the boxes and finally the daunting task of painting. Lol

[Tkuhn]

UPDATE!

Started the weekend off on Friday night by getting the cage back up on the rocker boxes and welding them in for good then welding the cage in for good as well.

That task took all night and was definitely frustrating. But it's done . Then I hit everything with some sandpaper in preperation for painting.

Saturday morning I got to taping and making off the entire car. Which took alot longer than I planned lol.

Pro tip: tin foil is a lifesaver and cheaper than tape and easier than plastic.

Wiped the cage down with some prep solution and then played down 2 coats of self etching primer.

"Pro tip #2" : I used my shop vac to try and keep over spray to a minimum and it did seem to work decently.

Obviously next came color! I did 2 coats of color and then a third to finish off the last can in the areas that will be "higher traffic" like the door bars and a pillars. I do plan to put down clear vinyl on the door bars to keep them from scratching as well.

I will spare you the repetitive photos and jump right to the ones with clear which I did on sunday afternoon. 

I am super excited at the way this turned out. 

Every aspect was daunting for me just because I wanted to do it as well as possible, since we pride ourselves on good looking and also functional drift cars haha.

I chose to use rattle can for a few reasons. With this tight area and the fact that I wasnt doing the entire interior a actual 2 stage paint with a gun would have made a huge mess with the air pressure and the hose.

Secondly if it does get scratched, which I'm sure it will, touch up will be easier if necessary.

And thirdly I do like to pride myself on tricking people to think that it was done with a gun but it's just spray paint lmao.

Super excited to un-mask everything and get rolling on putting the interior back in along with a few other projects for the season yet!

[KaiserRolls]

Looks good. Could always toss some 3m clear vinyl on the high wear areas.