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Old 14-03-2011, 11:04 PM   #501
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Well around one area it was really thin, as soon as i touched it with the pool it blew, so I just left it.

Pug only had a handful of spot welds on the outer skin so its much stronger than it was. Once the sd cage is lined up the seam sealer will be out and the black paint.

Few smaller areas to weld up in the boot but confidence is growing
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Old 27-03-2011, 05:50 PM   #502
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Purchased an Sd roll cage in a forum group buy through Chris Birkbeck rally school. Item has been in the garage awaiting fitting...

Friday night: I spent around 2 hours just unwrapping the bloody thing, seriously!

Saturday: Motorbike test, got in the way of cage progress!

Sunday: hangover til around 4pm, started fitting cage.

Very impressed with the SD cage compared to the OMP item i had before. Item is loosely fitted into the car, areas marked which need prepping for cage plates. With the lighter evenings I hope to get the cage and plates lined up this week and hopefully tig weld the plates in on the weekend.

Photo:
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Old 27-03-2011, 05:59 PM   #503
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Old 28-03-2011, 10:29 AM   #504
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Good work that man
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Old 30-03-2011, 09:54 PM   #505
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Pushed the xsi into the garage tonight for another couple of hours prep on the roll cage.

Cleaned up all areas around the cage plates, removing all seam sealer to allow best fit of plates. Areas prep'd ready for welding.

Removed the fuel lines to clear the middle leg of the roll cage on the passenger side. Fuel lines will require 2 new holes drilling and moved over an inch or 2.

Removed interior loom, cleaned out car. Refitted cage, ready now for plates drilling/welding
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Old 01-04-2011, 08:15 PM   #506
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Old 11-04-2011, 06:42 PM   #507
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Have not been able to find the time to work on the XSi.

So decided to send it to a local race/rally prep garage. Which is also the home of my MGB GT project.

XSi is being collected tomorrow and back soon i hope, featuring a sexy SD roll cage

Last edited by curl666; 11-04-2011 at 06:46 PM.
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Old 27-04-2011, 07:25 PM   #508
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Progress
  • 2 repair patches welded in boot floor
  • Interior rattle canned satin black
  • SD mounts welded (thanks to tram road motors), cage fitted.





seats n harnesses tomorrow!
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Old 27-04-2011, 07:42 PM   #509
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Nice job dude. Looks mean!
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Old 27-04-2011, 09:46 PM   #510
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Mountain fire! O no curl just has the welder out again ;-).
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[COLOR="Red"][SIZE="2"]Engine:[/SIZE][/COLOR][SIZE="1"]C2 VTS JP4 engine, JP4 cam covers, J4 cams, followers, valve springs and caps, Lightened flywheel, Pug racing gear linkages, heat wrapped 4-2-1 raceland manifold, 2" decat pugsport system, Pugsport group N engine mounts, powerflex exhaust mounts, 106 GTI airbox with K&N pannel filter, standard,S2 gearbox, [B]153bhp @ 7,310rpm 112ft/lbs @ 6,739rpm[/B][/SIZE]
[SIZE="2"][COLOR="Red"]Interior:[/COLOR][/SIZE][SIZE="1"]Standard interior apart from Sparco Evo bucket seats, Sabbelt 3" 6 point harnesses[/SIZE]
[SIZE="2"][COLOR="Red"]Body:[/COLOR][/SIZE][SIZE="1"]Brand new S1 vinals all round, red FG bonnet[/SIZE]
[SIZE="2"][COLOR="Red"]Chassis:[/COLOR][/SIZE][SIZE="1"]Poly bushed diesel spec wishbones, lowered on Gaz coilovers on the front adjustable height -40mm-90mm, S1 rear beam poly bushed and lowered 45mm with Rear Gaz rear dampers, S2 steelies,[/SIZE]
[SIZE="2"][COLOR="Red"]Brakes:[/COLOR][/SIZE][SIZE="1"]Front brakes:Godspeed brake set up consisting of Brembo Max disks (on order), standard calipers and mintex 1155 pads with braided flexi pipes. Rear brakes: standard S1 drums and shoes with goodridge flexi pipes[/SIZE]

[CENTER][SIZE="5"]SEX, PUGS AND ROCK 'N' ROLL[/SIZE][/CENTER]
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Old 28-04-2011, 08:29 AM   #511
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Didn't fancy welding those in yourself then?
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Old 28-04-2011, 09:19 AM   #512
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Quote:
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Didn't fancy welding those in yourself then?
I would of liked to have given it a go but I have been super busy as of late, its the first time in 2 years I have paid a garage to work on my car. But atleast the biggest job on the list is done!

The guy runs a race/rally prep garage and is also making progress on my MGB GT. I done all the prep work and fitted the cage, he welded the mounts in for the grand sum of 100.

Lovely

Also I forgot to mention, when welding the boot floor I set fire to the car Back bumper now is super light weight with even more of the inner skin gone and the rear light is frazzled.
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Old 28-04-2011, 09:56 AM   #513
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LOL! I was welding the other day and thought that there was a bit more smoke than normal, turned out a bead of weld had fallen onto the cushion I was kneeling on and had set it on fire and I hadn't noticed

This cued a comedy moment as I then tried putting it out and transferred the fire to a roll of papertowel that was nearby. Fortunately the whole thing was put out fairly quickly with the bucket of water i always have nearby for dunking things in. Haven't had to use the extinguisher yet, but it's there just in case

Fair enough on the cage mounts though, I paid to have mine done a couple of years ago and although I might consider doing them now I have a lot of welding hours under my belt and feel much more confident in my ability and skill with the torch.
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Old 28-04-2011, 10:44 AM   #514
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I too had the comedy moment, tried wacking it out with the welding gloves but the inner plastic was properly caught on fire. My dad came running over with the hose which couldnt reach so instead just soaked the inside of the car. My mother came running with a bowl and rather than passing it to me so i could aim it at the fire underneath the car, she just lauched it soaking myself in the process!
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Old 28-04-2011, 07:53 PM   #515
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LOL at the bowl of water!

I've just caught up on this, looks awesome bro! Is the hydraulic handbrake not in the way a bit there when going for quick gear changes?

those welds look tidy too, wish my welds were so tidy... I hate welding thick metal to piss thin shells...

Last edited by rajjinator; 28-04-2011 at 07:53 PM. Reason: Automerged Doublepost
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Old 29-04-2011, 10:45 AM   #516
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Not sure about the hydraulic handbrake, I had a good fiddle trying to find a nice position. (kinky) Will only really find out when its on the road.

I cant take the praise for the welds, I had the cage fitted at a local race prep garage. 100
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Old 29-04-2011, 08:32 PM   #517
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Potched with the car on and off today, due to working in the garden and dribbling over kate's sister.

Fuel lines required new holes to route through behind pass seat due to SD cage.
Sd cage bolted in place, bar the bolts on front legs.

Drivers seat, hydraulic handbrake and bias valve fitted in place.
Pass seat lined up, but need longer bolts to suit.

Rear bumper is now even lighter, just left a small section of the inner skin in the middle just to space it correctly and give me a fixing point. Tempted to cut the outer skin to remove the air brake effect of the lower half.
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Old 01-05-2011, 11:41 PM   #518
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Photo update :





* interior loom refitted
* washer motor wired up in boot
* fitted centre caps
* fitted fire extinguisher
* fitted windscreen spray bars due to fg bonnet

Nice to be doing some final touches rather than the never ending tasks...
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Old 02-05-2011, 04:58 PM   #519
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Potched for a couple of hours again today, lots of small jobs off the list.

Refitted the front wheel arch liners
Connected the fuel lines up & secured down inside car.
New locking wheel nuts
Battery & Raceland induction fitted

FIRED into life

Few small jobs left, but the big job is the brake lines.
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Old 19-06-2011, 01:39 PM   #520
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how's this comeing along, can't be far from the finishing post now? the safety devices cages look a real nice bit of kit, when its time to re-shell mine i think i'll be going for one
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Old 19-06-2011, 07:46 PM   #521
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Still waiting on brake lines
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Old 22-06-2011, 02:14 PM   #522
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gotta say im really liking this build man keep it up
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Old 22-06-2011, 02:54 PM   #523
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make the brake lines up yourself mate or just run copper to everything
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Old 22-06-2011, 04:50 PM   #524
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Just bought 3 spare 14in speedline wheels, plan on bolting down one in the back of the xsi when its on the road.

Had 3 of them from a breakers due to the car being written off, other rim damaged. 30 including tyres.

Also bought a fibreglass bootlid so I can finally fit my poly rear screen. Was 215 delivered got it for 150.

Sticker for the car: "ebay fuels this vehicle"
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Old 17-09-2011, 04:08 PM   #525
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Sold my rallye today, so all efforts will be back onto the xsi.

I have all parts in house to finish, finally have my hands on the braided lines!

Will hopefully be lots of progress and a MOT in here shortly!
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Old 15-10-2011, 06:34 AM   #526
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Should be MOT'd on Monday or Tuesday
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Old 15-10-2011, 08:01 AM   #527
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Old 03-11-2011, 08:16 PM   #528
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MOT'd

Not had chance to give it a blast, obviously MOT is just the start. Lots more planned but this time I'm just going to make sure I have all the parts and time to complete. I took a running jump into the 16v conversion, cage, strip and its taken me for ever.

Not making that mistake again, time to enjoy the car, see how it feels on the road/track then look to improve the suspension. Engine wise its going to stay a standard 16valver, plenty of power for me! Suspension wise I want a track setup, I have a set of 21mm torsion bars so will look to get a disc beam rerfurb'd with bilstein grp n suspension all round and coilovers on the front.

Track day Nov 26th Llandow
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Old 03-11-2011, 08:49 PM   #529
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got some group n front dampers here for sale then you can get the better black cap rears of rallyedesign
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Old 06-11-2011, 09:33 AM   #530
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I've got a nice 17k jp4 here curl? ;-) only want 200quid for it to you. 150bhp anyone?
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[CENTER][IMG]http://i32.tinypic.com/2gtntd3.jpg[/IMG][/CENTER]
[COLOR="Red"][SIZE="2"]Engine:[/SIZE][/COLOR][SIZE="1"]C2 VTS JP4 engine, JP4 cam covers, J4 cams, followers, valve springs and caps, Lightened flywheel, Pug racing gear linkages, heat wrapped 4-2-1 raceland manifold, 2" decat pugsport system, Pugsport group N engine mounts, powerflex exhaust mounts, 106 GTI airbox with K&N pannel filter, standard,S2 gearbox, [B]153bhp @ 7,310rpm 112ft/lbs @ 6,739rpm[/B][/SIZE]
[SIZE="2"][COLOR="Red"]Interior:[/COLOR][/SIZE][SIZE="1"]Standard interior apart from Sparco Evo bucket seats, Sabbelt 3" 6 point harnesses[/SIZE]
[SIZE="2"][COLOR="Red"]Body:[/COLOR][/SIZE][SIZE="1"]Brand new S1 vinals all round, red FG bonnet[/SIZE]
[SIZE="2"][COLOR="Red"]Chassis:[/COLOR][/SIZE][SIZE="1"]Poly bushed diesel spec wishbones, lowered on Gaz coilovers on the front adjustable height -40mm-90mm, S1 rear beam poly bushed and lowered 45mm with Rear Gaz rear dampers, S2 steelies,[/SIZE]
[SIZE="2"][COLOR="Red"]Brakes:[/COLOR][/SIZE][SIZE="1"]Front brakes:Godspeed brake set up consisting of Brembo Max disks (on order), standard calipers and mintex 1155 pads with braided flexi pipes. Rear brakes: standard S1 drums and shoes with goodridge flexi pipes[/SIZE]

[CENTER][SIZE="5"]SEX, PUGS AND ROCK 'N' ROLL[/SIZE][/CENTER]
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Old 06-11-2011, 02:25 PM   #531
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Built not bought? Well bodged not built atleast









As she stands, MOT'd just needs tax and insurance.

Probably have a fair few teething problems, as its been off the road over 2 years! But happy! Aiming to do Llandow 26th Nov

Gearbox is making a bit of a noise, not sure if its any issue as it selects all gears fine. Clutch is new valeo item, but parts have just been sitting on the car for 2 years. Might just be the stripped out and GRP A engine mounts. Will be dropping the box oil and have a nose about!
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Old 06-11-2011, 03:57 PM   #532
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Nice one pal.
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Old 06-11-2011, 04:54 PM   #533
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Good going loon!
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Old 06-11-2011, 05:19 PM   #534
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Pop over in it sometime. We'll have a look at the box or atleast the sound out it.
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[COLOR="Red"][SIZE="2"]Engine:[/SIZE][/COLOR][SIZE="1"]C2 VTS JP4 engine, JP4 cam covers, J4 cams, followers, valve springs and caps, Lightened flywheel, Pug racing gear linkages, heat wrapped 4-2-1 raceland manifold, 2" decat pugsport system, Pugsport group N engine mounts, powerflex exhaust mounts, 106 GTI airbox with K&N pannel filter, standard,S2 gearbox, [B]153bhp @ 7,310rpm 112ft/lbs @ 6,739rpm[/B][/SIZE]
[SIZE="2"][COLOR="Red"]Interior:[/COLOR][/SIZE][SIZE="1"]Standard interior apart from Sparco Evo bucket seats, Sabbelt 3" 6 point harnesses[/SIZE]
[SIZE="2"][COLOR="Red"]Body:[/COLOR][/SIZE][SIZE="1"]Brand new S1 vinals all round, red FG bonnet[/SIZE]
[SIZE="2"][COLOR="Red"]Chassis:[/COLOR][/SIZE][SIZE="1"]Poly bushed diesel spec wishbones, lowered on Gaz coilovers on the front adjustable height -40mm-90mm, S1 rear beam poly bushed and lowered 45mm with Rear Gaz rear dampers, S2 steelies,[/SIZE]
[SIZE="2"][COLOR="Red"]Brakes:[/COLOR][/SIZE][SIZE="1"]Front brakes:Godspeed brake set up consisting of Brembo Max disks (on order), standard calipers and mintex 1155 pads with braided flexi pipes. Rear brakes: standard S1 drums and shoes with goodridge flexi pipes[/SIZE]

[CENTER][SIZE="5"]SEX, PUGS AND ROCK 'N' ROLL[/SIZE][/CENTER]
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Old 02-02-2012, 08:17 PM   #535
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Did you take it out tonight as you said??

Come on chop chop.
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Old 02-02-2012, 08:34 PM   #536
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looking good mate
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Old 02-02-2012, 09:14 PM   #537
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Nope the little racing battery he has is as flat as a pancake. He was ment to be popping over to have a chat and check out my garage queen. :-P
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[COLOR="Red"][SIZE="2"]Engine:[/SIZE][/COLOR][SIZE="1"]C2 VTS JP4 engine, JP4 cam covers, J4 cams, followers, valve springs and caps, Lightened flywheel, Pug racing gear linkages, heat wrapped 4-2-1 raceland manifold, 2" decat pugsport system, Pugsport group N engine mounts, powerflex exhaust mounts, 106 GTI airbox with K&N pannel filter, standard,S2 gearbox, [B]153bhp @ 7,310rpm 112ft/lbs @ 6,739rpm[/B][/SIZE]
[SIZE="2"][COLOR="Red"]Interior:[/COLOR][/SIZE][SIZE="1"]Standard interior apart from Sparco Evo bucket seats, Sabbelt 3" 6 point harnesses[/SIZE]
[SIZE="2"][COLOR="Red"]Body:[/COLOR][/SIZE][SIZE="1"]Brand new S1 vinals all round, red FG bonnet[/SIZE]
[SIZE="2"][COLOR="Red"]Chassis:[/COLOR][/SIZE][SIZE="1"]Poly bushed diesel spec wishbones, lowered on Gaz coilovers on the front adjustable height -40mm-90mm, S1 rear beam poly bushed and lowered 45mm with Rear Gaz rear dampers, S2 steelies,[/SIZE]
[SIZE="2"][COLOR="Red"]Brakes:[/COLOR][/SIZE][SIZE="1"]Front brakes:Godspeed brake set up consisting of Brembo Max disks (on order), standard calipers and mintex 1155 pads with braided flexi pipes. Rear brakes: standard S1 drums and shoes with goodridge flexi pipes[/SIZE]

[CENTER][SIZE="5"]SEX, PUGS AND ROCK 'N' ROLL[/SIZE][/CENTER]
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Old 02-02-2012, 09:20 PM   #538
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He's an electrician and a battery let him down??

I'm stopping him working in my department tomorrow!!!!

LOL
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Old 03-02-2012, 03:51 PM   #539
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Xsi is taxed, insured and mot'd! Just put my first couple of miles on it for over 2 years!!

Gearbox is noisy but just going to abuse it for the weekend see how the car holds up! Need to get some miles on it, expecting it needs some tlc! But huge smile on my face
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Old 03-02-2012, 04:29 PM   #540
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Old 03-02-2012, 05:23 PM   #541
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Old 03-02-2012, 07:48 PM   #542
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High five!
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Old 04-02-2012, 09:07 AM   #543
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Old 10-02-2012, 11:48 AM   #544
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Good stuff! Had any maladies yet? That seat definitely isn't for soaking up the miles on a cruise!
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Old 11-02-2012, 09:59 AM   #545
curl666
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Well the S1 Rallye box or clutch is noisy as hell. Hoping its the clutch as thats a cheaper fix, even though the clutch is brand new. Maybe just from where the car has been standing un used for sooo long!

The engine idles and pulls well, occassionally feels like the fueling isnt quite right. Either has a noisy hydraulic lifter or the injector. Hoping its the injector, which would tie in with the fueling issue.

Did get the low oil pressure warning light on briefly, but the wiring to the sensor on the block looks old, so hoping its just a dodgy connection/sensor. Will improve the wiring asap.

Recently purchased a VTS box incase my S1 Rallye box is shagged. This will be fitted as a replacement and tempted to leave it fitted for a trip to nurburg.

Purchased another disc beam, which has recently been lowered, so hoping it doesnt put up a fight coming apart. This will be rebuilt with the GRP N shocks and 21mm torsion bars I have

Freddy6868 has sorted me out with a low mileage JP4 16v lump incase mine has any issues. Will be stripping my 16v and using the best bits from both to hopefully make a good reliable lump.

Ok so its suckered a bit of cash, but I had expected it. The car has been standing a while which hasnt helped it, but I do love it. Much more fun than my diesel 320d barge!
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Old 16-02-2012, 08:39 PM   #546
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Aboustley stunning build, well done
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Old 10-04-2018, 06:20 PM   #547
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