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[Spain] Kadett 400 - aka "el batallas"
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Re: [Spain] Kadett 400 - aka "el batallas"
Well, bought some iron profiles to build what here in Spain we call "chicken rotisserie" (car stand holder)... It was not originally on my planning, but having in mind that our elevator is usually busy and it will make easier to work in the car, I decided to build one. Next week or something.
By now, I made the new engine mounting. Rookie welding skills! (laughs accepted) Last welds, were better, but aren't seen on this picture, I promise you LOL.
P9130274.JPG
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Back again in there,
I think it's good moment to update this thread, as there has been some news.
It all began moving to a new garage. The old one was plenty of dust and also shared with more people, not always good idea. Then, start again almost from zero. Roughly, idea is to put front Astra MK4 axle and rear Ford Focus multilink suspension.
Just arrived to it's new home... uj71XGRaqCoBBndOzoLdOZ7_wi0k1yXl2gdu8UAo8ifSR-Gsp77M80GeMd3doNDZV5mc7xAInL7F2ta6j4_kIUrhjlSplsjbMdgAyTg5fYDuwduh0AtHqToe8magR0BdDWJ8FEpAnxWawBTpuSGcn7N7RPohFi4ykP_GJxkFFW7NanRp7TQqm_V3YxwPDpnI1AceyE0bwQa1TxkCy8SupHMWj40KyPnrXaBnzPrtdn23H7EbXbKm5TArLHBvsID
And next to it's new stand for a while... pgO9BBeYJEXtS-MAJQM8HBlB5i_ZQWuHQm9NtlcxhYvyuEtyfkqES9sY34b7_aHnQ35rblleisO36SPNkuK8cUMbq5WTFYKn_O8iqwSCmqBNnj2xM-43vPyMNuTeWLvo3LyGNcOSFI43lxMKgS_RFfWU6ale0EnP9FawzyZnKnZ4NvjbCaMeee2Zjg5st2DevJsEfqpPm_B0qYovQhD8ILN6NXPXbRZooaKq8r9m4OIAWPBSQ5dW8Jc_wqqK_Zo
Dismantling: 14kxOCezrMHLabZvQmEcb5TXN-mHIv81bG3QpIf8CN4yEbrpWWiK-7ReuJibSuuQ-kEpXumu8c10ufDgtkwKCMzWG2OfBX6C2OWnD5wyEBaoXD69iCoOhNDmZZV-_VqZzd9pDAzpuUrSJ8We0xuirIpJMDN8R_t5uLO1HhckyQ07A6nfTzJ6NmN5aP1E_zzb8c3mBAgzHy6ghtVzCEg077EelLgXkOTQ0S5t_JvU45WAaggrAgUCMY314Okasw1
Up in there... wbFaxyVY0G2bisi2KzqbYQTUUSyxC2tbCaHL5ibgaMp0tbVWozCOTzvIGvSc83OQWJ9ylVEIyBqI-OQsEAouItybyL7o7MrFFBgEZOIDkMf8095du7drVl7al-lVtuyWtGaceIp05C_spbObpv6rJwsxnibxASgfDjBWW9AMTptyXrOxC2uP8VZwfeFBSmDI4uOq0HMbOfN4j7QPDCgKmrY4CAaFyJbTL6fyq7GDKt7SGJy8gmdH8emXlbAzjN8
And a bit more: FYZOB1J3jeXoKMdYFPeMJSHsf6XxSQwpZETQjeNR8HLZzZe7rM1ts4cXfYqC6ijGRj3d3IQ0_5wlS_giV8c9HCjWL_IA0vYIBpbKU-Li8hx_HMZAJZJcDBLA_GsrpYK3QGJrAi1CTpdIMXOvpvBsP4xvOjiu8EnT6bFDidirI9Bl07uZqqb4jj4DNiyGnP3WB3F0-kce4_i7ebi9MwhDD7oz13vwxIaqKjcytJ_rGtslS9LgcV7vD5cO_MY1YmB
Healthy of significant rust, next step will be set reference pins for wishbone ball joints. They will be 20 mm ahead when new setup is made, but I want to let it set properly: n38cgmj4p0aKNCAjHH2_HntSU4gSix5yVQ1fWK5j9JFXiZGnwJ5mBTaJ55gCt-Yd2S6SaIOqzfN5Zx9K6DB1ioDqAaMM2FdvBL74oa-e46D8uYPv-_1_cREbw1KwBOmY02Xr1Z3lqiD2RwXmMCk5Rmg7X3Bp-A7iKHXmZFqe7Brj-dQGn8CesHeB3Qu3LKKOa_rzfmOityjaB-lu81V6ZigD6iZRP9o_Ssg5Qf4iLmcyEsnitl7CoaU_XnChCuV
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Time now to remove center floor section, no longer needed: T1dxouLvgrXJ17RcCOEK2Soff3FeZprSChtVnpSF8eACcJ8nP2ZICqU-syUU4OJBY047GIWzKagZSo34HKAL7hMrMyzic_iCxXqRcEes9_hM-7lcwW4s8-4yXGY7sulHgXNJde85oJVfzGQ51b13Aq1cBatUpmqcY18KRlxNPypp2S3iLNH8OREKauJV54odsVDUaytOOAJXbKAF-7wm0F-1tHtSamhQD4-wHQPAl2cHNhWqVeqiMa4TaKJQzvT
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Big gap in there. Next step was to set a new cross bar between front rails. Common in new cars, will help in this one, but before, let's make a quick check: -lPj3TlWq9majN6JugDXTRvvx11HaF7d3r21QvoEy-PwzOHVk5WsQ-hbLeq939AZJkgPIY9-vllEC5Oi4knbVotUczjj3S47-K6q7a2LW_qHoCM-nb6an8eYYPt0JjxgbrtwO_piX7QEWpskOZxGIz5-pdLMZIPpCcediHlzEPXj3TtQFup8IzyeJH6CIqgU_mzgQSobZTK4xiry7Bu4efB3bSJMl8Oc_zHXlb2OM3yi1C-HxC-3OeClCIuaCbO
And until now, my biggest headache, the ARB. No place for it in standard setup, I have still pending the best way to sort it out. Jbt5aPMbHVEC87nr_s2nwzcNLI3qv9CmnK1CFi55lr6ZCilgs5PBIUOS8UDmOVitTKcP9y8DXmP_V1R4Qifl5MqELfMRO80G7SNQ_WRRi3yxVeYroGTLHnO5rCqdfPfk-vsXu8WXTKKrnubDU4vh0tqdeY7LGwjSYaDXgWhlUnohiUoqvpts_q1eKdiddNnnZuSCG9yToRNXcfqOPjUdGjAUjI_L1MfXc1W5sthIXiuh0zDWUDlupWq6-5c0u6m
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And then finished: Io1EYdhxAngtPQVLSXFZYTCsYw9gK8d-ClqPHFz1mbRzt0DznGEzZPzGcpdaxLODB0JSWrSW8pMGIr7Q1KjTQtRNd9tEfcEyNljwDl8J2pOYdpL_g5MS0ew00YMhmoBeVZJXz79imcBY8HhHax8sLr9QGin4o6aLsVGgyb7Xg_6rbVs-Lp0dCzzfc0tCaCh39jee0-KJCZHjLQ2cdcUNfihjkIZzSnukG7GQWQX6iQqDk-w0sAa27vv-tjhLvHb
After applying brush seal, (not the best looking, but not seen finally): oS3Ka1AeUqeEO4syHk5AKBty_zQuHRIbaF1jwIwchFL-QwF9kkWnYKryvDrguv3zZmBH4gssNmeOTCbiTqde3w1Rpj_JBbNnXiR6uu3ZmP-GGkIIrSfEvsYejfTln9vO4mGgveNNBYIrm0oOEE4Zx9PLN44T2vUdvIExuEe9_Wpk0Brjm5MOQWrZpYfjgdjXpZSVsnY-5a5vG3xM1DbG2QuinRoLBvAb3JTXIWrEJDyMPzApN6vD7qFTPZFMWxa
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Following, I decided to add 2 rails, as I need to relief rear K-frame attachment efforts. As I don't want to loose ground clearance, and I have plenty of space under carpet "biting" isolator foam, no problem at all. Also, some reinforcements will be added later outside cabin: NGmfrIXMiOd2Q-2t-86wsZ_Wdlywk0a4pTHDraibI3sU-iEzO1zPFwIvOl2AH8dSfJ77CuE5MlYQx5VKutVCoujS9vKgZGTt4ZuZ78y66tiUoPBASCE8YBoKqGIVcq_YodOxehg9nD0SuVfdtMAwinYjPI6DmGgHyy-05aUyOoA3GMnQhWlszFf7kQUTiUHm9n3dCjNMrD0oOIwHv0_Na3GslNvYhGwQ34dfpI-1Sx5vTowUPjzwT1vjqBQ6kWx
Closed drain holes also, rusty spot usually.
After welding and sealing, it comes like this: LC8LowwmK_VBN1uQzuESduLf4P9zs_P-UYnh0u-PJhWC1tpi8AT4yRYZvBzdixqpqqibU-OjOeejFfS7uQ8tCf3QzOrQyFvkT3zkQauIB1qsa3hwp6qwWRfblC5JM1ox0g1KhkQXolHVekRa9tL_3kD2ruUt-HqNzrKDNISvJ0wm49Rtsw3H5OdYnd8nKCj6Uu0NydK0L1NKQS1kJmD6XeZtH8Q3gWzEwZdcDNgD4JDo915aa4kXepL3zmrZJJu
The other side: 6U2OCQjGZsNg4l9RHqVPJPEqjVGISgE5fxKUUa0YyIIOj5D1tLqnORrJ3ICF-hXbPGOOiBNz3302OOwMZxY1gvGPnE4rhZfVmg6NOlDn50J0jsQAVmtv-5aneI3n0BSuDgNw55AruxtBxB_GLnkp6VOW3NB6gdQkcW05lIr05gqylCCQ3Kd-lMfNgKocFoSLp6W7p8IjA1xzxEd9l09UVuk70667z9voI-uRr3A1xeniPafhZb6kxivY9OiCpbT
3eZpZvJPq-7Kmr_ut5MQtAHP2fxJjL-tgacb3ld_rd_65mht-3M3ekWBBx0GkbgJHgk9NwZGJgeNNqD9js_lySGchy7KGSWPizOYRje62_pbmUUVg2XsB2D9LkOguEST8zajjqS8SYq7TGJVI6Y9aPhrwU85PswXCE77Yr-QPTzHt7SwspTK5hRZE7kYnCaz7cqE6gxlCHb0JCF7TFvrD1LddaxJMyBXoEftA3J5RAI5CuH9ckWD9DcQoYYhpvr
I had to modify front rails, as spot welded flange makes interference with steering tie rods and probably, center K-frame attachments: uMWWMptM5HJ-okQ5_YhJeJqLaa0GXGWIBBSiGxdhYu7HjIBfzWJr-R3Pe2JQIFqnyVSEyco88givMD4YQJScI0tMg6d-qxLipr9PUvlEpvqF7xbqvJS5Iwn-eyG72yLv_kkHtBvjOQ9YkEXMWEF6koV-rNUcn5BjHUVUSOjLrXDiDWB8-UpHuKuoTFuD6o8rF9VbNV-9EOiOVn8KO0weW-FXrPIKZUO_2fPnv5yUpOBHzmAdHBj-3V2LRjS3I9I
Bite a hole, and new fabricated brackets: WGRUjp2-rugyFTJFMwbfrWG5YI2ySFvisbk7iBS5ra8pSzY1YyWeL8b5RJWMEua8blJxAy7aXCeU_gBhsyCkrnSQDOonzBID8egVuggeCPkUP39t9wHXAgg7TLwY9hXzxrlt5Zg0Ka76ASwrlT6vNDGxXkhcNZcCsQoGMZLJjYt9DnlKJTq0IpmiETKp5IOhv3mJ4HG_mmklj-Wtx1gEkKQSnq1DB5G02SJh2qU-8qL1iIni7veEb0t8uXp-PXf
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Same on the other side and we have the whole thing fitted: dP8Uz2GvlQlWNGuSAbftEFGOSv15ai3td2XXzjriWoOrXJ3peEib7JgzUm1Z-C8qejHbEcE36tcTbjSG-m71UpinaTrDg2a3E9Qlyr-m5qGvof0TrmEDnMXNZLd5QrhAK7urHm29oAhUDQhC7zq73nMhr1LnuByr2M9AtBIYY-BMCgU7vVjo5MFToNb61ImVS3fY32ed44iB5gikqE5yo9tQG2UE4UhrWk_6Ew6HHtMB-cFQIij-gPSdyNJJGxg
All in the proper place, and rear attachments in line with new rails. Good looking now! JwTMnV59tVKo427GdSJmzQYLOD6jtO3F--eDi8XgS0cFOw4ClwwABMx8iURECRZcoOe98Hoj_GVh4p29jUjsT_tQ3-JtlzgvKwe4_rs2QmCBVzfZdkroYsOvXR4JCgtc-vxXfFi9RDyYwy5qdTPypKfh6Z59r1DaeH0EcLjWhQP9uWdLq5ZeNiUwS1DCovG013DiNShiHaoSukh2SE6e8w8quJBD4ziBWtJyDQQ-MAxoW_n2qUaREQiK8i7DuTM
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I forgot to count an extra 15 mm distance from ball joint, so a small liner will need to be added before bolt the frame. No problem at all, as this distance can be easily adjusted with some spacers. Also, it gives me an extra gap for rear engine mount, actually a bit tight. Maybe will need to make a small boxing to save interference, if finally it is. imcyvq9N4Mv_pDlWjFwkzNoH67VsCQR0gNm193KrgAT15-c4yNm_xA60JAb6St8Ljff-yikfbDUVBS8RExkyYsE3rMuad_5PaFSNDTHGrNscq2Ingey0Q6TGZUTn6XeM-yBUs7szKS6LZcbzrT0ZWyS95cy0GnDZGePF8KI5yhPigWidXVedewbD0FeZgrG5wEhMAgK4fM3T8YLVpq-3f0JydSX98jCxROQaB4AIh-S1_g76ULU54jasYGCKQMa
Nice, wishbones have plenty of clearance even in full bound. Everything seems ok by now, ARB apart. wWKEwqhwUKTUMBxj4TT04KkLy8ORwT1tevLv9ua3kRqHJAGs1isHxXqFVi-hHGpdOlMzOoU5qFRuuW90jVLCuN_VnfoD8F7RXNYhUojcSZK_849QPaRD_LoN_i27LogqyoBO8aGsfzoyHKtsdbMqr7GlO6Smq5nVhRIB3vT94ee8dAywQywac-dQNNP87k5dWqxP75Iisoz7XCw1yYZmhnqy9CUZuyj8ke_rJjHs2NN9XyQaZutOnO02nIKJS1H
I will make a reinforcement on these brackets, I sealed them, but it worth adding extra strength. Once painted, result should be nice. SyLX04ckj4KPIljPEtmstAnTxbiiX0vN1Ytc5ISdoxp5beOywE2pt6vGcT11net42OOXSk6rN4wjzTyEgtRQ_ihf9ZPtV9mc_-ozVXwn9Rue29mD4u6p7rKLVJYBP4TgHcyqVamtRLDqIKeJtL9nkNhgAE5_IR_7Khg_WI7QG-D2l_QzggDz1lZZoF_943RhCFRE1wHSQbSi-QcaRRlA6DQY4r_pOXKtyjY4v5bVpLlIv8VRK2x26MNyLnt8Tnx
This weekend will make front ones, extending 2 legs from front rails. Then rear ones, coming from new rails to side sills (stronger part). And then, I'm actually planning to build new turrets. I want to gain caster angle, and need to increase in ~60 mm front trail, to go from 1.5 to something like 6 degrees. 20 mm were given down on wishbones, 40 ones, will be set on top.
I hope you like the plans for this. At this point, I completely forgot the engine. I will probably leave the big throttle bodied V6 idea, and then build a 2.2 - 2.3 stroked and ITB'd XE. But anyway, it will be NA.Attached Files- FYZOB1J3jeXoKMdYFPeMJSHsf6XxSQwpZETQjeNR8HLZzZe7rM1ts4cXfYqC6ijGRj3d3IQ0_5wlS_giV8c9HCjWL_IA0vYIBpbKU-Li8hx_HMZAJZJcDBLA_GsrpYK3QGJrAi1CTpdIMXOvpvBsP4xvOjiu8EnT6bFDidirI9Bl07uZqqb4jj4DNiyGnP3WB3F0-kce4_i7ebi9MwhDD7oz13vwxIaqKjcytJ_rGtslS9LgcV7vD5cO_MY1YmB (755.1 KB, 21 views)
- n38cgmj4p0aKNCAjHH2_HntSU4gSix5yVQ1fWK5j9JFXiZGnwJ5mBTaJ55gCt-Yd2S6SaIOqzfN5Zx9K6DB1ioDqAaMM2FdvBL74oa-e46D8uYPv-_1_cREbw1KwBOmY02Xr1Z3lqiD2RwXmMCk5Rmg7X3Bp-A7iKHXmZFqe7Brj-dQGn8CesHeB3Qu3LKKOa_rzfmOityjaB-lu81V6ZigD6iZRP9o_Ssg5Qf4iLmcyEsnitl7CoaU_XnChCuV (631.6 KB, 21 views)
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Huh, more than a year since last update, too much!
Everything went really slow this year, as my MK4 turbo has gotten more attention (as a daily driven car). But back from holidays with plenty of strenght, now there has been some recent updates.
Back then, had to chop front subframe attachments, to weld them near front rails end, and build a proper bolt-on bit.
Yup, somwhere like that:
Some of old material had to be removed:
There we go! Here it is, one side welded.
Making new section:
And then finally welded:
Both sides done:
Then, as other users did, I decided to go for more caster. For my purpose, which is to go between 6 and 7 degrees, I calculated to make travel back ~40 mm the whole turret, and 10 mm forward wishbone ball joint. As wishbone was yet moved forward when setting subframe position, then built a reference frame able to be attached 40 mm back. Having in mind that front MK4 dampers are overall longer, I thought it would be a good idea to raise the whole thing something like 20 mm. As there are still room before hitting the bonnet, it will be helpful when setting vehicle posture.
Got rid of stock turrets:
And see what happens when it is set a little bit backwards:
Here you can see original attachment, and new one:
I wasn't able to resist a trial with dampers, just to see what happens:
And consequences... As the whole axle is wider track, new turrets with camber adjustment incorporated, needs room outwards to compensate.
Sits nicely, only one interference on rack feed, that was solved boxing a section:
Playing with full rebound and extension lock to lock, to see if there are interference, just a very small rail lip, 1 cm chop and will be trouble free:
Time to make rear attachments, as usual, cardboard prototyping, and after that, metal replica:
Welded, primed, and sealed:
Boxed section to avoid rack feed interference:
And final result. It took long time, as one side sat slightly bent, and had to repeat:
New toys arrived:
Intially, central subframe attachments were meant to need a spacer, but at some point decided to re-do them to fit the whole thing with no need of liners/spacers:
Laser cut upper plates for new turrets... they are 4 mm thick, don't think they are going to bend!
One of my worst nightmares was the ARB. Original one hits the rails at their proper position. I kicked forward this issue without having a very clear picture of how to solve it, until one day, looking at subframe sitting on the floor I had an idea, and tried it. Reverse the ARB. It needs minor subframe mock up, and wishbone mod, but after that, it saves rack tie rods, and leaves no interference.
I will make room for the bar to move, and then, a good range of ARB's come in to play, from 18 mm up to 24 to play with.
Built then the new strut towers:
Welded them by double stitch, shouldnt have problems. Plus, this is how I bent the 2 mm thickness sheet with that round shape, by using pipe bender:
And here we are:
Closing sections:
Then welded primed sealed:
And new reinforcement, down to subframe attachment:
And front section. No pictures of the whole process, but good to make just an idea:
After priming:
There are areas where results could have been better, but overall I'm quite happy with results. As usual, opposite side is getting better, but it's predictable. You spend less time, and better results. Expect to finish this weekend. I'll update with next plans, and in a short period, not next year LOL.
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Round 2, let's move to the right:
Firstly, as side section is reduced, I added a reinforcement on side rail. It will also help on holding the strut tower.
Welded side main panel and top:
I stitched in both sides, just in case...
And then after proper cardboard templates, final shapes:
And finally closed, with some difficulties at certain areas, but finally closed:
Prepared also same reinforcement as left side:
And after applying proper PU sealant:
Ahhh lomng time since I saw it "closed". Now it empowers me to not give up!
And a thin coat of primer:
I hope the bonnet won't hit the extra height, I added only 20 mm, which is less than you can find on side fender+bolts. Let's see...
At this stage, I had to try the front axle, to see if everything fits ok, pretty satisfied with results:
Seems I will need to use shorter ARB tie rods . Anyway, as you may be aware, ARB is reversed, I need to make some arrangements on subframe + wishbones, as it's impossible to get it fitted on it's original position. Anyway, I'm quite happy as it seems there aren't any interference, by now. I need to try also steering rack which shouldn't mean more issues, but need to check.
Let's dig now into the rear axle...
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Lot of time since last update... and lot of stuff happened.
Basically I screwed up positioning subframe, wanted more caster and I gave it by pulling backwards strut towers, and placing subframe slightly forward... too much. In my first mock up with fenders I saw clearly that I would run out of space front tires with front bumpers, plus several attempts modifying subframe resulted in a total meltdown. Spent many time along 2019 without getting anything sorted and I was kinda frustrated. Had nostalgia, wanted an MK2 able to use, and bought a good 8v unit that I planned to get in decent shape for use.
How it started and how it finished:
All stock. Initially nothing intended to do, but eventually ended swapped, refinished... bla bla bla...
Here with the rest of starting lineup:
Running with my old 16v unit, F17 cable gear linkage, and Saxo EHPAS, it was going like a dream.
But 2020 has been crap, and on 9th January, one of my worst nightmares came true:
The car caught fire for unknown reason (defective battery or current leak), causing a complete disaster in my garage. It never had current leaks, nor any failure, so I don't know exactly what caused that. Day before I started it just to be sure all was OK and had on plan to drive next day. Of course never happened.
I spent many time this year getting garage repaired, solved, tidied, cleaned, but COVID has been a problem with constant home lock up, and so on. Somehow I finally got it sorted in july, and I was able to keep progressing with my Kadett. Stripped any bit useful and got rid of the chassis, as it had severe fire damage...
As many problems were on the list with current setup, I decided to go for a total different way. Fabricated some reference chassis to keep all internal attachments in the same place, and following, I decided to rebuild all the floor again, with new rails, platform, front axle attachments, and rear axle.
Repeated all sealings as I managed a new gun for this purpose.
Reinforced jacking points:
Finished floor. Notice all bars ar stitched to floor, so there's almost no distortion, that's why no beadings were done. On boot floor, I did them as bigger area was there.
Looking fresh again!
Coming up next, Astra MK5 rear axle swap. It will demand an extra 2-3 cm widening each side, but it's feasible. Same at front.
Hope you guys like it, and I will keep posting updates now I'm recovered.
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