Build Table Build

Made good progress this weekend putting together the build table. Started by putting the wooden top together so I had a flat surface to lay the steel box section on to weld it together.

Lighting and Welding Practice

Today I replaced the single light bulb in my garage with two fluorescent strip lights. This has made such a massive improvement to the light that I can actually see what I'm doing now!

  

Last week I had some metal box section arrive which gave me the chance to start welding practice. I haven't welded anything for over 15 years and quickly realised I am going to need a lot of practice :-)

Its a good job I have small welding project to practice on. I have designed a build table which will be used to build the chassis upon. Hopefully by the time I have welded the table my welding skills will be good enough to start welding the chassis. If not I'm going to find a welding course.

Chassis Design - Continued

Over the last month I have done a lot of design work on the chassis design. As now I am able to measure the parts from the BMW I have been able to finalise parts of the design such as the rear suspension.

The rear suspension will use the BMW hubs and bearings but the upright will be fabricated from sheet metal. I have also decided to use the same handbrake method as E36 with brake shoes within the disc actuated with cables the the brake lever. For the caliper I have decided on Wilwood Dynapro Singles (See Design & Components section).

As I am getting close to being able to start fabricating the chassis I wanted to confirm that the body work would look right over the chassis I have designed. Because the BMW M44 engine is quite tall I had to increase the height of the bonnet section whilst trying to maintain the correct lines. I am really pleased how this has come out as I was worried that it may not look correctly proportioned.

After much contemplation I have decided to make my own nosecone. I realise this is going to be difficult but I think the end result will look much better as I can get the clean lines I want.

 Rough dimension-ed sketch of the engine to make sure it all fits in OK.

Engine Removal

Very busy day today! Earlier this week I purchased the mild steel box section for building the chassis and as it was going to be delivered today I took a day off work. I had decided that whilst I was waiting for the delivery I would finally finish removing the engine.