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Extreme Forums => Build Threads => Topic started by: dads360 on January 18, 2018, 10:44:23 PM

Title: DADS360 - THE Build diary!
Post by: dads360 on January 18, 2018, 10:44:23 PM
Hello all.

This will now be the home of the offical DADS360 Build Thread. I have been posting on a number of threads! (My Mistake!)

All new pictures of my build will be here on this thread. And this thread only. Sorry for the confusion!

Title: Re: DADS360 - THE Build diary!
Post by: dads360 on January 18, 2018, 10:53:36 PM
Here are some of the latest images of the front end build. These show the new front sub-frame coming to shape.


Title: Re: DADS360 - THE Build diary!
Post by: dads360 on January 18, 2018, 11:08:20 PM
Here are some images of the front bumper air intakes I have made and the front radiators they will be feeding!
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on January 18, 2018, 11:13:56 PM
Here are some images of the card templates I made to create the inner wings in sheet steel.
Title: Re: DADS360 - THE Build diary!
Post by: ferrari360jd on January 19, 2018, 08:21:14 AM
Coming along nicely now Steve , looking forward to updates , jd
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on January 23, 2018, 05:59:05 PM
shots of the drive train installed in chassis
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on January 23, 2018, 06:04:32 PM
more photos of the drive train
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on January 26, 2018, 05:45:04 PM
Recent photo of front end work.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on January 26, 2018, 05:47:58 PM
Additonal front end photo.
Title: Re: DADS360 - THE Build diary!
Post by: Mickey_London on January 26, 2018, 08:42:14 PM
Great skills
Looking forward to more updates
Mick
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on January 28, 2018, 07:58:06 PM
As you will have noticed I working on the front at the moment, but I have done a fair bit of work at the back . Photos of the exhaust mounted on the transaxle etc.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on March 07, 2018, 10:17:05 PM
Here are few images of the OE Ferrari Screen Washer Tank mounted in its final position.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on March 15, 2018, 12:11:10 PM
Front closing panel fitted along with screen wash bottle.
Title: Re: DADS360 - THE Build diary!
Post by: CdRsKuLL on March 16, 2018, 01:02:08 PM
Wow.. very nice build :-)  love the attention to detail and the metal fabrication.  Is it a complete space frame or is it still a 406 underneath?
Title: Re: DADS360 - THE Build diary!
Post by: dangerrous on March 16, 2018, 05:15:38 PM
Just curious, I've followed this build since it was a posted in the old days, is it still the dad building with the son doing all the media work, has the scope of the car development changed as I haven't seen any pictures or video of DAD working on the car?
D
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on March 16, 2018, 11:38:41 PM
Hi, everybody. Yes it's dad doing the fabrication and now dad trying to do the madia work. Ben my son has started his own fabrication business and this takes up most of his time. Google "iron octopus " to get an idea of the work he does.
The build itself has turned into a massive project, the basis is a Lotus V8 chassis powered by a 5.7 litre Chevrolet V8 engine. on top of the chassis sits the passenger compartment of the 406 with a space frame at the rear and a space frame at the front.
Title: Re: DADS360 - THE Build diary!
Post by: ferrari360jd on April 09, 2018, 12:47:42 PM
Hi Steve this is the details for Bradleys liquid paint cheers jd
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on April 09, 2018, 12:49:19 PM
Hi John, as ever your a star.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on April 09, 2018, 12:56:44 PM
The text that went with seat pictures seems to have been lost on the ether. I stripped the seat down so I could lift it into the car to see what was needed to bolt them in. The subframe with the elctric motors in is heavy with a capitol H.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on April 19, 2018, 08:35:39 PM
Latest work on the front compartment. Using the well tried CAD [cardboard aided design] method I made up a panel to close the gap at the nearside rear.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on April 24, 2018, 08:00:04 PM
Done a bit more today. Got the drives side infil plate made, same process as the passenger side. Next job is to fabricate the luggage compartment rear bulkhead. Then stip it all down and get the lot powder coated.
Title: Re: DADS360 - THE Build diary!
Post by: Mickey_London on April 24, 2018, 08:30:32 PM
Not sure you should be blatantly advertising Diet Coke like you are  ;D haha

Anyway, great work and skills
This is going to be a fantastic car when finished
Mick
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on May 21, 2018, 06:54:47 PM
Couple of photo's of the air intakes back from galvanising and powder coating.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on May 29, 2018, 06:39:14 PM
More hours on the computer setting up the CAD for the cover over the wiper motor. Bits of card board actually.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on June 07, 2018, 08:19:31 PM
Photo's of the plastic coated wiper motor cover and the front panel I made to mount the screen wash filler and to support the front compartment seals
Title: Re: DADS360 - THE Build diary!
Post by: Mickey_London on June 07, 2018, 09:44:13 PM
Amazing skills
Have you set a time for when you want to be paint ready
Mick
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on June 10, 2018, 07:38:21 PM
Hi Mick, thanks for the kind words. I am aiming to be ready for paint spring time next year. Trying to get the front compartment done at the moment, then on to moving the nearside B post and finish off the door cap in steel etc etc etc.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on June 29, 2018, 01:10:13 PM
I thought I would have a break from sheet metal work so made up the power steering hoses just to be doing something different.
Title: Re: DADS360 - THE Build diary!
Post by: ferrari360jd on June 29, 2018, 06:31:52 PM
Looking fab Steve , great work as allways  :)
Iv had a look for my recipe for my wheels buddy  and can't find it  sorry ,jd
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on June 30, 2018, 11:55:22 AM
Hi John, thanks for the positive comments, keeps my mojo going. Cheers for the update on the wheels.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on June 30, 2018, 12:03:19 PM
Managed to get the front compartment finished.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on June 30, 2018, 12:06:22 PM
Couple of shots of the interior .
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on July 17, 2018, 05:29:03 PM
Restarted work on the drivers door. Fitted the OE door handle, and mounted the internal collision bar on the outer skin on the door [photo to follow]. 
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on July 24, 2018, 08:19:20 PM
Photo's of the door bar taken from the inside of the Peugeot door, this has been modified and will be bonded and bolted to the ouside of the door under the Ectreme door skin. Also a couple of shots of the door handles which work by cable to the lock itself.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on July 25, 2018, 08:48:58 PM
I got around to organising the gear lever gate to go on the centre console only to realise the gear lever I made years ago was the wrong diameter 12mm should have been 10mm and was also too short. So had to make another this time 10mm 304 stainless steel along with an o/e knob. It's all part of the learning curve.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on July 31, 2018, 07:49:18 PM
Thought I would share a couple of photo's of the fuel system. I have isolated the ferrari intank high pressure fuel pump and pressure regulator. They run @ 65 PSI far to high when feeding the holley carb I will be running when the car is first running. I have installed in the tanks fuel pumps from a 7 litre Buick Riviera feeding a Holley fuel pressure regulator set @ 4 PSI.
Title: Re: DADS360 - THE Build diary!
Post by: 360brian on August 01, 2018, 11:22:56 AM
Thought I would share a couple of photo's of the fuel system. I have isolated the ferrari intank high pressure fuel pump and pressure regulator. They run @ 65 PSI far to high when feeding the holley carb I will be running when the car is first running. I have installed in the tanks fuel pumps from a 7 litre Buick Riviera feeding a Holley fuel pressure regulator set @ 4 PSI.

this is a epic build, great to follow. Are you in the UK? would be great to see this coming together and compare notes (nb, I don't work for Ferrari or their connected companies).
Title: Re: DADS360 - THE Build diary!
Post by: peggyontherun on August 01, 2018, 06:11:06 PM
Would you sell the gear lever that your not going to use email me on peggy390521@gmail.com as I don't have pm on here if admin can confirm why ?? Cheers
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on August 05, 2018, 06:25:40 PM
Hi brian 355, I am base in the UK up in West Yorkshire.
Peggyintherun I have sent you a pm.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on August 07, 2018, 01:00:14 PM
shots of the door bar in place, the nearside fuel tank and air intake trunkingalong with the interior panels to go inside the rear quarter light glass.
Title: Re: DADS360 - THE Build diary!
Post by: peggyontherun on August 08, 2018, 11:05:50 AM
Email sent
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on August 15, 2018, 12:11:23 AM
Update on the drivers door. Photos of the end cap in place. Couple of shots of the B post, I ended up cutting the fibre glass return off the quarter panel, it was so thick that the door rubber would not go over it.
Title: Re: DADS360 - THE Build diary!
Post by: ferrari360jd on August 15, 2018, 06:00:52 PM
Great work as allways Steve , she is coming together slowly but surely  :)
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on August 15, 2018, 06:06:47 PM
Hi John, thanks for the comments, now the weather has cooled down I am back at it. Would it be possible for you to send me a PM ?.
Title: Re: DADS360 - THE Build diary!
Post by: zxrjohn14 on August 15, 2018, 09:35:54 PM
Beautiful project. Some excellent ideas and work.
Loving the idea of the extra metal for the quarter panel on the B post.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on August 22, 2018, 12:25:59 PM
Further news on the drivers door. Photo's of the Ferrari door handle mounted on the Peugeot door skin on the mounting bracket I made. This was not without it's challenge since I had to work out the shape with the outer extreme skin in place. The handle and mount are fitted from the outside, I have done it this way so should the handle ever need replacing the outer fibre glass skin does not need to be removed. The door actuator extends into the Peugeot door so cable replacement would not require the skin to be removed either. 
Title: Re: DADS360 - THE Build diary!
Post by: 360brian on August 22, 2018, 03:00:08 PM
its a pleasure to see such great engineering!
Title: Re: DADS360 - THE Build diary!
Post by: dman1409 on November 06, 2018, 01:56:07 AM
looks great to see you use oem levers... i have them also, along with motors inner door levers etc... are you going to use them also?
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on November 06, 2018, 01:38:26 PM
Hi, I have only used the OE outer handle, linked by cable to the Pug door lock. I will be posting some photo's soon.
Title: Re: DADS360 - THE Build diary!
Post by: 4u2nv on November 21, 2018, 08:35:26 PM
Wow this is epic work . Looks stunning .

Got some real skill there :)
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on November 21, 2018, 08:38:51 PM
Shots of the door card, inner and outer. The inner shot shows the two additional towers made to locate the attachment pins. The location of the operating servo is shown on the shot of the inside of the metal door panel . The photo of the Audi window lift gear box shows the Peugeot gear drive modded and mounted .
Title: Re: DADS360 - THE Build diary!
Post by: zxrjohn14 on November 21, 2018, 09:50:17 PM
What have you used as the spline adaptor?
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on November 22, 2018, 10:39:15 AM
Hi ZXRJohn,
The mod to the lift mechanism is really simple, no adapters required. The drive gear from the Peugeot lift motor is removed, it looks like two gears one on top of the other. Carefully grind down the teeth on a bench grinder the larger gear off the two. Although the spline count is different , the Peugeot is coarse, the Audi fine. Keep carefully grinding until the gear starts to engage in the Audi splines. Now come the the magic, the Audi housing has a 6mm hole in the back of the housing .Put a 6mm bolt in the vice that is long enough to pass through the Audi housing and the Peugeot drive gear and space for a nut. Then get the gear red hot, drop it on to the bolt quickly put on the nut and then tighten the nut with a fully charged powerful cordless drill. Once fully seated cool the gear with water.
I know it sounds long winded but it worked for me.
Title: Re: DADS360 - THE Build diary!
Post by: zxrjohn14 on November 22, 2018, 06:33:22 PM
Thank you for that.
It makes perfect sense and I'll give it a go.
I've already robbed one of your ideas and put angle iron behind the front of the rear quarters  :)
Title: Re: DADS360 - THE Build diary!
Post by: 4u2nv on November 22, 2018, 09:41:01 PM
Hi ya I love this build , can ask what's rad are you using ? Also are you also running a separate water pump at the front also ?

Cheers
Chris
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on November 23, 2018, 01:23:52 PM
Hi 4u2nv, the rad I am using is from a lotus esprit V8. See photo. The water pump is  gear driven Chevrolet high volume unit, the engine has idled for several hours without over heating. the car has consumed ten gallons of fuel and not moved an inch !.
Title: Re: DADS360 - THE Build diary!
Post by: 4u2nv on November 23, 2018, 09:40:58 PM
That's great :)  thanks for the info .

Love this build.  Really top notch .
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on December 23, 2018, 06:21:56 PM
Not done much lately, got distracted by MOTing four cars in the family. Then having taking up half the driveway to repair a blocked foul sewer. Along with not being able to access my man cave until the wasp man had got rid of the nest along with all the little darlings. I am still sporting a number of stings. So i got back to it and decided to do the drivers door mirror. I looked high and low for the fibre glass triangles supplied by Extreme, but could not find them any where ,so decided to make one in steel. A morning later it's job done only.............. to find the Extreme piece.
Merry Christmas and happy new yer everyone, lets keep going it in 2019.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on January 08, 2019, 03:46:10 PM
I found a lost file with some build photos on. The little guy shown with the engine is now ten years old !. I thought I should share them with you guys
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on January 08, 2019, 08:23:45 PM
Found some shots of the exhaust mounted on the trans axle. This is the same as the O/E 360.
Title: Re: DADS360 - THE Build diary!
Post by: zxrjohn14 on January 09, 2019, 07:18:25 AM
The work on this is something else....very special!
Love it.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on January 10, 2019, 11:52:35 AM
The reason this build is taking so long is that I am easily distracted.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on January 23, 2019, 05:51:28 PM
weather strip mounting done on drivers door.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on January 23, 2019, 06:22:53 PM
New B post ready for fitting. This allow full size strength but not visible through the quarter light.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on January 23, 2019, 06:26:22 PM
shot of other side.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on January 24, 2019, 12:22:07 AM
Just found on YouTube a video of a dyno test of the same specification engine that I will be using. The interesting bit is at 5.22 mins.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on January 24, 2019, 12:25:22 AM
It might help if I told you where to find it !!!!.  Search on YouTube for LT1/LT4 carburator conversion 350 SBC. I know the carb spelling is wrong but that's how the yanks spell it.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on January 31, 2019, 05:11:17 PM
I have always been aware of the relative weakness of the door end cap and it's strength. So I have made some metal strips to attach the outer skin to the inner structure.   
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on February 22, 2019, 03:59:34 PM
Just going through some files on the lap top and found this ,a shot of the chassis with the engine sitting in it.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on February 22, 2019, 04:23:51 PM
couple of shots of the fuel tanks and heat shields.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on February 22, 2019, 06:25:54 PM
I mentioned a while ago I plan to fit a steel roof in place of the one that came in the kit. Here's a photo of the doner .
Title: Re: DADS360 - THE Build diary!
Post by: 4u2nv on February 25, 2019, 02:09:22 PM
great work , love this build
Title: Re: DADS360 - THE Build diary!
Post by: Mickey_London on February 26, 2019, 10:07:49 AM
Yeah. What Chris said  ;)
Mick
Title: Re: DADS360 - THE Build diary!
Post by: 4u2nv on March 07, 2019, 11:30:32 AM
im interested as mine is also space frame , is are you going via IVA ? as i feel thats what ill be doing i just prey and hope i dont have to go on a Q plate :(
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on May 30, 2019, 11:40:59 AM
Hi, everybody, I have not posted any updates for ages. This is because I have not done anything on the car. This is because of a number of factors, firstly my Mum pasted away suddenly, she lived 120 miles from me, so this meant multiple visits to the midlands and then the complexity of solicitors ,probate wills etc.
Then on a less serious note, severe weather tore down 60 foot of fencing down the side of the house which I had to replace, alone with a water leak into the kitchen . This resulted in me repairing the roof along with fitting new facia boards and guttering. However I did have the chance to buy a Ferrari hand brake lever and have sent the 360 seats I got a while ago to a specialist for cleaning and restoration. With a bit of luck and the wind in the right direction I will be back on the car early in June, after a short interlude for the Le Mans 24. 
Title: Re: DADS360 - THE Build diary!
Post by: 360brian on May 31, 2019, 09:48:50 PM
Hi, everybody, I have not posted any updates for ages. This is because I have not done anything on the car. This is because of a number of factors, firstly my Mum pasted away suddenly, she lived 120 miles from me, so this meant multiple visits to the midlands and then the complexity of solicitors ,probate wills etc.
Then on a less serious note, severe weather tore down 60 foot of fencing down the side of the house which I had to replace, alone with a water leak into the kitchen . This resulted in me repairing the roof along with fitting new facia boards and guttering. However I did have the chance to buy a Ferrari hand brake lever and have sent the 360 seats I got a while ago to a specialist for cleaning and restoration. With a bit of luck and the wind in the right direction I will be back on the car early in June, after a short interlude for the Le Mans 24. 

Can I ask who you are using to restore the seats?
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on June 01, 2019, 12:55:22 PM
Hi Brian, the company is called the leather doctor, based near York. Stuart is the man to speak with, 07941571264.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on June 25, 2019, 08:20:07 PM
Picked up my seats from the leather doctor, I thought at first he had swapped them for a pair out of another car !. I could not believe they were the same ones that I had left with him. Fantastic job, the only problem I have is to find somewhere safe to store them until they are needed.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on August 16, 2019, 04:50:46 PM
More work done on the drivers door. I have now fitted an additional strip to support the weather strip. Working on the rear under bumper aero fins. Photo's to come. 
Title: Re: DADS360 - THE Build diary!
Post by: dangerrous on August 17, 2019, 04:56:58 PM
Keep posting, always interested in your progress on this special build
D
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on August 18, 2019, 01:28:45 PM
Thanks for the kind words. They keep me going. I am working today on the rear diffusers. Will post some photo's tonight.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on August 18, 2019, 06:06:17 PM
Shots of the rear aero plate ,folded as required and the fins profiled ready for tig welding. More photo's to come when they are completed.
Title: Re: DADS360 - THE Build diary!
Post by: zxrjohn14 on August 18, 2019, 10:02:37 PM
Ooh.....I'm liking these.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on August 19, 2019, 08:53:29 PM
Can any of you guys guide me on where to cut the Peugeot door rubber to suit the Extreme kit once the mods have been done. I cut mine at the join on the sill and the up near the where the door mirror is but it's not ideal. Info greatly received.
Title: Re: DADS360 - THE Build diary!
Post by: zxrjohn14 on August 20, 2019, 09:29:09 AM
I started mine in the mitred corner then pushed it all on and made the cut at the bottom of the cill in the middle.
My thought that this would be the place furthest from water ingress.
I do intend to also put some Tiger Seal inside to bond it together on my final fix stage of the build.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on August 20, 2019, 01:46:49 PM
Thanks for the info John, I will do the top mitre style when I get another rubber.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on August 20, 2019, 02:06:11 PM
Powder coated and ready to fill the hole at the back of the front boot.
Title: Re: DADS360 - THE Build diary!
Post by: Mickey_London on August 21, 2019, 09:24:19 AM
Great skills put into this build
Do you have a time scale of when she will be finished
Mick
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on August 21, 2019, 05:18:58 PM
Hi Mick the build is just a fascinating hobby , I try to do a bit most days. However my dear lady wife often has other ideas. When i was working I had a great deal of time away from home .For many years I would leave early Monday morning and not be back til late Friday.So her indoors regards my time now as hers, payback for bringing up the family and running the home. With a bit of luck spring/summer 2020 will see it completed
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on August 22, 2019, 01:57:10 PM
A couple of sots of the drivers door with the ferrari door handle fitted and working.
Title: Re: DADS360 - THE Build diary!
Post by: Sparx01 on August 22, 2019, 08:53:59 PM
A complete different class.

Love looking at your progression.

Tone
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on August 25, 2019, 05:03:52 PM
Update on the difuser plates, all welded up ready for the joint between fins and plates to be tidy up. More work on the computer doing the CAD for the nearside closing panel [ seems only fitted to the CS version]. Random shoot of drivers side rear corner.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on August 26, 2019, 04:57:14 PM
Another bullet bitten, I hope my wife never looks at my build diary and checks with Eurospares the price of the parts.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on August 28, 2019, 01:36:11 PM
That "random photo of drivers side rear corner" got me thinking about how much clearance there is for the wheel on full suspension deflection. It turns out not enough, the oil cooler needs to be higher and further in so I need to mod the mounting brackets. Photo's to follow.
Title: Re: DADS360 - THE Build diary!
Post by: zxrjohn14 on August 28, 2019, 09:51:18 PM
That "random photo of drivers side rear corner" got me thinking about how much clearance there is for the wheel on full suspension deflection. It turns out not enough, the oil cooler needs to be higher and further in so I need to mod the mounting brackets. Photo's to follow.
This is the reason I've procrastinated on bonding my panels on. I seem to be alternating something somewhere often, and want to make sure things work right before I commit to the undoable
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on August 29, 2019, 12:43:55 PM
Your dead right John, I must have had the rear quarter panels on and off 20/30 times during the course of the build so far. the drivers side one is going to be R+I many more before the oil cooler is in the ideal position. 
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on October 17, 2019, 05:42:15 PM
Finally got the oil cooler re positioned, Had all the removable parts powder coated. One shot shows the " hole " left when the drivers side fuel tank was removed.The others show the new position.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on March 16, 2020, 10:20:11 PM
Update from my last post, finished the closing panel at the back. The bolts I used are Porcshe front wing mounting.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on April 07, 2020, 01:28:29 PM
Shots of the passenger side rear structure back from powder coat. Along with the parts installed.Rear bumper fitted with the aero fins. The next job is to install the drivers side sill cover.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on April 07, 2020, 01:35:41 PM
Additional shots of the rear.
Title: Re: DADS360 - THE Build diary!
Post by: Mickey_London on April 09, 2020, 09:54:37 AM
What a great build this is
Simply Jaw Dropping
Keep the updates coming
Mick
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on April 15, 2020, 09:04:47 PM
Been working on the infill panel on the drivers side. More CAD in cardboard, the panel is made just need to make the support tabs. I have decided to do the side sills as bolt on,since they are cosmetic, couple of shots of the attachment studs and a view of the final result.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on April 25, 2020, 07:52:17 PM
Front end sheet metal stripped off ready to go for powder coating. Don't panic no breaking of the stay at home rules. The parts will be collected,coated and then returned. Next job is to tidy up the guttering rail behind the door mirror.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on April 26, 2020, 06:43:25 PM
Decided to send all the removable parts to be powder coated, shots of the front end stripped down. The rad pack sits on a separate sub frame which has already been coated so left that in. It will be like Christmas when they all come back.
Title: Re: DADS360 - THE Build diary!
Post by: CdRsKuLL on April 27, 2020, 08:42:57 AM
Can't wait :-) It' naked now!!  Thanks for keep posting updated, it's been one hell of a build diary this!

Steve
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on April 28, 2020, 01:10:58 PM
OK, i said the next job to do was the gutter at the drivers side. Well that's just boring so instead I made the mounting bracket for the gear selector gate.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on April 29, 2020, 02:30:54 PM
Shots of  the mounting made to support the gear change gate to the o/e centre console.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on April 30, 2020, 07:56:43 PM
Another piece of the engine bay puzzle purchased.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on May 03, 2020, 06:19:12 PM
Done come work on the drivers side gutter. First photo show the hole, second the infill piece I made, third show it fitted and finally a shot of the profile piece needed to blend into the screen side pillar. 
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on May 04, 2020, 07:53:47 PM
Thought I would clean and paint the front bulkhead today, but then noticed I have not made the recess panel for the drivers side bonnet hinge. Some shots of gap to be filled and the template to make in steel. ( photo of the passenger side for reference ).  Once done I can then paint the bulkhead.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on May 05, 2020, 08:20:12 PM
The cardboard has been turned into metal and fitted to the front bulkhead. Applied a couple of coats of satin black.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on May 08, 2020, 03:59:06 PM
The parts are back from powder coat, a fantastic job done by the boys. Shot of the drivers side wing support installed, and a shot of the "hole" that needs to be filled.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on May 10, 2020, 01:54:36 PM
Made the infill piece for the drivers side wing to A post, only a skim of filler needed. Shot attached. Will post more when its in place.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on May 12, 2020, 08:33:09 PM
The infill plate is now attached. Made from 50mm X 25MM ERW box section. This is ideal since it provides the smooth radius curves needed.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on May 15, 2020, 06:50:19 PM
Couple of shots with the front wing installed to give an idea of the completed fit. Some shots of a little bracket made to align/secure the bottom of the front wing. It never seemed to line up with the door/sill, the bottom of the wing pointed out .This bracket boned to the wing will do the trick.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on May 19, 2020, 09:01:30 PM
When cruising the web I found an interesting article on brake balance. Applying the maths to my project I determined  I was well over braked on the front. The set up was front a BMW M5 with rotors @ 375 mm diameter . So following advice from Colin Chapman AKA Mr Lotus ( my chassis is Lotus V8]  I have followed their lead and converted to the big brake set up used on the last of the GT3 Esprits .
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on May 23, 2020, 05:03:23 PM
Fitting the alternative brake rotors requires new mounting plates for the calipers.Photo of the new plates along with two mounting bolts made out of two Peugeot rear subframe mounting bolts. these are for mock up, I have four 12 mm x 1.5 10.9 tensile strength on order. The spacers are bits of tube from a kids garden swing capped with two washers, awaiting the return of four customer spacers from the machine shop.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on May 26, 2020, 09:07:56 PM
Update , wipers and servo cleaned and painted. Bolts arrived for the calipers. Started to assemble the powder coated frame work.
Title: Re: DADS360 - THE Build diary!
Post by: AIG1355 on May 26, 2020, 10:44:52 PM
Hi,
That's all looking impressive.
How long do you reckon you have left on the build until paint?
Given your obvious skills, will you paint this yourself or go to a bodyshop?

Have you joined the DNA and Extreme Owners Kit Car Group on facebook? There is more activity on there of recent, I've been posting on both.

Cheers
Rich
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on May 27, 2020, 11:02:31 AM
Hi Rich, I don't have the facilities ,[or enough skill] to do the paintwork. But I have contacts who are up for doing the body prep and paint. I am a member on the Extreme and DNA Facebook site but have not as yet posted anything, I will have to give it a whirl. Thanks for the positive comments , they keep me going.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on May 31, 2020, 05:44:55 PM
The front brake rework is complete, Assembled some of the sheet metal for the " trunk". I will leave the rest of the panels for later as before long I will have to separate the body from the chassis to seal all the seams and to give it an under coating of body schutz. 
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on June 04, 2020, 12:39:49 PM
Revisited the engine cover lock mounting. The way I had made it originally made it very difficult to access/adjust the lock. So after checking with Enzo [ looked at photo's on the internet] I remade it his way. The setup is quite complex, the lever on the door jam opens the engine cover, but should this fail there is a knob to pull inside the fuel filler cap to open the engine cover. Should the switch on the centre console not open the fuel filler flap you can open the engine cover and then access the hidden knob which opens the fuel filler flap !!!!!!!!!!. Photos below .
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on June 10, 2020, 04:41:57 PM
More work at the rear, stripping out the engine/gearbox frame to enable all the brackets for the oil tank to be made and fitted. Then on to making the outer mounting brackets for the rear bumper. Some shots of the steel roof being prepped in readiness for it to be installed. The tricky bit is rolling a wire bead into the rear edge to line up with the engine cover.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on June 15, 2020, 08:43:26 PM
Work started on mounting the engine bay oil tank. Couple of shots of the the tank mocked up and shots of one of the mounting brackets. Will post more when I have completed the second mount.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on June 22, 2020, 12:03:50 PM
The two oil tank mounting bracket I made turned out to be prototypes !!!!!. I had not figured in the mounting for the clutch slave cylinder mounted on the trans axle, it's the silver housing in the first photo. So two new mounts had to be made. All done now.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on June 28, 2020, 01:43:47 PM
Made a start on the nearside door, hockey stick and end cap sorted. Collision bar removed from inside the door and prepped ready to bolt and glue to the outside of the door.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on July 03, 2020, 05:13:44 PM
Sorry for the poor photos in the previous post. I have now completed the refabricating of the Audi A3 door window mechanism for the passenger side. Shown are the handed pair of mechanisms. The door bar is fitted to the door, so now it's time for all the hard work of fitting the frame into the door shell and doing the internal linkage and outer door handle. Just out of interest it was me who identified the Audi A3 two door as a candidate for the Extreme 360 kit .During my day job I drove around the country visiting customers and dealerships, so took the plastic window that came with the kit and used to walk around the company car parks offering up the window to see if any were suitable. When I had identified the Audi as suitable I shared the info with the team at Extreme. The engine support frame is back from powder coating. It's coming along now, next is repositioning the B post and then the steel roof.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on July 10, 2020, 04:27:58 PM
Door mechanism now fitted in the nearside door. photo's show the misalignment of the back edge of the drop glass to the rear quarter panel. This is fixed by putting in a new B post. This corrects the misalignment and also becomes hidden under the rear Ferrari quarter light glass. The roof rails are next to be modded and then to work on the outside handle and stiffen up the back of the door behind the fibreglass door cap.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on August 03, 2020, 12:18:24 PM
I have been busy with family MOT's so progress has been slow on the passenger door. But I did have chance to sort out the steering wheel.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on August 07, 2020, 07:40:26 PM
Back on the passenger door, reinforcement  plates made, these will be welded and bolted in place. Shot of the inner door modified and ready to go.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on August 14, 2020, 07:57:01 PM
Been busy looking after my grandson ,it's school holidays .Mrs Chevy and I took him yesterday to East Kirby to see "Just Jane" this is an up and running world war two Avro Lancaster. The roar of four Rolls Royce Merlin V 12 engines screaming at full chat literally takes you breath away .The smell of 100 + octane avgas is enough to make you go funny.
In the time I had on the project I made the bracket that hold the outer door handle to the door skin. Next is to make the two brackets that secure the inner door cable.
Title: Re: DADS360 - THE Build diary!
Post by: AIG1355 on August 15, 2020, 10:37:32 AM
Looks like you're pretty safe in the thought that its not going to snap off in your hand at the most inopportune moment.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on August 17, 2020, 01:00:45 PM
Yes you right, a lot better than a bit of fibreglass bonded to a kitchen door hinge.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on August 17, 2020, 01:03:23 PM
Done the mounts for the inner door cable, there little parts that take hours to make.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on September 02, 2020, 08:22:54 PM
More work done on the nearside, made the mounting support for the door catch. Unfortunately ran out of MIG wire.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on October 11, 2020, 12:53:55 PM
Sorry for no updates, I have been plagued by jobs on my "other" vehicles. My daughter is into the VW camper van scene. Her recent trip to Santa Pod did not go well with reports of down on power from the 1.9 TD engine. So many hours of investigation revealed a partially blocked exhaust. Had to buy a special tool to get the down pipe off !!!!. Once that was resolved it was agreed we would fit an intercooler, this resulted in many more hours of fabrication and parts buying along with fuel pump and turbo mods. All went well until we tried to start the engine, what was once an easy engine to start was not having any of it. So undid all the fuel pump mods but still it would not start. More investigation revealed the cold start was inop. So had to rewire and and replace the cold start relay. Job done, three PSI boost is now twelve pounds of boost. 
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on October 11, 2020, 01:06:11 PM
That was not the end of it, my daily driver BMW decided that it would throw up an rear door thorax yellow airbag light. It's never the airbag, oh no it's " resistance too high ". More hours of my life I will never get back. Two days later it throws up a red drivers airbag light, this was resolved by replacing the ZSL module in the steering column ,did that fix it ,no because it has to be coded to the car. So once that's resolved it throws up an engine management light, "adaptive mixture control bank one and bank two limit reached" this was a ruptured crankcase diaphragms. Did replacing them fix it, no the engine ECM has to have an adaptive control reset. Still have not fixed grand sons quad, I have the parts just not got round to it.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on October 25, 2020, 03:59:54 PM
Back to the project at last. The nearside B post is now in position. Just the edge for the door rubber to trim and then onto extending the roof drip rail to allow the drop glass to seal against the repositioned rubber.
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on November 16, 2020, 06:10:11 PM
The two new guides for the door rubber are now in place, this allows the Audi window to seal to Peugeot body shell. 
Title: Re: DADS360 - THE Build diary!
Post by: dads360 on November 16, 2020, 06:15:54 PM
Sorry guys, reposted the earlier photo,s , new ones below.