Toyota Freestyle GT

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Toyota Freestyle GT

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Demon
Posting Freak

1,614

04-04-2018, 01:34 PM

#201

I spent about an hour sanding the fuel rail. Starting with 180 grit, then 400,600,1000 and 1200 grade until nice and smooth. The fuel rail was in really good condition and you can see that Ricky has taken care not to scratch it while making it. Then got it on the buffing wheel and it now looks like chrome Big Grin

Thats now wrapped up safely and put in the big box of parts that are waiting to be fitted.

Got the thottle body taken off the inlet so i can get the main body polished up and have made a start with hand sanding. Again you can see that Ricky has taken really good care with making the manifold and there are very few scratch's on it so will come up really nice.

throttle body taken off.....
[Image: DSC01220.jpg]

Inside of manifold.......
[Image: DSC01219.jpg]

I spent a little bit of time sanding the top and back of the manifold and you can see how nicely it has come up! This hasn't been on the buffer yet and its looking fantastic.

[Image: DSC01226.jpg]

Now that the hubs are all cleaned up and ready for the machineing im going to continue with the polishing now this week. Im waiting for the laser cutting company to get back to me with the quote for the fuel cell parts but they have promised that they will this coming week.

Hopefully i will get a chance to get up to TGT next Saturday with any luck and see what is going on with the chassis. Hopefully they have found time to do a little bit???

Jason Big Grin

The 'Demon' is on its way :Shooting:

Now driving a Sh!tbox Sad

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Demon

04-04-2018, 01:34 PM #201

*** little udate ***

Well today i went to my work's workshop to get a few little things done.

Have spent all week stripping down the mini hubs and getting them cleaned up and hopefully in a few weeks they will be getting machined to accept the new discs. I managed to get the disc flanges cleaned up and bolted up to the new discs. While they are all clean and the rust starts building up again i got a coat of black hammerite on them.

[Image: DSC01217.jpg]
[Image: DSC01224.jpg]

I spent about an hour sanding the fuel rail. Starting with 180 grit, then 400,600,1000 and 1200 grade until nice and smooth. The fuel rail was in really good condition and you can see that Ricky has taken care not to scratch it while making it. Then got it on the buffing wheel and it now looks like chrome Big Grin

[Image: DSC01222.jpg]
[Image: DSC01223.jpg]

Thats now wrapped up safely and put in the big box of parts that are waiting to be fitted.

Got the thottle body taken off the inlet so i can get the main body polished up and have made a start with hand sanding. Again you can see that Ricky has taken really good care with making the manifold and there are very few scratch's on it so will come up really nice.

throttle body taken off.....
[Image: DSC01220.jpg]

Inside of manifold.......
[Image: DSC01219.jpg]

I spent a little bit of time sanding the top and back of the manifold and you can see how nicely it has come up! This hasn't been on the buffer yet and its looking fantastic.

[Image: DSC01226.jpg]
[Image: DSC01227.jpg]

Now that the hubs are all cleaned up and ready for the machineing im going to continue with the polishing now this week. Im waiting for the laser cutting company to get back to me with the quote for the fuel cell parts but they have promised that they will this coming week.

Hopefully i will get a chance to get up to TGT next Saturday with any luck and see what is going on with the chassis. Hopefully they have found time to do a little bit???

Jason Big Grin

The 'Demon' is on its way :Shooting:

Now driving a Sh!tbox Sad

Smurf SOLD
Outlaw No: 016 Cool

dimis
Posting Freak

3,795

04-04-2018, 01:54 PM

#202

Very nice work mate.

LEXUS IS200 - The most fun car to go sideways

dimis

04-04-2018, 01:54 PM #202

Very nice work mate.

LEXUS IS200 - The most fun car to go sideways

steviewevie
Posting Freak

7,993

04-04-2018, 03:10 PM

#203

Nice Jason ! :drool:

IS200 Turbo project now just about complete ! See my thread here and leave your comments.
Now running standalone Syvecs ECU and no stock ECU !

steviewevie

04-04-2018, 03:10 PM #203

Nice Jason ! :drool:

IS200 Turbo project now just about complete ! See my thread here and leave your comments.
Now running standalone Syvecs ECU and no stock ECU !

Demon
Posting Freak

1,614

11-04-2018, 01:06 PM

#204

Thanks Guys, starting to get there now Big Grin

*** Sunday Update ***

Well its been another busy week but im happy with the direction its going and the next few months are going to be interesting Big Grin

Started off the week by cutting a small section off of my intercooler pipework to look at making a custom made oil catch tank. There is plenty of bends, straight etc so just cut a 120mm piece off. The oil catch tank is going to have AN6 earls fittings with a bottom bung to drain the oil. Not going to have a site tube on it as it looks messy, will just empty it every now and then.

Top end......
[Image: DSC01232.jpg]

Bottom.........
[Image: DSC01233.jpg]

Its not welded up yet but James will do it when the intercooler pipework gets done. Will have a small bracket added and will attach to the side of the engine somewhere so i don't have to run stupidly long hoses.

Then started with one of the jobs i have been meaning to do for some time now, sort out the arch's for the wheels. As i have new brackets made up for the front and rear i needed to make a template to work out what size arch's i need and where to mount them. Im going for the smallest arch's i can get away with as i like the wheel being on show more. Im going for close fit arch's that fit as close to the tyre as possible. 15mm above to be precise, but as the arch moves up and down with the hub this shouldn't be a problem and shouldn't ever touch the tyre.

After alot of measuring, angles, more measuring i have a template.........
[Image: DSC01235.jpg]

You can see the small arch that is possible and the template is mounted directly to the hub to work out the correct placement of the arch, the template is reverseable so i can do both sides!

Now came the arch's, the only arch's i can find that i like are the carbon mods ones, and im not paying £200 a pair!!!! So i have decided that the rest of the project is custom i may as well make the arch's from scratch! My bro has moved to Japan for a year or two and left alot of resin, fibreglass and gelcoat. So in theory the arch's won't cost me anything but time to make!

So after a few minutes thinking about how to do it i started knocking up a template.....
[Image: DSC01236.jpg]

finished mould, rounded the corners ever so slightly.......
[Image: DSC01240.jpg]

The arch's are 220mm wide so i can run some wide slick tyres for track days and the arch curve should match exactly to that of the template so i can mount them properly. I have found some proper woven fibreglass material so hopefully will knock out a arch or 2 during the week. Big Grin

Also got up to TGT yesterday and they have started work back on the buggy! Its looking good and the back has been welded onto the main chassis so is almost in one piece again! It still needs the topmounts welding on the rear and i have to get some steel tube to reinforce the back. I don't have any pictures but give me a week or so and i will. Plan is to get up there next saturday and hopefully this should see most of the fabricating work on the chassis finished off. This will mean that the engine should be going back in shortly after and i can begin getting the driveshafts made, and connecting things up! WHOOP WHOOP!

Also had a little chat about paint while i was up there and this has changed, AGAIN!!!! Plan now is to spray the chassis Matt black and have bright green arch's, nosecone, sides, spoiler, engine cover etc. Should look better in Matt black against all the polished engine parts.

thats all for now........... Big Grin

Jason

The 'Demon' is on its way :Shooting:

Now driving a Sh!tbox Sad

Smurf SOLD
Outlaw No: 016 Cool

Demon

11-04-2018, 01:06 PM #204

Thanks Guys, starting to get there now Big Grin

*** Sunday Update ***

Well its been another busy week but im happy with the direction its going and the next few months are going to be interesting

Started off the week by cutting a small section off of my intercooler pipework to look at making a custom made oil catch tank. There is plenty of bends, straight etc so just cut a 120mm piece off. The oil catch tank is going to have AN6 earls fittings with a bottom bung to drain the oil. Not going to have a site tube on it as it looks messy, will just empty it every now and then.

Top end......
[Image: DSC01232.jpg]

Bottom.........
[Image: DSC01233.jpg]

Its not welded up yet but James will do it when the intercooler pipework gets done. Will have a small bracket added and will attach to the side of the engine somewhere so i don't have to run stupidly long hoses.

Then started with one of the jobs i have been meaning to do for some time now, sort out the arch's for the wheels. As i have new brackets made up for the front and rear i needed to make a template to work out what size arch's i need and where to mount them. Im going for the smallest arch's i can get away with as i like the wheel being on show more. Im going for close fit arch's that fit as close to the tyre as possible. 15mm above to be precise, but as the arch moves up and down with the hub this shouldn't be a problem and shouldn't ever touch the tyre.

After alot of measuring, angles, more measuring i have a template.........
[Image: DSC01235.jpg]

You can see the small arch that is possible and the template is mounted directly to the hub to work out the correct placement of the arch, the template is reverseable so i can do both sides!

Now came the arch's, the only arch's i can find that i like are the carbon mods ones, and im not paying £200 a pair!!!! So i have decided that the rest of the project is custom i may as well make the arch's from scratch! My bro has moved to Japan for a year or two and left alot of resin, fibreglass and gelcoat. So in theory the arch's won't cost me anything but time to make!

So after a few minutes thinking about how to do it i started knocking up a template.....
[Image: DSC01236.jpg]
[Image: DSC01237.jpg]
[Image: DSC01238.jpg]

finished mould, rounded the corners ever so slightly.......
[Image: DSC01240.jpg]

The arch's are 220mm wide so i can run some wide slick tyres for track days and the arch curve should match exactly to that of the template so i can mount them properly. I have found some proper woven fibreglass material so hopefully will knock out a arch or 2 during the week. Big Grin

Also got up to TGT yesterday and they have started work back on the buggy! Its looking good and the back has been welded onto the main chassis so is almost in one piece again! It still needs the topmounts welding on the rear and i have to get some steel tube to reinforce the back. I don't have any pictures but give me a week or so and i will. Plan is to get up there next saturday and hopefully this should see most of the fabricating work on the chassis finished off. This will mean that the engine should be going back in shortly after and i can begin getting the driveshafts made, and connecting things up! WHOOP WHOOP!

Also had a little chat about paint while i was up there and this has changed, AGAIN!!!! Plan now is to spray the chassis Matt black and have bright green arch's, nosecone, sides, spoiler, engine cover etc. Should look better in Matt black against all the polished engine parts.

thats all for now........... Big Grin

Jason Smile

The 'Demon' is on its way :Shooting:

Now driving a Sh!tbox Sad

Smurf SOLD
Outlaw No: 016 Cool

DaveEdin
Posting Freak

5,657

11-04-2018, 02:11 PM

#205

Sounds great bud!

Knock us up a photoshop of what things should look like finished?

I reckon this is going to be an awesome beast when finished... you should get one of those plates made up with Demon etched onto it to fit somewhere...

The Demon Mk1 :thumbup:

DaveEdin

11-04-2018, 02:11 PM #205

Bandit
Posting Freak

6,464

11-04-2018, 04:51 PM

#206

Awesome work as always mate, everything you make is pure quality :thumbup1:

Looking forward to seeing it all together :thumbup:

Lexus IS200 Sport Navigator (Now being stripped again) :blink:

Now Don't Forget The REP!!!

Bandit

11-04-2018, 04:51 PM #206

Awesome work as always mate, everything you make is pure quality :thumbup1:

Looking forward to seeing it all together :thumbup:

Lexus IS200 Sport Navigator (Now being stripped again) :blink:

Now Don't Forget The REP!!!

Demon
Posting Freak

1,614

18-04-2018, 08:26 AM

#207

Thanks for comments guys. Im trying to get this mostly done before we start looking at houses as otherwise i may not have the funding to complete it Sad

*** She's Rolling ***

Been a busy old week really, as usual at the moment :lol:

Took the nice MDF mould i made for the arch's and spent the evenings during the week fibreglassing up the first arch. I didn't know if the fibreglass would stick to the mdf or if the mould release would actually release the arch. Took a gamble and it paid off. Came out pretty easily to be honest and the second arch is currently in the mould awaiting its final layers. I have used 2 layers of woven fibreglass and 3 layers of CSM so the arch's are really thick!!!! They are about 4-5mm thick so i can get away with having no edging trim and just round the edges over. Im going to try and see if i can support them just at the side also and not have any metal under the arch. This means i can get them closer to the tyre, aiming for a 15mm space between arch and tyre Big Grin

in the mould.........
[Image: DSC01241.jpg]

taken out.......
[Image: DSC01242.jpg]

and trimmed down, the template shows the smallest arch legally possible and i am just over the limit, you can see how thick the fibreglass is........
[Image: DSC01245.jpg]

Here is what the arch's i bought before look like on the wheel, you can see that they don't follow the wheel radius well and they are quite big in size.....
[Image: DSC01248.jpg]

and my design, follows wheel radius perfectly and is tiny in size Big Grin

I think these arch's will look great when they are properly on!

Whoop Whoop! Well got up to TGT yesterday morning at 9am and got things rolling, literally, yep thats right she's back to a rolling chassis Big Grin

Spent the day getting the rear frame welded up to the main chassis and its all there. When i had arrived James had already got the bottom welded up but we just needed to sort out the topmounts. Sleeved the downtubes and got the new topmount plates in place.

[Image: DSC01249.jpg]

and welded up.......
[Image: DSC01251.jpg]

the gaps are getting filled with metal/weld and then ground flush so the topmounts and light brackets sort of blend into one another........
[Image: DSC01252.jpg]

Rear engine mount has been removed also as the location will have changed with the work and new one will be going on shortly.

Also managed to knock up the seat bars, these will get welded to the bars that are along the floor.
[Image: DSC01253.jpg]

I have also got a few things on order, the laser cut pieces for the fuel cell have been ordered and should be here tuesday. As well as some rather nice Green TRS harnesses and a knock off HKS SSQV BOV. Yes its a knock off but if its really that bad i will buy a proper one and swap the internals over so it looks all new and shiney. Will give me the chance to weld the adaptor to the pipework and mock things up.

I owe James for 2 full days labour but if my budget can stretch to it this month im aiming to get the suspension brackets on, cambelt change and new Cam pulley installed, and the engine and gearbox going back in the chassis...............fingers crossed.

Next jobs are to start working out the fuel cell. I have a fuel pump form a starbo, it is missing a few bits but its mostly there! as always i will keep the updates rolling.

Jason Big Grin

The 'Demon' is on its way :Shooting:

Now driving a Sh!tbox Sad

Smurf SOLD
Outlaw No: 016 Cool

Demon

18-04-2018, 08:26 AM #207

Thanks for comments guys. Im trying to get this mostly done before we start looking at houses as otherwise i may not have the funding to complete it Sad

*** She's Rolling ***

Been a busy old week really, as usual at the moment :lol:

Took the nice MDF mould i made for the arch's and spent the evenings during the week fibreglassing up the first arch. I didn't know if the fibreglass would stick to the mdf or if the mould release would actually release the arch. Took a gamble and it paid off. Came out pretty easily to be honest and the second arch is currently in the mould awaiting its final layers. I have used 2 layers of woven fibreglass and 3 layers of CSM so the arch's are really thick!!!! They are about 4-5mm thick so i can get away with having no edging trim and just round the edges over. Im going to try and see if i can support them just at the side also and not have any metal under the arch. This means i can get them closer to the tyre, aiming for a 15mm space between arch and tyre Big Grin

in the mould.........
[Image: DSC01241.jpg]

taken out.......
[Image: DSC01242.jpg]

and trimmed down, the template shows the smallest arch legally possible and i am just over the limit, you can see how thick the fibreglass is........
[Image: DSC01245.jpg]
[Image: DSC01246.jpg]

Here is what the arch's i bought before look like on the wheel, you can see that they don't follow the wheel radius well and they are quite big in size.....
[Image: DSC01248.jpg]

and my design, follows wheel radius perfectly and is tiny in size Big Grin
[Image: DSC01247.jpg]

I think these arch's will look great when they are properly on!

Whoop Whoop! Well got up to TGT yesterday morning at 9am and got things rolling, literally, yep thats right she's back to a rolling chassis
Spent the day getting the rear frame welded up to the main chassis and its all there. When i had arrived James had already got the bottom welded up but we just needed to sort out the topmounts. Sleeved the downtubes and got the new topmount plates in place.

[Image: DSC01249.jpg]
[Image: DSC01250.jpg]

and welded up.......
[Image: DSC01251.jpg]

the gaps are getting filled with metal/weld and then ground flush so the topmounts and light brackets sort of blend into one another........
[Image: DSC01252.jpg]

Rear engine mount has been removed also as the location will have changed with the work and new one will be going on shortly.

Also managed to knock up the seat bars, these will get welded to the bars that are along the floor.
[Image: DSC01253.jpg]

I have also got a few things on order, the laser cut pieces for the fuel cell have been ordered and should be here tuesday. As well as some rather nice Green TRS harnesses and a knock off HKS SSQV BOV. Yes its a knock off but if its really that bad i will buy a proper one and swap the internals over so it looks all new and shiney. Will give me the chance to weld the adaptor to the pipework and mock things up.

I owe James for 2 full days labour but if my budget can stretch to it this month im aiming to get the suspension brackets on, cambelt change and new Cam pulley installed, and the engine and gearbox going back in the chassis...............fingers crossed.

Next jobs are to start working out the fuel cell. I have a fuel pump form a starbo, it is missing a few bits but its mostly there! as always i will keep the updates rolling.

Jason Big Grin

The 'Demon' is on its way :Shooting:

Now driving a Sh!tbox Sad

Smurf SOLD
Outlaw No: 016 Cool

Demon
Posting Freak

1,614

23-04-2018, 03:55 PM

#208

started to modify the fuel filler cap. I would have loved to of just left it as is but under IVA regs it must lock the key in position or be tethered to the tank. Checked the cap and the key can still be removed when the cap is off the main unit so my only option is to have it tethered to the tank. So its getting modified, won't be too bad hopefully........

[Image: DSC01265.jpg]

Then finally my fuel sender arrived on Thursday. Its a 180-0 Ohm unit and the gauge i have reads 100-0 Ohm so the tank will read full until its about 60% remaining then will read right down to empty. The important part is that at full tank the gauge will read FULL and at empty it will read EMPTY.

[Image: DSC01266.jpg]

I like this fuel sender as its more compact and doesn't have a huge swinging float like some others do.

Then got the flanges for the back box drilled, i have 2 of these as im making 2 exhaust systems. I have most of the parts for this now so when the fuel cell is getting welded i will get James to switch over to Stainless and knock up the exhaust.

[Image: DSC01267.jpg]

Then got these........

[Image: DSC01268.jpg]

Don't really need words do they? God i love them, im going to pop up to TGT tomorrow to double check they fit but im 95% sure they will. Will get a few pics of them drapped over the sexy white seats.

Finally got hold of the laser cutting company and they lost my address, hence why my parts have not arrived yet but they have promised me they are going out today so should have them monday/tuesday and i can begin making the fuel sell, from scratch.

Im also planning on having a steel box welded in in the rear compartment. I have room for one just to the side of the fuel cell. This will be big enough to hold a helmet and steering wheel (when i eventually convert it to a removable type). Will be lockable also...........flippin chav's!

Hopefully next weekend i will be up at TGT really cracking on with it again. Big Grin

Jason

The 'Demon' is on its way :Shooting:

Now driving a Sh!tbox Sad

Smurf SOLD
Outlaw No: 016 Cool

Demon

23-04-2018, 03:55 PM #208

May as well update now as im not planning on doing anything much on the Beast this weekend, going to just spend the weekend chillin out with the misses. I think this has come along quite well now so going to have a few days off, but don't worry guys come monday morning at 7:00am i will be back on it Big Grin

started to modify the fuel filler cap. I would have loved to of just left it as is but under IVA regs it must lock the key in position or be tethered to the tank. Checked the cap and the key can still be removed when the cap is off the main unit so my only option is to have it tethered to the tank. So its getting modified, won't be too bad hopefully........

[Image: DSC01265.jpg]

Then finally my fuel sender arrived on Thursday. Its a 180-0 Ohm unit and the gauge i have reads 100-0 Ohm so the tank will read full until its about 60% remaining then will read right down to empty. The important part is that at full tank the gauge will read FULL and at empty it will read EMPTY.

[Image: DSC01266.jpg]
I like this fuel sender as its more compact and doesn't have a huge swinging float like some others do.

Then got the flanges for the back box drilled, i have 2 of these as im making 2 exhaust systems. I have most of the parts for this now so when the fuel cell is getting welded i will get James to switch over to Stainless and knock up the exhaust.

[Image: DSC01267.jpg]

Then got these........

[Image: DSC01268.jpg]
[Image: DSC01269.jpg]

Don't really need words do they? God i love them, im going to pop up to TGT tomorrow to double check they fit but im 95% sure they will. Will get a few pics of them drapped over the sexy white seats.

Finally got hold of the laser cutting company and they lost my address, hence why my parts have not arrived yet but they have promised me they are going out today so should have them monday/tuesday and i can begin making the fuel sell, from scratch.

Im also planning on having a steel box welded in in the rear compartment. I have room for one just to the side of the fuel cell. This will be big enough to hold a helmet and steering wheel (when i eventually convert it to a removable type). Will be lockable also...........flippin chav's!

Hopefully next weekend i will be up at TGT really cracking on with it again. Big Grin

Jason