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MY00 RSTi Open light rally build
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Old 12-04-2018, 10:53 AM   #71
CornCob
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After I got all those bars done I pulled all the bars out to remove the millscale/surface rust. I think next time I'll go with CDS instead of DOM to save some time on prep.

While they were out I started on the main hoop support bars







and I modified my rear plinth boxes a little so they would take up more surface area, since I wasn't happy with how the cage sat on them.







I made it more into an L piece for the top so it can sit more on the rear bench and not just the small section of rocker panel.


and while starting on tacking everything in last night I managed to do this like an idiot....








I got lazy while quickly sharpening my tungsten for the last tack after I dipped it. Instead of walking to the normal sharpener with my drill, I decided to try my angle grinder since I could reach it while still in the car..

After a quick ER trip I can safety say I won't be doing that again..
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Old 12-04-2018, 12:06 PM   #72
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What? No blood?

Re-do!
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Old 12-04-2018, 12:31 PM   #73
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I have a habit of stabbing myself with the filler right after stopping a weld, 99.9% it sears the hole shut
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Old 12-04-2018, 02:03 PM   #74
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What no new video!? Lol jk
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Old 12-04-2018, 03:37 PM   #75
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Quote:
Originally Posted by Rsfanatic View Post
What no new video!? Lol jk
There's a few new ones out since I last posted in the thread, I just forgot to throw them in with the update.



Quote:
Originally Posted by bue car View Post
What? No blood?

Re-do!

Lol I was really surprised by the lack of blood when I pulled it out of my hand and it was in there about an inch.


Quote:
Originally Posted by Bansheeboy11 View Post
I have a habit of stabbing myself with the filler right after stopping a weld, 99.9% it sears the hole shut

Haha I do that all the time too. Too many pairs of pants with small holes in them from the filler burning through.
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Old 12-05-2018, 05:48 AM   #76
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Cage is looking good so far! Our cages are almost twins so far. Are making the car right hand drive?
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Old 12-05-2018, 12:31 PM   #77
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[QUOTE=CornCob;3603811]
Quote:
Originally Posted by Rsfanatic View Post
What no new video!? Lol jk
There's a few new ones out since I last posted in the thread, I just forgot to throw them in with the update.


I already watched them all... 😅
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Old 12-10-2018, 07:36 PM   #78
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Quote:
Originally Posted by Ted View Post
Cage is looking good so far! Our cages are almost twins so far. Are making the car right hand drive?
Sweet! I'm planning on keeping it LHD, I did have everything to do the RHD swap but I ended up getting rid of all of that.
[QUOTE=Rsfanatic;3603871]
Quote:
Originally Posted by CornCob View Post
There's a few new ones out since I last posted in the thread, I just forgot to throw them in with the update.


I already watched them all... 😅

Haha my bad, thanks for watching them!
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Old 12-10-2018, 07:59 PM   #79
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Since I'm pretty bad about keeping this updated as I move along, here's another large update over the last week or so.


Once the main hoop support bars were done I started on the rear bars, I managed to knock all six out in one night. I must have gotten lucky with all the measurements..






I'm kind of stupid when it comes to gravity and welding..






Then I started on the optional front windshield reinforcement bars




They came out pretty good on the first try which is always nice.
I realized I needed to drop the cage one more time to weld those in though.
So, I dropped the cage again and welded the rear stays on and the windshield bars into place and put it back into place.


Then came the sill bars.



Those were probably the easiest bars so far, simple 90 degree notches and no bends, what's not to love.


And since I can't really use my stock dashbar since I wanted to tuck the front laterals up so far I started on one.




I roughly followed the same pattern as the stock bar and it sits at the same height, I can still get the stock heater core in and out without an issue and the blower motor.
The dash seems like it will fit without too much of an issue but I'll see about that later on.


aaand thenn


I started on the optional front intrusion bar/strut tower tie in


These were pretty crappy to make fit right and get them fully welded into place and in a position where I can still use the blower box without too much trimming.


That's a pretty crappy picture but they tuck nicely against the side of the car and meet the center of the strut tower.






and then today, I spent about ten hours welding all the bars in.

Every bar in there is fully welded into place and to the cage boxes.
The only thing left are the door bars, a pillar supports, harness bars, and gussets for the cage to be complete.











I also primed the top of the cage/ sides that will be almost impossible to get at once it's in place with some weld through primer. Hopefully that can help with surface rust on this thing.

Last edited by CornCob; 12-11-2018 at 04:21 AM..
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Old 12-11-2018, 04:31 AM   #80
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The only reason I asked was you technically installed your main hoop X in reverse. Generally the long part of the X supports the portion above the driver's head rather than the passenger.

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