Floor Pan Swap - haldex to come...

[All_Euro]

Re: Floor Pan Swap - haldex to come...

Looking good weather wise for at least another week too...loving the updates and the progress!!!!

Thanks - ya, I can't believe how the weather has been holding up. I've lost a month or so to the cold and work but, for this time of year, I couldn't ask for more.

Progress is looking good!

Thanks Rob - this is definitely the most exciting part of the swap so far. Once I've been on the road for a bit, and everything seems solid, I'll pick a "warm" weekend and swap in the TT transmission.

[All_Euro]

Re: Floor Pan Swap - haldex to come...

DAY EIGHTY

Fit a few more things under the trunk - just finger tight for now as I want to put some new grease in the inner CV joints and haldex fluid in the diff. Would have loved to clean and paint all the rusty bits before they went in but that'll have to be fun for another day...

[RobG]

Re: Floor Pan Swap - haldex to come...

Progress is looking good!

[Geobmx4life]

Re: Floor Pan Swap - haldex to come...

Looking good weather wise for at least another week too...loving the updates and the progress!!!!

[All_Euro]

Re: Floor Pan Swap - haldex to come...

Solid work, you have an ETA in mind? things are starting to wrap up!

Thanks - yes, things are finally coming together... who knows what surprises I'll run into but I'm pushing to be back on the road by the end of the month!

Monty you're one crazy mama jama!

Haha, well I've been called much worse so I'll take that as a compliment Seb

[All_Euro]

Re: Floor Pan Swap - haldex to come...

DAY SEVENTY NINE

Another late one at the office but I skipped dinner when I got home and pulled the rear-end out of the basement for a test fit. Fit like a glove - no clearance issues with the filler neck. I do need to secure the gas-cap area of the neck but it's on the to-do list...






I could tell I was a little excited to bolt his baby in as I kept hitting my head on pretty much every sharp metal edge under the car - good thing I had my safety toque on...

[sabbySC]

Re: Floor Pan Swap - haldex to come...

Monty you're one crazy mama jama!

[GingerBeef]

Re: Floor Pan Swap - haldex to come...

Solid work, you have an ETA in mind? things are starting to wrap up!

[All_Euro]

Re: Floor Pan Swap - haldex to come...

DAYS SEVENTY TWO - SEVENTY EIGHT

Nothing really happened last week, as I was too busy with work, but I did get a little done this weekend. Finished the exterior welding and sealing touch ups - there's some left inside but I'll do that after I get rolling again. Since the inside of the floor pan is just primed, I was able to warm up the panels pretty good to help the sealant dry too...




I ended up wrapping the filler neck ,with more FiberFix, from the base of the neck/tank all the way up to the upper connection as there was still a good amount of flexibility in the neck. While the tank was out I wiped the inside out really well so it's nice and clean going back in. It's in place and hooked up - just need one replacement bolt I seem to have misplaced...

[All_Euro]

Re: Floor Pan Swap - haldex to come...

Monty you animal!!!
Sorry I have been out of the country for a while and I didn't think you had started this project yet. I thought you were waiting for spring?
Not just a beast at crossfit!! haha, but you took this project by the horns. Great work!!
I will be back in the city soon, hopefully we can link up.
Cheers.

Hey bud - thanks, and good to hear from you. Well... yes, I was definitely going to wait for spring... but here I am somehow

Thankfully this bull has been cooperating for the most part. Hopefully I'll be done by the time you're back and we'll catch up!

[All_Euro]

Re: Floor Pan Swap - haldex to come...

DAYS SEVENTY - SEVENTY ONE

Knowing what I know now, I think I'd just split the GLI filler neck off the tank and have it welded on to the TT tank after it's neck had been removed. In this shot you can see the sandwich effect where the neck and tank join and then just inside is a plastic guide/fuel hose that feeds the tank. Hindsight hey...




The latest adhesive I bought is strong stuff for sure but still doesn't melt into the plastic at all - just adheres to the imperfections. It is strong though, so once the joints were nice and solid, and after some helpful advice from Bob, I sanded the filler neck down and reinforced the joints with FiberFix - I'll double check it in the morning and might add another layer. I do want to keep some flexibility in the neck so that any twisting from the chassis doesn't work the joints loose. Also got the vent connections beside the gas-cap squared away...

[24vr86]

Re: Floor Pan Swap - haldex to come...

Monty you animal!!!
Sorry I have been out of the country for a while and I didn't think you had started this project yet. I thought you were waiting for spring?
Not just a beast at crossfit!! haha, but you took this project by the horns. Great work!!
I will be back in the city soon, hopefully we can link up.
Cheers.

[bobkatkat]

Re: Floor Pan Swap - haldex to come...

Thanks for the kind words fellas - this is taking forever but the "finish" line is just around the corner at least. I want my car back!

I appreciate the offer Bob - I did keep the scraps as I was thinking of plastic welding the joints once the male/female parts of the connections are sealed. Not that I've ever plastic-welded anything before... a little experience would def come in handy here.

Pm Replied to

[All_Euro]

Re: Floor Pan Swap - haldex to come...

Thanks for the kind words fellas - this is taking forever but the "finish" line is just around the corner at least. I want my car back!

I appreciate the offer Bob - I did keep the scraps as I was thinking of plastic welding the joints once the male/female parts of the connections are sealed. Not that I've ever plastic-welded anything before... a little experience would def come in handy here.

[All_Euro]

Re: Floor Pan Swap - haldex to come...

DAY SIXTY NINE

I stopped by a body-shop supply store on the way home from work today and picked up some professional strength adhesive that they said would work on polyethylene. It seems to be ok - I'll test the joints, a little more enthusiastically, in the morning and we'll see...




Here's an overall shot of the filler neck from the final test fit. I still have the two tank vent connections to take care of as well - I'm planning to plumb them into their usual locations on either side of the gas cap. They both feed a single vent line on the trunk side of the gas-cap so I can then run that line through a charcoal canister or something when I get one...