So I topped off the tank and was doing some final messing around with some ties/brackets for the gearbox cables and I notice a very strong smell of gas.

First things first - turn off the heater!

Second look under the car to find a puddle of gas :(

Looks like whomever did the welding on the filler didn't do such a great job and it has a hole or 5. It didn't show up before as wasn't under static pressure.

http://i168.photobucket.com/albums/u...ps7c63fa27.jpg

Off to find someone who can MIG weld aluminum

So a few steps forward with some cosmetic items whilst I wait for the filler connector to be welded...

I installed the new gear shift knob - very nicely machined. If anyone has a brandwood setup this is definitely the way to go...

http://i168.photobucket.com/albums/u...ps981f01aa.jpg

Next up I replaced the hose connection from the tank - it used a really nasty looking plastic elbow. Found a nice HPS 1" to .75" 90 degree elbow with a .75" 45 degree pipe.

http://i168.photobucket.com/albums/u...ps971a2ad2.jpg

Next up was replacing the front wheel bearing - I contacted RCR and bought one directly from them but for reference if you that the 3 bolt it is part WBI-513020 which Summit stocks.

ttp://www.summitracing.com/parts/wbi-513020

http://i168.photobucket.com/albums/u...ps20056955.jpg

In addition you will likely need to do like I did and replace the studs with ARP 1007713.

Step 1 - Remove the old hub
http://i168.photobucket.com/albums/u...ps88ea965f.jpg

Step 2 - Replace the studs on the new hub - I made a small jig to push out the installed ones on the bench without putting any load on the bearing. The new ones were installed by using the pull through method with some throwaway nuts.

http://i168.photobucket.com/albums/u...psef9c8b99.jpg

Step 3 - Put everything back together again
http://i168.photobucket.com/albums/u...psd2983017.jpg

Steps 4 - The result - No change :(

Click on picture for video...
http://i168.photobucket.com/albums/u...ps16bzb7vb.mp4

So is it a bad batch of bearings or is this normal? I've torqued the stub axle bolt to the required 118ft/lbs.

Thats looking cool arct1k. Do you auto cross at the metlife stadium in Newark? you might see me there this summer

The intent is to give that a go...

Have you done much autocross? I've done 2 in Tennessee with family but i want to join a local one, i didnt get to join last season as my track car was fubar

I've never done it before - I've done a few track days in the UK but never with my own car. I have to get this one through NJ registration next. What's your ride?

Last few bits before I start the NJ title process...

The fuel filler was re-welded and re-attached with new hoses. All appears to be well with no more leaks!

http://i168.photobucket.com/albums/u...ps861f6179.jpg

http://i168.photobucket.com/albums/u...ps99246891.jpg

I was able to resolve the issue with the hub - I contacted the bearing manufacturer and they recommended tightening further the axle nut to 180ft/lbs. Turns out there is actually a service bulletin to increase the torque. In the end though it was the distorted threads on the nut that were causing the issue. on a 1" bolt they are so strong its over 120ft/lbs to just thread the actual nuts let alone apply any torque to the bearing.

No more slop now :) but I probably didn't need to buy a whole new bearing :( ...

http://i168.photobucket.com/albums/u...psaf7a1ef3.jpg

Finally the stainless engine covers weren't really popping - out with a can of Rustoleam High Temperature engine paint and I had some blue covers... Looks a bit better and easy to go back to stainless if desired with an Acetone bath (I know this as the first finish didn't come out as desired and had to re-do it)

http://i168.photobucket.com/albums/u...ps5a9ca3e1.jpg

http://i168.photobucket.com/albums/u...ps26a7a2b7.jpg

Lastly a quick vid with the new exhaust... It was a v cold start (-15C in NJ) and I don't have a heated / attached garage.

http://i168.photobucket.com/albums/u...pshscbw6ee.mp4

http://vid168.photobucket.com/albums...pshscbw6ee.mp4

Looks good, sounds good - can't wait to see how it GOES!!

If the snow isnt too bad and I dont have to work I hope to at least get it onto the group and take it up and down the driveway this weekend. When is spring again!

That sounds and looks great!
Keep up the good work!

It was -6C but due to snow this evening but was able to give it a quick drive up and down driveway!

http://i168.photobucket.com/albums/u...ps5fbfb0ed.jpg
http://i168.photobucket.com/albums/u...ps9c5a54f1.jpg

:yipi:

Congratulations!
Did you like it, as far as you could feel it in such a short drive?

It seems to move rather quickly

That's always a good thing :)

A 98 Saturn sc2, 5 spd with a 11.3:1 compression ration full port and polish on lowering springs. The cars good i just need a driver mod. Looks like it was fun taking your wip for the first drive

http://i168.photobucket.com/albums/u...ps1e13nbhq.jpg

Weather improving quickly! Just need the DMV to get moving so that I can get this thing street legal.

Lots of updates over last few weeks... After speaking to the specialty inspection site I got the distinct impression that they were going to require fenders so I jumped on getting them mounted ASAP

First up was to create a secure mounting points on each of the hubs - I opted to use 3/4" 1/16" square steel tubing following some advice from Allan.

Front
http://i168.photobucket.com/albums/u...psscagkpge.jpg

The front actually has a second mount under the top plate...

Rear
http://i168.photobucket.com/albums/u...psagvmmuip.jpg


After that I used some 3/4" oak to mock up the mounts and check for clearance though the complete range of movement.

Front
http://i168.photobucket.com/albums/u...pshjkip0s5.jpg

Rear
http://i168.photobucket.com/albums/u...psbqbskuqr.jpg

Onto the fab - A good friend mike from RC-Monster came over for a night and together we cut and welded up the front and rear fender mounts and attached them to the hubs. Thank you so much Mike for all your help.


http://i168.photobucket.com/albums/u...psmcfio9sh.jpg

I finished them off with flat grey primer and flat enamel top coat as black I felt would stand out too much against all of the silver.

I finished off the open ends with caps from McMaster (Let me know if anyone needs any I have lots spare!) All in all very happy with the results.

http://i168.photobucket.com/albums/u...psbijpaco7.jpg
http://i168.photobucket.com/albums/u...psr3eizt7j.jpg

http://i168.photobucket.com/albums/u...psvoejeh39.jpg

All that was left was to mount everything:
http://i168.photobucket.com/albums/u...psvmpibqat.jpg

http://i168.photobucket.com/albums/u...psebpd7vp8.jpg

Looks great, Chris - good luck on the state inspection - soooo looking forward to getting a rip in that little beast!

That looks great again!

Looking good Chris! I so want to do a build, but just do not have the time.

A quick trip to the DMV ...

http://i168.photobucket.com/albums/u...ps05nzki0y.jpg

http://i168.photobucket.com/albums/u...psljzzq42g.jpg
First time I was missing some minor stuff:
- Rear view mirror - side two don't count
- Gear shifter pattern
- Muffler heat shield

Completed all and went back again on Friday...

After the second trip they decided I now need a "hood" to cover the whole engine...

So this weekends work came up with this:

http://i168.photobucket.com/albums/u...psde8ttz6p.jpg

http://i168.photobucket.com/albums/u...psvqj7fm61.jpg

http://i168.photobucket.com/albums/u...psdhw3akav.jpg

http://i168.photobucket.com/albums/u...pstfai8nsa.jpg

I hate the slab/box back - The intent is to use this to pass inspection and then come up with a v lite design that just covers the muffler and top of exhaust...

You would think they should have mentioned the "hood" on the 1st trip?!
That upper centered rear guard kind of defeats the point of the rear-view mirror, doesn't it? It has a few holes, but I can't imagine the view is particularly effective? NJ seems hell-bent on taking some of the fun out of the car!

That sucks to see all the additions the dmv is requiring.

It's cool to see this is almost on the road.

Nice work Chris! Tube frame cars are very interesting. You simple can leave the hood at the DMV once you have approval.

Indeed. I received a pass on Friday and here is the "light" version that I came up with this morning...

http://i168.photobucket.com/albums/u...pskelemy0s.jpg

http://i168.photobucket.com/albums/u...psxxvagdu9.jpg

http://i168.photobucket.com/albums/u...psoooemjz0.jpg

That looks better in my opinion!
So it is road legal now?
Awesome, have a lot of fun with it, but drive save!

And the big news is....

http://i168.photobucket.com/albums/u...pss8cbi2st.jpg

I just have to drive the car to the DMV to get the inspection sticker. In NJ cars get 5years free and as the car classes as a 2013 nothing to do until 2018!!!

Finally!

Is this just a fun on the weekends ride, or will you do any competing with it? I bet it would stomp the competition at autocross events.

Congrats!
Have a lot of fun with it!

Little video of a run around the countryside.

https://youtu.be/EtM4Sg0H5QA

Sweet - looks like a fun ride. :-)

An American driving manual?! ;)
Just kidding, looks cool!
What is the scraping noise when changing gears?
Does not sound like a normal turbo to me?

What I always wonder about these sort of cars, are you wearing a helmet or some sort of glasses in this to prefent flies or bees slapping onto your face?

A Brit living in NJ driving manual. Lol

Honestly no idea - it doesn't sound crunchy when driving. I have no idea what the camera is picking up. I think it might be vibration from my exhaust heat shield.

It's a supercharged engine vs a turbo.

I have a helmet but confess I'm just wearing sunglasses at the moment. Probably not the best idea.