Progress on the bmw1602.com car ...** UPDATED 05/05/20 *

[bmw1602.com]

I have a small break at work and I'm hoping to get alot done in the next 2 weeks....

....so much to do I, I have to really get my ass in gear and start working....sometimes keeping working on big projects like this is hard.

that said my project looks like a walk in the park when compared to what this kid is doing in his garage.

http://forums.vwvortex.com/zerothread?id=3277830&page=1 (spend some time on THAT thread!)

The next goals is to get to a point where I can start working on the motor.

On list ,

-Weld firewall holes and tube holes shut and seal the firewall.

-Fabricate and install rear "firewall". (alum. or steel I dunno yet)

-Position and fabricate pedal mounts.

-Install Master cylinders and install brake lines.

**major milestone**get brakes operational!***

Then If I'm really lucky to finish all that, start working on the new dash fabrication and gauge positioning.

Oh yeah.....paint the engine bay.....paint all the new tubes inside the car.....

I have 2 weeks....lets see......

and here are some pics of the reason I haven't been working on the car.......

The only bad thing about working with movies and cutting edge technology is that your working with all this cool stuff and all these cool projects that you have to keep quiet about....so this is about all i can show....

To say I'm excited about what I'm doing is an understatement. Especially in this economy, I just happy to have a paycheck! Also, it's nice to have some funds to be able to complete the car......

me on the left on a pre-production prep day....and yes that a rally car

me trying to figure out what does what on our Avid DS system.

Like my co-worker says " I'm just a monkey in a spaceship, pushing buttons. " eventually I figure out what I'm doing!

Pretty much sums up how I learn things......

[alp]

what's with all the blurred out subject matter? If you tell us are you going to have to kill us also?

[Colin]

Like my co-worker says " I'm just a monkey in a spaceship, pushing buttons. " eventually I figure out what I'm doing!

Pretty much sums up how I learn things......

At some point that feeling fades away and all you want is piece and quiet and no monkey's over your shoulder telling you what to do.

[bmw1602.com]

what's with all the blurred out subject matter? If you tell us are you going to have to kill us also?

I'm working on prototype digital cinema cameras and optics/lens systems. Like I said, at the moment it is secret. As soon as it becomes "declassified" so to speak I can give out more information.

so yeah either you sign a NDA or I would have to kill ya!

Since I signed one and want to live, I have to blur things a bit.

[bmw1602.com]

Well, I haven't done as much as I wanted but I finally welded up my firewall......

and fabricated the "taco" gussets for the door bars.

Started with a poster board template and ended up with my 4 gussets, The lines are reference lines for bending. I was debating adding a dimple (I have the die) but decided not to.

There are many ways to do this but this is how I did it. Pure brute force.

Custom "hand formed"

nice and symmetrical bend, it sits flat on the table.........

[bmw1602.com]

Hammer it gently into place to check fitment.

and ta-da!! Perfect gapless fitment.

Ready to tack weld and then do final welding.

Since I'm not in a rush I decided to tig the gussets. Also hoping I could lay down some nice looking beads since this is a highly visible area.

Tig is great for welding thin matrial like the gusset (16ga) to thick materials (like the tubing) since you can really control the arc and where you apply the most heat.

First I adjusted the contour on the gussets to ensure a near gapless fit. Next I secured in place with clamps and tacked it in.

[bmw1602.com]

Me getting ready to spark it up, finding a comfortable position is 80% of getting a good tig weld. When I did this one I was very comfortable and got a good bead. In another where I had a hard time finding a good position the bead came out like crap.

But every gusset I do my welds get better, which is why I'm doing the driver door last!

In one of the pics you can see me running the bead up the tube.

One down, 3 more to go.......fixture the second one....

[bmw1602.com]

second one....the welds are getting much better....

Check out the macro closeup.....not perfect but not horrible either......especially considering the weird positions.....

[bmw1602.com]

ahahahahahahahahah.............

I'm BACK!!!!!!!!

After a long hiatus, while I have been working myself to the bone...(no complaints) today I picked up my crank from Castillios.........10lbs lighter....and knife edged....

Dropped off parts with Jake at Metrix Motorsport........he's building my motor while I start work on the rest of the projects needed to get the car back to the track in 2011!!

Wooooohoooooooooo!

Soon the mighty M10 will scream again!

p.s- Sorry about all the pictures on the build thread. I have to see how to get those all fixed again....

[MAD02]

Holy crap this thread is back from the dead! Glad to see youre finally finishing your 02! We want more drifting videos!

Good luck

[Tommy]

Hey, good to hear about you Pedro! You sure have some pretty pieces going in your car.

Tommy

[tinkwithanr]

Sweet, I just went through your whole build the other day and wondered what happened to you lol.

I think your build also inspired me to repaint my own car, so I guess I have you to thank (blame) for that

[kbmb02]

... today I picked up my crank from Castillios.........10lbs lighter....and knife edged....

Looks great . . . you may need to relearn how to blip the throttle on downshifts!

[ponchis]

hey was your car at gromas?

Alfonso

[bmw1602.com]

Just picked up the car today from Ed at Groma Fabrications. While I was in India working Ed and the guys at groma worked thier magic and did a amazing job fabricating and installing the pedals/mc/lines etc...

...because I chose to still use the stock steering column he had to mount it more to the left....then cut the pedals and offset them to the right to put them back into proper position...

The new fabricated pedal mount is Adjustable for height (from floorpan) and also adjustable back and forth (towards firewall)..........badass.....

All new hardlines were installed and engine bay line had thermo shield material on them.....very nice work by Groma.

New gas pedal also fabricated.....It's a good start but I will probably cut and customized it later.....

It's all downhill from here!

Unfortunately/fortunately.....I have to go back work....I have a 8week movie to shoot in India....I'm lucky to have the best job in the world.....but for sure when I get back work on the car will resume at a furious pace!