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-   Show your rotary car build up. (https://rotarycarclub.com/forumdisplay.php?f=66)
-   -   MG Midget Madness (i.e. It was either this or kill it with fire) (https://rotarycarclub.com/showthread.php?t=18681)

GySgtFrank 03-02-2017 10:25 AM
Quote:
Originally Posted by TitaniumTT (Post 340210)
:smilielol5: & :awesome:

Looks great Gunny!

So the FC is making the trek to DGRR this year?
If I can get out of here it will. That's why I haven't touched it all winter. That way it's not in a pile of parts if I get a chance to go. I seem to have a problem that way. :suspect:

TitaniumTT 03-02-2017 12:10 PM
I have no idea what you're talking about :suspect:

GySgtFrank 03-02-2017 05:16 PM
Quote:
Originally Posted by TitaniumTT (Post 340245)
I have no idea what you're talking about :suspect:
Yeah riiight! My bullshit-o-meter just snapped off the needle.

TitaniumTT 03-03-2017 09:30 AM
Butt seriously, I haven't touched any of my rotaries for about a year now! But they're all broken right now :(

GySgtFrank 03-05-2017 02:28 PM
... and done with the midpipe ... finally. I got the welds smoothed out, primered and painted. Bolted into final installed position. Now on to creating a really screwy muffler that fits in front of the rear axle, in the little bit of space that I have. Then I have to go over the axle with the pipe and connect it to the rear section and muffler I already did. The things we won't go through to ensure a relatively free flowing exhaust that has a chance of surviving backfires. :o

https://c1.staticflickr.com/4/3936/3...81028b1c_z.jpgmidpipe painted by Kevin Frank, on Flickr


https://c1.staticflickr.com/4/3758/3...b431876e_z.jpgmidpipe final install by Kevin Frank, on Flickr

GySgtFrank 04-16-2017 08:56 PM
Finally got the middle muffler cut, bent, and tacked with the TIG. The thin wall perforated pipe is a stone cold b***** to try and TIG. Ugly, but it's going to get wrapped in steel wool and closed up in a case so ... meh.

https://c1.staticflickr.com/3/2896/3...afc58756_z.jpgmiddle muffler (guts) by Kevin Frank, on Flickr

in other news, The latest snow has mostly melted off and I broke out the FC today. Zipped it around for a bit to get everything lubed and let the battery come back to a full charge. It's nice to be driving something fun for a change.

chibikougan 04-20-2017 03:59 PM
Woohooo!

FC Zach 04-21-2017 03:54 AM
That's freaking cool man! Kudos to you for making your own muffler! I guess you have no choice but to. :cheers2:

RXtacy 04-21-2017 09:13 AM
Quote:
Originally Posted by GySgtFrank (Post 341155)
Finally got the middle muffler cut, bent, and tacked with the TIG. The thin wall perforated pipe is a stone cold b***** to try and TIG. Ugly, but it's going to get wrapped in steel wool and closed up in a case so ... meh.
middle muffler (guts) by Kevin Frank, on Flickr

in other news, The latest snow has mostly melted off and I broke out the FC today. Zipped it around for a bit to get everything lubed and let the battery come back to a full charge. It's nice to be driving something fun for a change.
Cool. I'm curious why the muffler has to be such a complicated shape? It looks like there are lots of straight sections in the exhaust that could have housed a muffler?

GySgtFrank 04-23-2017 12:50 PM
Quote:
Originally Posted by FC Zach (Post 341239)
That's freaking cool man! Kudos to you for making your own muffler! I guess you have no choice but to. :cheers2:
Thanks, yeah off the shelf stuff wasn't going to work. So, I have to make something that I can stuff into whatever space is available.


Quote:
Originally Posted by RXtacy (Post 341252)
Cool. I'm curious why the muffler has to be such a complicated shape? It looks like there are lots of straight sections in the exhaust that could have housed a muffler?
After looking at what is used by the factory, and others, I need around 24" of pre-silencer. Which is why I went with two mufflers before the main muffler. This one has to fit in front of the rear axle with around 12 inches of length and still allow me to get the pipes up over the axle. The car only has 2 to 3 inches of ground clearance from the pipe I used, which was part of the reason for using such heavy pipe. I was afraid that if I tried to build a muffler in those sections I would tear it up trying to get in and out of parking lots. It already scrapes on the aftermarket swaybar mounts up front. I do worry about the front muffler, but I plan to build a skidplate to tie my front rails together more solidly and protect the oil pan and muffler a bit. I'm hoping that will be enough. That's my thinking anyway. I may be full of shit, but it's mine. ;)

GySgtFrank 05-03-2017 11:01 AM
New tool to get the outer case bent for the muffler from hell. This is going to be one of the most expensive little mufflers in history I'm afraid.

https://c1.staticflickr.com/3/2812/3...5e520b7cfc.jpgsheet metal brake by Kevin Frank, on Flickr

Getting the core wrap around all the bends has been a painful experience. My fingers have been poked so many times with wire from the screen and wool that they will be hurting for a week.

https://c1.staticflickr.com/3/2884/3...96ce9ed08a.jpgmuffler wrap 1 by Kevin Frank, on Flickr

chibikougan 05-03-2017 01:07 PM
I'll Poke you So many Times....:o16:

GySgtFrank 05-03-2017 01:42 PM
such a tease you are. ;)

GySgtFrank 05-07-2017 02:11 PM
Middle muffler is fabricated, packing in, and tacked together.

https://c1.staticflickr.com/5/4172/3...a80b77e9a1.jpgmiddle muffler 1 by Kevin Frank, on Flickr

https://c1.staticflickr.com/5/4180/3...b3c920696c.jpgmiddle muffler 2 by Kevin Frank, on Flickr

https://c1.staticflickr.com/5/4194/3...435112ca35.jpgmiddle muffler 3 by Kevin Frank, on Flickr

https://c1.staticflickr.com/5/4189/3...d0c3aa857b.jpgmiddle muffler 4 by Kevin Frank, on Flickr

GySgtFrank 05-15-2017 12:20 PM
Muffler is welded and cleaned up ready to install. My TIG welding skills are even worse than my MIG skills. It's going to take a lot of practice to get the hang of TIG.

Pre-cleanup ....

https://c1.staticflickr.com/5/4185/3...79b1d7a5_z.jpgmiddle muffler - welded (pre-clean up) 1 by Kevin Frank, on Flickr

https://c1.staticflickr.com/5/4168/3...4b72f9fb_z.jpgmiddle muffler - welded (pre-clean up) 2 by Kevin Frank, on Flickr

Quite ugly, but it's together in spite of myself. Had to grind them off a few times and redo welds a couple of times.


Post-Cleanup ...

https://c1.staticflickr.com/5/4174/3...ec0d312b_z.jpgmiddle muffler - welded (post -clean up) 1 by Kevin Frank, on Flickr

https://c1.staticflickr.com/5/4166/3...7df24787_z.jpgmiddle muffler - welded (post -clean up) 2 by Kevin Frank, on Flickr

Ground the welds down a bit to smooth them out some, but mainly looking for pin holes. Only had a couple that I could find. I'm sure more will show up once it's running. Folding would be better, however the oddball shape precluded that.

TitaniumTT 05-17-2017 09:18 AM
It'll never fit!!!!!!!!!!

Oh wait, nevermind. Looks good, want to hear some brap!

GySgtFrank 05-17-2017 05:32 PM
Quote:
Originally Posted by TitaniumTT (Post 341662)
It'll never fit!!!!!!!!!!

Oh wait, nevermind. Looks good, want to hear some brap!
Bullshit! I can make it fit, I has torch and am not afraid to use it. :lol:


Pictures of it installed, which should shed some light on why it is such an oddball shape and size.

view from the bottom of the car ...
https://c1.staticflickr.com/5/4185/3...260d7eeb_z.jpgmiddle muffler mounted (bottom) by Kevin Frank, on Flickr

passenger side ...
https://c1.staticflickr.com/5/4163/3...718e3476_z.jpgmiddle muffler mounted (passenger side) by Kevin Frank, on Flickr

driver's side ...
https://c1.staticflickr.com/5/4161/3...74b38b47_z.jpgmiddle muffler mounted (driver's side) by Kevin Frank, on Flickr

GySgtFrank 05-28-2017 09:35 PM
Over the axle pipe is welded up. All the different turns, bends and little whoop-te-doos for clearance made it look like something Dr. Frankenstein would have come up with. Just need to smooth the remaining welds to check for pin holes, then get paint on it. At that point this tour in building the world's most frustrating exhaust should be finished.

https://c1.staticflickr.com/5/4246/3...bf62104f_z.jpgOver the axle pipe 1 by Kevin Frank, on Flickr

GySgtFrank 05-29-2017 07:45 PM
... and done.

https://c1.staticflickr.com/5/4219/3...406d3661_z.jpgOver the axle pipe - finished by Kevin Frank, on Flickr

GySgtFrank 06-07-2017 08:12 PM
I got the exhaust system bolted together and everything fitting. I only had one area where I had to clearance some of my previous work on the gas tank surround for clearance on a flange.

Over the axle pipe bolted and in final position. Lots of odd bends and offsets to make this work.

https://c1.staticflickr.com/5/4280/3...b8cefdfa_z.jpgOver the axle pipe - bolted in by Kevin Frank, on Flickr

This is about the best shot I can get of the entire exhaust system finished and bolted together without putting it on a lift. (which I do not have anyway)

https://c1.staticflickr.com/5/4266/3...c29e2685_z.jpgexhaust system - finished by Kevin Frank, on Flickr

FC Zach 06-07-2017 10:57 PM
That's a lot of work! Good job!

GySgtFrank 06-08-2017 07:53 AM
Quote:
Originally Posted by FC Zach (Post 341888)
That's a lot of work! Good job!
Thanks. It was a lot more involved than I thought it would be when I started on it ... as usual.

GySgtFrank 06-17-2017 01:35 PM
Dash is stripped of padding so I can try to build a template. Trying to make the FC instrument cluster fit in here somehow, along with a tilt column from a 1986 Mustang. It's going to be a challenge, that's for sure.


https://c1.staticflickr.com/5/4230/3...8dff2a36_z.jpgDash work by Kevin Frank, on Flickr

GySgtFrank 06-23-2017 05:47 PM
Stainless steel dash roughed in and bolted.

https://c1.staticflickr.com/5/4280/3...1f8d3473_z.jpgDash - roughed in by Kevin Frank, on Flickr

hades 06-25-2017 08:57 AM
Good job.

Nutsid 06-25-2017 10:18 AM
Great job Mister, mister.

GySgtFrank 06-25-2017 11:32 AM
Quote:
Originally Posted by hades (Post 342008)
Good job.
Quote:
Originally Posted by Nutsid (Post 342009)
Great job Mister, mister.
Thanks guys, more pictures to come as I figure out how to make this thing actually fit in there. I have found that the 16 gauge stainless steel sheet is a lot harder to work than a mild steel equivalent. I've heard that, but never had much call to work with stainless steel before. I had to do some repairs to my plasma cutter to get it cut out as it's a bastard to do any other way.

edit:

...and the doors close! Getting those ends trimmed and hammered into shape for this to happen only took me a large chunk of the weekend, but success at last. :)

GySgtFrank 07-08-2017 11:46 AM
progress report ... slow with a strong chance of cussing storms. I need to weld in some finishing bits to make it all look integrated with the car.


https://farm5.staticflickr.com/4282/...1d91e487ae.jpgDash work 1 by Kevin Frank, on Flickr


https://farm5.staticflickr.com/4211/...be9e5fa9de.jpgDash work 2 by Kevin Frank, on Flickr


The bolts will eventually be replaced with SS allen head button screws like I have bolting down the sides of the dash. I plan to adhere a sheet of walnut to the steel when I have the face of the dash in final configuration. The foot well sides are to be covered in carpet.

speedjunkie 07-09-2017 03:09 PM
Nice work on that dash!!

GySgtFrank 07-10-2017 08:25 AM
Quote:
Originally Posted by speedjunkie (Post 342105)
Nice work on that dash!!
Thanks, beware - sharp edges cut the shit out of you while reaching up underneath to work on stuff. Who'd'a thunk? :lol:

speedjunkie 07-11-2017 01:15 AM
Yeah what a surprise! lol

GySgtFrank 07-31-2017 12:03 AM
The dash shell is complete. Had major problems with the TIG tying to warp everything out of shape. Ready to cover with leather and wood once I have the gauge openings, steering column cut out, and all the miscellaneous other openings located and cut. All the openings above and below the center console have been filled to provide extra stiffness (this booger needs all the stiffness it can get in the cowl area) and make it look like part of the basic structure. Idiot lights are in place, I wanted to keep them and this was the only logical place to put them. I may have to do something about the plastic see through cover eventually though.

https://farm5.staticflickr.com/4292/...951dbb7e37.jpgDash work (shell complete) by Kevin Frank, on Flickr

GySgtFrank 07-31-2017 10:21 PM
I just came to the realization that I am going to need to get the Vintage Air heater/AC unit and control panel before I can finish up this dash. :banghead:

Also considering trying to source an 86 - 88 FC tilt column and turn signal unit instead of the Ford part. It sits a lot closer to the dash panel which is one area that I am struggling with. Right now the wheel is right in your chest with the aftermarket steering wheel, which is damned uncomfortable. A few inches closer to the dash panel would make a huge difference.

tech54K 10-04-2017 01:26 AM
Quote:
Originally Posted by GySgtFrank (Post 310542)
https://c2.staticflickr.com/8/7569/1...b404ca10_z.jpglowered by Kevin Frank, on Flickr

1975 MG Midget - 1500cc; 4 speed. 1640lbs. with the cast iron engine and trans.

For those of you that don't know what kind of an idiot I am, I will give a brief explanation. I bought the above green hair removal tool to get around with until I could get my 79 SA back up. It seemed to only need a few things and I could either do a swap on it later, or fix it and make a little bit of money by selling it.

No dice. Every time I fixed one thing something was broken/screwed up that had been hidden away by the previous owner(s), or broke in the process of fixing something else. After about a year of fighting with it non-stop, and putting far too much money in it, (2 engines, 2 transmissions, carb, manifold, ignition, switches, wiring fixes, radiator, lights, etc etc. ad nauseum). I have had enough with the weak kneed, poorly designed and built, crappy 55hp engine and glass transmission (and worse wiring). Time for something infinitely better.

I have put quite a bit of work into suspension/interior/exterior so not all the money dumped into it will be wasted.

I will be cleaning up the '87 S4 NA 13B and 5 speed that I have and transplant the whole shebang into it. Hopefully I'll be able to retain the fuel injection, but we'll see as I go along. In addition all the wiring will be stripped out of it and either tossed in the trash, or burned in a black Sabbath bonfire to help it on it's way to hell. I will be using the GSL-SE front cover and pan to utilize the front engine mounts. The trickiest part (other than wiring) is going to be building a header, as there isn't a lot of room.

More pictures to come as I get stuff done.
she's a babe!


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