LamboClone - The Premier Site for Lamborghini Replica Builders

Build Diaries => Murcielago => Topic started by: Simple Man on February 03, 2017, 11:15:00 AM

Title: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 03, 2017, 11:15:00 AM
Over the years I have been reading and lurking here, and on other forums. Learned a lot form other members who have failed and some that have succeeded.

Having traveled to look a number of unfinished cars across the country, visted Mike Vetter and Michael Chase, I finally purchased a G28.

This car is based on an 87 Fiero and has a 3800 Series II SC for a power plant.

So many thing to REDO on this car that it can make your head spin around. It will not be a "Simple" project but we will plug away on it.

I will try to post my progress and appreciate any help from others who have gone before!

Thanks
Simple Man
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on February 03, 2017, 01:31:29 PM
That's why they call it the 3% Club.  That's the percentage that finishes their replicas.  It's a HUGE & OVERWHELMING challenge.  Tighten your belt and stick it out and the rewards will be yours.  Keep your family first and pace yourself. ::thumbup ::thumbup ::thumbup
01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 03, 2017, 06:41:46 PM
The 87 cradle in the car is pretty trashed.  So an 88 cradle will be stretched and installed. The engine, which is leaking badly from the crank area, will we resealed.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 04, 2017, 10:17:14 AM
With the engine removed time to take a look and see what we have here...beautiful!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 04, 2017, 04:21:59 PM
grinding and welding away!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: jrule78 on February 04, 2017, 10:26:32 PM
   While you're under there I  would get rid of that compression fitting on the brake line.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 04, 2017, 11:58:24 PM
   While you're under there I  would get rid of that compression fitting on the brake line.

Thanks, Brakes will be completely redone.... yes a REDO!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 05, 2017, 11:31:40 AM
Got up early, por 15 paint after degrease and prep.  Now I need some sheet metal for the stretch area and Lizard Skin for the fire wall
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on February 07, 2017, 09:56:10 PM
I can see you are already making it much better,  what a difference a little paint does.  What are your plans for body color and wheels?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 08, 2017, 09:10:49 AM
I can see you are already making it much better,  what a difference a little paint does.  What are your plans for body color and wheels?

Thanks Pedro, here is a picture of the wheels on the car. I will be upgrading to 13" rotors and wide track all the way around.   I have a few colors in mind but will figure that out later...much later :)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 08, 2017, 09:09:30 PM
Got the 3800 swap brackets for the trans and engine in the mail today from FeiroRog over at Pennocks.  Also bought the brackets to relocate the alternator to the power steering pump location from him as well.

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 08, 2017, 09:15:18 PM
Now to stretch the nice 88 cradle hopefully Saturday as I will need some time to get this done... correctly :)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 08, 2017, 09:16:34 PM
As far as I can tell you cut and stretch it here?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on February 08, 2017, 09:39:16 PM
Boy I love those wheels, I wish I would have bought one of those sets when they were available.

It's great when you get parts in, it means you can get stuff done.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 08, 2017, 09:47:04 PM
Boy I love those wheels, I wish I would have bought one of those sets when they were available.

It's great when you get parts in, it means you can get stuff done.

thanks !! I had the rims before I even had a car :) lol.  just got the rubber last month
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Neils88 on February 08, 2017, 10:00:49 PM
As far as I can tell you cut and stretch it here?


Here's a link to my Aventador build thread.  Built on an '88 Fiero.  My stretch is documented about halfway down the first page.  Hopefully that shows you everything you need to do.

http://www.fiero.nl/forum/Forum2/HTML/134807.html (http://www.fiero.nl/forum/Forum2/HTML/134807.html)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on February 09, 2017, 10:25:04 AM
Why did you choose to cut the cradle rather than to repair/replace the front mounting cradle crossbar? ::scratch

01

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 09, 2017, 10:40:26 AM
Here's a link to my Aventador build thread.  Built on an '88 Fiero.  My stretch is documented about halfway down the first page.  Hopefully that shows you everything you need to do.

http://www.fiero.nl/forum/Forum2/HTML/134807.html (http://www.fiero.nl/forum/Forum2/HTML/134807.html)
[/quote]

Thanks !! I took a look and printed out the photo for a reference point, will be useful Saturday. ::thumbup
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 09, 2017, 10:43:43 AM
Why did you choose to cut the cradle rather than to repair/replace the front mounting cradle crossbar? ::scratch

01

Thanks for the comment, something to think about for sure.  The car had that set up and was working fine.  I just feel the bar is in the way.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on February 09, 2017, 11:08:03 PM
Good point.  Stretching the cradle will give you more room for exhaust and such.  Looking good.
 01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 11, 2017, 03:19:32 PM
the original cradle in the car.  Pretty ugly!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 11, 2017, 03:20:37 PM
mocked it up
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 11, 2017, 03:23:34 PM
test fit, then weld.  Had to use a come along to pull the frame in as it was off about 1/2 bolt.  The rear of the car has no support beam to hold it in place.  One will have to be added.   

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 11, 2017, 03:26:37 PM
Took it back out of the car, and check measurements, and finished the stretch.

Does any diagonal buttress pieces need to be added?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 11, 2017, 03:36:47 PM
Now to clean the engine :)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: eddie on February 11, 2017, 04:11:03 PM
 got a question for you, are you going to use the  Fiero ac/heat ? 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: ★Murci-Me★ on February 11, 2017, 04:29:29 PM
I love seeing things done right, great work!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 11, 2017, 08:58:03 PM
got a question for you, are you going to use the  Fiero ac/heat ?

Good question! what would you suggest and why?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 11, 2017, 08:59:35 PM
I love seeing things done right, great work!

Thanks MM!!  it helped to have the picture from neils88 at pennocks as well as various other threads I have read over the years.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: eddie on February 12, 2017, 06:17:56 AM
 well if you are using a vintage Air system , they do not recommend of using Stock A/C compressor . I got the 3.8 s/c  ( in Diablo) and Vintage said it will not work right, got to use their compressor. and it will not fit in stock ac bracket ,but small mods it can be done.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 12, 2017, 08:57:19 AM
well if you are using a vintage Air system , they do not recommend of using Stock A/C compressor . I got the 3.8 s/c  ( in Diablo) and Vintage said it will not work right, got to use their compressor. and it will not fit in stock ac bracket ,but small mods it can be done.

thanks!! that is good information to know.  Any issues with using a fiero system that anyone knows of ?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: eddie on February 12, 2017, 09:58:35 AM
one more thing, I'm not sure on Murcie builds but on Diablos and using the 3.8 S/C Alternator sits high and if you want to use the engine cover must lower Alt or re located. i did not do it, i changed the alt 120 amp out of gmc and mod the engine cover.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Neils88 on February 12, 2017, 10:21:30 AM
Any issues with using a fiero system that anyone knows of ?

You can use any system that fits.  I decided not to use the Fiero system for two reasons.  Firstly, the Fiero system is all mechanical linkages which I didn't like and was harder to integrate with the electronic controls that will eventually be in the car.  Secondly, I put a large structural beam right across the air output of the Fiero system so I really needed to move the main HVAC unit.  Since my system didn't have AC I was forced to replace it anyway, and so I decided to install a newer system out of a Grand Prix.  It was a pretty extreme installation....you probably don't want to go that route.   :o
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 76mx on February 12, 2017, 10:38:08 AM
SM,
   That Vintage Air system is HUGE and difficult to install under that low and narrow dash. The Old Air Products system is much smaller, fits much better, and is a few bucks less. I think the reason your stock Fiero compressor will not work with either one is that all of the new units use a different Freon than the old Fiero stuff.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 12, 2017, 11:05:31 AM
one more thing, I'm not sure on Murcie builds but on Diablos and using the 3.8 S/C Alternator sits high and if you want to use the engine cover must lower Alt or re located. i did not do it, i changed the alt 120 amp out of gmc and mod the engine cover.

I purchased the FerioRog set up to relocate the Alternator to the power steering pump location as the power steering pump is still on the engine.

An AD244 170amp alternator for this build.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 12, 2017, 11:13:55 AM
SM,
   That Vintage Air system is HUGE and difficult to install under that low and narrow dash. The Old Air Products system is much smaller, fits much better, and is a few bucks less. I think the reason your stock Fiero compressor will not work with either one is that all of the new units use a different Freon than the old Fiero stuff.

76mx, will the old air system work with a 3800sc ac compressor?  thks
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: eddie on February 12, 2017, 11:19:54 AM
SM
 Charley said it will not work with either unit due to diff freon.
 I paid like 1400$ complete pkg incl. extra long pressure hose and 45* fittings. and ac condenser
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 12, 2017, 11:26:40 AM
SM
 Charley said it will not work with either unit due to diff freon.
 I paid like 1400$ complete pkg incl. extra long pressure hose and 45* fittings. and ac condenser

Thank you, good information to know!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: eddie on February 12, 2017, 11:31:55 AM
 SM one thing, is 170 Amp a little over kill??  my BMW has 65 modules and use 140 , and some beemers new one use water cooled 150. just saying.
would you after you  relocate your Alternator post picture please ? love see how's mounted .
 take care ,good work. 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 12, 2017, 11:54:44 AM
SM one thing, is 170 Amp a little over kill??  my BMW has 65 modules and use 140 , and some beemers new one use water cooled 150. just saying.
would you after you  relocate your Alternator post picture please ? love see how's mounted .
 take care ,good work.

lol, could be :)  but the flux capacitor requires a lot of power!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on February 12, 2017, 12:33:51 PM
Guys, guys, when Zingus43 was giving me my annual physical last week, I perused the same question to him.  He said that flux capacitors went out with the flip phone.  It has been replaced with the X-97b zeon smasher.  If you don't believe me, he gave me the co-ordinates of the black hole that will prove it to you.

01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 76mx on February 12, 2017, 01:07:55 PM
Flux Capacitors may have gone out but J.C. Whitney still has them, along with their atom smasher distributors and vortex inducing hood ornaments, all of which greatly improve gas mileage. I am not sure of the year it happened, but the type of Freon used in automotive AC units was changed and the old stuff like a Fiero is not compatible. I sell Old Air systems modified for the special line requirements of a mid-engine car, and with your choice of compressor mounting bracket, $1,250.   
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 12, 2017, 08:20:34 PM
I sell Old Air systems modified for the special line requirements of a mid-engine car, and with your choice of compressor mounting bracket, $1,250.

does the old air system work with a new Pontiac Gran Prix GTP ac compressor?  thks!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 76mx on February 12, 2017, 08:47:25 PM
I started to say yes if it was a new Pontiac, but then I thought about it again, where did you find a new Pontiac?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: sisqocracker on February 13, 2017, 10:46:17 AM
HA HA!  Good one 76!  My 95TA was a "new" type, so yeah should be good.  I'm sure 76 would say (y/n) if he knew the year you were talking about.  I reckon ya meant newer GP instead of old 80's an older GP.   ::headbang
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 76mx on February 13, 2017, 02:36:12 PM
Exactly right Sisqocracker. The Freon changeover was late 80's-early90's, there is not a firm date for all models. You can drain, clean, and modify an old compressor to work with the new Freon but it is more trouble than it is worth, and you still have an old compressor.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: armyman on February 13, 2017, 02:47:31 PM
I'm no certified mechanic, but when I changed my Fiero over from R12 to R134 all I did was drained the old freon installed the new fittings for R134, then oiled and refilled it with R134. No cleaning or modifying of the old compressor, just drain and refilled with new and drove it almost 5 years no problems. Agian I am not a certified mechanic so what worked for me may not be right but it worked, make sure to check with an actual mechanic before doing this as not doing it the right way could end up ruining the compressor.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: armyman on February 13, 2017, 03:10:50 PM
Let me comment a little further so not to confuse anyone, some of the old ac compressors could handle R12 and R134 and some can't. If you put R134 in a compressor that it isn't meant for it will burn it up. Just check and see if your compressor is compatible with both before doing the change over.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 13, 2017, 03:28:35 PM
I called old Air
They state the Hurricane system requires the use of a fix displacement compressor. They also recommend a parallel condenser.

The Grand Prix Gtp has a variable compressor, which could be made to work with the fiero system... or so I have been told.

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 76mx on February 13, 2017, 03:48:55 PM
SM,
   That compressor is a couple of hundred dollar part that comes with the complete system for $1,250. You can buy all of the parts individually, without the compressor, but that is probably going to be over $1,250 and you still do not have the system tailored to a mid-engine car.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 13, 2017, 04:01:51 PM
SM,
   That compressor is a couple of hundred dollar part that comes with the complete system for $1,250. You can buy all of the parts individually, without the compressor, but that is probably going to be over $1,250 and you still do not have the system tailored to a mid-engine car.

Can you provide a list of the parts included for the 1250$? Would also like the electronic version & billet slide control #45-0114B.  Also I'm not sure which would be best for the ferio the series 1100 2100 0r 3100. Thks 76!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 76mx on February 13, 2017, 04:52:43 PM
The 1100, 2100, and 3100 are electronic and what was quoted. The 1000, 2000, and 3000 are cable. That electronic controller adds $200. Parts are the entire Hurricane System but they make a special one for me that has a hoses and fittings package more suited for a mid-engine configuration. You want the 1100 for that application.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: sisqocracker on February 13, 2017, 06:33:21 PM
Say 76, I'll probably look ya up when I get to the A/C part myself.  I'm thinking I'll smoke the 32 year old system out of my 85GT and put in a new one.  :-)  Right now I can only have the Alt as I have no other bracket ready to go for having both compressor and alt.  I'm using the A/C compressor location to put my alternator at the moment.

Glad I ran across this post.  Thanks guys.  Not trying to hi-jack it.  Now back to our regularly scheduled program.  ;-)

Thanks,
Coop
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 76mx on February 13, 2017, 07:49:45 PM
Sisqocracker, Old Air Products, who I have been a dealer for years, has many styles of alternator and compressor mounts depending on location desired and engine/head combination. Once more I have found that the unique requirements of a mid-engine car called for something not quite a standard piece. They were adequate but the stock items did not exactly give me the combination of low and close that I wanted, and I tried several of them before I finally reinvented the wheel and made my own billet CNC design. They fit a small block Chevy with aluminum heads, $150 for the pair.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: sisqocracker on February 13, 2017, 08:07:53 PM
Sounds good.  I have an LT-1 from my 95TA. 6-rib serpentine belt.  V-8 Archie kit so it is ready on the bottom next to the harmonic balancer with the A/C mount.  I need one that I can hang my Alternator on and work out a belt tensioner.  On the LT-1 the water pump tends to get in the way.

Thanks,
Coop
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 76mx on February 13, 2017, 08:44:03 PM
Simple Man, I am not trying to hijack your thread either but this info might be of use.

Sisqocracker, I use a small block instead of the newer LS blocks for several reasons, the shape of the bellhousing, the price, the lack of computer problems (especially when connecting it to a non-computerized and probably foreign transmission), and others. One other reason is the accessory drive belt assembly. When a serpentine system starts rearranging things, it is not easy to do, especially with the idler pulley(s), it is expensive, and it is limited. Also the water pump is a nuisance as you stated. With a small block, I can I can start with the old style but readily available short (5-3/4") water pump, which allows me to move the rear bulkhead back and gain critical inches of legroom, then choose any combination of readily available brackets and v-belt pulleys. Even if I cannot find the right bracket, ones for the small block are easy to fabricate, and no idler pulley to deal with. I find it a much simpler and much more economic solution.   
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: sisqocracker on February 13, 2017, 08:49:24 PM
That's what's kind of ok about the LT-1, it's a newer gen of the small block.  Lots of those holes are in the same place on the front.  I.e. heads,  block,  where to mount.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 76mx on February 13, 2017, 08:57:04 PM
Yep, if anyone is using the newer LT version, make sure you tell Eric at AE Auto this if he is making your adapter plate so he can pocket for the external balance weight. The one piece rear oil seal alone is worth the updated style.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 14, 2017, 09:15:21 AM
Engine and trans separated and crank nut off!!
will replace, water, oil pump, alternator, ac compressor, oil pan, crank and various other gaskets. Upgrade headers to pace setter ceramics, smaller pulley, thermostat, plugs and pcm upgrade.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 16, 2017, 10:10:43 PM
lots of caked on oil and oxidized aluminum.  Seals were replaced, filter and pan gasket and a new torque converter. 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: ★Murci-Me★ on February 16, 2017, 10:16:01 PM
Amazing! What did you use to clean the transaxel?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 16, 2017, 11:28:52 PM
Amazing! What did you use to clean the transaxel?

Thanks!! A special concoction, not approved by the EPA or for use in CA!  :) ::angel
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Supercobra on February 17, 2017, 09:29:51 AM
Please tell us - a lot of us are struggling with how to get our transmissions cleaned up and it looks like you found a way.

Thanks
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on February 17, 2017, 12:45:09 PM
Woah it looks brand new!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: ★Murci-Me★ on February 17, 2017, 08:12:53 PM
Amazing! What did you use to clean the transaxel?

Thanks!! A special concoction, not approved by the EPA or for use in CA!  :) ::angel
 
Wow ok, thank you.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: AsantiLP on February 17, 2017, 08:45:00 PM
Amazing! What did you use to clean the transaxel?

Thanks!! A special concoction, not approved by the EPA or for use in CA!  :) ::angel
 
Wow ok, thank you.
LOL..perfect reply to that reply!!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 76mx on February 18, 2017, 09:45:08 AM
Looks to me like it came out of the hotvat at any local transmission shop.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 21, 2017, 11:54:32 AM
Cleaned up some of the engine components.  Used boiling water bath then aluminum de-greaser, followed up by dawn.  Like the transmission, I soda blast them, then metal prep then paint.  Obviously the gasket surfaces and or critical areas are protected from blasting.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 21, 2017, 11:58:43 AM
Made some sheet metal pieces for the stretch area and sprayed the fire wall with Lizard Skin - sound.  I really like this product, so much easier than dyna matt or an equivalent product.  Will spray the Lizard Skin Heat shield tonight.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 22, 2017, 11:39:10 AM
I'm really liking the Lizard Skin, it so easy to use!!! Final application of the ceramic heat shield at 4am this morning :)  The firewall has a real solid sound to it now.  Just have to top coat the product once it has cured.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 25, 2017, 11:52:28 AM
I got the Rodney Dickman poly mounts and the FerioRog 3800 engine and trans mounts in and mounted to the cradle!  Nice products from both!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 25, 2017, 07:54:43 PM
Engine all cleaned up and resealed. FerioRog bracket to relocate alternator to power steering pump location worked great!!

here are the before shots
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 25, 2017, 08:05:07 PM
here are the after shots in the cradle.  Must say the FerioROG brackets worked great!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: eddie on February 25, 2017, 08:05:18 PM
its easy also to change the S/c oil ,use GM only .hey that oil  thing stinks so watch out.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 25, 2017, 08:08:45 PM
its easy also to change the S/c oil ,use GM only .hey that oil  thing stinks so watch out.

Roger that!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 26, 2017, 02:15:05 PM
Did a test fit of the engine today.  Need to move the upper engine mounts over a couple of inches. 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 26, 2017, 02:19:20 PM
Will have to cut the sheet metal and fabricate a new piece so the alternator doesn't rub .
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 27, 2017, 07:31:19 PM
Suspension parts cheap 8)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 02, 2017, 02:33:23 PM
yay!! suspension!! 8)

Ordered January 9th.  Still waiting on Spindles and Brakes hopefully next week, cant wait to get this thing on the ground.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: sisqocracker on March 02, 2017, 04:02:17 PM
I know what ya mean, I had mine in the air for so long I forgot how low to the ground it was supposed to be.  Was about two weeks before I got used to it being down there.  hee hee.

Looking good man!

Thanks,
Coop
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 03, 2017, 09:01:29 PM
Before the engine goes back in the fuel filler system needed a REDO!

Oops I turn the gas cap and it falls off.

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 03, 2017, 09:40:24 PM
So The obamination is cut out.

Metal plates used to secure piece.

Fiber glassed from the rear

Dremel tool used to "V" front side and screw holes

Dyna Glass

Rage gold

primer
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 03, 2017, 10:01:30 PM
So the fuel filler line was a REDO as well

Used filler line for sale !! Cheap, Beautiful!!

Purchased flexible fuel filler line form "Filler Neck Supply" .  The line was wrapped in Heat reflective fiberglass tape.

The over powering smell of gasoline in my shop is gone!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 03, 2017, 10:07:59 PM
The area by the gas tank inlet is a REDO as well.  The way it was cut, left jagged metal that was rubbing and quite abrasive on the fuel filler line. 

More metal was cutout and a grinder used.  Rubber edge trim was purchased from McMaster Carr, to cover the metal edge and protect the new fuel filler line

Next!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 04, 2017, 10:39:22 AM
Another REDO is the radiators.  Currently the cooling setup is in the front of the car.

Yes the that trunk lid is a REDO....so is the hinge, the wiper mounting bracket, the headlight wiring.........
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 12, 2017, 09:34:23 PM
Been down with the flu for a week.... just going to work and coming home and vegging.  Still waiting on the rest of my suspension from Arraut which was ordered January 9th. :(

But was able to get the rear radiators installed not much else.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 12, 2017, 09:38:07 PM
Also got the steering rack cleaned up and boots and stabilizer replaced.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on March 13, 2017, 09:33:22 AM
Your rebuild parts come out amazing, even better than brand new.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 13, 2017, 09:03:07 PM
Your rebuild parts come out amazing, even better than brand new.

thanks Pedro!!  I figure I have them out might as well clean them up.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 15, 2017, 06:27:21 PM
Went with the ZZP SS headers.  From what I read, prior to ordering, they didnt have the fitment issues of the Pace Setter product. 

Well what do you know, the internet was correct this time :LL: , there were no fitment issues.

I will get the inside and outside ceramic coated, while I wait for my spindles and brakes from Arruat. Talked to Richard today and he just ordered the parts. :o
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 23, 2017, 09:45:40 PM
Been pretty sick and havent done a thing on the car... o

Thanks to Murci Me for the very useful information on the switches for the dash.  With some semi-translucent buttons they will work out great!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 25, 2017, 12:32:31 PM
ZZP headers and OEM crossover are back from the ceramic coating place.
really turned out nice :)

Like them better than the raw stainless.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: AsantiLP on March 25, 2017, 02:56:58 PM
Do you have a web link for those switches?. Also, who did the switch graphics  for you? This will be a very clean build when done. Headers look niceee. Keep it up! ::thumbup
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 26, 2017, 03:05:43 PM
Here is the size of the stickers and the button.





Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 26, 2017, 03:09:36 PM
To test out how they worked on a domed button I used the blank sticker fro the set.

Used my fingers as a squeegee to heat up the sticker, so it would conform to the domed shaped button.

Worked pretty well.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: AsantiLP on March 27, 2017, 03:25:23 AM
Thank you! Where did you buy the switches?Did you end up putting stickers on those buttons from your pictures or different ones?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 27, 2017, 08:12:56 AM
Thank you! Where did you buy the switches?Did you end up putting stickers on those buttons from your pictures or different ones?

For the switches I will use a semi translucent button so the light shines through the white part of the sticker. I was just testing the stickers to see if they stuck to a domed button top.

Here are the two switches,  Google and you should be able to come up with them as it has been a while ago since purchased.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 02, 2017, 11:14:07 PM
Still waiting of Spindles and brake system from Arruat,  been 3 months since ordered and deposit paid.

I did make the modification to the rear.

Also front cross member taken out , for easier cut clean & paint.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 02, 2017, 11:25:29 PM
Made the mold for the translucent buttons for the dash switches.  I pressed the button into the play doh and the thickness can out really close, so not much modification needed.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 02, 2017, 11:42:22 PM
buttons all in a row.

Mounted the switches.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 02, 2017, 11:57:15 PM
A big shout out to Murci Me!! The LED switches are a great idea.

It came together pretty well, the last button I didn't work the sticker long enough or the button could of been sanded a bit more.  But over all pretty satisfied, will permanently mount the buttons later.

Now I just need the spindles and brakes!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 09, 2017, 05:34:51 PM
Cut the cross member for the Arruat wide track suspension.

Welded and Filled in the gap.

Grind.

Now just need to weld 1/8 inch plate to cover the area.

Then off to powder coat.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 13, 2017, 12:39:06 PM
Beefed up the front cross member in the cut area.

Should look nice after powder coating :)

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 15, 2017, 06:11:00 PM
WHY DEAR GOD WHY?!!!!

would you use rebar in a car !!!l :LL:

.

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 29, 2017, 12:56:47 PM
The six weeks that was told / sold on the Suspension system drop spindles and brakes has turn into almost 7 months (9 more days)

Still missing the front spindles  :)  Richard is a nice enough guy to talk to but for Ducks sake get the it done!!

So are we making bets that it will be 8 months when the spindles come in?

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Neils88 on June 29, 2017, 02:58:02 PM
The six weeks that was told / sold on the Suspension system drop spindles and brakes has turn into almost 7 months (9 more days)

Still missing the front spindles  :)  Richard is a nice enough guy to talk to but for Ducks sake get the it done!!

So are we making bets that it will be 8 months when the spindles come in?

You have to keep prodding Richard....eventually he'll send them.  Once I finally received mine, however, they looked great but I found that one set of balljoints (uppers or lowers...can't remember which) wouldn't fit properly.  They weren't drilled deep enough.  The downside is that this is a tapered hole, so you need a special drill bit.  I didn't dare return them to Richard...didn't know when I'd get them back so I just ended up getting the bit and drilling them myself.  Hopefully you don't encounter this...when they do finally arrive.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 29, 2017, 03:28:17 PM


You have to keep prodding Richard....eventually he'll send them.  Once I finally received mine, however, they looked great but I found that one set of balljoints (uppers or lowers...can't remember which) wouldn't fit properly.  They weren't drilled deep enough.  The downside is that this is a tapered hole, so you need a special drill bit.  I didn't dare return them to Richard...didn't know when I'd get them back so I just ended up getting the bit and drilling them myself.  Hopefully you don't encounter this...when they do finally arrive.
[/quote]

I read about your experience on Pennocks, I like your build!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 29, 2017, 03:41:21 PM
While waiting on suspension I have been working on the interior.  I purchased a set on door sill covers from IKR. fast speedy delivery and they will work nicely.

picture of the inner door sill cover.

oops, the story of my life a couple of inches short  :LL:

also not quite a good transition to the qtr window

and area below the qtr window
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 29, 2017, 03:49:23 PM
I added a bolster or what ever it is called to the inner door sill cover, Thanks Auto pro!

Modification had to made to the car, grinding metal removes fiberglass goop...and spray in insulation.

Basically every where I looked there was some clean up to my car :)

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 29, 2017, 03:53:43 PM
for me fiberglass stops itching in about 9 hours.. ::tongue

fixed the gap from the inner door sill cover up by the qtr window, using fiberglass CSM, then dyna glass the rage gold.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 29, 2017, 04:03:23 PM
then the length of the inner door sill cover was increased by 2-3 inches or so.



Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 29, 2017, 04:19:43 PM
For my firewall or rear window area I wanted to try to get a more oem look, instead of covering in carpet or a plain fiber glass panel.

But first I had to remove the rebar...

I did use it in some concrete I laid when I put my power to my shop undergound :)

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 29, 2017, 04:31:57 PM
for the rear window area I wanted to try for a more OEM look rather than a carpeted wall.

So I bought some sheets of fiberglass modeling foam, and now I get an email from them everyday!

the foam is easy to cut, glue, sand and sand
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 29, 2017, 04:33:33 PM
to answer a question on the brakes they are 6 piston front 4 rears

They are wildwood calipers
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Neils88 on June 29, 2017, 05:01:15 PM
I read about your experience on Pennocks, I like your build!

Thank you!  Enjoying your build too!  :)

Can you give the specs on your new Wilwood brakes.  Maybe you could post a few pics of them too.   ::toothy  I was planing on going with the Wilwoods as well.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 29, 2017, 07:43:15 PM

[/quote]

Thank you!  Enjoying your build too!  :)

Can you give the specs on your new Wilwood brakes.  Maybe you could post a few pics of them too.   ::toothy  I was planing on going with the Wilwoods as well.
[/quote]

I havent opened the boxes yet as they came in today.  Will do soon!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 29, 2017, 07:51:54 PM
In looking at some OEM pictures and going to look at a LP640 in person I didnt like what I was doing so I started over.

I also found that the opening for the rear window was way out of....lets just say they used a sawsall or something to make a cut so jagged!  :LL: 

so that had to be fixed.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 29, 2017, 08:09:34 PM
these is kinda what I want for the rear wall.

so made some parts....  these parts were modified a bunch of times. 

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 29, 2017, 08:27:13 PM
long story short here is my rough in of the behind the seat area have a few modifications still to make.  Then make the final parts. Then permanent attachment points.

I learned a lot doing this  ;D
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 30, 2017, 01:12:57 PM
opened up the packages from arruat, nicely organized and labeled with a parts list and instruction manual.

Also got the master cylinder. and front and rear brake set up with ebrake.

After the 4th will start installing the rear wide track and brake set up/ engine.  Then measure for axle lengthening, radiator pipe, tranny cooler...etc
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 01, 2017, 07:19:52 PM
Spent some time grinding welds out,  to take off the bar in the engine compartment for the upper engine mount.  They were located i the wrong spot.

Funny how things take longer than you thought!



Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 01, 2017, 07:29:19 PM
While grinding I was looking at the piece I made for the interior.

 Some how in the process of building it grew and is to wide

So I took it out and cut it.

Cut some material away, sanded, I like it a bit narrower... maybe be a bit more?


Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 02, 2017, 06:09:14 PM
While waiting for some fiberglass to set up, drilled out the bat wing hinges, put in a stainless pin.

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 03, 2017, 06:39:56 PM
trying to wrap up some stuff before the suspension and brake work is started

Bought the round center piece from a member here.  I fashioned the outer portion from foam sanded etc.  Took a few tries :)

Have it mocked up and looks okay.  I will check with the guy who did a most excellent job on my seats and see if he can cover the outer portion and the center piece less the bull emblem in leather. 

So airbag cover will be broken down into 3 pieces. 

Also need to get an aluminum piece for the air bag as well
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 03, 2017, 06:44:46 PM
I'm not sure if anybody needs any buttons, but I have few sets as my estimation on resin needed for fiber glassing is in need of improvement!!

Free!

I guess one could make a checker set out of them .....
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 05, 2017, 09:49:47 PM
Nice to have my Daughter home from college, putting her to good use cleaning the front end before the Arruat suspension is put in :)

My powder coated front cross member looks nice!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on July 06, 2017, 11:26:06 AM
Fantastic cleanup of the front suspension.  I made a connector support that mounts between the upper coilovers.  Hard to describe but look at the pic.  It mounts from the LH upper shock to the RH upper shock mount area and is bolted and then welded in the front trunk area.

01 Jim
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 06, 2017, 11:58:15 AM
Fantastic cleanup of the front suspension.  I made a connector support that mounts between the upper coilovers.  Hard to describe but look at the pic.  It mounts from the LH upper shock to the RH upper shock mount area and is bolted and then welded in the front trunk area.

01 Jim

I like that idea!! I was also thinking of putting my battery up there as well, maybe do a double bar for mounting a tray.  Where is your battery located?

thks!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on July 06, 2017, 12:19:20 PM
In front of the RH rear wheel.
01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 09, 2017, 05:29:44 PM
For the seat belt adjusters, I made a bracket to test fit how everything would fit together with my cover.

After a few tries :)  .... the top of the adjusters need to be 1 inch from the fire wall for it all to work.  I plan on putting a  1 inch, thick walled square tube (15-20" long) at the top and weld it to the fire wall.

For the bottom there is access from the engine side, plan is to use six bolts,  and a piece of steel tube on the engine side.

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 19, 2017, 11:01:58 PM
Getting a few things ready for when the drop spindles and hubs come in from Arruat.

Took out the booster, will be using new nuts as sometime during the life as a Fiero, the booster was replaced and the nuts reused ... one nut was rounded off... but finally got it off the car with out messing up the stud :o

Got some stuff powder coated and cut the rear knuckle to accept the Arruat bracket.

The directions from Arruat are pretty straight forward, just hope there are no issues with the parts.

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 20, 2017, 02:29:56 PM
After 6.5 months, (when promised 6 weeks)  the final parts needs for my suspension install are out for delivery :drool

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 21, 2017, 12:08:45 AM
Finally!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 22, 2017, 03:11:09 PM
Checking out seat fitment and Parking brake handle location.  the car didn't have a parking brake lever. so at least I dont have to redo that! :LL:

Floor pan was modified per a pennocks thread, so the seat will seat about an inch lower. A frame structure will be made and attached underneath the car. Sat in the car and I fit.

For the parking brake handle fitment the interior side fiberglass piece will have to be cut so it fits closer to the outside of the car.

Also if the seat could be pushed to the passenger side by about 1 inch it would be better.

On the console side the floor has an angled to it as it meets the floor.
Going to see if I can cut the floor pan and take out the angle and get the extra inch.

Anybody else have this issue?

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 22, 2017, 03:35:42 PM
Looking at the underside of the car cutting the floor pan to get rid of the angle of the console to floor pan would require messing with the gas tank mounting strap.?

Looking at the fiberglass side piece, it should be able to be trimmed up by a couple of inches and give me the room for my brake lever.

A brake lever from a 94 Ferrari is being used.  Its nice and beefy when compared to the fiero lever.  But it is wider than the fiero lever.

We will have to see how it goes :)

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 25, 2017, 06:53:27 PM
Well well well, go figure, 888o  A couple of brackets for the front  suspension arent quite right and will not work  :LL:

The 3 vertical holes all line up with the frame, the horizontal bolt holes, in the Arruat bracket,  do not line up with the cross member.  The bracket holes were enlarged but the the front hole is so friggin close to the shock mount arm that you cant turn the bolt to tighten it.

Getting the specs from Richard to check the part

So its a redo!!



Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: ★Murci-Me★ on July 25, 2017, 10:49:49 PM
Couldn't you use a grade 8 socket head bolt instead, the type that is a round head (for clearance) and a socket top that fits a large Allen wrench to tighten it down?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 26, 2017, 07:35:18 AM
Couldn't you use a grade 8 socket head bolt instead, the type that is a round head (for clearance) and a socket top that fits a large Allen wrench to tighten it down?

That is a good idea!  Thanks!  The other problem is the holes in the part are not in alignment. Almost 3/4 of the bolt width dont line up with the cross member holes.

Once I get the specs for the part, the round bolt will work after the two holes in the part are reworked.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: msaby on July 26, 2017, 09:00:46 AM
Just an FYI... your upper ball joint is installed incorrectly. The ball joint should sit on the top of the control arm.

Thanks
Mike
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on July 26, 2017, 10:41:37 AM
If I recall, Arraut's instructions state to bolt the upper ball joint on the underside but the ball joint has teeth on the underside which makes sense to mount it on top of the A-frame.  Since you had the cross member off of the car, is it possible that in remounting it that it got remounted rearward causing the bolt problem?  You might try loosening the bolts of the crossmember and pulling it forward to install the problem bolts.  Murci-Me's cap screw cure will work also.  The same bracket on my front end was tight in that area also but I could still put a washer under it.
01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 26, 2017, 12:55:17 PM
Thanks guys for the comments!  Much appreciated!

The brackets are wrong, Richard is sending out 2 new ones priority mail.

Stay tuned!   :LL:

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambo_sam on July 26, 2017, 08:17:18 PM
Looking at the underside of the car cutting the floor pan to get rid of the angle of the console to floor pan would require messing with the gas tank mounting strap.?

Looking at the fiberglass side piece, it should be able to be trimmed up by a couple of inches and give me the room for my brake lever.

A brake lever from a 94 Ferrari is being used.  Its nice and beefy when compared to the fiero lever.  But it is wider than the fiero lever.

We will have to see how it goes :)



Hey Simple, I'm using the same handle Ferrari and Lambos share it as well, I here is pics on how I did mine successfully, also in my flickr account, You just need to build a stand alone bracket for it.

(https://farm1.staticflickr.com/761/32105987693_57d6f1a526_z.jpg) (https://flic.kr/p/QV6zzX)130 (https://flic.kr/p/QV6zzX) by Lambo Samm (https://www.flickr.com/photos/147611676@N08/), on Flickr

(https://farm3.staticflickr.com/2697/32796930361_e68d4af021_z.jpg) (https://flic.kr/p/RY9QLz)132 (https://flic.kr/p/RY9QLz) by Lambo Samm (https://www.flickr.com/photos/147611676@N08/), on Flickr

(https://farm4.staticflickr.com/3936/32796930491_383eb4c191_z.jpg) (https://flic.kr/p/RY9QNP)133 (https://flic.kr/p/RY9QNP) by Lambo Samm (https://www.flickr.com/photos/147611676@N08/), on Flickr

(https://farm1.staticflickr.com/680/32796930441_f64b54d3f4_z.jpg) (https://flic.kr/p/RY9QMX)134 (https://flic.kr/p/RY9QMX) by Lambo Samm (https://www.flickr.com/photos/147611676@N08/), on Flickr

(https://farm3.staticflickr.com/2472/32105987853_77be82ebcd_z.jpg) (https://flic.kr/p/QV6zCH)136 (https://flic.kr/p/QV6zCH) by Lambo Samm (https://www.flickr.com/photos/147611676@N08/), on Flickr

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 26, 2017, 10:44:05 PM
Lambo_Sam

That is a nice bracket!!  I will be using it for sure. 
Thanks!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 26, 2017, 10:52:54 PM
Checked out the rear suspension parts a little fitment issue but fixable.

The one rear extension bracket isnt wide enough to fit the spindle.

Two of the plates that the rotors attach to will require just a little adjustment to work with the hubs/spindles.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambo_sam on July 27, 2017, 10:49:27 AM
Lambo_Sam

That is a nice bracket!!  I will be using it for sure. 
Thanks!

No Prob! you can also use the existing fiero cable and the cable catch from the old brake handle (Just a minor mod).
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 27, 2017, 11:08:14 AM
Lambo_Sam

That is a nice bracket!!  I will be using it for sure. 
Thanks!

No Prob! you can also use the existing fiero cable and the cable catch from the old brake handle (Just a minor mod).

My car came with no E brake lever or ebrake cable.  I have a parts car, would you recommend the fiero cable or is there a better alternative? thks!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on July 27, 2017, 11:42:53 AM
Don't modify the bad parts.  Contact Arraut and get replacements.  Casually mention that your build diary is being viewed by hundreds on this forum.  Maybe they will expedite replacement parts if they want to have accountability with customers.

01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambo_sam on July 27, 2017, 11:48:34 AM
Lambo_Sam

That is a nice bracket!!  I will be using it for sure. 
Thanks!

No Prob! you can also use the existing fiero cable and the cable catch from the old brake handle (Just a minor mod).

My car came with no E brake lever or ebrake cable.  I have a parts car, would you recommend the fiero cable or is there a better alternative? thks!

Oh ok, yes if you can find a cable and old handle (for the catch) from another fiero, it will work just fine, That's what I'm using, However there are after market brake cable systems out there that can be used.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: eddie on July 27, 2017, 08:31:24 PM
I used Lada hand brake and after market cable for 15$ it's ok ,you can't see the handle much anyway. but that's me
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 76mx on July 28, 2017, 09:07:41 AM
So what model of car was the kit that they sold you for?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 28, 2017, 06:59:27 PM
So what model of car was the kit that they sold you for?

hmmm, not sure what your are asking  ::toothy, but the car is a fiero with a G28 body.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 76mx on July 28, 2017, 08:06:19 PM
Simple Man, it was a joke. I know sometimes my humor is too dry. I was asking if it did not fit a Fiero, then what car was it designed for? Best wishes with your endeavor.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 29, 2017, 12:05:56 AM
Simple Man, it was a joke. I know sometimes my humor is too dry. I was asking if it did not fit a Fiero, then what car was it designed for? Best wishes with your endeavor.


 It hard to convey humor via the written word.  Use an emoji like this  :LL: or :)

The suspension kit was built for a Fiero.   You can read about other quality control issues people have had on Pennocks.

It will all work out in the end but what a PITA  ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on July 29, 2017, 11:03:30 AM
Hang in there, Simple Man.  A custom made part sometimes is a "modification may be necessary" part.  They just don't tell you that.  It's just a "speed bump" on your way to the 3% Club.  ::thumbup ::LAMBO

01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 01, 2017, 02:10:36 PM
The new brackets came in from Arruat, and they are a REDO 888o.  Hindsight 20 20 I should have gone a completely different route since it has been 7 months when I was told my order would be ready to ship in 6 weeks.

Live and learn. ;)

Richard sent me new brackets and the bolts that Murci-Me suggested, but actually they are to long to work, but I purchased ones that are the right size  ::toothy

When the upper strut bracket, Richard made, is bolted to the crossmember, the 3 frame bolt holes are 1/2 a bolt off.

Since the frame and cross member bolts are fixed, The vertical bolt holes in the Arruat bracket will have to be relocated.

Since I have two sets of Arruat bracket I have basturdized one set.
The rear hole, if enlarged, Will leave only about 1/8" of metal left on the bracket. 
The front hole, if widened and Murci-Me bolt used,  will cause one of the welds to be weakened as it has to be ground completely off.  There are no welds on the inside of arm.

Sooooo!  going to move the forward arm 1/8" back, It appears this adjustment will work.  Adding material to the rear portion of the bracket should work as it looks to be 1/4" before the edge of the cross member. 

 8)




Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on August 01, 2017, 06:18:16 PM
Just to back-track a bit...if you take the Arraut bracket off and reinstall your original bracket, do all five hole line up?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 01, 2017, 06:51:29 PM
Just to back-track a bit...if you take the Arraut bracket off and reinstall your original bracket, do all five hole line up?

yes
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 01, 2017, 07:39:56 PM
For kicks here is the basturdized part that will fit.  Drivers side not as bad.  8)

Also the OEM piece re-installs nicely. 

since originally only one side of the Strut arm is welded, I might be able to weld on the inside of the arm, as the weld on the outside has been compromised/weakened by grinding to get the Arruat part to fit  ;D

Then add material on the rear side and fill in the hole. This would save me moving the forward arm back an 1/8"

When the bracket is mounted there is also at least a 1/8" inch gap between the cross member and the Arruat part. ::tongue



Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on August 01, 2017, 10:14:00 PM
What a mess.  You could cut the bottom plate off and weld in a new redrilled plate or make two little plates to be welded on top.  Definitely weld the shock brackets on the inside.  My son purchased a Strange spool and a Richmond gearset for his '92 Firebird drag car and the ring gear wouldn't sit flat against the spool because of lack of sufficient chamfer on the back side.  Stuff like this just happens in our league.
01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: ★Murci-Me★ on August 01, 2017, 10:40:37 PM
I'm sorry to hear all the problems you are having with these parts. I once considered buying a system from them for my friends car, now I'm glad I didn't!
I remember having a similar problem with bolt holes lining up properly with the NAERC widetrack system I bought, much the same as you are having. I to had to modify the parts to get them to fit correctly, and then ended up trashing both upper control arms they supplied and building a set of my own along with modifying the lowers as well.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on August 02, 2017, 10:20:25 AM
I mentioned prior that you might loosen the 4 lower attachment bolts to see if that would help with the alignment and I still think that a thin washer inserted between the crossmember and the frame on the front bolts will help with the hole alignment.
(I drool every time I see how nice a job you did on your clean up of the Fiero parts.  Mine were so rusty ::salute ::thumbup)

01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 02, 2017, 11:53:17 AM
I mentioned prior that you might loosen the 4 lower attachment bolts to see if that would help with the alignment and I still think that a thin washer inserted between the crossmember and the frame on the front bolts will help with the hole alignment.
(I drool every time I see how nice a job you did on your clean up of the Fiero parts.  Mine were so rusty ::salute ::thumbup)

01

thanks 01!!  Every bolt is  loosley bolted. 

For the two washers, not sure how that would help, but I will give it a try... you never know :)

Richard picked up the phone this morning and he thinks he has a solution. 
I am heading out of town with truck an trailer to get my daughter into he apt as she will be starting and internship.  Sooooo, with a 4 hour drive each way I will have time to ponder an think about this problem  :LL:

I do like the idea of cutting the bracket, as suggested by 01.  I will also make the bottom piece thicker to get rid of the gap that is there.

Here is the OEM vs the Arruat .


Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 02, 2017, 11:58:55 AM
I'm sorry to hear all the problems you are having with these parts. I once considered buying a system from them for my friends car, now I'm glad I didn't!
I remember having a similar problem with bolt holes lining up properly with the NAERC widetrack system I bought, much the same as you are having. I to had to modify the parts to get them to fit correctly, and then ended up trashing both upper control arms they supplied and building a set of my own along with modifying the lowers as well.

Thanks MM!

I just hoping that this is the only issue I have with the Arruat Set up   :o  Had I known then, what I know now, I would have gone in a different direction. Or maybe not even started  :LL:  But I actually enjoy working on this POS... I mean REDO  ::toothy

At this juncture, just want to get the car on  four wheels, so I can work on the A-pillar issue and drivers door,  outside, before the weather turns. ::toothy

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 02, 2017, 07:40:49 PM
I had a friend who owns a fabrication shop come by and look at the Arruat parts and the car.   After measuring the Drivers and passenger side brackets the passenger side Arruat bracket is off by between 3/16" & 1/8".

the drivers side is doable with very minor modification & Murci Me suggested bolts.

He took the replacement bracket that Arruat sent and is going to fix it and have it back to me Monday. 8)

The basturdized bracket will be a paper weigh.

Onward!!




Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 02, 2017, 11:02:46 PM
Modified the drivers bracket and installed it.

Onward!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on August 03, 2017, 12:55:38 PM
The two lower bolts on that bracket were replaced with longer threaded bolts for my cross brace which connects the two upper shock brackets (RH & LH) together.  Due to limited clearance, I added spacers to reach the support plate which was then welded to the frame rails and then the crossbar was welded to those plates.  (hope this makes sense) ::scratch

01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 05, 2017, 09:21:56 PM
Got back from my trip and installed the driver side Arruat front suspension and brake set up.

First is read the instructions and have a cocktail   :D

I ordered the bearing set up for the QA1 adjustable coil overs.



Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 05, 2017, 10:29:09 PM
The front bumper needed to come out and be beefed up.

It consisted of a 2x2 coming out from the frame, a 1/8 by 4 inch for the front of the bumper ...tack welded in the center. and some misc, 1/2 and 3/4 inch tubing.

Looked at jets303 set up and it will solve the lack of weight in the front end as the car is very tippy, and maybe make me feel safer,

It came out pretty easy.

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 05, 2017, 10:37:29 PM
got started cutting the steel for the REDO front bumper.

Using rectangle tube that has the same dimensions as the fiero front frame.  The wall thickness is 3/16.

Started cutting the pieces, but need to get a new saw blade. One saw for cutting length, but the angle saw is great!  Borrowed from a friend.  A real time saver!!

The fiero frame wasn't cut evenly at the ends.  Using a tool to get the angle as both sides are different.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: ★Murci-Me★ on August 05, 2017, 11:35:32 PM
Get this saw, I bought one last month.
https://www.sawblade.com/trajan700.cfm (https://www.sawblade.com/trajan700.cfm)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 07, 2017, 12:40:25 PM
Get this saw, I bought one last month.
https://www.sawblade.com/trajan700.cfm (https://www.sawblade.com/trajan700.cfm)

Would buy if I didnt already order up a blade for the compound saw.
Thanks!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 07, 2017, 12:48:46 PM
Looking at the front bumper on the REDO it still has the sag.  Will have to take out some steel tubing that has been bonded to the fiber glass fender well to fix the sag.

Looked at Nickmmkk's build, Thanks for the pictures! It should help.  Is the goal to get the rockers in line with the front bumper?

Jets303 post on bumper sag fix ... photo bucket issue http://lamboclone.com/index.php?topic=151.msg1711#msg1711 (http://lamboclone.com/index.php?topic=151.msg1711#msg1711)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 07, 2017, 06:47:30 PM
got the revised Arruat upper strut bracket from my friend  ::toothy  So now the passenger side is installed :)

The Qa1 coil over instructions say use anti seize compound on the threads, but that seems like it will collect a lot of road dirt?

Waiting for the QA1 bearings.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 12, 2017, 09:13:59 AM
Cut the front bumper off, shout out to Murci Me for the pointers and drawings.

With the bumper off there will be some time spent fixing the cracks and scrapes as well as the sag.


Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 12, 2017, 09:39:37 AM
Made some progress on the frame for the front end, until my welder started bird nesting  >:(  Dont know if it needs a new liner or what..it is old.  ::toothy

The steel frame will have another section that will be just a tad lower than the fiberglass bumper, hopefully that will stop the repaired bumper from getting damaged






Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: ★Murci-Me★ on August 12, 2017, 06:53:53 PM
Wow that's some serious overkill on that frame!!! Remember, you don't want to make it to strong, it should absorb the impact and crumple, not transfer it to the main frame and rack the whole chassis.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 13, 2017, 10:33:35 AM
Wow that's some serious overkill on that frame!!! Remember, you don't want to make it to strong, it should absorb the impact and crumple, not transfer it to the main frame and rack the whole chassis.

 ::toothy Ramming Speed?  :LL:

  https://www.youtube.com/watch?v=AjmbgZ2wZvk (https://www.youtube.com/watch?v=AjmbgZ2wZvk)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on August 13, 2017, 11:56:46 AM
Aye, aye, Capt'n!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 13, 2017, 12:38:14 PM
Aye, aye, Capt'n!

lol, yeah, might be a bit to much... :)  plus it could be in the way of my latching mechanism.  Have to figure it out.  Appreciate the comments, keep them coming!

Might be a REDO of a REDO   ;D
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 13, 2017, 07:39:45 PM
REDO of the REDO on the front framing, tack welded it together.  8)

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 13, 2017, 07:54:40 PM
Sanded the front bumper to see the extent of bondo, looks to be about 1/4 to 3/8 of inch thick in places....why?  ::scratch

The other damage is a bit worse than I thought.  The big crack difficult or impossible to reach from the back side.  There are numerous other issues on this bumper.....  Not a REDO but a POS!!   888o
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: ★Murci-Me★ on August 15, 2017, 10:04:40 PM
I'm sure you know the solution to this problem.......;)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 16, 2017, 07:32:40 PM
Got the QA1 bearing kit in today.

Worked on the floor pan, two objectives make the space wider to fit the seat & brake handle, and drop the floor 1.5 or so inches.

The IKR fiberglass piece was trimmed to fit closer to the inside of the door sill, which gave me about 1/2 inch

The slope from the console was reduced and it gave an additional
+1.5" or so of space.

I used weld through primer....not to happy working with this product or how the welds looked using this stuff,  but it will be covered up anyway  ::toothy

Now there is plenty of room side to side for the seat and e brake set up ;D

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 16, 2017, 07:36:04 PM
I'm sure you know the solution to this problem.......;)

Yes! a good solution would be to get one of your primo SV front bumpers with the grills !!!   ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: ★Murci-Me★ on August 16, 2017, 09:31:44 PM
I'll have it ready for you :)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 17, 2017, 09:58:42 AM
 
I'll have it ready for you :)

 :drool
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 17, 2017, 09:39:44 PM
Using 01Lambiero's design for the e brake handle bracket.

made the pieces and welded it up.  Just need a few adjustments.

Thanks 01!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 17, 2017, 09:46:15 PM
The QA1 bearings were installed and finished up the front end everything came together nicely. ::toothy

need to order some black lug nuts


Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: eddie on August 18, 2017, 05:35:05 AM
nice wheels , but I would after all set up remove and  get old BMW or Corvette rims with crappy tires , so when doing body work and paint they not gonna get damaged. OH BMW /Vette are 5 X 120  maybe you have dif bolt pattern 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 18, 2017, 08:14:08 AM
nice wheels , but I would after all set up remove and  get old BMW or Corvette rims with crappy tires , so when doing body work and paint they not gonna get damaged. OH BMW /Vette are 5 X 120  maybe you have dif bolt pattern

 ::thumbup
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambo_sam on August 18, 2017, 02:37:35 PM
Using 01Lambiero's design for the e brake handle bracket.

made the pieces and welded it up.  Just need a few adjustments.

Thanks 01!!

Umm You might want to scroll back through this thread to be sure you are Thanking the right person...lol
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 18, 2017, 02:51:38 PM
Using 01Lambiero's design for the e brake handle bracket.

made the pieces and welded it up.  Just need a few adjustments.

Thanks 01!!

Umm You might want to scroll back through this thread to be sure you are Thanking the right person...lol

$hit!  :-[ sorry Lambo Sam!  Let me thank you for the pictures of the e brake bracket, it is working out great so far.  I also checked out your build pictures, love the car and the color.  Did you paint it?

thanks
Simple Man
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambo_sam on August 18, 2017, 03:05:21 PM
lol no worries just had to mess with ya, Thanks, nah a friend of mine that had a shop painted it for me, Still could use another cut and buff or a good polishing for sure.

Don't forget to drill the hole for the cable and grommet (piece of hose) through the L bracket
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 19, 2017, 04:13:45 PM
worked on my cooling system pipes.  Going to try a series system first.

Cut Some aluminum pipe roughed it in.

Have to weld in fan temp sensor and fill cap. Will be interesting welding aluminum  ::toothy

The diagram of the system came off this website I think
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 76mx on August 19, 2017, 10:23:18 PM
SM,
   You are going to need a second cap in the run from the engine to the first radiator. The cap in that diagram will let trapped air out of the system at the second radiator, but not the first one or the block. It should be at the highest point of those two, then a bleed valve is sufficient at the other location provided it is lower than the cap.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: ★Murci-Me★ on August 19, 2017, 10:50:31 PM
WOW that's a lot of hose clamps! Series doesn't work well, they need to be run parallel. You'll also need to get some shrouds for those fans or you wont get full cooling.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 20, 2017, 02:44:43 AM
SM,
   You are going to need a second cap in the run from the engine to the first radiator. The cap in that diagram will let trapped air out of the system at the second radiator, but not the first one or the block. It should be at the highest point of those two, then a bleed valve is sufficient at the other location provided it is lower than the cap.

my cap that is located in between the two radiators is higher than the caps on the radiators.

Are you suggesting a cap at the thermostat housing as in the picture? then that would be the highest cap?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 20, 2017, 03:28:30 AM
WOW that's a lot of hose clamps! Series doesn't work well, they need to be run parallel. You'll also need to get some shrouds for those fans or you wont get full cooling.

Yes a lot of clamps.... :D  Checked with a bunch of shops and could not find anybody to bend aluminum tube in the right configuration.

Shrouds , Yes!

Long story short, I'm running out of dry weather!!!!  Hindsight 20/20 when promise 6 weeks on the suspension.  I should have left the car as is, at least I could drive it in and out of the shop and then I could of worked on the F'd up drivers A pillar and removed the drivers door skin. Dusty dusty dusty!! :o

Okay I dont like a dusty dirty shop as it coats my other cars  888o

Soooo, the car can be rolled out side, but its on a slope and getting it back inside would be impossible.  think a wench will have to be purchased to bring the car back in. 

That way the windshield fitment issue resolved before the rains come.

When the weather changes I can get back to the mechanical.

lol Ill ponder it Sunday  :LL:

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 20, 2017, 06:55:42 PM
decided to clean up the trunk lid :) 

here are the before pictures :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 20, 2017, 07:21:07 PM
so the framing was taken out,  It a custom piece for sale cheap!!  ::toothy

It appears mainly resin was used to attach the frame to the fiberglass lid,

Used a scraper to remove as much as possible then 40 grit sander to get back to the original surface.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 20, 2017, 07:31:41 PM
thanks to Dustin for the OEM inner trunk liner  8)

Its a bit short.  Thinking of extending it where the blue tape is.

Using OEM hinges.

has anybody done this?

thanks!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 76mx on August 21, 2017, 09:30:40 AM
SM,
   You are going to need a second cap in the run from the engine to the first radiator. The cap in that diagram will let trapped air out of the system at the second radiator, but not the first one or the block. It should be at the highest point of those two, then a bleed valve is sufficient at the other location provided it is lower than the cap.

my cap that is located in between the two radiators is higher than the caps on the radiators.

Are you suggesting a cap at the thermostat housing as in the picture? then that would be the highest cap?


SM,
Yes, I did not see in the diagram where it had one there but yes again that it should have a cap at the highest point, then a bleed valve at every "Hump".
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambobuilder on August 21, 2017, 01:31:50 PM
This was solution I used on my 6.0
http://kitcentral.com/index.php?name=PNphpBB2&file=viewtopic&t=3444 (http://kitcentral.com/index.php?name=PNphpBB2&file=viewtopic&t=3444)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 21, 2017, 02:51:24 PM
This was solution I used on my 6.0
[url]http://kitcentral.com/index.php?name=PNphpBB2&file=viewtopic&t=3444[/url] ([url]http://kitcentral.com/index.php?name=PNphpBB2&file=viewtopic&t=3444[/url])


Thanks!
 
Is this the system?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 24, 2017, 09:11:12 PM
Well for what ever reason I changed my mind on where to cut the inner hood panel. ::toothy

But it will work out in the end, like I have a choice now :LL:

The outer hood skin it pretty even with the fenders.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 24, 2017, 09:30:31 PM
The prior owner must have tried a couple of different version of hinges as there are a few holes to be fixed ::)

The OEM hinges work but not sure I really like them as it required additional modification to the body.

thanks Murci Me for the picture of your hinge and trunk set up, I might have to give that a try!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 28, 2017, 09:05:52 PM
spent a few hours working on the finished side of the front trunk.

Dyna glass, rage gold... wash rinse repeat  :LL:

Well the error in cutting the lid is apparent,  888o my first choice would have been better.

My hinge mount will change and the shock mount has to be modified.... depends on using oem hinge or self made hinge

Will probably cut and fiberglass the panel again and make it OEM shape ... ::)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 29, 2017, 08:35:09 PM
shout out to Murci Me for the hinge idea ::wave

I scabbed together a prototype with some scrap metal and nuts and bolts. With a few modifications it worked great!

Now I can make the final pieces ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 01, 2017, 05:53:46 PM
Forgot to post pictures of the rear wide track suspension and brake set up.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 01, 2017, 05:57:25 PM
Nothing like a sequel.... but dont they always sux?

Trunk lid II ....aka muffler cover  :LL:

Is it a horror or a comedy?  ::)... or both?!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 05, 2017, 02:11:15 PM
Brutal weekend, glad it is over!!!  Borrowed an excavator from one friend and a dump trailer from another.

Will take today and let my body recover..... zzz:)

back on the REDO build Wednesday!!   :)

Still have to pour concrete, spread out 20 yards of soil and seed for grass ....  :o
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 10, 2017, 11:11:35 PM
Another long weekend...and not working on the car that much. Poured concrete blah blah blah  ::toothy glad to be done with that!!!!

The car is finally on four wheels and just a few more issues with Arruat Motorsports lack of QC ::)

But I can see the light at the end of the Arruat tunnel..... and it has been loooong!  :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 11, 2017, 09:58:27 PM
Finally the car is out of the shop!!!  ::beers

One of the front spindles is wrong.  When mounted the brake pad is pressed up to the outside side of the rotor, and the wheel wont even turn.   ::) Thinking its a weld that warped the spindle during the mfg process 888o

Using 5k lb atv wench to bring the car back into the shop.

Wednesday will be fiber glass grinding and cutting day, which is always a good time!!  ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 12, 2017, 07:32:56 PM
Well as frustrating as it has been with Arruat, At least they communicate and seems to want to resolve things  :)

I thought it was the outside brake pad that was causing the problem of the wheel not to turn that  easily and lock up when the Rim and tire were mounted.

took it all apart and...

the distance from the top caliper mounting hole to the rotor is off by a little over 1/16 of an inch or so, when compared to the bottom mounting hole.

the other issue in the mounting holes on the spindle, to me seem, to be to far in, or could stand to be a little further out, as the rotor is gouging the caliper as it turns around.

Talked in depth with Richard and will be sending the caliper back so they can test the new spindles with rotors and caliper, prior to shipping this time.   888o   When you send $hit in stages you cant QC the product.  ::tongue

Onward!! :LL:





Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 14, 2017, 10:10:24 PM
Grind, fiberglass, fiberglass, fiberglass, Sand, Dyna glass, Sand, Rage gold
Sand, Wench back in side
Almost done, needs a tweak  ;)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on September 14, 2017, 10:49:23 PM
Hey, the title of this thread is "Simple REDO of an G28 LP640".  When are you going to get to the "simple" fixes???

01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 15, 2017, 07:20:09 PM
Hey, the title of this thread is "Simple REDO of an G28 LP640".  When are you going to get to the "simple" fixes???

01

 ::toothy they dont exist!   ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 16, 2017, 10:45:45 AM
Next on the simple redo is the windshield.

First problem is the A pillars were built up so the windshield when in place was flush with the doors and roof.

the passengers A pillar had a nice chunk of rage and a hump that was removed

the recess along the roof and doors was sanded and a 5/8" space was created for the windshield to rest in
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 16, 2017, 10:48:53 AM
while working on the recess ...hmmmm?

that doesnt look good... ::)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 16, 2017, 10:53:57 AM
Go figure we have an issue  ;D

the curvature of the A pillar on passenger side wrong, driver side okay
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 16, 2017, 10:37:48 PM
With the windshield installed in the recess, thanks Murci Me for the guidance, much appreciated!  8)

... another problem? 888o

If the windshield in set correctly on the passenger side, the windshield sticks out or overhangs the drivers "A" pillar and the Drivers door will not close  ::)

The prior owner got the doors to close but neglected to make sure they would work with the windshield?  ::tongue

So the drivers "A" pillar width needed to be increased.

Grind off a $hit ton of Rage filler to get to fiber glass.
Fiberglass, Fiberglass, sand etc

Then the Door needed to be cut back, Cut Check, Cut Check, Cut Check,  Sand, Sand Check Sand Check.

Yes the windshield is cracked now ::toothy

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 18, 2017, 08:47:34 PM
With the Windshield fitting on the "A" pillars, a couple of other problems.  Let me rephrase that a  multitude of issues ::) 

The weather strip flange was removed and the roof was altered.

The door probably needs to be moved out by about 1/2 inch or so

The Door has no window channel with the Saturn glass.

So the door skin has to come off ::toothy

yes it was rainy!

Hot tub time!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 18, 2017, 09:18:48 PM
It's like Christmas!!!   Opening up and finding out what is inside! :santa 

Saturn glass -  rubs on fiberglass
Impala regulator
Nice piece of rubber in the front for glass to rub on
A bit of fiberglass work in latch area

 888o

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 18, 2017, 10:44:36 PM
Saturn glass VS OEM Glass  ::study

Been waiting months to check out the aftermarket OEM tempered safety glass that I bought.

You can see the size difference between OEM and Saturn

Saturn glass works but is not that smooth in operation

OEM requires some modification, Not sure how much will still be sticking up when fully lowered but it will be better than the Saturn glass.

I would of liked to have had a set of Murci Me's G28 glass, but I think this is the best that can be done?   ::scratch

Lexan? No Glass? Fixed Glass? ::tongue



Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 20, 2017, 10:03:07 PM
Rainy and didnt have much time but got something off the list ::thumbup

Its is amazing how it can take twice the time that you originally thought  ;D
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 23, 2017, 10:14:08 PM
Super nice day out!! got a lot of things done around the house  ;D Was able to squeeze in some time on the REDO and get another thing off the list.

welded up, painted &  installed the trans cooler. However was foiled as I needed a 3/16 to 3/8 fitting to hook up the lines to the transmission.



Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: AdrianBurton on September 27, 2017, 04:05:37 PM
yeah man it all takes at least twice as long and costs 4x as much
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 27, 2017, 09:50:27 PM
yeah man it all takes at least twice as long and costs 4x as much

Quit tracking time and $ in February  ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 01, 2017, 09:41:30 PM
Spent some time prepping rusted metal for por15,  All previous metal work done on the car by prior owner had a nice patina of rust & dirt. 

 Added mounting points for tail lights.

Push Pull Radiator fans.

Exciting stuff, I know!   ::)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 02, 2017, 12:48:20 PM
woo hoo, parts!! :drool
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 03, 2017, 07:56:33 PM
One small step for the Simple Man, and one small step for man kind!  :LL:

Tranny cooler done

one Fan down 4 to go! Using this fuse block to run all my fans.

Ever get done doing something and wonder what happened to your hand?    ::scratch

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 04, 2017, 07:51:15 PM
Got the two puller fans wired up.  The sensor kit had the relay etc,

Onward!!

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 04, 2017, 08:39:07 PM
with the fieroROG cradle mounts for the engine and transmission the engine moved from the original position by 2 to 2.5 inches to the passenger side.  That was not the only problem it also moved the engine to the rear by about an inch.

The original bar was a massive 1/4 thick 2x2  tube!! It weighed a ton!! ;D
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 04, 2017, 08:44:36 PM
bought new engine mounts.  A more accurate bar size is 1.5 x 2 and 1/8 inch thick.

Not sure if these upper mounts are necessary, as the engine and trans are secured by 3 mounts on the cradle.

Now just need to prep for paint, weld into car and paint

onward!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 11, 2017, 07:56:49 PM
Not much progress been down with some flu bug and slowly getting back at it.

Had the radiators in and out a few times and noticed some funky wiring on the rear side marker lights..... REDO :o

Driver side had one set of crimp connectors the passenger side two sets.  Removed all three and rewired.

Have the feeling this process will be repeated again and again and again ::toothy

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 12, 2017, 09:32:24 PM
Try to get something done everyday in the limited amount of time available :D

Made a fiberglass tray for back trunk area. 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 12, 2017, 09:38:47 PM
More exciting stuff  ;)

Decided on different relay so they all looked the same ::toothy

Shrink tubing, Strip wire, Crimp female connector, more shrink, tubing apply heat.

 8)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 12, 2017, 09:46:56 PM
Was just going to put the relays next to the battery in the rear trunk?  ::scratch

Or put up under by the frame member?  ::scratch

Upgrading the Radiator wiring for possible HO spal fans if need be.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on October 13, 2017, 01:26:03 PM
Good job on insulating the terminals with the shrink tubing.  If you like, check my post in "Electrical" on the terminals that come with shrink already incorporated into the terminals.

01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 13, 2017, 08:03:55 PM
Good job on insulating the terminals with the shrink tubing.  If you like, check my post in "Electrical" on the terminals that come with shrink already incorporated into the terminals.

01

01 thanks!  I saw the terminals in the hardware store, but I have a few male and female and shrink tube around, that I would like to use first...dont want to bust the budget on this build and buy more :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 14, 2017, 01:48:11 PM
REDO on the radiator wiring complete ::toothy

Havent settled on a final place for relays, will figure out as the build goes forward.

Quite the mess with all the stuff out for install!!  888o

Onward!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: CCIE on October 14, 2017, 03:37:10 PM
Very Nice....

I would recommend a clearly visible and accessible place to put the relays and fuses. In my NAERC the fuses and relays are all over the place and I had to spend ton of time finding them, Also when/if someone else works on your car you will wind up spending ton of money for them to figure out what is where. Planing up front will save you time and money in the long run.
Also.... Why do you have 2 relays, one for push and one for pull (to be honest I haven't read the full thread yet)
Are you using 2 fans per radiator? one on each side , one to push and one to pull? or are you just planing ahaid just in case you want to flip the air direction. I have a severe heating issue in my Diablo that I am working on currently (lol when I can work and family comes first)

CCIE
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: eddie on October 14, 2017, 05:49:45 PM
doing good job, how ever I still would change the rad fans now while you have all open, those fans that comes with the Honda radiators are only 1100 CFM + - 50 . Spals are like 1850 cfm.
also if you are going to store relays not in the cab use oem ones. I went to pick part and got few exterior relays . they are water proof. and more or less last longer then made in CHINA .just my opinion
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 15, 2017, 07:39:27 AM
Very Nice....

I would recommend a clearly visible and accessible place to put the relays and fuses. In my NAERC the fuses and relays are all over the place and I had to spend ton of time finding them, Also when/if someone else works on your car you will wind up spending ton of money for them to figure out what is where. Planing up front will save you time and money in the long run.
Also.... Why do you have 2 relays, one for push and one for pull (to be honest I haven't read the full thread yet)
Are you using 2 fans per radiator? one on each side , one to push and one to pull? or are you just planing ahaid just in case you want to flip the air direction. I have a severe heating issue in my Diablo that I am working on currently (lol when I can work and family comes first)

CCIE

Thanks CCIE!

The relays are easy to get to and marked what they control.  One for the Trans cooler, one for pull and one for push.  On each radiator one fan pushes and one pulls.

I put two fans on each radiator because I had them :)

Good luck on your build as well and yes family first!! 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 15, 2017, 07:50:09 AM
doing good job, how ever I still would change the rad fans now while you have all open, those fans that comes with the Honda radiators are only 1100 CFM + - 50 . Spals are like 1850 cfm.
also if you are going to store relays not in the cab use oem ones. I went to pick part and got few exterior relays . they are water proof. and more or less last longer then made in CHINA .just my opinion

Thanks Eddie!  I have been looking at the Spal 30103202, but will hold off for now.

On this car the body was already mounted when I purchased it.  The radiator was in the front of the car.  It was a bit of a PITA putting in the rear radiators with the body on the car.  But They come in and out the car very easily at this point.  The wiring for the Fans as well as the mounting of the fans are such that it can handle the added amps and depth/thickness of the fans, when a HO Spal fan or fans are added.

Good idea on the relays!

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 18, 2017, 06:15:14 PM
took the engine out for final assembly.  What a nightmare!! the passenger side rear bolt was a pita!! 

Only known issue is the  alternator relocation bracket (sold by FieroROG on pennocks) requires a short spark plug.  Even then the alternator will have to be unbolted and lowered to get it out.

Been so long I'm not sure why it was relocated  ::toothy

Before the engine is put back in need to:
Change super charger oil
New fuel injectors
Install and check new rear brake brackets from Arruat... god I hope they are right!
Install lengthened axles







Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: eddie on October 19, 2017, 11:24:49 AM
Hey Simple, when you are changing S/C oil that stuff smells like dead road kill , don’t spill any
Seriously
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 19, 2017, 08:34:37 PM
I try to get something done on the REDO everyday  ::thumbup

The prior owner had the PCm just laying loosely on the bar that holds the rear engine mounts

Bough the GM pcm mounting bracket and welded up  mounting points

Decided on having the wiring hanging in the down position as it seemed cleaner.... but that could change once the engine is back in  ::scratch
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 20, 2017, 05:02:26 PM
Received my inner & outer doors from Rhode Island.     ;D

Half the price of other quotes received.  ::thumbup

Packaged well and are really finished off nicely !!  ::toothy

Some mods needed for the OEM window glass.

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: AdrianBurton on October 21, 2017, 01:13:58 AM
those doors look GOOD!!!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 21, 2017, 11:01:07 AM
those doors look GOOD!!!!

Yes the door have no voids and the gel coat is flawless!!!  Now just need to install :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: RT on October 21, 2017, 12:11:04 PM
Simple Man...
It is a lot more work but think about making the door skins removable.  That will make it so much easier to work on anything and everything inside the door while you are building AND when you are done and need to service it.
My Flickr page has a lot of pictures of how I did mine.
https://www.flickr.com/photos/49982981@N00/ (https://www.flickr.com/photos/49982981@N00/)

RT
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 21, 2017, 04:25:40 PM
Simple Man...
It is a lot more work but think about making the door skins removable.  That will make it so much easier to work on anything and everything inside the door while you are building AND when you are done and need to service it.
My Flickr page has a lot of pictures of how I did mine.
https://www.flickr.com/photos/49982981@N00/ (https://www.flickr.com/photos/49982981@N00/)

RT

Thanks RT for the link Very useful pictures.  It going to be a while before I get to the outer doors.  But a great set up for sure!
Is your set similar to this? https://www.youtube.com/watch?v=q7iHitSSHAs (https://www.youtube.com/watch?v=q7iHitSSHAs)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: RT on October 21, 2017, 07:41:10 PM
Simple Man...
My Taj Garage did a nice job but with that method you still have to remove the inner door panel to access the screws to remove the door skin.  My method has the removal screws at both ends of the door, inside the door jambs.
See video:
https://www.youtube.com/watch?v=8WnHHdWn3QU (https://www.youtube.com/watch?v=8WnHHdWn3QU)

RT
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 23, 2017, 01:33:48 PM
Super fast service from ZZP 8)  Cant wait to get new injectors and billet fuel log installed! :D







Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 25, 2017, 08:11:03 PM
ZZP fuel logs and injectors installed.  I really like them over the oem fuel rail.

Arruat shipped the REDO on the front spindles and rear caliper brackets today.  Hopefully they are correct this time.

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 28, 2017, 07:19:56 PM
The existing sebring column rear mount was rubbing on the brake booster lever an had to be cut out.

Time sure does fly a MM post back in 2009 on the sebring column.

To attach the end of the fiero steering column to the Sebring column, used a tight fitting bushing to go over the splines. Then cut two slits in the fiero column end, the bushing and welded all three together. 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 28, 2017, 07:28:39 PM
With the steering column out.... some rust and jagged edges to clean up.  Will use rubber edging to protect the instrument cluster wiring.

Prepped the rust and used po15

Also cleaned and prepped the floor and any cuts to the body that had rust on the drivers side.

Time for a cocktail!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 30, 2017, 12:26:43 AM
had to do a REDO on what was a nice set of MM paddle shifters, that came with the car.

gouged metal, drops of resin, chipped paint, gray primer over spray 888o

Sand, base & clear
That works!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 30, 2017, 08:47:18 PM
Worked on getting my seat mounted to the lowered floor pan so I could finalize the steering column.

Made a simple frame to mount the seat to.  Will cut a notch in the front of the frame and cut the frame in the rear so it slopes.

Mocked up the frame the seat and the e brake handle.  Seems to work/fit nicely, although the e brake need to go towards the rear to be closer to the OEM position
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 31, 2017, 09:25:25 PM
Semi final position of seat. ebrake and seat belt.  I can gain another 1/2  inch head room by adjusting my Simple frame.

Pretty tight where the ebrake handle is.... thinking  ::scratch about a REDO of IKR side pieces to smooth out the top edge from the 90 degree it is now.  This would give me 1/2 inch at the top of the piece. Also maybe move the ebrake handle forward Since the seat is pretty much in the back position. 

Will mull it over while drinking an adult beverage! ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: CCIE on November 01, 2017, 10:44:23 AM
Love your seats

Who did you Upholstory

CCIE
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 01, 2017, 09:30:24 PM
Love your seats

Who did you Upholstory

CCIE

Thanks CCIE!  Went to the high end car show room that sells  lambos, ferraris, and so on, and was looking at a murci,  Told the guy I didnt like the red leather.  He said they used a guy that did all of the upholstery for them, I asked him who, he told me and that is who I used.

It was a big shop and pretty busy talked to the owner, He has done a complete OEM Murcie and he will be doing my REDO... someday  :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 01, 2017, 09:52:07 PM
Well well, I would say,"out with the old and in with the new", but that has been done once already :o

Got Version 2 (V2) of the Arruat Motorsport Suspension today,  I pray to the old gods and the new gods, that there will be no V3.   Its the front drop spindles that are the biggest concern,  They said the QC'd them with the Caliper I sent them... so who knows.....
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 02, 2017, 09:17:44 PM
One side of V2 was installed and all the V1 issues are still there.  Richard stated he QC'd them, I asked if he mounted a tire to the setup, he stated he did not.  I said you didnt test them correctly the mounted tire holds the rotor to the hub... oh well ::tongue

A couple of issues with the Caliper bracket

1. The tapped holes are just slightly to far toward the center and therefore the caliper is to far in when mounted.  This causes the caliper to rub the outside edge of the rotor.

2. The Rotor is not centered in the caliper/brake pads. . There is no adjustment in that direction.

My machine shop friend will take .030 off the diameter of the rotor. The caliper mounting bracket will be reduced by 1/16 of an inch in the area where the caliper is bolted and on once side of the bracket only.

This will be done on one rotor and bracket and tested out before the other side of the front end is done.

Haven't even tested the brackets for the rear.... but I'm sure they are okay, right?  :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 02, 2017, 09:23:55 PM
Made a cardboard template for my rear wheel wells.  Used 1/8 inch ABS.  Will have some adjustments to make once the rear end is in. but close for now.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 02, 2017, 10:04:48 PM
Got the switches for the REDO on the steering column.  Besides having drops of resin and paint over spray, the car must have been in the sun/weather as they were really rough and beat to hell.  ::)

The pictures dont really show how bad they are!

Probably wise to use the old ones until this build closer to being competed  :LL: 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: String on November 03, 2017, 12:42:49 PM
To get more room by the side of your handbrake lever , you may want to consider mounting the seats in the OE orientation which is inwards at the front and not parallel to each other.
There is also an angle to the steering column , but that may be a step too far...
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 04, 2017, 07:49:34 AM
To get more room by the side of your handbrake lever , you may want to consider mounting the seats in the OE orientation which is inwards at the front and not parallel to each other.
There is also an angle to the steering column , but that may be a step too far...

Thanks String! that is a great idea, wouldn't have to be that much and not really noticeable.   A simple solution for a Simple REDO ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: String on November 05, 2017, 11:46:29 AM
The example picture I was looking for that I knew I had  , but couldn't find. Makes these suggestions have a bit more clarity.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 06, 2017, 09:39:49 AM
The example picture I was looking for that I knew I had  , but couldn't find. Makes these suggestions have a bit more clarity.

Thanks For the picture it is worth a thousand words !!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 07, 2017, 06:28:51 PM
Getting no work done of the redo, as I'm on holiday. ::thumbup

My girl friend got me this for my birthday   :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 15, 2017, 08:09:02 PM
After a couple of trips to the machinist to correct the Arraut Motorsport wonderful product  ::scratch   The front wheel can actually turn now with the tire mounted!!!

The drivers side is next and that will be back tomorrow, since it is known what has to be done to the system for it to actually work!

Picture of the wheel turning  8)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 16, 2017, 06:12:38 PM
Sweet!! just in time for the weekend my extended heat treated chromoly 300 axles arrived today!!

Initial quickie measurement on the right axle would make one believe it was done correctly ::toothy ..... but the proof is in the pudding!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 18, 2017, 04:01:25 PM
It nice when you have parts custom made that fit !!!   ;D  Other wise its a  PITA!!  ::toothy
A little clean up on the 88 knuckles.

Old axles for sale ...cheap :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 20, 2017, 08:20:43 PM
The calipers on the rear of the fiero sit opposite to the Murcielago placement.  the standard Arruat rear brackets follow the fiero location.

New V2 bracket put the caliper more inline with the Murcielago..... although the 4 piston caliper is small.

The rear bracket has to be machined a bit more to correct the rubbing issue.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 23, 2017, 01:06:28 PM
thanks to everyone who has helped me on the build during the last year!

Much appreciated!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 30, 2017, 09:27:01 PM
Back at it after the holiday of eating/drinking to much, and tolerating certain family members  ;)

The drivers Arruat bracket and rotor came back and was machined the same as the now working passenger side.

Well The drivers is more out of wack than the passenger side.

The upper area has clearance the lower is still off and rubbing.  After screwing around with it for a couple of hours, I've come to the conclusion that the  caliper holes in the bracket,  will have to be redone about a 1/32 to 1/16 of an inch.  :o :P 888o ::)  ::scratch


If any body has seen this before and has a solution ......
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on December 01, 2017, 09:53:16 AM
It's your call.  Either cut the rotors down another .050" or get out the dremel.  I wouldn't mess with the mounting holes.

01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 01, 2017, 06:39:23 PM
It's your call.  Either cut the rotors down another .050" or get out the dremel.  I wouldn't mess with the mounting holes.

01

thanks 01

Took off .030 which reduced the diameter by 1/16.  Taking another .050 would reduce the diameter by another ..... well that amount is too much.

I have another set of brackets to play with :LL:  dropped them off at a "real machine shop"  :o owned by my friend.  Either adjust the caliper holes or make a new bracket that works.

Richard at Arraut Motorsports is a nice guy but the product is sloppy. As my machine shop friend says... "what kinda crap are you bringing me now?"   :LL:  told him I still have the rear brackets to go..... ::toothy  888o  .


Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on December 01, 2017, 11:07:00 PM
That will work too.  My adapter plate bolts to the oem fiero spindle.  My problem is that the oem caliper mounts to the inside of the mounting arms and the Corvette adapter plate bolts on the outside surface.  I'm going to have to remove my spindles and mill the arms flat and on a 90 degree to the spindle.  As it is now, the caliper is cocked.
01


Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 03, 2017, 10:48:22 AM
Took a look at the existing headlights on the REDO. They are the G28 buckets.

Dont think I will be reusing these ::toothy

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 03, 2017, 10:29:11 PM
The REDO headlight parts are pretty beat.  The rings are melted and out of round.  Not sure if it was caused by the heat from the projectors.

Using a 3" for the larger light which replaces the 2.5".  The fog light will be the Hella used in the OEM headlight.

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 04, 2017, 11:36:53 PM
bought oem sized replica headlight buckets a couple of years ago.

time to get them cleaned up!

Sand, putty, sand prime, and prime sand prime ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 05, 2017, 04:16:55 PM
Lost count of how many times I have had the front brake bracket, calipers and tires off :LL:

The adjusted bracket is back and in and everything appears to work correctly!! ::toothy   Finally? ::scratch

The rears brakes will be next, although the issue will probably resolved by taking .030 off the diameter of the rotor...we will have to see.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 05, 2017, 08:31:42 PM
Need to make some adjusters and brackets for my headlight lamps.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 05, 2017, 08:35:47 PM
The smaller hella light ....

bought a bracket which made it easier to mount in the confined space.

Onward!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 06, 2017, 11:11:38 PM
made some changes to the back side of the buckets.

Dyna glass to build/smooth the egdes

Used some 3m adhesive then reinforced with fiber glass
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 07, 2017, 08:48:38 PM
yaawn.....
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on December 08, 2017, 10:47:00 AM
SM:  Awesome work. ::thumbup  Do you plan on driving under water? ::scratch  Is there a chance that vapor will cloud the lens later when used? or will these be sealed units?
01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 08, 2017, 05:07:41 PM
SM:  Awesome work. ::thumbup  Do you plan on driving under water? ::scratch  Is there a chance that vapor will cloud the lens later when used? or will these be sealed units?
01

Thanks 01! Well mine will be sealed but not by using silicone around the rings and lamps. Hopefully work out as planned and keep moisture out, we will see :)

Oem lights fog up as well
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 08, 2017, 05:14:58 PM
 More progress  8)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 09, 2017, 10:58:20 AM
Assembled the lamps in the bucket and did a mock up with the lower bucket. A nice seal with the weather striping ;D

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 09, 2017, 06:36:09 PM
before hooking up the wiring a mock up was done. Pretty happy how it is coming out so far ::toothy

The edges of the top bucket need to be cut down to fit inside the glass.

Also no sure if the top surface (where the glass rests) needs to be thickened. ::scratch

I want to be able to put a straight cutting blade in from the side to cut the adhesive easily that will be between the glass and the bucket.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 10, 2017, 11:03:46 PM
Wiring is a tedious activity :o

Makes my eyes blurry  :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambobuilder on December 11, 2017, 09:02:10 AM
Very Nice. Love the matte finish.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 11, 2017, 07:23:54 PM
Very Nice. Love the matte finish.

Thanks LB!  I believe Murci Me gave me the info on the paint that he used on his headlights.  I used a clear over the color.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 11, 2017, 07:31:07 PM
For mounting the bottom tub, The location of one of the studs was moved.  The stud that was attached to the aluminum bracket, for the 3" lamp was removed.

Should be better in the new location.

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 11, 2017, 07:39:28 PM
Using some rubber washers with wing nuts.  Pretty happy with the seal.

I was putting a desiccant pack in my gun safe and was thinking of putting a couple inside the headlight once it is sealed to absorb any moisture.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on December 12, 2017, 11:11:57 AM
I would hold off on the desiccant unless really needed.  It seems like it occurs mostly on daily drivers with seam problems which are driven in the rain.  The youtube fix? is to blow low pressure air into the headlight for a few minutes through the bulb hole thus removing the humid air that has accumulated inside the headlamp.  The warmer the air blown in, the less time needed.
01

(my thinking on this problem is that hot air expands inside the headlight when lights are on.  This breaks the seal of the unit.  As the air cools, it pulls in the moisture where ever it can like rain or washing the car.  Possible cure might be to drill a 1/4 inch hole at a location that is not visible (in the bottom?) and glue a cigarette filter in the hole.  This would allow for the air expansion/contraction without pulling moisture into the light bucket)  my $.02
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 12, 2017, 07:43:42 PM
I would hold off on the desiccant unless really needed.  It seems like it occurs mostly on daily drivers with seam problems which are driven in the rain.  The youtube fix? is to blow low pressure air into the headlight for a few minutes through the bulb hole thus removing the humid air that has accumulated inside the headlamp.  The warmer the air blown in, the less time needed.
01

(my thinking on this problem is that hot air expands inside the headlight when lights are on.  This breaks the seal of the unit.  As the air cools, it pulls in the moisture where ever it can like rain or washing the car.  Possible cure might be to drill a 1/4 inch hole at a location that is not visible (in the bottom?) and glue a cigarette filter in the hole.  This would allow for the air expansion/contraction without pulling moisture into the light bucket)  my $.02

Something to think about for sure.  Im not sure the heat blows the seams in the OEM headlights as the OEM headlights have drains in them. 

there is a youtube video that states having the lights on causes the problem in the OEM lights. 

I think the main thing I am thinking about when putting these together is how to get them apart if the lens get cloudy. With my removable bottom tub I can inspect the desiccant packets and replace if needed.  They turn color as they fill up.

I'm not sure what the solution is and even Audi hasn't figured it out :)

I'm a ways from sealing mine up so I will have to ponder.....

Thanks for the comments 01!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 12, 2017, 07:46:16 PM
Well made some attachment brackets, or at least the first version  ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 12, 2017, 08:37:09 PM
How to attach the replica tubs to the glass  ::study

Thinking about this way. Trim the tub to rest on the inner ledge of the glass lens. Put a bead of sealant as pictured.

If the lens fogs up over time, the sealant will be easier to remove than if the bucket had the OEM flange.

something to ponder for a few days  :o
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 13, 2017, 08:31:00 PM
Well the headlight build for the drivers side will go smoother from all that I have learned from the passenger side  ;D

Decided to mount the upper tub recessed into the glass on the ledge.  The ledge at the top and bottom of the glass is wider and some adhesive will be used to affix it to the glass.  Going to try to locate another set of tubs for future use  ::toothy

A recuring theme with the REDO... there always seems to be issues :LL:.

The fiberglass headlights are warped  888o  After sanding the tub to fit inside the ridge and resting of the ledge the tub flares up.  Going to have to add fiberglass CSM to the inside to build it up.

onward!!

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 14, 2017, 06:41:09 PM
Added about 6 oz of csm to the top side,  then removed the original material from the bottom side, if that makes sense. 

Pretty happy the way it turned out.  Some dyna glass and rage gold to finish.  8)

Really leaning towards adding the fiberglass flange all the way around the lens.  ::scratch

Good news on the drivers side very little warp and fits nice in the lens.   ???
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 15, 2017, 03:28:17 PM
got the last dregs of engine items needed and installed engine hopefully for the last time ::scratch

Now I can sort out the rear brakes ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 16, 2017, 11:15:59 AM
For the headlight made a flange/lip for the upper tub.  Clamped  in place inside the glass. Now there is a decent surface for the sealant and I like the way it sits in the glass
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on December 16, 2017, 12:30:12 PM
SM: You are really starting to scare me.  You actually look like you know what you're doing!  Nice work. ;-)  Will you be coming to Carlisle next year?

01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 16, 2017, 07:52:58 PM
SM: You are really starting to scare me.  You actually look like you know what you're doing!  Nice work. ;-)  Will you be coming to Carlisle next year?

01

thanks 01 - actually I don't no $hit, but I can tell if something looks like crap :LL:

For the headlights had the order of steps a bit off but turned out okay
S/B
1.  Make upper tub fit glass , fiberglass flange
2. Cut holes for lights
3. Sand tub, fill pin holes primer sealer - repeat
4. Make lamp adjusters
5. Mock fit
6. make bottom tub - Mold not out of cardboard but mdf
7. Color paint and clear
8. Assemble

or something like that
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 17, 2017, 07:18:34 PM
Got a start on the ugly wiring harness. Parts I had for the camber and lower strut bolts.... were the wrong ones  ::) had to reorder....

Finished adding the sensors to the pipe and barbs to my tank for the cooling system...yes a series system :o  Will have to see how it works out...or not  ::scratch  The pull sensor will be just before the first radiator the push sensor on the exit of the 2nd radiator.



Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 17, 2017, 08:45:56 PM
headlights

Drivers side well under way, had an issue on bottom tubs which required surgery.

Passenger headlight - eyebrow affixed next will be sealing the glass.

A lot of time in these, and more to go!!  8)


Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 17, 2017, 11:05:44 PM
Crisis averted!! ::toothy

3m adhesive was applied the to eyebrow.  after about an hour I put the glass on and something didnt look right.....

Was able to remove the eybrow.  Will have to add a 1/2 inch to the top and right side edge.

REDO!!  888o
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 18, 2017, 11:40:59 PM
Someday I will have headlights ::toothy

Ground down both sides
Fiberglass both sides
Sand test fit sand

pretty close
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 19, 2017, 07:10:20 PM
Ho ho ho!  :santa

Got some great parts from Murcie Me, fantastic. :)

If my headlight parts were only as good! I would be done with them  :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 19, 2017, 08:23:50 PM
working on the eyebrow. Rage, Sand, Evercoat, Sand, Prime, Sand, Prime Sand.

Put on a coat of rattle can black just so the imperfections could be seen. 

It pretty close, will take back down and final after Xmas.  :santa

Mocked it up.  Will have to figure some way to get the eyebrow exactly where I want it for gluing.   ::scratch ::study
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 21, 2017, 07:44:30 PM
Now I have das Stoßstange, I will have to REDO the front structure. So out with the old.

 At least the old frame plus a 2x4 holds the bumper at a close height to get an idea of what it looks like.

 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 23, 2017, 07:47:53 PM
 :santa Merry Christmas !   :santa
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on January 16, 2018, 03:01:55 PM
Well after almost a month off, I need to get the mojo level up, and get back on the redo ::zzzzz

Used 3M windo-weld to affix the glass to the headlight tub. Waited 48 hours for max bond.

Pretty happy how it came out.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on January 17, 2018, 01:52:27 PM
You've made some amazing progress my friend and excellent workmanship  ::beers
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on January 18, 2018, 12:55:10 PM
You've made some amazing progress my friend and excellent workmanship  ::beers

Thanks Pedro!!  The progress on your build is a great motivator for me!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on January 20, 2018, 08:37:22 PM
When I was in 2nd grade my dad bought me an erector set!

Wax on! Wax off! I mean bumper on bumper off.. bumper on bumper off and so on...

not sure what I was thinking with the 1x3 steel  ::scratch... but its part of the car for now.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on January 21, 2018, 08:14:35 PM
just keep chipping away.....
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on January 21, 2018, 08:18:14 PM
The automotive stuff is a real  ::zzzzz  More enjoyment to be had working on the "kit" part of the build.....

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on January 21, 2018, 08:24:45 PM
My buddy made me some aluminum rings after seeing my plastic ones   ::thumbup
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on January 22, 2018, 02:03:41 PM
Good job as always man!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on January 25, 2018, 10:10:29 PM
Slow going on the REDO  :o

Got the new steering column and the intermediate shaft in. thought about putting the new light and turn signal switches in, but decided to use the old ones for now.

The light switch had the purple wire cut and another wire was attached to it when everything was plugged in on the original setup.  Not sure what that is about but we will find out  :LL:

Not sure what the deal was but had a heck of time with the two nuts., sometimes it takes 3 times as long to do... for no apparent reason  888o  :LL:

Tested out the brake pedal with no binding or rubbing. The way the old uncompressed sebring column was installed, it had a funky lower bracket that had to be cut out as it interfered with the brake pedal ;D
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on January 28, 2018, 09:01:46 PM
Worked on the fun part of the car for a bit

Mounted the front bumper to the frame using rubber washers for vibration pretty happy with how it turned out until I tried to mount the head light :LL:.

The bumper needs to go forward about 5/16 for the headlight to fit correctly.   ;D

Made some brackets out of 1/8 inch thick steel, a bunch of 1/8 rubber washers etc. Using the rubber washers I can adjust the height of the lens to match the body.  I used 3 brackets to hold the head light in place.

The lower Fiberglass tub that I made will have to have the corner cut off so it can fit better in the wheel well.

Pretty happy with how the headlight assembly is mounted in the car, nice and solid  ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on January 29, 2018, 12:10:58 PM
Nice bro, I like how you can adjust them easily.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on January 31, 2018, 12:48:29 PM
Nice bro, I like how you can adjust them easily.

 8) thanks!  shouldn't need to be adjusted but just in case  :D
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 11, 2018, 03:31:53 PM
back on the car after having the flu (103.1 fever)

Mechanically speaking the engine has all systems hooked up so it can be fired up
Radiators
Trans cooler
Heater hoses
Wiring for engine
Steering column and so on

When to start it and no power to the Ignition switch.  Put a hot lead to an exposed portion of wiring and the car turns over

On further investigation the way the Fiero system was spliced to the sebring system... is a REDO

The wires from the two  systems were just wrapped (not twisted) around each other and then wrapped in electrical tape.  :LL:

Went through and soldered and shrink wrapped each one.  Still no power to the switch.

Will have to investigate further ::scratch 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambobuilder on March 12, 2018, 09:05:40 AM
This is always one of the challenges in building. Being able to interpret wiring diagrams and translate those to a mass of colored wires buried deep in a wiring harness and then make the correct connections.  And people wonder why these are so hard to build. Keep up the good work.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Havemurci on March 12, 2018, 09:46:18 PM
Oh the jail of colorful spaghetti, my least favorite part of a build.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 13, 2018, 08:34:38 AM
This is always one of the challenges in building. Being able to interpret wiring diagrams and translate those to a mass of colored wires buried deep in a wiring harness and then make the correct connections.  And people wonder why these are so hard to build. Keep up the good work.

Thanks Dale, I keep plugging away!
The fiero wiring diagrams are pretty basic and easy to read.  The bigger problem is the sloppy, half a$$ work that was previously performed... :LL:   

I understand that the prior owner was in a hurry to get the car running, but #$%#, can you at least use some solder?  :o  :LL:  Going through and looking at every connection... and its a REDO!!    888o
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on March 13, 2018, 10:41:30 AM
Shucks, that aint nuthin.  The Cadillac Northstar has over 150 wires leading from the engine compartment through the firewall.  Trying to read the wiring schematics is a zoo of misery.  Stick with it.  You can do it.  ::scratch ::study ::thumbup

01

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on March 13, 2018, 09:10:58 PM
I hate wiring also, I get really frustrated trying to find bad connections
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: RT on March 13, 2018, 11:14:32 PM
You aint seen nothin" yet...

RT
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Havemurci on March 13, 2018, 11:57:12 PM
God bless you RT, that brings tears to my eyes. :'(
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: AdrianBurton on March 14, 2018, 08:50:46 AM
pure heaven RT
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on March 14, 2018, 12:27:47 PM
That's only a picture of RT's wiring for the radio/amp!
01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 14, 2018, 04:13:27 PM
 :LL:
Mine should be pretty Simple... relatively speaking  ::thumbup
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 25, 2018, 03:34:19 PM
okay, quite a bit of soldering and fixing of shoddy work...... and we have power!  Fuel pump pressure good, no leaking.

Now switching gears to the Transmission setup (4T65eHD) .  The REDO came with a Dakota digital shifter system, actuator etc. and  MurciMe paddles for the steering column.  Need to do some research on how it all is suppose to work, and get the Trans in neutral :)   ::study



Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 06, 2018, 09:34:57 PM
The shift system is ..... how come there is not the triangular pile of poo for and emoji to choose from?   ::scratch  ;D

So the GSS-2000 just tells you what gear your in and that is about it. 

The shiter system, pun intended, in the REDO  :LL:... was basically shift by feel.. you tapped on the paddles, the paddle hits an impala window switch and that triggers the actuator.... you tap too much you go passed R and so on.

God forbid your doing 70 mph and you accidentally go into reverse :o

New part installed.

I will be using the GSS-2000 for trans gear indicator only.

A big thanks to Fiero King , USMC and Murci Me for taking the time to talk to me about their systems.   

Here the vids of each if you haven't seen them before

https://www.youtube.com/watch?v=GbLzpjineU4 (https://www.youtube.com/watch?v=GbLzpjineU4)       - -  Fiero King

https://www.youtube.com/watch?v=tnN8E3JT6Wc (https://www.youtube.com/watch?v=tnN8E3JT6Wc)     - -  USMC

https://www.youtube.com/watch?v=gQgwH2viEVA (https://www.youtube.com/watch?v=gQgwH2viEVA)   - -   Murci Me



Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 08, 2018, 11:53:30 AM
Master cylinder blead, Arruat system, had pre bent brake lines,  The old fiero block is used and fitting brazed, Wilwood proportioning valve with supplied bracket installed.  All brake lines, and fittings installed.  Ready to bleed system.

Actually went smoothly ::scratch  :o
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Havemurci on April 08, 2018, 09:26:07 PM
Kit car build....went smoothly? Are you with the Illuminati? LOL.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 09, 2018, 01:35:12 PM
Kit car build....went smoothly? Are you with the Illuminati? LOL.

https://www.youtube.com/watch?v=UmzsWxPLIOo (https://www.youtube.com/watch?v=UmzsWxPLIOo)   :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 16, 2018, 02:55:57 PM
Just when I thought I was through with Arruat mfg parts!!

 http://www.fiero.nl/forum/Forum1/HTML/098195.html#lastpost (http://www.fiero.nl/forum/Forum1/HTML/098195.html#lastpost)

The drop spindles are a REDO!! and dangerous 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on April 17, 2018, 09:10:26 AM
That sucks, can they be beefed or modified some way?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on April 17, 2018, 10:04:29 AM
Wouldn't a pic of the failed part be of more help rather than a pic of the new knuckle?
01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 17, 2018, 01:48:47 PM
Wouldn't a pic of the failed part be of more help rather than a pic of the new knuckle?
01

It's like the first picture on the link, to the thread on Pennocks  :LL:

but here it is

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Purple LP670 SV on April 17, 2018, 04:54:45 PM
Nice Work Simple Man, to bad for your Arraut parts, I wanted to buy them in the worst way but I'm now glad I made my own stuff after seeing this!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Neils88 on April 17, 2018, 05:42:57 PM
I have a complete Arruat suspension system on my build. My biggest complaint with respect to the drop spindles is that the tapered holes drilled for the ball joints weren't drilled deep enough. I'm now forced to buy a tapered drill bit and drill them properly myself. Those bits are expensive... and I'll likely only need it this one time.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lp670mike on April 17, 2018, 06:52:27 PM
That's scary! Glad you found out before it cause any damage to you or your car. You are doing a great job by they way. Keep up the good work  ::thumbup
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 17, 2018, 10:26:33 PM
I have a complete Arruat suspension system on my build. My biggest complaint with respect to the drop spindles is that the tapered holes drilled for the ball joints weren't drilled deep enough. I'm now forced to buy a tapered drill bit and drill them properly myself. Those bits are expensive... and I'll likely only need it this one time.

I think you would have a bigger complaint if your car was on the road, and the spindle gave way like the guy on Pennocks did.  ::toothy

 

 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 17, 2018, 10:46:10 PM
 ::bounce  the failed spindle appears to be a different design than the ones that I have.   :o

My version appears to resemble the old HELD design.

You can see the differences and maybe why it broke. The failed spindle is missing the angled support.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 23, 2018, 09:44:57 PM
Started to fire up the headlights and sort out the messy wiring.

Well the signal light works. 

Inspection of passenger side wiring, lot of tape no solder.

REDO
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 23, 2018, 09:53:09 PM
Fixed all the connections and still no HID lights

Took headlight a part to examine wiring
everything connected.

Saw a few possible suspects
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 23, 2018, 10:10:26 PM
Saw  Murci Me's wiring diagram on the Fiero to Sebring light switch.

Checked the inside wiring to the switch and the REDOs wiring, looks correct.

No power to switch. Examined power distribution block

Saw a couple of things, a hack job on taking an old fuse link out and splicing the wires together & and frayed wire on the other one.

tested both and found "the good the bad, and the ugly" In other words the hacked one was good, the frayed was bad and the both are ugly and need to be replaced

Put a temporary jumper to by pass the bad fuse link.

Now when the switch is turned on the the fiero headlight plug has power.  Although the high beam switch shuts power off between the small (lt green) and the large (tan) lamps.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 23, 2018, 10:17:17 PM
So after all that, there is power to the Ballasts but nothing coming out of the ballasts.

When the passenger wiring setup is lightly shaken the driver signal light shut off and comes back on  :LL:

Have to mull it over and have a glass of wine  ::study
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on April 24, 2018, 08:36:49 AM
Hope you resolve your wiring issue, problems in the wiring can be tricky to find.  At least it looks like you are going in the right direction.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on April 24, 2018, 12:30:51 PM
SM: Is the purple wire Fiero or Sebring?  What year Sebring column?
01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 24, 2018, 03:06:28 PM
Hope you resolve your wiring issue, problems in the wiring can be tricky to find.  At least it looks like you are going in the right direction.

Yes I feel pretty good about the progress made.  I have decided to get the Morimoto set up with relays and start fresh from the power distribution block. Then remove the old system and wiring, because its a god awful mess!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 24, 2018, 03:09:48 PM
SM: Is the purple wire Fiero or Sebring?  What year Sebring column?
01

The purple wire is on the Serbring light switch, which is from year 95-99.

There is a mystery red wire (from the fiero side) wrapped  around the purple one.   
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on April 24, 2018, 10:21:52 PM
SM: Here is a pdf of the Sebring wiring.  Hope this helps.

http://ww2.justanswer.com/uploads/TrevHelpsYou/2008-05-12_011655_Binder3.pdf (http://ww2.justanswer.com/uploads/TrevHelpsYou/2008-05-12_011655_Binder3.pdf)
01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 25, 2018, 11:12:11 AM
SM: Here is a pdf of the Sebring wiring.  Hope this helps.

[url]http://ww2.justanswer.com/uploads/TrevHelpsYou/2008-05-12_011655_Binder3.pdf[/url] ([url]http://ww2.justanswer.com/uploads/TrevHelpsYou/2008-05-12_011655_Binder3.pdf[/url])
01


Thanks 01!

The link for the diagram mainly has the engine functions.

Autozone has a diagram for the headlight wiring.  But the internal wiring of the switch isnt on the diagram.

There are 4 wires, purple being the one that is spliced.  I can cut the wire and see what function it controls.  Or trace the red wire into the fiero and see. ::scratch
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 26, 2018, 01:24:20 PM
Wow fast shipping on the morimoto system!  The Internet !!! I am located out in the sticks and I dont think I could get as far on the build without it.  As well as my local hardware store...
 
Also having folks to contact with questions and the comments on here is a must have!  Thank you :notworthy

Friday is the day to fire up the REDO,  all necessary fluids have be obtained.  Hopefully goes as well as it does on the "reality" car shows. :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lp670mike on April 26, 2018, 01:27:06 PM
Awesome! good luck with the start up ::thumbup
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on April 26, 2018, 01:35:49 PM
Awesome can't wait to hear your engine running.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 26, 2018, 01:41:10 PM
Awesome can't wait to hear your engine running.

You and me both!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 26, 2018, 10:52:00 PM
When you sorta know what you are doing things go faster.  Driver side has taken about a 1/3 of the time as the passenger side ::toothy


Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 28, 2018, 08:43:22 AM
Started the REDO for a brief moment.  ::toothy

I put a brace to make the rear more rigid.  Unfortunately it was in the way of the exhaust pipe by about an inch.

Will get a new one.

The REDO came with a Magna Flow system. Will have to see how it sounds with the ZZP front and rear headers (power Log)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: eddie on April 28, 2018, 01:29:22 PM
are you going to use the cat? is a law at your state?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 28, 2018, 01:38:32 PM
are you going to use the cat? is a law at your state?

Not sure about the CAT or the law :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 28, 2018, 02:07:42 PM
Thanks to Murci Me for the confirming I was keeping the right wires.  ::thumbup

removed all the plastic wire loom.  Not sure I like the stuff as it was all brittle.

The REDOs wiring theme is "twist them together"  & "duct tape"  Only use electrical tape if necessary. Don't use any solder as you might burn yourself :LL:

Barely used HID system for sale cheap, wire included ::tongue
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: eddie on April 28, 2018, 04:33:20 PM
ok then ,but I would check with local emission test requirement . Here in Ontario CN if the car is registered as home build or Kit no need emission test
btw good work on your buid
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 29, 2018, 11:04:40 PM
ok then ,but I would check with local emission test requirement . Here in Ontario CN if the car is registered as home build or Kit no need emission test
btw good work on your buid

Thanks! I did a quick check and the CAT will stay in!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 29, 2018, 11:13:21 PM
Well I changed my avatar to a pile of poo with a couple of flies flying above.

The REDO...what can you say....

I traced the 3 non OEM wires from the trunk to the instrument cluster.  They were connected to the L&R indicators.

A quick survey of the wiring.  No duct tape this time just a bunch of twisted connections with electrical tape.   ::thumbup

half of the dash lights are out.

When the wiring is lightly moved the dash goes completely out.

purple marks the poo!

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 29, 2018, 11:24:15 PM
After being totally disgusted yesterday. I took most of today off.  Then after dinner started to look at this POS.

Thanks Murci Me for the wiring diagram,  You are right this type work gives Kit Cars a bad name.

With half the dash lights out and wiggling the wires and having it go completely dark.  I located the offending connection. 

The dash has 2 of the blue boxes that run the instrument gauge lights, pretty cool.

One of them has a hole  ::scratch  So I made a temporary jumper and the all the gauge lights came on.  I'm not sure if it the inverter or some shoddy work....

Since I'm ahead, I better quit for the day!!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambobuilder on April 30, 2018, 08:28:22 AM
And people wonder why these never get finished. Hats off to you sir for taking the time to fix it and do it right.  ::thumbup
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on April 30, 2018, 09:02:31 AM
Wow you really have your work cut out fixing that wiring, but it looks like you are making good progress.  The gauges look great
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on April 30, 2018, 12:08:50 PM
SM Redo:  One look at your spaghetti wiring leads me to advise you to install a "Painless Wiring" kit.  You really don't want a hidden problem to bite you later on.  I think that 76mx is an authorized seller or he can direct you on who to contact for purchasing.  Summit Racing sells them also  ::scratch ::thumbup

01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 30, 2018, 07:44:55 PM
And people wonder why these never get finished. Hats off to you sir for taking the time to fix it and do it right.  ::thumbup

Thanks Lambobuilder!  Its  puzzling why the PO didn't do it right in the first place.     ::scratch
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 30, 2018, 08:00:53 PM
Wow you really have your work cut out fixing that wiring, but it looks like you are making good progress.  The gauges look great

Thanks Autopro! I will be taking it one connection at a time  8)

The instrument cluster is a Murci Me design.  It comes with a G28 size instrument cluster trim piece tooth that looks OEM.  As well as the cover on the top/back side.  the layout of it is pretty cool and well thought out.  The Back lighting on the gauges is great !!

The PO painted the instrument cluster trim piece, then dripped fiberglass resin and scratched it all to heck. 

The Plexiglas cover is scratched up pretty badly.  The Plexiglas piece in the rear is cracked in one corner.

So, some of it will be a REDO to make it decent.  Glad to have this as it will give the build the OEM look that I am striving for.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 30, 2018, 08:11:16 PM
SM Redo:  One look at your spaghetti wiring leads me to advise you to install a "Painless Wiring" kit.  You really don't want a hidden problem to bite you later on.  I think that 76mx is an authorized seller or he can direct you on who to contact for purchasing.  Summit Racing sells them also  ::scratch ::thumbup

01

Thanks 01 for the idea,  but its the connections that need to be soldered.  If I pulled the Fiero harness and put in painless, Which would be a ton of work..... I would still have to solder all those connections in the instrument cluster. To much pain putting in the painless  :LL:

I think I have about 30-50 connections to REDO at the instrument cluster and under the steering column.

 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 30, 2018, 10:33:20 PM
Trying to get a bit completed on the wiring.

The mystery of the purple wire on the Sebring headlight switch and the spliced red wire to the Fiero has been resolved!!   This red wire spliced to the purple was the power source for the dash lights.  :LL:

Testing the sebring switch, the black wire with the white stripes is the only one that is hot when the parking lights are switched on.  That black wire was traced to a blue crimp junction which was connected to a black fiero wire that is constant hot.  But also connected to it was the wiper motor.

Looking at the Fiero fuse box there is a fused wiper circuit, I will use this fused circuit as I don't want my wipers to run without the ignition "on" or "acc" position. ::study



Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lp670mike on May 01, 2018, 05:40:07 AM
Wow you have quite a project with that wiring! Looks like you have the skills fix it though.
Keep at it, you will have it sorted out eventually. ::thumbup
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 02, 2018, 01:17:27 PM
Wow you have quite a project with that wiring! Looks like you have the skills fix it though.
Keep at it, you will have it sorted out eventually. ::thumbup

thanks LP670Mike!  It looks worse than it appears.. or is it .... worse than it looks?  I have some skills but being OCD seems to help  :LL:  Just keep plugging away!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 02, 2018, 09:47:05 PM
Good times under the dash of the REDO  :o  Made a little progress on the wiring, only 3 more REDOs on twisted and taped connections.   

There are a bunch of fiero connectors that are not connected to anything.  ::scratch   Some were constant "hot" with the key in the off position.

 Some were only "hot" with the key in the on position.  Since I have no clue what the various fiero connectors are for.  I had to pull the fuses one by one until the test light went out. Marked each one.  I'll use these later in the build

I have no clue on some of the connectors.  Maybe some one here can shed some light what the heck they are for.   ::help ::toothy


 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambobuilder on May 03, 2018, 09:01:40 AM
I do believe I recognize those printed instructions.  ::tongue  If you don't have the Fiero Haynes manual I think you can download from here http://www.fieronews.net/fusion/downloads.php (http://www.fieronews.net/fusion/downloads.php)

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 10, 2018, 07:23:03 PM
I do believe I recognize those printed instructions.  ::tongue  If you don't have the Fiero Haynes manual I think you can download from here [url]http://www.fieronews.net/fusion/downloads.php[/url] ([url]http://www.fieronews.net/fusion/downloads.php[/url])



Yes I have read a lot of your info from your website!  thank you!!

Got few more of the connectors identified from a post I put on pennocks.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 10, 2018, 07:41:23 PM
Just came back from a visit down to OKC.  Just getting back to the REDO.

I have an issue with the signals. Running lights work great.  Test light lights, going into the flasher is super bright, but coming out it is rather dim regardless of the signal switch is in the on or off position.

There is power coming out of the signal switch for left and right, when turned on just no signal.  I think I have a ground issue or continuity issue.   ::scratch
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 15, 2018, 08:18:35 PM
Well that took a while.... but The problem with the signals was tracked down and resolved  ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Purple LP670 SV on May 18, 2018, 05:57:25 PM
Nice work fella!  ::beers
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 19, 2018, 01:47:41 PM
Nice work fella!  ::beers

Thanks! Talked to the PO, it appears that the hazard lights were not working.... so have to sort that out now :)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 30, 2018, 09:12:49 PM
With the signals working, Time to get the headlights up and running.

The morimoto system is pretty straight forward and worked right out of the box in a quick test using the Fiero wiring and Sebring steering column

My projector has a shutter and was wired to the high beam switch.

I'm using a 13 pin trailer plug to run all my wiring into the headlight enclosure. For some reason the HID light would not work using this plug so the two wires were ran through the headlight housing.  These holes will be sealed later.

 It was very tedious and took some time to test each connection into and out of the Plug.  It will make it quicker to remove the headlight unit from the car.   

Shout to Murci-Me for some guidance on the signal, test tube and side marker light wiring 8) ::salute

The fog light will be controlled from the dash switch to the left of the Steering.  As usual need one part to complete this.  ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 30, 2018, 09:33:53 PM
ahhhh!! my gal made me a nice cocktail after that mind numbing wiring....

Oh gee! The drivers side is almost ready to wire up :LL: :o
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 31, 2018, 08:16:15 PM
While waiting on my H3 bulb plugs the H1 ballast and relays were mounted

Wanted to clean up the wiring in the front trunk.  I used the same wire loom wrap that the HID system came with.

Before and after Pictures. you can see all the HID wiring laying there :LL:

Much better! ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 03, 2018, 10:44:05 PM
The old exhaust didnt have a flex pipe in it so one was purchased.

It hung down too low and didn't line up with the opening in the back of the car. After making a few measurements,  the pipe was cut and welded back together.

Turned out pretty decent and lines up well.

Just need to mount the metal replica LP640 exhaust tip...after I REDO the finish and make a bracket to mount the tip  ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 03, 2018, 10:50:29 PM
Both headlights are finally done  8)  They easily go in and out of the car, and the electrics connect and disconnect quickly.

Just need the H3 bulb connectors, Do final test and then store in a safe place   :o

Pretty happy with how they turned out. A bit of time was spent on these, for sure  :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: m-will on June 04, 2018, 09:29:49 AM
Excellent work  ::salute
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 05, 2018, 11:28:49 PM
Excellent work  ::salute

Thanks M-will!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 05, 2018, 11:45:18 PM
The HID H3 bulb connectors came in the mail today . 

The Hella Micro DE is the projector that I am using for my fog lights

An aluminum bracket was made to hold the bulb in place, using the existing screws, as the base of the HID bulb is longer than the halogen
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 06, 2018, 11:33:43 PM
Working on my bumper...which side marker light ::scratch
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: AdrianBurton on June 07, 2018, 03:50:42 PM
triangle
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 08, 2018, 06:18:06 PM
triangle

Yep I think so too  8)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: usmc_butler on June 09, 2018, 05:26:47 PM
Outstanding work on the headlights!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 10, 2018, 09:54:10 PM
Outstanding work on the headlights!

Thanks Dustin!!
 It has been interesting ::toothy

The PO used a lot of crimp connectors   Solder and shrink wrap seem better to me over the long haul. 

Wiring for the rear tail lights is in need of a REDO, as the crimp connectors are failing. As you move the rear wiring harness, lights go on and off.  Its crazy!!  :o

 I wish I had started with an unmolested car, yes this car has been molested!!  every where I see a crimp connector, I will be redoing them.   8)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: usmc_butler on June 10, 2018, 09:59:37 PM
Yep I feel your pain! My new car is about 95 percent good the other 5 percent looks like this
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 11, 2018, 12:26:04 PM
Yep I feel your pain! My new car is about 95 percent good the other 5 percent looks like this

yep those yellow ones........  :o
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 13, 2018, 09:24:13 PM
So the rear tail lights   ::toothy

Passenger side -
The PO used a connector that was spliced into the Fiero wiring.  Then made  a decent harness to go to the Lambo tail light. I actually like this set up.   :o
By why oh why leave the old fiero tail light plugs  ::scratch, and they still work  8)

Divers Side -
Lets do something different here this time, Lets not use the nice connector, like on the passenger side.  Lets use some crimp connectors.  But this time we remove all of the fiero tail light plugs :LL:    And leave a hot brn wire with insulation removed to short out every now and then ::thumbup 

Still have to clean this up but at least the lights work...

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: nickmkk on June 17, 2018, 12:13:15 PM
How do you plan to fix the broken lens, will you make a replacement lens?  I've been thinking about making replica tail lights since I could 3d print the buckets but I have no way to make the lenses.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 17, 2018, 01:07:43 PM
How do you plan to fix the broken lens, will you make a replacement lens?  I've been thinking about making replica tail lights since I could 3d print the buckets but I have no way to make the lenses.

I heard someone was working on making some lenses.  I don't plan on using these. 

Bought a new pair back in 2015, and just pulled them out.  They still have the plastic costing on them and a nice harness attached. The cracked pair is nice to have for mocking up the car. 

The new ones will stay in the box until after paint, and god only knows when that could be  :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: nickmkk on June 17, 2018, 01:10:56 PM
Nice, well when you're all done mocking, I'll take that other set off your hands  :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Purple LP670 SV on June 18, 2018, 03:27:26 PM
Nice work fella, I'll be stealing some of your learnings for my project. This is the beauty of sharing details like this with others, we can all learn and better our builds!!!  Thank You!!! ::wave
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 18, 2018, 09:15:18 PM
Nice work fella, I'll be stealing some of your learnings for my project. This is the beauty of sharing details like this with others, we can all learn and better our builds!!!  Thank You!!! ::wave

I try to keep a pretty detailed build thread, so glad you can gleam some ideas.  Its not like we are protecting our daughters from a loser boy friend  :LL:

So it is nice when folks show how they did it, not just I did it.  8)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 18, 2018, 09:33:48 PM
So after milking fathers day for as much as I could.....  ::toothy

I worked on attachment points for the bumper to fender area. 

made some metal brackets, welded some nuts to them,  This way the bumper can be bolted from the bottom once the headlights are in.  used  3m 08115 will fiber glass in later.

The brackets are about 1/8 inch up from the edge of the fender, will use rubber washers to make up the difference.

Might add as 1/2 tube/bar to the frame and weld to the brackets, if needed  ::scratch
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 20, 2018, 08:39:43 PM
Sometimes the excitement  of the build is over whelming ::zzzzz....

For the E brake system, made a bracket that will be welded to the side of the cradle. 

Final one will be 1-2 inches off of the cradle, or not... ::scratch

Then measure for the cables so they can be ordered.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 24, 2018, 06:12:37 PM
Mounting the Murci-Me front bumper went pretty smoothly.

Added a little bit bigger flange to the bumper

With everything bolted up, some fiberglass work needed.  The way it is attached the REDO is flush with the MM bumper.

Will adjust the bolt hole in, and see if the gaps decrease.  Probably will, but then will have to add fiberglass to the outside edge of the REDO so it is flush with the bumper.

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on June 25, 2018, 10:39:45 AM
The front bumper looks great, it really changes the whole look of the car.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 25, 2018, 11:11:22 PM
The front bumper looks great, it really changes the whole look of the car.

Thanks!  I think it looks great!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 25, 2018, 11:43:21 PM
I moved the upper fender attachment points in by about a 1/4 of and inch.

 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 25, 2018, 11:54:49 PM
Looking at a Murcielago hood and headlight alignment.  It appears the glass lines up with the end of the hood.

Mine appears to off by 1/4 inch.

The gap between the hood and the bumper is good. So probably move the headlight up 1/4, to fix this

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 25, 2018, 11:59:25 PM
But wait there is more...  :LL:

The headlight needs to be adjusted up as the fender sticks up about 1/4.  ::toothy

or the fender needs to be taken down or a combination of both 8)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 01, 2018, 06:34:10 PM
Needed to fix the gap between the fender and headlight. 

Added 2 layers of 1.5 to the back side.  Sand.  Then added 2 layers of 1.5 to the front.  Sand Then 2 layers of 1.5 to the back side.

Added another bracket for an attachment point, to the fender.

Worked on repairing a retaining wall while waiting for the fiber glass to set up.  55 -  63 lb blocks kicked my a$$!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 02, 2018, 08:43:13 PM
Drivers side pretty close.  On to the passenger side.

Thanks Murci Me for the guidance on dimensions
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 02, 2018, 09:07:01 PM
Received a PM asking what parts I used for my headlights

Amber Lens - tired a fiero lens but melted it to much, So bought  a VW Golf Jetta Mk3 amber euri E code front bumper turn light. Thanks String

Amber fixture - 98-01 passat front fender side marker light - thanks Auto pro

Small round lens - used a test tube 20 x 150mm - thanks Murci Me and a t10 fixture and an amber LED - thanks  USMC butler

Big projector -2x 3.0" H1 Bi-Xenon Projector Lens For Custom Headlights HID Conversion Retrofit  - ebay seller motoringmax (186187)

Small projector - HELLA H13090611 Micro DE Series and hella bracket 8HG 153.152-001 bracket that fit the fixture

Morimoto Elite HID Kit - ebay seller Hid IllusionZ - would have used LED but already purchased
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 04, 2018, 02:31:57 PM
Happy 4th!!  ::usa

More of the same on the REDO.

Passenger side - A little different.  Added 6 - 1.5  layers on the backside, then grind on the top to bring the surface level with the head light.

Up higher on the headlight opposite problem added 3 - 1.5 layers.

Adding 4  - 1.5 layer to backside.... hope this will be the last.

Wall in between  ::toothy  glad when it is done to much like real work :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on July 05, 2018, 07:44:02 AM
Nice work, now your headlights will have the proper gap all around.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 05, 2018, 06:36:28 PM
Nice work, now your headlights will have the proper gap all around.

Thanks !! they will be close enough for now  ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: AdrianBurton on July 06, 2018, 09:03:41 PM
Just looked at the pics of the wall.... I didnt notice any kind of drainage behind it
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 07, 2018, 06:19:05 PM
Just looked at the pics of the wall.... I didnt notice any kind of drainage behind it

1.5 inch crushed rock
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: AdrianBurton on July 08, 2018, 12:47:48 PM
Just looked at the pics of the wall.... I didnt notice any kind of drainage behind it

1.5 inch crushed rock
Ok, I just saw it in the base not behind it
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 08, 2018, 08:28:15 PM
more fiber glass on passenger headlight surround, pretty close

Having taken the bumper and headlights on and off the car numerous times, weld nuts were added.  Really speeds up removal of head light assembly.

Have to adjust the height of bumper on the passenger side by about 1/4.

Using rubber washers to span the void between the frame and bumper.  Will use weld nuts on frame at bumper attachment points.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 10, 2018, 10:04:56 PM
Side markers - thank to Auto Pro for the picture of his fender, worth a thousand words  ::thumbup

Used a mini router.  Might add material to the inside of the fender and router more material off, to recess the fixture a little more.  ::scratch

passenger side next

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on July 11, 2018, 09:58:53 AM
Awesome work once again buddy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 19, 2018, 11:40:35 PM
Not being able to take the mess my parts area had become, spent a good bit of time organizing and cleaning up the dust.

Hung some fiberglass reinforced tarps to contain the dust. Set up an exhaust fan to keep air pressure flowing in the right direction.

Hopefully the area wont revert to the way it was before  ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on July 20, 2018, 01:57:58 PM
I'll go $15 for the hand truck.  Just wait until you get done with the cleaning ;-)

01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 20, 2018, 03:10:11 PM
I'll go $15 for the hand truck.  Just wait until you get done with the cleaning ;-)

01

Uh, I am done with the cleaning,  :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 20, 2018, 03:37:07 PM
Yay!  ::scratch. My SS brake lines came in today.

The old lines sprung a leak, and were very thin due to rust.

Fun times a head, on the REDO.  Now brake system will be new from stem to stearn ....
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on July 21, 2018, 10:13:49 AM
I posted in the "Brake" section some problems that occurred with SS lines.
01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 06, 2018, 01:55:25 AM
Working on the wheel well openings.

Made a pattern out of the old bumper flange as it was close

Added flange to the new bunper

Wheel well opening is close, will wait until an alignment is done before fianlizing
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 06, 2018, 01:59:59 AM
87 Fiero brake line set,  for sale , Cheap!!   :LL:

Also eliminated a compression fitting in the brake line that the PO installed, when the stretch was performed  ::toothy

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 19, 2018, 09:00:26 PM
Working on the exhaust tip mounting.

Used washers/spacers for fine adjustment of the tip in the opening.

Some fiberglass work will have to be done to the opening as it was cut unevenly by the PO, and looks like crap.

The Tip is lined with a metal mesh but will probably have to cut the top of the tip as the muffler it to close.



Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on August 20, 2018, 12:03:35 PM
Which Borla muffler did you get and how do you like the sound?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 21, 2018, 11:01:11 AM
Which Borla muffler did you get and how do you like the sound?

I believe it is the Borla S muffler, I don't like the sound,  a little loud, but will do for now. 

But then again the sound might drown out any squeaks and rattles the car may have :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 09, 2018, 08:21:18 PM
Been working on a bunch of little things to get the mechanical completed.  But alas!  foiled by Arruart .... again.  In tightening up the rear axle nuts, the car was lowered to the ground.  The car would not roll in neutral.

Long story short disassembled the rear end down to the axles and the issue is the Arruat caliper bracket pushes the hub back so it grinds against the CVC.

The Knuckle needs to be machined 85mm around and 11mm deep, which is the thickness of the caliper bracket.  Well that is what appears to need to be done ::toothy

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 09, 2018, 08:53:16 PM
The other issue, with the car on the ground is the length and weight of the front Springs.  They are currently 8 inch and 350 lb, which seems to short and to stiff, with the 1.5 inch drop spindles.  I was advised by Arruat to get that size spring.  :o

I was thinking 10 inch and 250lbs.  ::scratch
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 09, 2018, 09:06:38 PM
Big shout out and thank you to Murci-Me for the molds for the center console  lid ::salute

Today I made the lid. I might be able to modify the G28 center console. Not sure if I will use that mold or not

This will be a big improvement to my interior!


Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Footcutter on September 10, 2018, 09:59:25 AM
Nice! ::thumbup
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 13, 2018, 12:43:31 PM
Nice! ::thumbup

Thanks FC!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 14, 2018, 12:44:57 PM
just in time for the weekend!   8)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on September 17, 2018, 09:49:56 AM
Oh man lots of goodies, what did you get?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 18, 2018, 11:08:34 AM
Oh man lots of goodies, what did you get?

Electrical connectors, AC pressure transducer, dryer, front springs, AC hose.  and other misc crap  ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 19, 2018, 11:18:50 AM
So it was time to clean up the mess, after the REDO on the wiring under the dash.  While doing this one of the brake switches was loose, and actually not mounted.  The other one had a cracked plug for brake lights.

Wondered what all the connectors were for. ::study

Switch #1
Connector - with yellow & yellow and blk http://www.fiero.nl/forum/Forum2/HTML/141811.html (http://www.fiero.nl/forum/Forum2/HTML/141811.html)
Connector - With purple and Pink/blk stripe - TCC

Siwtch #2
Connector - Orange, White and Lt Blue - brake lights
Connector - Blue plug - Cruise

Got the info in the wiring schematic and Pennocks.

knowing what I know, about the REDO, both Switches will be replaced ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 23, 2018, 04:14:33 PM
The G28 center console is pretty chunky,  Thanks to Murci-me I was able to use the mold to make the center console piece. 

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 23, 2018, 04:33:52 PM
The G28 console & lid compared to the Murci-Me Console and lid.

I think the Murci -Me Console and lid are pretty Kick a$$!!! ::thumbup
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 24, 2018, 09:43:03 PM
Got the REDOs rear knuckles back today from my friends machine shop.

Hopefully Arruats wide track set up will work now ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on September 25, 2018, 10:59:00 AM
What a difference between those two consoles, Mike sure does good work  ::thumbup
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 25, 2018, 06:59:04 PM
What a difference between those two consoles, Mike sure does good work  ::thumbup

It will be a nice upgrade to my build for sure !
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 03, 2018, 10:45:19 PM
Ah, the REDO's electrical..... :LL:

I think every wire and connection that the PO modified will eventually have to be checked and fixed.

I'm having an intermittent electrical problem and started with the wiring at the rear of the car. All the poly loom and electrical tape was removed from the rear harness. 

More quality electrical work was uncovered/found with exposed hot wires, twisted connections and crimp connectors.

Also the brake light was run from the cab to the brake light above the rear window, then a wire spliced into that one to the rear tail lights.  I'm not sure why this was done. I will be using the OEM wire from the power distribution block by the engine and removing the green wire

Also some wires that might not be needed?

More soldering and heat shrink to clean this up....  now had it been done right the first time,  by the PO....  :o

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Footcutter on October 04, 2018, 09:01:53 AM
I would rip all that poopie out.  That is just me.  :o
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 04, 2018, 12:51:16 PM
I would rip all that poopie out.  That is just me.  :o

You mean this?    :LL:

its almost there.... ::)   :LL:

This car should make it painfully obvious to builders that are using the fiero. Do all the modifications correctly, solder, heat shrink!!!!!  do not  f'ing twist wires together, use f'ing electrical tape, or use the crimp connectors!!

I feel better now after venting, thank you! ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Footcutter on October 04, 2018, 02:53:06 PM
I would rip all that poopie out.  That is just me.  :o

You mean this?    :LL:

its almost there.... ::)   :LL:

This car should make it painfully obvious to builders that are using the fiero. Do all the modifications correctly, solder, heat shrink!!!!!  do not  f'ing twist wires together, use f'ing electrical tape, or use the crimp connectors!!

I feel better now after venting, thank you! ::toothy

Oh my.... zzz:)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on October 04, 2018, 04:29:53 PM
That would drive me crazy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 04, 2018, 11:46:40 PM
Making some headway...  Since my new tail lights have the OEM connector I wanted to test the PINs

had this chart from the web about a old Murci up Tail light upgrade to the new style. Made some leads using 2.8 mm connectors and  the chart is correct.

For the body side connector, Had a JPG that Mr Bull had posted to this forum a while back, but  hard to make out the part number  1J0973835.  But doing a parts search  1j0973735 is the one I believe is needed. 

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Purple LP670 SV on October 05, 2018, 09:45:09 PM
Nice work Simple! Really dreading going through wiring so as usual I will procrastinate!!!  :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 05, 2018, 10:31:07 PM
Nice work Simple! Really dreading going through wiring so as usual I will procrastinate!!!  :LL:

I wish I had started with a unmolested car , yes this car has been molested!  as the electrical is chopped up!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 05, 2018, 11:08:35 PM
Good times to be had on the REDO!

Put the new brake switches in. 

I see someone drilled the backing plate for the upper switch. Why, I have no clue....

Cut a piece of metal and welded it over the hole.

I used Nuts for the switches 1/2 -  20 (fine threads)  from the electrical section of my hardware store

Cocktails and hot tub !
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 06, 2018, 10:51:52 PM
After yesterdays under the dash experience, my body was feeling some pain. 

Went to the salvage yard and acquired two 1J0 973 735 connectors.

I found that the connectors had 10 openings but only 7 pins.  Search around and found a 6 pin connector with the same 2.8mm pins.

Using paper clips removed the 6 PINS

Removed the rubber stoppers form the 10 pin connector.
Added the 3 missing PINs

Cleaned up the rear harness and pulled all unused wire.  This really cleaned up the mess that was back there.

Soldered and shrink wrapped the OEM connector to the Fiero wires.

Now the the fiero is plug and play with the OEM tail light.

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 08, 2018, 08:55:41 PM
The wiring gods smile on me today!!

I found the wire that was a cause one of my problems.  I still don't have hazard lights, but then the PO never had the hazards working on the car.

I have the fog lights hooked up with the brake lights, but not sure if I will leave them like that or not.  That is how an actual Murcielago owner did his upgrade.

http://www.safeer.us/diy-upgrade-lamborghini-murcielago-with-the-lp640-or-lp670-taillight-conversion/ (http://www.safeer.us/diy-upgrade-lamborghini-murcielago-with-the-lp640-or-lp670-taillight-conversion/)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 08, 2018, 09:41:20 PM
So back under the dash  :LL:

A few more bugs to work out. ::study
Coming out of the bundle of wires, that mainly go to the ignition, are two green and a tan wire. These wires are attached to a black connector.   

These might be the two wires that are identified in Murci-M's fiero to sebring conversion.There are also 2 wires that were also attached to the black connector,  red and orange.

Coming out of the of the same bundle are a a red and orange wires twisted together.  These might have at one time been connected to the black connector but the red wire seems to be a heavier gauge.

Does anyone know what this connector did?  :LL: ::help
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 10, 2018, 05:06:40 PM
Pennocks a great place to get info on the fiero. Got a couple of explanations for the 2 grn and tan wire. Both of them lead me to believe that they are not needed

"Grounding the tan/white wire turns on the BRAKE light on the cluster.
The lever has a switch that provides ground when ebrake is engaged.
Low pressure in the brake circuit allows the spool to move far enough to trip a grounding switch on the OEM bias valve.

The two green wires provide GROUND for the BULB CHECK function of the ignition switch. Pontiac made an error when wiring the Temp Gage and the HOT light, proding the bulb check ground to the Gage, rather than the light."

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Purple LP670 SV on October 10, 2018, 08:12:43 PM
Good stuff Simple! I'm very jealous of your 640 taillights, I'll be running the original Murcielago one unless I find a good deal on the 640's but that's not very realistic  :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 10, 2018, 10:21:27 PM
Good stuff Simple! I'm very jealous of your 640 taillights, I'll be running the original Murcielago one unless I find a good deal on the 640's but that's not very realistic  :LL:

I think they keep going up in price. Mine are tucked away back in bubble wrap and boxed ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 12, 2018, 09:05:44 PM
Ah Ha!  Figured out what the twisted Orange and Red wires were!! :LL:
They are part of the wiper system. 

The black connector with only one wire not cut (white) was hot and was traced it to fuse block space for the wiper motor.

Not sure why the PO didn't use the fiero wiper motor power, or fuse ::scratch

What I did find was a Red wire run over the top of the dash and spliced on to some wire up by the  the A/C relay and fuel pump relay, up in the front trunk area.  ::scratch

I feel like I'm making some head way on this wiring mess :o
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 14, 2018, 04:26:34 PM
It took a while to sort out the wiring under the dash,

Learned a lot about fiero wiring, and still have more to learn.

Fiero connectors for sale cheap, slightly used!! ::toothy

On to the instrument cluster!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Footcutter on October 14, 2018, 04:45:57 PM
Nice clean up job!  ::thumbup
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 14, 2018, 10:29:18 PM
Nice clean up job!  ::thumbup

Thanks FC!  I just keep plugging away! 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 17, 2018, 11:26:02 PM
Like everything on the REDO, the instrument cluster is filthy.   It needs to be removed for a complete disassembly and cleaning.

The PO even it left an assortment of dried leaves in all the nook and crannies ::toothy

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 17, 2018, 11:54:35 PM
ah where to start :LL:

Uncovered a few more wires that need to be soldered and wrapped.

All the wires are on top of this jagged edge added rubber

Had to cut and reroute a few wires as the wiring was spaghetti.  Bundle wire that were cut and not being used. they might be useful later.

Cleaned up nice!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 18, 2018, 12:13:40 AM
have some extra wires that are cut and not used.  Might come in handy later ::scratch
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 19, 2018, 09:22:01 PM
Moving right along...

Passenger side - tagged and tested all the wring. I might be using the Fiero wiring for the side view mirrors and power windows, its  there, will have to see.

The floor pans..... my 88 parts car has mint floor pans. :o  The PO must have left the REDO in the weather or something...  clean, wire wheel, metal prep por15.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 22, 2018, 09:39:16 PM
The REDO  windshield wiper system was a fiero motor.  The car came with a Yaris wiper blade and arm. 

The wiper arm mounting holes were perhaps to  close to the glass. When the wipers turned on the arm undulated and maybe that was causing the windshield to crack. Either way it has to go

Underneath the mounting was creative and included a bolt welded in  :o

Easy enough to take out the interesting bracket with the plasma cutter

A nice access hole was cut buy the PO  ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 22, 2018, 09:59:09 PM
The REDO will use the Yaris  motor and linkage and a Sebring switch. 

Tired to get the intermittent wipers to work but failed.  I did get the slow and fast to work with the park on off. 

Did a mock up of the system in place. Just need to add my mounting points.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 23, 2018, 07:01:59 PM
Not seeing this info on this forum so this might be of help to someone. These are the schematics for the 98 Sebring and 2012 Yaris Wiper systems.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Purple LP670 SV on October 23, 2018, 08:25:13 PM
That's gonna come in very handy! Thanks Simple for sharing!!!  ::beers
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 24, 2018, 06:54:13 PM
The instrument cluster,  Covered in dust, Fiberglass resin and nicked up pretty bad.
A couple of leds not working.

Sanded, epoxy glaze, primer, paint.  New plexi glass.

Would be nice to get a new gauge face, but imperfections not to noticeable.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 24, 2018, 06:59:40 PM
before and after.

My gal  "what happened to all the Q-tips"   ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 28, 2018, 03:52:51 PM
Got the machined Rear knuckles in and installed.  The Arruat design flaw is solved and the car is a roller.

New 250 lb 10" Spring also installed in the front.  My custom front sway bar is still in not here.

Only one more issue in the Arruat system, (knock on wood).  Its the holes for the bolts in the bushings that are for the rear links, are too big.  This allowed a little play in the the rear tires.

So Its either a new bushing or a sleeve insert.   ::scratch
Need 3 for each side.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 28, 2018, 07:50:00 PM
Started to make the windshield cowl drip piece, but it turn into a mold.  :LL: 

For me it was easier to sand, dura glass and rage filler the mold and get it to fit just right.  Another plus is when I use a mold, I am way more consistent in resin and CSM usage.  Plus the finished surface is nice  and smooth with the Gel coat.    8)

Gotta make the holes for the wiper, also have to do the final adjustment to the piece so it matches the black windshield border better
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 28, 2018, 08:37:22 PM
**CAUTION * the following images may be disturbing to some viewers *** 


  :LL:

Next on the REDO are the Doors  ::study

The doors on the REDO worked.  It appears the doors were put on the car before the windshield was fitted.  The PO had cut the Drivers A pillar and roof so the doors would go up and down.

If you put a windshield in place, the drivers door could not close.  So the A pillar width was increased to allow for the proper gap on passenger and drivers side.

Here are the REDO's doors......
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Footcutter on October 29, 2018, 02:12:47 PM
The doors are challenging!  Good work, love the build.  :drool
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 29, 2018, 08:34:15 PM
The doors are challenging!  Good work, love the build.  :drool

Thanks FC!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 29, 2018, 08:51:05 PM
Finished mounting the Wiper motor by counter sinking a bolt, for one of the attachment points and for the other a bracket was welded and then the linkage was secured by a bolt.

It is pretty solid

Drilled holes in windshield cowl drip piece.

See a few changes needed for the cowl piece but might have to go take a look at a real one.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 30, 2018, 12:59:08 PM
Toyota Yaris part numbers
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 30, 2018, 07:14:02 PM
Trying to wrap the wipers up.  Added nozzles to the cowl. 

Thinking about putting the reservoir here. The reservoir will be up a little higher and set just under the trunk opening.

Made a bracket and will weld to the frame. 

Still have to run the wiring for the motor to the switch.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Footcutter on October 30, 2018, 07:57:53 PM
Nice! ::thumbup
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 31, 2018, 09:52:57 PM
Nice! ::thumbup

thanks FC!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 31, 2018, 10:17:52 PM
The threaded shaft on the wiper nozzles were a little short and was unable to use the bolt to secure the nozzles.    No way to drill a hole from the bottom so a nut could fit up into a counter sunk hole.  Had to drill a larger hole from the top.  Used a bolt with a washer and nut... marked at the right depth.  Then Dyna glassed from the top.  Kinda messy but should work... I hope  :LL:  Will find out tomorrow
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 31, 2018, 10:52:28 PM
So the problem with the driver door was the area by the side view mirror was tilted in on the new widened A pillar.

In between the metal door frame, (wrapped in CSM), that was welded to the hinge, and the fiberglass inner door, was a bunch of fiberglass resin. 

Using a saw, about 1/4 inch of resin was cut out.  You can see the gap that was left between the metal frame and the fiber glass door.  This is highlighted by the blue tape behind it.

A hole was drilled into the frame and a bolt/washer/nut was used to pull the fiberglass inner door in. Now the door doesn't rub on the widened A pillar  :LL: and open and closes nicely.

Call me crazy  :o but this door might be salvageable  888o  :LL:

I still have the problem of the roof and door seal flange that was cut off so the door would close.  This needs to be added. 

The passenger side wasn't modified, so maybe this will be my guide to restore the drivers side.

Will have to ponder this and possible salvage, while waiting for parts to REDO the driver side.   ::study ::scratch
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Footcutter on November 01, 2018, 09:03:02 AM
Keep with it.  I feel your pain... :sosad
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 02, 2018, 10:26:41 AM
Keep with it.  I feel your pain... :sosad

FC,
Its a slow process for sure !
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 04, 2018, 05:19:58 PM
Not sure what possessed me to make a mold of the inner door skin, but i did.  Not sure if I will use it still haven't decided on grafting a new section where the latch goes, or replace the whole thing.   All I can say is what a ton of work!  My hat goes off to you folks who make these!!

   
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 04, 2018, 05:45:21 PM
The driver side roof and A pillar were cut by the PO to get the door to shut.

I widen the A Pillar to get a windshield to fit. The Roof needed to be widen by about 1/2 inch and the flange for the door seal needed to be added.

The Passenger side was unmolested and I made 2 templates, one for the curve of the roof and one for the edge.

Drilled in to the drivers side to see how deep the rage gold" filler was. 1/4 inch or so.

Ground down to a solid surface,  used 1.5oz CSM to build it up and Dyna Glass. Will skim with rage to finish.

The door seal flange is still a bit wide but will adjust later.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 04, 2018, 06:01:28 PM
I also need to add a flange for the door seal that goes under the windshield.   
The PO pretty much removed it. 

The passenger  flange seems pretty wide  ::scratch 

The driver side flange was cut down to a jagged edge, of about 1/8 - 1/4 inch. The passenger side has fiberglass that covers the metal A pillar.  The driver side is exposed metal, not sure what happened there 

Thinking about making one and screwing it to the metal.....   Will have to mull it over  ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on November 05, 2018, 06:11:24 PM
Doors really take a super long time.  I always heard people talking about them but I didn't fully understand until I started doing mine.  You are making great progress on those.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 06, 2018, 06:58:49 PM
Doors really take a super long time.  I always heard people talking about them but I didn't fully understand until I started doing mine.  You are making great progress on those.

Thanks Autopro!!   I hope to be where you on your build some day!!!   
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 10, 2018, 11:34:50 AM
Busy work week as trying to get ready for vacation,  but was able to get the flange made for the windshield area made, now just to trim it up and mount it.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 10, 2018, 03:09:04 PM
Put the door seal in just to see how everything lined up.

The flange that I added on top needs to be a little thicker and less depth.

The flange along the bottom is not straight.

Going to have to add some CSM.

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Purple LP670 SV on November 11, 2018, 12:13:25 AM
Absolutely impressive the amount of work you are getting done in such a short amount of time! Keep it up and you'll be done in no time!!!  ::beers
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 12, 2018, 02:57:49 PM
Absolutely impressive the amount of work you are getting done in such a short amount of time! Keep it up and you'll be done in no time!!!  ::beers

Thanks LP670!   It was 2 years a go that I flew out to take a look at the REDO.  The PO pretty cool guy and very helpful.

In the 2 years I think I have accomplished at lot on the car but have a long way to go! :LL:

I'm having a blast working on the REDO!

Thank to all that have offered help, suggestions and encouragement - but specifically Merci-Me, Autopro, USMC Butler, Fiero King, Lambo Sam and yes the prior owner   :notworthy

Got zero done this weekend heading out today for a vacation with my gal. Be back on it after Thanksgiving!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 12, 2018, 06:00:16 PM
Back on the REDO after 24 days off.  Went to Italy and toured the Lambo and Maserati factories :drool,  Then caught the stomach flu when we  got home  :LL:.  Then my gals father passed last week. Things are slowly returning to normal......
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 12, 2018, 06:13:14 PM
The flanges are almost done on the driver door. The roof now has a flange and the lower flange is now straight.

I also added the flange just under the windshield,  not sure what type of weather strip goes there  ::scratch ::help 

The flange that is horizontal and toward the front of the car will require some REDO as it is pretty flimsy as it was ground down and cracked in places.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Footcutter on December 12, 2018, 06:13:58 PM
I am happy, and sad for you... ::scratch
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 12, 2018, 06:15:27 PM
I am happy, and sad for you... ::scratch

thanks man.  He was 91 and had a great life, did a lot of traveling and was retired for 32 years!!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Footcutter on December 12, 2018, 06:18:42 PM
We should all be so lucky.  I admire your patients on getting things right!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 12, 2018, 06:20:14 PM
My buddy with the machine shop did the REDO on the Arruat bushings. 

the 1st two pictures are the Arruat fit :o  The 2nd two are the REDOs

A tighter fit is always good !!

Hoping I can put Arruat behind me now!!

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 15, 2018, 11:30:18 AM
Started working on the doors yesterday.  Had my new used latch for the drivers side and some thing was off ::scratch.  After looking at numerous pictures of latch installs on this website the PO had installed the passenger side latch on the drivers side. 

So the Striker plate is in the wrong position and will require a REDO. 

I test fitted the inner door.  With the inner door clamped in place I test fitted the outer skin.
Need to move inner door to the rear 1/2 inch, this will require fixing a few things.
lower right corner and upper vertical piece. The front isn't sealing so the gap needs to be closed.


Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Footcutter on December 15, 2018, 11:53:21 AM
 Nice work.  ::headbang
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 15, 2018, 12:07:23 PM
Nice work.  ::headbang

 it only just beginning  :santa  "all I want for Christmas is my two front teeth I mean doors " with power windows  :santa 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 15, 2018, 06:16:23 PM
The inner door is hitting on the lower rear corner. Which is not allowing it to go back the 1/2" needed.  I added material on the inside and took material off the outside.  It is getting close.   Added another 3 layers, and will grind it down tomorrow.

Might have been quicker to pull a mold off the door that came with the REDO  and fiberglass it to the new inner door.... but too late for that now ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Footcutter on December 15, 2018, 06:18:15 PM
Master of glass.... ::thumbup
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 15, 2018, 06:32:29 PM
While waiting for the fiber glass to cure, the new custom front sway bar was installed.  It solved two problems, the coil over was rubbing on the OEM sway bar, and it wasn't not long enough.

Now the angle is better with the Rodney Dickman Zero Lash End Links. And it doesn't touch the coil overs

Looking through old pictures, the REDO's front end has come a long way!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 15, 2018, 06:39:16 PM
Master of glass.... ::thumbup


Im not sure about that  :santa
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 16, 2018, 08:22:21 PM
Progress on the latch area of the Door.  The fiberglass where the latch mounts was warped as well. 

It takes time to let the multiple layers of Fiberglass cure.  I can see why the PO just loaded it up on Rage filler  :LL:   

For the corner it took 9 layers and the latch area 6. At least The REDO doors will have a thin layer of dyna glass and rage.

The  inner and outer doors line up pretty good in the latch area now
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 16, 2018, 08:33:54 PM
Now that the inner door is pushed back to the correct position the issue now moved to the wheel well area.  I have a huge gap.

When compared to the Old doors the shape is completely different.

 The old door has a hump in the curved part the new door does not.  The old door is longer. The new door is warped pretty badly.

Decided to make my own curved section for the inner door.


Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 19, 2018, 06:01:16 PM
To fill the gap between the inner door and the front seal the door length had to be increased.

Once a good seal was obtained,  the curved piece was fiber-glassed in
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Footcutter on December 20, 2018, 10:43:03 AM
 ::thumbup
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on December 20, 2018, 05:44:15 PM
Your fiberglass skills are awesome,  you are doing a very good job on those pieces.  Lining them up properly now will make it so much easier for you when it comes time for the bodywork phase.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 21, 2018, 08:52:59 PM
Your fiberglass skills are awesome,  you are doing a very good job on those pieces.  Lining them up properly now will make it so much easier for you when it comes time for the bodywork phase.

Thanks !!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 21, 2018, 09:00:05 PM
Made the frame for the Door. 

The old door was attached to the frame in one location, which to me seemed iffy. 

I will be making a frame so the hinge will be attached to the REDO frame on three sides.

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 21, 2018, 09:05:33 PM
Tested to see if the door hit the fender in the raised position.  Attached frame to hinge with two spot welds.  Then taped the outer skin to the inner

Test was a success, the outer door skin cleared the fender with a small gap between the two panels
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 22, 2018, 01:13:32 PM
I think the REDO on the drivers door is headed in the right direction.

Here is a picture of the Old door install before the driver side A pillars width was increased. Alignment not so good.

Here is the REDO alignment  better
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 23, 2018, 10:31:46 AM
Using the reducible gas shock from McMaster Carr 6465K7 that have been previously mentioned in other posts here.   

These have 13mm ball studs.  The REDO had a 10mm mounted on the body.  Thought about REDoing and installing a 13mm, but ordered a 10mm Ball Socket End Fittings with Safety Clip for Gas Springs. 

Did a test mounting and these shocks are excellent, very powerful!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Footcutter on December 23, 2018, 11:17:53 AM
I am using a dual system based on the same shocks.  They work great!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambo_sam on December 23, 2018, 01:16:10 PM
Using the reducible gas shock from McMaster Carr 6465K7 that have been previously mentioned in other posts here.   

These have 13mm ball studs.  The REDO had a 10mm mounted on the body.  Thought about REDoing and installing a 13mm, but ordered a 10mm Ball Socket End Fittings with Safety Clip for Gas Springs. 

Did a test mounting and these shocks are excellent, very powerful!


Hi Simple, it's always good to see builders take attention to detail such as using ball joints and sockets like OEM...

I hope you know this already, to Not reduce the gas pressure untill your doors are completed, or not reduce them at all, These doors get pretty heavy when completed the right way. just my .02
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 23, 2018, 01:22:13 PM
more exciting stuff on the REDO... front flange, thinner than my hair...  Just tore it off with my hand.   It was good to have the unmolested passenger side as a guide.

Then all this spray in expando foam ,is this a good product to use to fill in voids or is there something better?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 23, 2018, 02:49:47 PM
Using the reducible gas shock from McMaster Carr 6465K7 that have been previously mentioned in other posts here.   

These have 13mm ball studs.  The REDO had a 10mm mounted on the body.  Thought about REDoing and installing a 13mm, but ordered a 10mm Ball Socket End Fittings with Safety Clip for Gas Springs. 

Did a test mounting and these shocks are excellent, very powerful!


Hi Simple, it's always good to see builders take attention to detail such as using ball joints and sockets like OEM...

I hope you know this already, to Not reduce the gas pressure untill your doors are completed, or not reduce them at all, These doors get pretty heavy when completed the right way. just my .02

Lambo Sam, Thanks for the .02!!     I'm trying to REDO the REDO correctly. ::toothy
  I appreciate the helpful advice from builders who have dealt with the issues before and were successful, like yourself.

My motto - however long it takes to do it right and make it look good, that is how long it will take  :LL:  Happy holidays to you and your family  Lambo Sam      :santa

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 23, 2018, 07:45:26 PM
All flanges on drivers side fixed and seal installed
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 23, 2018, 08:01:07 PM
Door latch - Well the fiberglass on the door end is warped, and short. Thinking about either adding material to the door on the outside and removing from the inside.  Or just cutting the end off and welding up a mounting plate for the latch in the correct position and angle.  Then fiber glassing a new end on.

have to think about it, over the next few days
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 25, 2018, 11:19:34 AM
Merry Christmas  :santa. My gal is a keeper, got some supplies instead Of socks and underwear  :LL
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 29, 2018, 10:53:05 PM
Added multiple layers of CSM to the outside of the door skin. Once close enough to door jam; ground inside down to correct thickness.

Made a one piece plate to mount the Latch to using my plasma cutter, getting better at using this tool  ::toothy

Good times lining up the latch to the striker plate  :LL:   

Got a start adding support for the latch. 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 29, 2018, 11:04:32 PM
Couldn't find any pictures of G28 latch mounting except this screen shot form a video on you tube.
 
https://www.youtube.com/watch?v=4x3XFFlj8Ts (https://www.youtube.com/watch?v=4x3XFFlj8Ts)

Here is the REDOs,  have a little clean up to do but getting there.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 30, 2018, 06:39:05 PM
These inner doors are a really just POS :LL:

It great to have nice straight door flanges for the weatherstrip ::thumbup  To bad the inner doors are just so warped. Spent a few hours grinding away.  Will have to add some material on the inside of the doors in a few areas.  Material will have to be added in on the door seal side too.

The upper inner door skin.... :o

Hopefully my part for my door shock will be in a few days



 

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Footcutter on December 30, 2018, 06:57:45 PM
Bugger... :P
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on December 30, 2018, 11:35:27 PM
Why have you chosen to install the interior door latches rather than the oem exterior latches?
01

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on January 01, 2019, 06:55:10 PM
Why have you chosen to install the interior door latches rather than the oem exterior latches?
01

Happy New Year 01! 
I'm not really sure why I am mounting the latch on the interior. Or if I should even use the W126 or the W115. ::scratch

 I've only seen 3 G28s latch installs and they were both installed on the interior, Murci-Me, MDMurcy and the orange car on you tube.  Looking at the W126 latch I'm not sure if it is conducive to and OEM type install on a G28. ::scratch

The W115 latch might be better for exterior install?  But will it work on a G28?

If any one has any helpful info, feel free to contribute your $.02, I'm still trying to get the inner door to seal against the weather strip :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on January 02, 2019, 11:54:14 PM
The reason for using the exterior latch is that it is mounted rearward towards the striker.  With an interior latch, the door needs to be moved to the rear and close to the striker.  Look at all 3 of your pictures and you can see where the door is rubbing on the striker.  Hope yours come out OK.

01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on January 03, 2019, 12:24:48 AM
The reason for using the exterior latch is that it is mounted rearward towards the striker.  With an interior latch, the door needs to be moved to the rear and close to the striker.  Look at all 3 of your pictures and you can see where the door is rubbing on the striker.  Hope yours come out OK.

01

O1 so what latch is it that mounts externally?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on January 03, 2019, 04:33:15 PM
Boy, you're really stretching my grey matter.  I know that there are a few that look similar but the strikers are different.  My advice is to go with the W115 but make sure that you get the strikers that are the same year as the latches.  Make sure that they are the stamped steel and not the cast ones.  Note that the 3rd picture has the child safety button it (I think that this button keeps the door from opening from the inside).  This latch is from a rear door.
5th picture shows reinforcement placed behind the latch.  It can be welded to the door inner framework for strength.
01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on January 03, 2019, 06:24:05 PM
Boy, you're really stretching my grey matter.  I know that there are a few that look similar but the strikers are different.  My advice is to go with the W115 but make sure that you get the strikers that are the same year as the latches.  Make sure that they are the stamped steel and not the cast ones.  Note that the 3rd picture has the child safety button it (I think that this button keeps the door from opening from the inside).  This latch is from a rear door.
5th picture shows reinforcement placed behind the latch.  It can be welded to the door inner framework for strength.
01

Thanks 01!

I was able to locate my W115 that I bought in 2015.     When compared to the W126 it is a bit narrower which I like.  It also looks like it would work for external mounting where the W126 doesn't look like that would be possible.   Something to mull over as I work on getting the upper door to seal.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on January 04, 2019, 02:29:29 PM
That's a winner.  Being that we are mounting the latch 90 degrees from the oem Mercedes location, I don't know if the weight on the latch is really necessary and could be cut off.  Maybe someone on here could chime in and correct me on that.  Also the amount of pull to unlock the latch leads me to think that as there are 2 springs on that lever, the stiff spring could be removed.  (I have done this but as yet I haven't finished my doors)  I don't know how this would affect the latching mechanism when closing the door but it would certainly require less pull on the interior release handle.  The OEM release lever is make out of plastic and breakage results are common.  Some of the guys have made handles made out of aluminum.  These are a great advantage.
01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on January 05, 2019, 08:09:20 PM
Dear God! I spent a ton of time getting the twisted inner door to lie flush against the door seal  :LL:    It was like reconstructive surgery.  Pretty happy how it came out.

Compared the curve of the OEM glass to the opening and the old door that I took of the car. I can already see that I will be spending a ton of time getting the opening correct for the glass.  :o
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Purple LP670 SV on January 06, 2019, 12:02:30 PM
I feel your pain, I'm currently working on my inner door as well. I have countless hours into one door and. Not sure when it will end. Keep up the good work!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on January 07, 2019, 11:55:33 AM
I feel your pain, I'm currently working on my inner door as well. I have countless hours into one door and. Not sure when it will end. Keep up the good work!

Thanks!  I was hoping to start on the window install but we had a power outage early Sunday morning that lasted for 30 hours... So zero progress on the REDO!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on January 10, 2019, 09:10:53 AM
Doors are the most time consuming, I feel both of your guy's pain.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on January 14, 2019, 07:55:28 PM
My gal had a business trip to LA and I was able to tag along and stop by and see Murci-Me’s G28.

This is the second time to view the car and it was just as impressive as the first time I saw it over 3 years ago in January 2016.

Enjoyed my chat with Michael and picked up some great ideas for the REDO, plus a million pictures of his build.  Thanks Michael!

Can’t wait to get back at it!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on January 15, 2019, 09:23:35 PM
Mikes car is awesome, I got to ride in it a few years ago and it was a blast.  He really helped me in this hobby and is a great guy to talk to.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on January 27, 2019, 07:38:44 PM
To get the door glass to lay against the inner door took a lot of sanding as well as increasing the upper door seal flange.

Knowing what I know now,  I should have used the doors that came with the car and reworked them instead of using these "NEW" doors  :o
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on January 27, 2019, 08:51:25 PM
"NEW" inner doors have a warped bottom.

I see fiber glassing in my future.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on January 27, 2019, 09:03:55 PM
exciting stuff ......

cut, grind, fiberglass fiberglass, grind fiberglass
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on January 27, 2019, 09:08:17 PM
but wait there's more.....

Sand, dyna glass, sand rage, rage

pretty straight
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Footcutter on January 27, 2019, 09:14:18 PM
Mere mortals would just leave it.  Way to do it right!  ::thumbup
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on January 27, 2019, 09:37:15 PM
Mere mortals would just leave it.  Way to do it right!  ::thumbup

No doubt.

You are really taking your kit to a whole new level.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambobuilder on January 28, 2019, 08:44:17 AM
Great work. And people wonder why it takes years and exceptional skills to complete these beauties. They have no clue as to what is really involved.  Thanks for inspiration.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on January 28, 2019, 11:29:47 PM
Footcuuter , Autopro and lambobuilder  thank for the comments and encouragement.   It a battle with these builds as you all know.  Wish I had more uninterrupted time to work on these doors.  All I can grab is an hour or 2 here and there. 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 05, 2019, 12:19:31 AM
Made the upper frame for the door.

Test fitted the OEM inner sweeper and side channels.

I can see that some adjustments will have to be made steel door frame to get the it all to fit correctly
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 24, 2019, 07:50:24 PM
So I spent a lot of time making brackets and installing the track system that is sold by Jose from Spain, I think his user name is lambocars or something like that.

Long story short, The tracks system I received is junk.  I have purchased a few fiberglass parts from him with no problems at all.  Luckily I had a track system that other have used in these cars.  My mistake for not firing up the Jose system earlier.  oh well live and learn
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 24, 2019, 08:00:53 PM
Starting over with a working window track.....  for Way less coin!!

Modified the track, and used the original holder for the glass that came with the car.

When fully retracted about 2.5 inches stick up above the door. 

Still have to make a mount for the motor.

But pretty happy how it came out.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Footcutter on February 25, 2019, 09:49:01 AM
Nice work.  ::thumbup  I am about to embark on my window tracks.  Is your glass suppose to be 2.5" from the sill?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 25, 2019, 11:42:16 AM
Nice work.  ::thumbup  I am about to embark on my window tracks.  Is your glass suppose to be 2.5" from the sill?


Thanks FC!

The REDO originally came with Saturn Glass which really suxed!!  I think it was 8 inches up above the sill when fully retracted (see picture below).  Was looking around for side glass and found the Murci-Me's G28 glass could not be purchased and started a thread.

 Aftermarket source for oem size window glass      http://lamboclone.com/index.php?topic=3511.0 (http://lamboclone.com/index.php?topic=3511.0) 

Long story short went with OEM glass.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Footcutter on February 25, 2019, 11:53:18 AM
Me too.  I got a pair for the aventador for $400 a pop.   ::headbang
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 25, 2019, 12:23:13 PM
Me too.  I got a pair for the aventador for $400 a pop.   ::headbang

Cool!  glass is a must have. imho
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Footcutter on February 25, 2019, 12:26:10 PM
Came in this!  ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on February 27, 2019, 12:33:57 PM
Good job on the door glass, cars look totally different with it on.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 28, 2019, 11:19:05 AM
Good job on the door glass, cars look totally different with it on.

Thanks, still have a ways to go on the door! 

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 04, 2019, 04:05:38 PM
Had a ballast or transformer go out in a florescent light over the REDO. The LED replacement is super bright!!! 

Did some trimming on the outer door skin, it is pretty flush with the body.

Going to dyna glass and fiberglass the metal frame to the inner door, then reinstall the power window system.  Ive been plyaing around with the door handle and thinking about how it will function with the W126 latch.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on March 05, 2019, 10:17:59 AM
Good job on lining up that door, not an easy feat.  Even the door glass on the original Murcielago doesn't roll all the way down, so if yours sticks up it means it's perfect!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 09, 2019, 09:16:24 AM
Good job on lining up that door, not an easy feat.  Even the door glass on the original Murcielago doesn't roll all the way down, so if yours sticks up it means it's perfect!

Thanks Autopro!  biggest problem Im facing right now is finding the time, work looks to be pretty intense through the end of June. With Saturday afternoons being the only free time I have for the REDO. 

Liking the way your build is coming out !! 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 10, 2019, 09:35:57 PM
Took the door apart and prepped and painted the frame.  While the paint was drying  sorted out  the Fiero power window wiring and added a couple of relays, worked out nice to be able to use the exisitng wiring  ::toothy

I have spent a lot of time on that work stool lately  ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 10, 2019, 09:50:34 PM
When Murci-Me let me pull a center console from the mold he had, I made a mold to make the  console switch plate.  It took me a while to locate the part  :LL:   yes that is PVA on the part.. :o


Added the Audi switch and replica switch frame.  The wiring, relays, switch and motor all work great!    ::scratch    :LL:

 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 19, 2019, 09:58:06 PM
Bonded the metal door frame to the inner door.  Got a new set of tracks as the one from the pick n pull was rusted.

Got everything reinstalled and the new maxima track is waaay better.  Now to work on getting the outer skin to fit correctly.

About 3.25 inches of glass stick up above the door sill
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: RT on March 20, 2019, 08:33:44 AM
Simple Man...
The best you can do with how much glass ends up above your window opening when the glass is all the way down will depend on how far down the glass (and what holds the glass) can go until it contacts the bottom inside of your door.  If there is anything you see that can be trimmed or adjusted to get a better result, give it a try but don't expect too much.
I see the measurement you took and just remember you will also have an inner door panel with upholstery that will be up  little higher than the inside door panel, so that measurement will become less when you are finished your build.  All side windows on these cars will be exposed some when down so don't be too concerned.  You appear to be in the ballpark.
You are doing a great job.

RT
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 20, 2019, 07:01:36 PM
While waiting on my window tracks.  I made a sail panel mold and then made the part.

Pretty happy how it came out. 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Footcutter on March 20, 2019, 07:13:13 PM
Can you come to Colorado and make me a dash?   :LL: JK

Nice work!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Neils88 on March 20, 2019, 08:12:42 PM
That sail panel came out great! How did you make the plug for the mold? (Or how did you make the mold itself?)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 20, 2019, 10:11:52 PM
Can you come to Colorado and make me a dash?   :LL: JK

Nice work!

Thanks!  but I'm so swamped at work hard to find time to work on my door
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 20, 2019, 10:26:36 PM
That sail panel came out great! How did you make the plug for the mold? (Or how did you make the mold itself?)

Thanks.  Yes, I like the smooth gel coat finish. 

Murci - Me gave me the idea about the panel as it will look more OEM

For the plug  I used the car it self,   sanded, pva, gel coat, 8 layers CSM, then sanded the mold 600-1500 grit,  filled in a few imperfections, sanded.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on March 25, 2019, 10:10:52 AM
That panel did come out great man, that's a great idea using the original car for the mold.  Now that area of your car will look like the OEM car.  ::thumbup
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 31, 2019, 08:43:26 PM
The REDO's new outer door skins appear to be OEM sized where the door handle goes as opposed to the G28 size  ::scratch

Thanks Auto-Pro for the measurement on the location of the handle, mine will be close ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 31, 2019, 08:46:38 PM
Here is the handle set up :o

took a little work to clean it up.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 31, 2019, 08:54:48 PM
The outer skin when on the car is not in alignment with the body

The PO took a lot of fiberglass off the body to make it align with the old G28 door.

Also the NEW door skin needs to be lengthened by about 1/4 inch.

Grind, fiberglass, cure.  Turn over, repeat.

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 31, 2019, 09:04:44 PM
A test fit of the door..... skin fits a lot better.  Getting there :D

Still have some adjustments to do, really ?  :LL:

The horizontal body line that runs between the door and rear qtr panel, align nicely.





Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on April 01, 2019, 10:37:16 AM
Good job on that door handle, getting those installed and lined up is not as easy as it seems.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 03, 2019, 02:52:16 PM
Good job on that door handle, getting those installed and lined up is not as easy as it seems.

Thanks!! Only one spot needs about 1/16 of an inch of dyna glass.   Took my time, made the opening a bit smaller and carefully sanded....

Pretty much following your blue print for the way you did your latch and handle set up.  Appreciate the pictures in your build thread.



 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 29, 2019, 09:06:19 PM
Decided to go with the W115 latch, Instead of the W126.   Got the OEM measurements from Auto pro as well as a replica upper gasket.  Thank you AutoPro!!

The OEM lower gasket really wont work without major mods to the G28 inner door.  Made my own cover. 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 29, 2019, 09:13:11 PM
The OEM Latch is mounted lower than the G28 latch location.

The engine bonnet release handle had to be moved lower as well.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 29, 2019, 09:39:24 PM
Took a ton of time to fabricate the handle support.

 I had fond memories of this massive erector set my dad bought me when I was in second grade  ::toothy

Ordered up a remote door lock and unlock system.

 While Im waiting around, made additional adjustments and fiber-glassed the outer door skin  (again). 

Next is the reinstall of the window glass and mounting of the OEM outer wind sweep.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 04, 2019, 09:33:32 AM
Re-assembled the door, glass etc and checked fit and function . finalized the welding.

Took it all apart,  metal prepped and painted.

Fiber glassed in the frame. 

Once it dries re-assemble
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambobuilder on May 04, 2019, 09:49:54 AM
Great job. I love these types of pictures that shows it is ok to cut a hole and then repair it when conditions change. That's what makes these forums so helpful to give inspiration to other and future builders.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 06, 2019, 08:55:26 PM
Great job. I love these types of pictures that shows it is ok to cut a hole and then repair it when conditions change. That's what makes these forums so helpful to give inspiration to other and future builders.

thank you!  Although the some holes were inherited  ::toothy   
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 06, 2019, 09:04:10 PM
Cleaned up the window channel inserts and reinstalled along with motor and glass.

Then made bracket for attaching outer window sweep to outer door skin, after modifying the skin a bit

Pretty happy the way it is coming along
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Havemurci on May 06, 2019, 09:12:14 PM
Very nice, I'm taking notes!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 06, 2019, 09:15:13 PM
For the door locks I will be using MES Swiss made actuators and a cable system rather than a lever system.

Bought 2 of the same cheap Chinese systems with remote,  instructions were lame but got it to work.  I have to test it a bit more, but since it wont be inside the door, I will probably use it

Using the fiero wiring and two relays with the OEM switch

just waiting on some hardware for the cable install.

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambo_sam on May 07, 2019, 02:25:58 AM
I have preached it before and I will preach it again, Please do not use those cheap plastic door actuators, get either OEM GM AC Delco or the after market GM actuators for the main doors, You can see the difference in the motors, those plastic ones are Unreliable! ok for gas door, trunk lid or deck lid but not for main doors, see below. You will thank me later.

https://www.ebay.com/itm/NEW-ACDelco-Door-Lock-Actuator-22020256-Buick-Cadillac-Chevy-GMC-Olds-1977-1989/163553395722?_trkparms=aid%3D222007%26algo%3DSIM.MBE%26ao%3D1%26asc%3D20131003132420%26meid%3Da411e0d3ebb84f8cb7487b5d275c2dc3%26pid%3D100005%26rk%3D4%26rkt%3D12%26sd%3D372665795306%26itm%3D163553395722&_trksid=p2047675.c100005.m1851 (https://www.ebay.com/itm/NEW-ACDelco-Door-Lock-Actuator-22020256-Buick-Cadillac-Chevy-GMC-Olds-1977-1989/163553395722?_trkparms=aid%3D222007%26algo%3DSIM.MBE%26ao%3D1%26asc%3D20131003132420%26meid%3Da411e0d3ebb84f8cb7487b5d275c2dc3%26pid%3D100005%26rk%3D4%26rkt%3D12%26sd%3D372665795306%26itm%3D163553395722&_trksid=p2047675.c100005.m1851)

OR

https://www.ebay.com/itm/For-Chevy-GMC-Buick-Cadillac-Pontiac-Olds-2-Pc-Power-Door-Lock-Actuator-Pair/172548934100?_trkparms=aid%3D222007%26algo%3DSIM.MBE%26ao%3D1%26asc%3D20131003132420%26meid%3D6be25e0628df471c8cddd86a4e80d6c8%26pid%3D100005%26rk%3D6%26rkt%3D12%26mehot%3Dpp%26sd%3D372665795306%26itm%3D172548934100&_trksid=p2047675.c100005.m1851 (https://www.ebay.com/itm/For-Chevy-GMC-Buick-Cadillac-Pontiac-Olds-2-Pc-Power-Door-Lock-Actuator-Pair/172548934100?_trkparms=aid%3D222007%26algo%3DSIM.MBE%26ao%3D1%26asc%3D20131003132420%26meid%3D6be25e0628df471c8cddd86a4e80d6c8%26pid%3D100005%26rk%3D6%26rkt%3D12%26mehot%3Dpp%26sd%3D372665795306%26itm%3D172548934100&_trksid=p2047675.c100005.m1851)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 07, 2019, 08:43:54 AM
I have preached it before and I will preach it again, Please do not use those cheap plastic door actuators, get either OEM GM AC Delco or the after market GM actuators for the main doors, You can see the difference in the motors, those plastic ones are Unreliable! ok for gas door, trunk lid or deck lid but not for main doors, see below. You will thank me later.

https://www.ebay.com/itm/NEW-ACDelco-Door-Lock-Actuator-22020256-Buick-Cadillac-Chevy-GMC-Olds-1977-1989/163553395722?_trkparms=aid%3D222007%26algo%3DSIM.MBE%26ao%3D1%26asc%3D20131003132420%26meid%3Da411e0d3ebb84f8cb7487b5d275c2dc3%26pid%3D100005%26rk%3D4%26rkt%3D12%26sd%3D372665795306%26itm%3D163553395722&_trksid=p2047675.c100005.m1851 (https://www.ebay.com/itm/NEW-ACDelco-Door-Lock-Actuator-22020256-Buick-Cadillac-Chevy-GMC-Olds-1977-1989/163553395722?_trkparms=aid%3D222007%26algo%3DSIM.MBE%26ao%3D1%26asc%3D20131003132420%26meid%3Da411e0d3ebb84f8cb7487b5d275c2dc3%26pid%3D100005%26rk%3D4%26rkt%3D12%26sd%3D372665795306%26itm%3D163553395722&_trksid=p2047675.c100005.m1851)

OR

https://www.ebay.com/itm/For-Chevy-GMC-Buick-Cadillac-Pontiac-Olds-2-Pc-Power-Door-Lock-Actuator-Pair/172548934100?_trkparms=aid%3D222007%26algo%3DSIM.MBE%26ao%3D1%26asc%3D20131003132420%26meid%3D6be25e0628df471c8cddd86a4e80d6c8%26pid%3D100005%26rk%3D6%26rkt%3D12%26mehot%3Dpp%26sd%3D372665795306%26itm%3D172548934100&_trksid=p2047675.c100005.m1851 (https://www.ebay.com/itm/For-Chevy-GMC-Buick-Cadillac-Pontiac-Olds-2-Pc-Power-Door-Lock-Actuator-Pair/172548934100?_trkparms=aid%3D222007%26algo%3DSIM.MBE%26ao%3D1%26asc%3D20131003132420%26meid%3D6be25e0628df471c8cddd86a4e80d6c8%26pid%3D100005%26rk%3D6%26rkt%3D12%26mehot%3Dpp%26sd%3D372665795306%26itm%3D172548934100&_trksid=p2047675.c100005.m1851)


Yes it doesn't pay to go cheap here !

"MES Swiss made" is the same door lock actuators that Lamborghini uses
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambo_sam on May 07, 2019, 10:38:41 AM
I hear ya bro, I looked up the brand and doesn't seem to be those China/Taiwan junks, Although I still hate the strip brackets they come with, Just lookin' out as those have done before me.   
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 07, 2019, 11:40:27 AM
I hear ya bro, I looked up the brand and doesn't seem to be those China/Taiwan junks, Although I still hate the strip brackets they come with, Just lookin' out as those have done before me.

Just bought the actuators, will fashion mounting points using 12 gauge steel.

But going to have to wait, heading out for vacation ! 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 09, 2019, 10:27:08 PM
back from vaca and  on to the REDO :o

Go figure had a little issue with the fiero wiring for the door locks.   Not good to have the 12v supply exposed
 
Made a mount for the MES Swiss made door lock actuator.

Mounted the Chinese door lock control module

Video of the door locks  https://www.youtube.com/watch?v=wsAp-LKQZos (https://www.youtube.com/watch?v=wsAp-LKQZos)    :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 09, 2019, 10:36:51 PM
the doors just keep going :LL: and going

 and still there is more to do.....
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: eddie on June 10, 2019, 05:09:14 AM
you should put those clips on that rod, for safety so it wont jump out .
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 11, 2019, 09:53:52 PM
Test wired the Cadillac Catera power mirror switch to the existing Fiero GT power mirror wiring, then the Murcielago side view mirror.

https://www.youtube.com/watch?v=xMF2tIBwy9A&feature=youtu.be (https://www.youtube.com/watch?v=xMF2tIBwy9A&feature=youtu.be)

Soldered up the catera switch  to the fiero wiring, nice and neat    ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 17, 2019, 12:41:16 AM
While waiting on a cable to do my inner door latch release, Fiber glassed the outer door skin in a few needed areas

The gaps were just to large for just dyna glass

The bottom of the door was also to short.

Also created a little flange on the door skin just above the handle.

Nice thing about fiberglass I can lay it up and go do some yard work, come back and do the next bit  ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 17, 2019, 01:01:24 AM
Also started on the Install of an OEM fiber glass rocker. 

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambobuilder on June 17, 2019, 09:06:21 AM
Appreciate the progress photos. Especially when you demonstrate that just because something doesn't fit what you have, you can make it fit. Great inspiration for all builders.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 17, 2019, 02:44:31 PM
Appreciate the progress photos. Especially when you demonstrate that just because something doesn't fit what you have, you can make it fit. Great inspiration for all builders.

Thanks Dale, Not a whole lot fits on the REDO, LOL!  Its a slow process for sure!  Hope to have my car looking as nice as the ones you have built.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 07, 2019, 10:02:21 PM
Well it looks like I haven't done anything on the car  :LL:,  but a lot of fiddling around with the outer door skin, fiber glassing sand etc to get the side view mirror to mount.  I have had this door skin on the car, off the car so many times  ::toothy

had to add a flange on the upper part of the door, REDO the mirror mounting area, finalized my outer window scraper brackets (3m8115 then FGP). Added some wood blocks and bolts to mount the skin to get a better idea of how it all coming together

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Neils88 on July 08, 2019, 08:38:37 AM
The doors are looking fantastic! People who haven't worked on their doors yet can't fully appreciate the amount of work that goes in to them to get them right. Great job! Keep it up! ::thumbup
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 08, 2019, 07:14:18 PM
The doors are looking fantastic! People who haven't worked on their doors yet can't fully appreciate the amount of work that goes in to them to get them right. Great job! Keep it up! ::thumbup

Thank you Neils88,  yes the doors have a lot going on in them.  Im glad I didnt start on the doors, gave me some time to refine my skills.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 13, 2019, 07:32:33 PM
spent most the day working on the floor in a horizontal position.

Did some body work on the rocker and qtr panel as i cut out the G28 rocker /scoop and replaced with OEM replica

used dyna glass to fix the gap left where I cut out the G28 rocker, Between the qtr panel and OEM replica scoop
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 13, 2019, 07:50:07 PM
Made a flange on the qtr panel and scoop and welded up a frame for the NEW oil cooler and trimmed  and fitted the wheel well liner.

Pretty happy how solid the oil cooler mount is and the way the wheel well liner looks

I need a piece of ABS 10.5 x 76 inches.  this will be a cover and attach to the rocker and frame underneath to the car to give a clean look
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: AsantiLP on July 14, 2019, 05:50:25 AM
Wow that looks great! What is that plastic you are using for your wheel wells and where did you purchase it?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 14, 2019, 09:05:02 AM
Wow that looks great! What is that plastic you are using for your wheel wells and where did you purchase it?

Thank you, its ABS plastic 1/8 inch thick. Its pretty inexpensive.  Google ABS plastic near your home as you can get bigger sheets as shipping would cost more than the product.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 21, 2019, 03:29:15 PM
Trying to put to bed the wiring on the drivers door

ran about 18 wires into the door via a rubber grommet, then started to wire everything up.

Courtesy lights - door opens lights come on  ::thumbup 

Door Lock actuator  ::thumbup

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 21, 2019, 06:17:06 PM
Window motor wiring - My switch went bad and the connector cracked had a 118 mile round trip drive to a pick n pull.  loaded all the connectors and switches they had .

https://youtu.be/yMtoEphTQXU

Side view mirror - had the thing working weeks ago.  spent hours second guessing my catera to feiro to lambo chart.  Long story short the wire on the drivers side had been cut by someone   :LL:  Ran some new wires and got them working

Also added an $8 mirror folding system.  Here is a video.

https://youtu.be/bkCOIkax8fs

Need to add my interior actuator switch and to solder it all up ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 30, 2019, 10:13:07 PM
After finishing the door wiring, I moved on to the engine.

A shift system was purchased from Joe the fiero king and installed so you have to depress the brake pedal to before you can push into PNDR.  It a nice set up and I'm glad I have it for the build! ::thumbup
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 30, 2019, 10:31:24 PM
With The Fiero Kings shift system in I fired up the engine and it is running rich.  Replaced the MAF, TPS and IAC sensors and adjusted the fuel pressure.

I wanted to run a scan but the Prior Owner removed the ALDL port   :o

does anyone know the what PIN to wire up the ALDL port  :LL:  There are 4 wires unattached by the PCM   :LL:

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 31, 2019, 07:14:02 PM
Got a chart from Ryan at Sinister Performance LLC, a very helpful person.

http://www.gmtuners.com/files/Fiero_L67_PCM_wiring.pdf (http://www.gmtuners.com/files/Fiero_L67_PCM_wiring.pdf)

With the PIN layout for  for the OBDII port wires.

PIN 59 Purple wire was one of the cut loose wires  :LL:
PIN 15 tan is MIA  :o

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 18, 2019, 10:07:14 PM
Well Having been down with injuries to both thumbs for 7 weeks, project REDO has been restarted  ::usa

Finished the IDLA port and the wrapping of the wiring harness.

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 18, 2019, 10:14:44 PM
started on the engine hatch. The REDOs G28 hatch had seen batter dayz, so I went with an OEM replica.

The angles on the body are not right.  The gap from the hatch to the body is 1/2 inch.

Fiberglass, and some sanding and the gap is 3/16 of and inch.  Will use some dyna glass to dial it in later
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 19, 2019, 10:34:24 PM
For the engine bonnet hinge, I looked at Autpro and USMC butler build threads for some ideas, as well as some pictures of Murci-Me car.

I cut the old rusted inch tubing out.  I took an Audi A-4 hinge and modified it so it would mount in the holes in the OEM replica engine bonnet. 

Not sure if I'm going to try to create a  more OEM look like Auto pros but will wait until the bat wings go in to figure what to do ::study
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 20, 2019, 09:34:26 PM
happy Friday!   

The OEM replica engine bonnet is is about 2 2/16" to short.

Time to cut and then fiberglass!  Multiple times!!  ::toothy

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambobuilder on September 21, 2019, 10:19:57 AM
That's what I love about these type of posts. It's fiberglass, it can be fixed. Appreciate you showing us the reality of these builds.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 21, 2019, 09:42:04 PM
Was up late last night fiber glassing.  Got an early start today

The top of the engine bonnet is 1/2 "  wider at the top than the bottom.  Added CSM to make the distance the same.

Will need to cut the body to make the angle flow from the top of the engine bonnet to the body where the rear trunk is.

The other issue is the angle on the body is some how different from side to side  :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 21, 2019, 09:49:10 PM
Had to increase the length of the OEM sized Replica bat wings.

The bat wings that came with the REDO were pretty pitiful
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 22, 2019, 06:59:15 PM
Laid out some string to check the lines from roof over the engine bonnet to the body in the rear. 

I was off by a 5/16 of an  inch and finally figured out where.  The two cut grooves in the body on the driver side are just 5/16 wider than the same two grooves on the passenger side.  This made the engine hatch seem to narrow and wasn't lining up on the drivers side. 

Have to mull over my options  ::scratch
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambobuilder on September 23, 2019, 08:39:41 AM
That attention to detail makes a great builder!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 24, 2019, 11:34:27 AM
That attention to detail makes a great builder!


Some times I wish I could over look things  :-\   the REDO would be further along than it is.  Thank for the comments!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: diablodoc on September 26, 2019, 12:55:31 PM
I've been following your build for some time and I'm just wondering, you ever wish you'd just started from scratch?  I'd bet you'd be done by now!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 27, 2019, 09:08:10 AM
I've been following your build for some time and I'm just wondering, you ever wish you'd just started from scratch?  I'd bet you'd be done by now!

thanks for following the build! Im enjoying the build and having a great time working through the issues.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Jets303 on September 27, 2019, 10:31:06 PM
Dude! Just read through your door section and god did it give me goosebumps! When I did my doors on my murc replica, it was a nightmare! I feel your pain!

Great build thus far, keep it up brotha!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 28, 2019, 09:11:46 PM
Dude! Just read through your door section and god did it give me goosebumps! When I did my doors on my murc replica, it was a nightmare! I feel your pain!

Great build thus far, keep it up brotha!

Thanks Jets!  Will be starting the passenger door here in January!!! cant wait!! :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 28, 2019, 11:53:55 PM
Continued on the rear hatch.  Made some adjustments to the hinge mounting

Ground at least 1/4 of rage bondo that the PO applied and got the hatch to line up with the body on both sides
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 29, 2019, 02:21:30 AM
made a bracket for the engine bonnet latch
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 29, 2019, 02:33:36 AM
The REDO's rear trunk lid needed a bit of cleaning up
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 29, 2019, 08:46:55 PM
what a yawner on the REDO today, did some fiberglass repair,  Wash, rinse, sand, acetone, tin foil etc.  on the rear trunk lid and hacked up body
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 07, 2019, 12:26:07 AM
Made a plug and then a mold for the rear spoiler and started on the recessed area on the rear trunk.

Over all pretty happy with the part
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 28, 2019, 07:51:23 PM
Made some brackets to mount the bat wings to the body.

Got the actuators installed and the bat wings go up and down with the engine bonnet closed.  The actuators hold the bat wings nice and firm in up or down position.  Still need to wire up with relays.

Had to cut the fiberglass on the body and fiber glassed from below to remove the gap form OEM sized bat wing to G28 Body.  Ill do the drivers side next and a bunch of body work to to get the bonnet, bat wings and body gaps correct     
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 31, 2019, 07:50:38 PM
Major milestone of the REDO, Actually drove the car in and out of the shop  ::toothy

Cleaned up the shop, and will cut the passenger door skin off, so I can start that project over the winter months.

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 04, 2019, 10:55:12 AM
Added Dura Glass to the top side of the engine bonnet, to get it flush with the body, and also fixed the gap.

Ground down through the reverse side,  through the two layers of the bonnet to the dura glass,   and into the dura glass to get 1/8 of an inch or so thickness.

Then reinforced with CSM
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 04, 2019, 08:50:31 PM
Applied some rage gold.  Maybe be a bit to much as I sanded off a ton of  :LL:   

Second time applying did a better job  and focused on one side.  ::thumbup

either my internet connection suxs or this website has issues having a hard time up loading pictures  ::)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: AdrianBurton on November 05, 2019, 05:32:16 PM
thanks for the pics, they are motivation!!!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 14, 2019, 05:32:04 AM
thanks for the pics, they are motivation!!!!

I use the pictures from time to time myself.  For me focusing on one little piece of the car and completing that section, gives me some boost.

Being on day 9 out of 17 days of vacation, starting to get a little restless and wanting to work on the REDO!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 29, 2019, 07:40:15 PM
Back on the REDO after some R&R in a warm dry place ::thumbup

Finished welding, prepped and painted my rear engine hatch and bat wing structure.

Installed some struts on the rear hatch

worked some more on the gaps, getting there
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 14, 2019, 10:59:58 AM
Spending some time tying up a few loose ends.
Fixed the leaking transmission line, bled the Rad system.  Adjusted the throttle cable, adjusted the brake light switch. 

Then body work and flat black  paint on the back side of the bat wings, and finished the gap work.   For now anyways  :LL:

Started to look at modifying the dash but decided to change directions to work on the HVAC
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 15, 2019, 11:01:56 AM
well the REDO came with a groovy HVAC controller.    Plugged it in and was surprised that actually controlled the zones of the system.  Fan didn't come on.

Took off the cover to the Evaporator, more maple leaf seeds and mice poop than pictured. Took off the cover to the heater core more goo to clean.
 
Bench tested the blower fan an it is dead.

Parts ordered
Blower
Blower resistor module
Heater core - didn't like the aftermarket one as it was a little smaller than OEM
Two heater hoses for car with A/C

Cleaned up pretty nice.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 15, 2019, 11:18:29 AM
tried to get the pictures right side up ….. not sure what is happening
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: CCIE on December 15, 2019, 01:43:16 PM
That Fiero AC controller with the Lamborghini script and logo look well nice... Have you contacted Riceburner?
If Riceburner is out of the question then think about getting a Rover controller, I figured out some of the pinout, email me and I can help with the  rover controller. You have an awesome build dont waist your time with that Fiero thing at the minimum you can use a fake controller on top of the Fiero controller. In one of my Diablo replica I have a dummy removable controller and underneath there is a working Fiero controller, it adds to the look. Just my humble opinion

CCIE
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 15, 2019, 04:43:09 PM
That Fiero AC controller with the Lamborghini script and logo look well nice... Have you contacted Riceburner?
If Riceburner is out of the question then think about getting a Rover controller, I figured out some of the pinout, email me and I can help with the  rover controller. You have an awesome build dont waist your time with that Fiero thing at the minimum you can use a fake controller on top of the Fiero controller. In one of my Diablo replica I have a dummy removable controller and underneath there is a working Fiero controller, it adds to the look. Just my humble opinion

CCIE

 I contacted him with in the last 2-3 years , and again last week.

 I have the Rover controller.  A dummy cover might be a good idea.

Thank you
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 22, 2019, 03:53:10 PM
Heater core and Heater hoses came in and were installed.  Cleaned up and painted the rusted parts in the heater box and various brackets.  Installed new blower motor.  Also flushed the evaporator before it was installed
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 22, 2019, 04:02:48 PM
Tried to fire up the blower motor and no worky.

Started with the relay and it has power. 

Deja vu on the wiring,  Tape removed tells the tale. 

Checked out the relay connector, lots of corrosion.  Luckily was able to grab one from the parts car.

After the repairs tried the fan switch but still no worky. 

 ::study
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 24, 2019, 10:18:28 PM
Merry Christmas!!  I hope I get some expendable supplies  for the REDO from Santa, I'm running low  :LL: :santa
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 27, 2019, 09:31:23 PM
scored big and got an POS emoji phone charger from santa :santa  How fitting for the REDO! :LL:

Fixed the hack job of wiring on the fan relay and now the fan switch works on all settings!

Was idling the car and a radiator hose had a slit in it and will require a replacement. 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on December 28, 2019, 06:09:04 PM
Replaced the Rad hose that was leaking.  Will look for a gates hose if it leaks again

My gal and I, cleaned out the shop, and washed down the floor.. Radiator fluid smell is pretty much gone.

A break in the weather and was able to cut off the passenger door skin. Hope to start after the first of the year. Fun times ahead!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 19, 2020, 08:51:30 PM
Wanted to start on the passenger door in the first week of January but got side tracked.  ::toothy

First thing to fix is the A- Pillar .  made some adjustments to the width to match the drivers side and add a flange for the weather strip.

Used the windshield as a guide for the flange.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 20, 2020, 08:23:05 PM
laid up some fiberglass to repair the weather strip flange in a few areas.   

Installed the flange that was made,  that runs along the A pillar.

Installed the weather strip.

On to the inner door skin! ::salute
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 23, 2020, 06:41:22 PM
thought about using the original inner door skin, but after 1 minute decided it was a POS :LL:

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 23, 2020, 07:10:49 PM
the new inner door skin is warped on the bottom and had to be fixed as well as the front section.

also added csm on the insides to thicken areas that would be ground down on the reverse side.

good times ! ;D
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 23, 2020, 07:23:37 PM
The second door actually going better, as I actually feel like I know what I'm doing... to some extent      :LL:

 At least not making the same mistakes.

Up next the upper door curvature and the window tracks ::salute
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambobuilder on February 24, 2020, 08:33:32 AM
Wow, you have really created a fantastic build. Unbelievable how you take a POS piece and create something functional.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on February 26, 2020, 04:32:41 PM
Wow, you have really created a fantastic build. Unbelievable how you take a POS piece and create something functional.

thanks! the REDO is coming along, learning a lot as I go.  Wish I had more time for it during the week .
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on March 01, 2020, 07:51:49 PM
Didnt get as far I wanted to as I had to work Saturday  ::)

Cut and fiber glassed to correct the curvature of the inner door. 

While that was curing used 18 gauge made some tracks for the window

cut weld grind. Didnt have the touch this time when welding the thinner metal :LL:

Bent the upper inner side support.

Mounted the window motor, test fitted glass

Fiber glassed upper door .

On to the fiddly part, installing the inner window wipe and side tracks  ::salute
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 14, 2020, 08:54:43 PM
Got the car outside and started on the passenger rocker, waiting on a part for the passenger door.

Also have to REDO the Drivers rockers sitting to high in the rear, that is going to be a REDO
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 16, 2020, 08:43:40 PM
While waiting around for some parts for the door latch....

Cut the passenger rocker out and modified the OEM replica rocker. 

Widened the Sill.

Tested for fitment

Took off the Driver OEM replica rocker.  Definitely a REDO
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 17, 2020, 08:03:55 PM
Received the missing parts for the latch.

Did a little Dyna glass, Rage Gold.

The latch functions great now

Installed the reducible force gas door spring.  The drivers side some how leaked oil over everything, and no longer had the lift.  I used this one on the passenger side and installed a new on the drivers side. 

Test fitted the door skin.

On to the door handle  ::salute
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 19, 2020, 08:52:36 PM
Actually nice out today so took the REDO out side

Got the the final mock up on how I want the rocker to sit. 

Needed to add to the length of  Qtr panel and a bit to the rocker. So spent a bit of time cleaning and grinding the inside of the qtr panel for fiber glassing.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 21, 2020, 08:35:47 PM
Raining today so the REDO stays indoor.

Actuator bracket and handle mount made and painted.

now on to reassembly    ::thumbup
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 23, 2020, 01:23:58 PM
When using OEM side glass the G28 side mirrors wont work.  Jose and Pedro were both selling Murcielago two piece replicas, but they were not LP640 style. 

You can find some pretty good deals on LP640 style side view mirrors that are broken.  Both of mine were purchased as multiple basket cases over the span of 5 years. You just have to be patient.

Both driver and passenger side the folding mechanism were broken.  Lamborghini doesn't sell the parts to fix this but you can replace the plastic gear that is cracked  for $59

the worse part was aligning the silver metal bracket with the threads, with the black motor flange to bolt the two pieces of the side-view mirror together. 

here is a video link of mirror folding

https://www.youtube.com/watch?v=L7UiEqMa64Y&feature=youtu.be (https://www.youtube.com/watch?v=L7UiEqMa64Y&feature=youtu.be)

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on April 23, 2020, 09:25:08 PM
Reassembled the door then took it apart to start fitting the door skin.

Need a few adjustments on my door latch, but ran out of welding wire, Saturday before it arrives.

The cutting and sanding the door skin actually went well, this time

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 02, 2020, 08:00:26 PM
Worked on the frame stiffing in the rocker area.  Used 1/8 rec tube for the bottom and my machine shop friend brought by some high strength steel plate for the side.

Also added ladder for sill area and made a sheet metal piece backed by dyna mat to go over the spray can insulation.  Will caulk the seams later

avoided catching the car on fire
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 03, 2020, 08:18:54 PM
New windshield install on reworked A pillars. 

When the REDO was purchased the doors could not shut with out breaking the windshield.  (A pillars to close together)

Spent some time sanding the correct 2 angles and mocked up the height with 1/4 of washers.

Now the door install can continue. 

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 05, 2020, 08:12:40 PM
Its a ton of work to get the OEM side view mirror to work with the G28 door skin.

Wasn't happy with the way the body lines were from the door to the back of the car on the modified drivers side.

Had to cut the mounting system for the door handle and lower it 1/4 or so and welded it back together so the handle and lock aligns with the existing holes in the door skin.   ::toothy

After a bunch of this and that the door lines up better with the body.

Im still not 100% on the OEM mirrors on the G28 but Will move on to the passenger side.

Worse case scenario, I need 2 G28 door skins.   :LL:

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 10, 2020, 10:01:16 PM
The passenger door continues

Passenger OEM replica Rocker partially mounted.  Have some fiber glassing to do
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 17, 2020, 09:29:44 PM
passenger rocker

add foam, CSm for better panel alignment

Fibergalss the back side.

steel mounting frame for rocker

cut and adjust, cut and adjust, rocker panel

DYnaglass, sand, rage sand

still have some sanding but called for today!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on May 30, 2020, 08:35:35 AM
Man I've been catching up with your build, I'm amazed at all the great work you've been doing to this car.  This will be one of the great ones when it's finished.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Wookie77 on May 30, 2020, 05:41:11 PM
 ::helpThis is great! I have been reading back from the beginning and just in the first few pages I have found a lot of great ideas. I am in the same boat of having purchased someone else’s build and finding a ton that needs to be redone especially the stretch from a safety standpoint. Inspiring work!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 31, 2020, 03:17:57 PM
Man I've been catching up with your build, I'm amazed at all the great work you've been doing to this car.  This will be one of the great ones when it's finished.

Thank you!  When the C-19 is over I will head down your to check out your car!!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 31, 2020, 03:18:54 PM
::helpThis is great! I have been reading back from the beginning and just in the first few pages I have found a lot of great ideas. I am in the same boat of having purchased someone else’s build and finding a ton that needs to be redone especially the stretch from a safety standpoint. Inspiring work!

Hopefully your project is in better shape than the REDO  :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 31, 2020, 08:58:05 PM
So when the driver rocker (OEM Replica) was installed I did it wrong.   ::)  It was a while ago and not sure what I was thinking.  Some how I cut to much of the Quarter panel off.  888o  To fix this .....

Increase qtr panel by grinding backside of qtr panel and adding about 2-3 inches of CSM

Then Grind down the front and  CSM

Dura glass and Rage.  Good news Im getting pretty good at laying the duraglass on smoothly  ::toothy  Bad news, my mistake took a ton of time to fix

Now the rockers matches the distance to the ground from side to side.  :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 31, 2020, 09:09:57 PM
Domino effect.....  the steel mounting frame for the tranny oil cooler required a RED Not seeing a hand to forehead emoji  ::)

Normally I would grind down any goopy welds but this time I passed  :LL:

I did add extra space for more rubber washers for the tans oil cooler.


Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 31, 2020, 09:20:55 PM
One thing I noticed on the passenger side it the length of the OEM Replica rocker panel...seemed long

So I cut of the finished edge in the front of the rocker

the cut off the amount needed, to get the rear of the rocker where I wanted it to be

Then Grind, CSM flip Grind CSM grind CSM

dont forget to acetone ! 8)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 31, 2020, 09:30:31 PM
But wait there is more !!!
 
Over all I like the FGP parts but they put this nasty black primer on.  The gel coat is to thin.  So sand off the black primer

Once the black primer is removed you can see all the things they had to fix.  Used some rage to fix some issues

Pinholes  ::)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: RT on May 31, 2020, 09:47:37 PM
You are doing fine job with what you have.
Let this remind everyone why these should never be called a "KIT" car!

RT
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 31, 2020, 09:55:24 PM
You are doing fine job with what you have.
Let this remind everyone why these should never be called a "KIT" car!

RT


Thanks RT!  I know I go into a lot of detail on my build
thread  :LL:  But this is what these builds
 are like.

I am really enjoying the process, but have no clue when I will be finished  8)  ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 31, 2020, 10:10:58 PM
drivers rocker.... a few more adjustments to go ??    :LL:

Getting a glass of wine and hitting the hot tub!

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Wookie77 on May 31, 2020, 10:47:43 PM
Hopefully your project is in better shape than the REDO  :LL:
[/quote]

Nope, it’s way worse. Lol I will have a ton of trial and error. Once I dig in on mine you will see.

Keep up the great work!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 31, 2020, 11:12:44 PM
Hopefully your project is in better shape than the REDO  :LL:

Nope, it’s way worse. Lol I will have a ton of trial and error. Once I dig in on mine you will see.

Keep up the great work!
[/quote]

Sorry to hear your car is way worse!  power through it!!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on May 31, 2020, 11:32:27 PM
here are the two wheel wells on the redo

one looks like it is close the other ??

you can see I sanded the body line on the drivers side

AutoPro and OEM also shown

have to mull this over  :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambobuilder on June 01, 2020, 08:32:18 AM
Greatly appreciate you taking the time to document these efforts. Helps future builders that you can make parts fit with a little effort. So many will benefit from your build thread.
Thanks again.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 01, 2020, 03:41:08 PM
Greatly appreciate you taking the time to document these efforts. Helps future builders that you can make parts fit with a little effort. So many will benefit from your build thread.
Thanks again.

Thank you Dale!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: autopro on June 01, 2020, 11:26:19 PM

Thank you!  When the C-19 is over I will head down your to check out your car!!!

Awesome man I hope you make it down here some day soon.

Love al, the progress on your car.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 05, 2020, 08:42:20 PM
Sail panel II

a lot of work but worth it

now I have both sides

I have a Jose Ortiz fuel hole? and a fiberglass lid for sale , Cheap!!

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 06, 2020, 10:21:55 PM
spent my day limbing trees and doing manual labor.  ::help

When I could steal away, work on the passenger sail panel.

I can really say this is a big improvement to the build.

still have some adjustments
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 08, 2020, 08:26:17 PM
Got the fuel lid on, added an end piece so in can be fastened with a small recessed screw to the body.

Added studs to the driver sail panel, dura glass then CSM

Anyone know how the actuator is wired up?  I can get it to open, is the close wired into the ignition switch?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on June 28, 2020, 09:44:21 PM
 while back I spent some time modifying an OEM replica inner front trunk lid to fit the G28.  I abandoned that and started over as it just wasn't working

made a metal frame, cut bent and welded to match the curve of the fiberglass lid ...treated for rust prevention.  Added Latch  to frame

Used panel bond to attached to fiberglass lid

Made foam inner trunk lid glued in placed, sanded to shape

Fiberglassed over that

Rage gold then Rage Ultra to smooth everything out- love the rage ultra!!!

Painted flat black

here is a picture of the REDO trunk when I went to look at it to buy it....... ::toothy

what was I thinking?   :LL: 8)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 05, 2020, 08:39:52 PM
outer door skin take #2

new G28 skins came in

Mounted my outer window sweep a little different then the first time
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 05, 2020, 08:47:53 PM
taking my time to try an get the fit and finish to look proper.  One must resist the urge to go quickly.....

have a few adjustments to make...sand here, sand there....
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: mikemurci on July 12, 2020, 03:21:14 PM
THIS IS SOOOOO TRUE
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 17, 2020, 09:02:51 PM
well it very well could take all weekend to get the drivers door skin on. Making a ton of little adjustments :LL:

I had previously increased the length of the door but it is a bit warped added  CSM will grind back side.. Had to grind the lower door sill, sand the upper door flange  and so on

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 18, 2020, 09:33:30 PM
More glassing and grinding!  this tool made it ...pleasurable?    ::toothy 

https://www.youtube.com/watch?v=nrhxylDoheQ&feature=youtu.be (https://www.youtube.com/watch?v=nrhxylDoheQ&feature=youtu.be)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 20, 2020, 08:26:15 PM
Used the 3m panel bond, waited 24hours took the clamps off.   Pretty happy  how it came out, of course there is a ton on body work still to do on the door.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 21, 2020, 08:33:30 PM
now on to the qtr panels.

have some issues here, not sure if it is because these are roadster doors, but I did have to make quit a few adjustment to the doors to get  them to work. OR possibly operator error, or a combo of the above,   But whatever the cause have to make it work and look right

going to make a mold to make the part to either cover the existing mess or come from below.  gotta think about it. ::scratch 


Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 26, 2020, 09:01:37 PM
Problems  - The REdo has modified OEM replica sized batwings  The bat wings are not as wide as the G28  batwings. This leave about a two inch gap that has to be filled

The Door skins are from Carl in RI and are a bit different than the G28 doors.  this difference is  makes the top of the door stick out by about 3/8.

Plus the top of the qtr panel about mid point has a hump.  Not sure how this is, but it is.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 26, 2020, 09:36:13 PM
Made part for top of Qtr panel, 

3m 08115, yeah I spread the glue before clamping ::toothy

 CSM after Clamps removed and CSM underneath where I could reach

Duraglass,

Rage Gold
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 26, 2020, 09:54:47 PM
sanding and sanding.


Still a ways to go but progress
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambobuilder on July 27, 2020, 09:16:23 AM
I absolutely LOVE how you document the problem and then the solution. What a great example of what can be accomplished with a little bit of courage and willingness to make it right. Great job!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 28, 2020, 01:42:04 PM
I absolutely LOVE how you document the problem and then the solution. What a great example of what can be accomplished with a little bit of courage and willingness to make it right. Great job!

Thank you!  hopefully it will be helpful to other builders out there
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on July 29, 2020, 07:31:13 PM
door gaps, a little tight but good for now
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 01, 2020, 08:56:40 PM
made some headway on the body work today
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambobuilder on August 02, 2020, 12:29:02 PM
Love the crisp lines. Gaps are spot on. Great job!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 02, 2020, 08:34:47 PM
Love the crisp lines. Gaps are spot on. Great job!

thanks Dale!  using home depot  paint stir sticks   ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 02, 2020, 09:34:39 PM
taking a look at the side shot of the REDO vs OEM,  The angle of the scoop seemed off.  ::toothy

cut off some material sanded, refit, cut off some more sanded etc, until the angle seem right.

Made a flange on the Qtr panel to affix scoop, 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 05, 2020, 09:08:42 PM
Taking a break from the REDO to install 640 feet of 4 rail fence

only 77 - 36 inch holes to go  ::help
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 16, 2020, 08:31:56 PM
After a couple long weekends and a ton of rocks, 78 post and 640 feet of fence installed.  My gal did an excellent job of signaling when the auger was out of alignment.

I think she will be glad when Im back working on the REDO. :LL:

If the REDO comes out as nice as the fence I would be happy ::usa ::salute
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambobuilder on August 17, 2020, 08:29:25 AM
Awesome job!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on August 18, 2020, 06:20:07 PM
Awesome job!

thanks it was a lot of work!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 05, 2020, 08:17:33 PM
after a month of working on home projects good to be back on the REDO  ::thumbup

The lower portion of the driver door was sticking out too much when compared to the rocker panel.

Cut the bottom of the door,  attached blocks and screws to bring the lower portion of out door skin in.

Fiberglass  rage ultra  and sand

Now a nice smooth transition from the door to the rocker

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 06, 2020, 09:01:48 PM
pretty close on finalizing the gap between the rocker and bottom of the door.... for now anyways  :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 06, 2020, 09:15:27 PM
spent some time clamping the front bumper and making adjustments to get it to look right.... 

probably make a few more adjustments
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 08, 2020, 09:24:11 PM
tough to get stuff done while working, but got a little completed tonight

cut off the excess with my air saw

Sand with a block

fine tune with 80 grit on one side of a filler spreader.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 12, 2020, 08:48:26 PM
made some adjustments to the bumper and installed it.  Installed my headlights.  It had been so long ago since they were last in .

The passenger side install went well, as I had some pictures.  The drivers side, no pictures and I struggled. Ended up building a new drivers side one piece bracket. 

next up a bunch of body work on the hood and fenders
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 13, 2020, 07:21:17 PM
had to add 1/8 inch or so to the passenger side of the front trunk
Sandwiched DYNA glass between CSM

Also had to adjust the headlight area.  CSM Dynaglass CSM

Finished off with some Rage ultra.

Gap on the trunk close, headlight pretty tight  - will fine tune.... and sand slowly and not take too much off  :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 22, 2020, 08:27:01 PM
Trying to get some body work completed before the weather turns

front fenders:
since both wheel gaps and the actual shape are completely different, decided to take the best bits from each side
drivers side  Grind, CSM, Dynaglass, ez grip and lots of sanding.

got the door gap pretty close (tight) and somewhat happy with the shape
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 27, 2020, 09:21:53 AM
did some fiberglass work for the trunk area.

Thanks to Murcie me for the pictures of his set up, very helpful

Need a light and some grills

have a bit of work to do on a couple of pieces but over all pretty happy they way it turned out

First picture Is the REDO when I went to look at it to buy  :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on September 27, 2020, 02:11:19 PM
details of the fiberglass trunk build

the box was fiber glassed to the shelf
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on October 25, 2020, 08:01:11 PM
Basically giving up on doing any more body work for the next few months with the weather.

So on to inside projects

What to get my passenger door finished
so I can bond the  outer door skin

-Installed remote door lock actuator
-OEM door lock switch wired up
-Audi power window switch with relays
-Courtesy light on/off switch integrated to Door latch like OEM
-Routed wires  final connection

Amazingly only blew one fuse  ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 01, 2020, 06:48:07 PM
soldered and wrapped the door wiring

install interior door release cable and handle

mounted outer window sweep

adjusted outer door skin for bonding.  Forgot just how much adjusting they needed  :LL:   and still more to do ::thumbup
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man on November 08, 2020, 07:34:14 PM
rare day of sunshine   8)

final adjustments on passenger door - warped on the area that meets up with the outer door sweep CSM Duraglass etc - just need a bit of warm weather and i will bond the outer skin  ::thumbup

extend bat wing -  Something that needed to be done, used foam then CSM, dura glass

guide coat and a bit of body blocking- like the body work part of the build the best
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: italianknightrider on January 21, 2021, 12:24:34 AM
email me at : italianknightrider@yahoo.com
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: usmc_butler on January 22, 2021, 06:17:25 AM
He messaged me and is locked out of his account somehow, I’ll tell him you want him to email you.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on January 26, 2021, 11:01:11 AM
Not sure what happened but I'm back as Simple Man 2.0  !!

Been working on custom door cards will post soon

Thanks Dustin!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Superman on January 26, 2021, 01:28:26 PM
Glad we kinda got it fixed! Looking forward to some progress again!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on January 28, 2021, 07:17:22 PM
Had a set of G28 door cards which are far from the look the REDO needs.  Also a set of mangled OEM replicas that were cut in the center to make them fit the opening of the G28
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on January 28, 2021, 07:26:20 PM
Starting with foam to make a plug.

Lots of adjusting and then bondo sanding etc.

once the plugs were done made some molds
And had to sand the molds
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on January 28, 2021, 07:50:57 PM
many adjustments to the parts pulled from the molds.  Cut and adjust, grind fiberglass repeat!! :o

lost track of how many times and what was done to make them decent.

be so much easier if G28 was the same size as OEM
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on January 28, 2021, 08:12:33 PM
The REDO is using OEM grab handles.

Made brackets and welded to the door at the OEM grab handle attachment point, with weld nuts on the back side.

Easier to attached brackets and mount door cards prior to putting outer door skin on  :o ::toothy

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on January 28, 2021, 08:26:37 PM
The REDO door cards   ::usa

Passenger side turn out pretty nice - learned from my mistakes on the drivers side  ::toothy

Driver side - going to have to make another mold of the main piece for the card as it is pretty chunky as it was the first one I did

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: usmc_butler on January 28, 2021, 08:48:40 PM
Wow well done! That could help many G28 builders if you decide to make more from the molds! Door cards were never available except from Mike Chase which I’m not sure if he makes them any longer. 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on January 29, 2021, 11:03:14 AM
Wow well done! That could help many G28 builders if you decide to make more from the molds! Door cards were never available except from Mike Chase which I’m not sure if he makes them any longer. 

thank you, it was a lot of work

When I was in So. Cal in November I stopped by Michael place to look at his car.   He doenst have the molds any more.

I texted him last week and he told me he only sold 2 sets of the cards.

If I could sell at least 3-4 sets it would be worth it other wise, I will make a blow-n-go mold for the drivers side that I need to possibly REDO.

Is anyone interested in a set of the cards?  lmk
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Ukbaggio on January 29, 2021, 02:03:31 PM
Took the door apart and prepped and painted the frame.  While the paint was drying  sorted out  the Fiero power window wiring and added a couple of relays, worked out nice to be able to use the exisitng wiring  ::toothy

I have spent a lot of time on that work stool lately  ::toothy

hi mate did you print the switch covers?
thanks Baggio
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on January 29, 2021, 02:17:20 PM
Took the door apart and prepped and painted the frame.  While the paint was drying  sorted out  the Fiero power window wiring and added a couple of relays, worked out nice to be able to use the exisitng wiring  ::toothy

I have spent a lot of time on that work stool lately  ::toothy

hi mate did you print the switch covers?
thanks Baggio

no
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Jets303 on January 29, 2021, 07:39:41 PM
Door cards look great!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on February 06, 2021, 10:30:34 AM
Door cards look great!

Thanks Jets, they were a lot of work but I think the will be a great addition
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: ★Murcie-Me★ on February 20, 2021, 12:57:54 AM
Sweet  ::wave
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: VF1Skullangel on February 21, 2021, 05:20:26 AM
Sweet  ::wave


 ::bounce ::bounce ::bounce ::wave ::wave
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on February 27, 2021, 07:59:20 PM
door cards installed and on to fitting the OEM replica dash

A Murci Me instrument pod came with the REDO

had to rework the opening to make it fit

Using a template, The dash was cut  in two places and fiber glassed back together

Then adjust the width using foam and fiber glass
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on February 27, 2021, 09:08:05 PM
the REDO came with the standard G28 defrost panel

Made a  new one
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on February 28, 2021, 07:56:14 PM
The OEM replica dash ends had to be cut off and a portion of the dash removed so it would fit length wise. The space and angle has to be right,  so hopefully looks like the OEM car  ::toothy

There was some empty space on the top of the dash that had to be filled in, more fiber glassing.




Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on February 28, 2021, 07:59:38 PM
Need a airbag piece for the passenger side.

Not sure if I make a mold for this after final adjustment, and possible glove box or just delete it all together  :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on February 28, 2021, 08:09:52 PM
then a bunch of body work.

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Jets303 on February 28, 2021, 08:32:02 PM
Looks great dude! I'm jealous, I never had the opportunity to do these things on my Murc rep so its cool to see you doing it! Keep up the steam bud

Lol, dont be jealous, it was a total pain, but not as bad as the door cards!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: AdrianBurton on March 01, 2021, 10:27:08 AM
I have to do the same thing to make the OE 6.0 bezel I have fit in the "OE 6.0 dash" that I have so I REALLY appreciate the detail in this one
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on March 01, 2021, 04:53:50 PM
I have to do the same thing to make the OE 6.0 bezel I have fit in the "OE 6.0 dash" that I have so I REALLY appreciate the detail in this one

Thanks!

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on March 28, 2021, 06:30:38 PM
Nothing like work to get in the way of progress on the REDO  ::)

back at it  after about 3 weeks.

Lots of fiddly issues in  mounting the the dash,  console, grab handle and the lower dash panel.  Fabricated some brackets, blah blah blah

If work doesn't get in the way, it will be on to the drivers side ::salute
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on April 10, 2021, 08:53:36 PM
So the REDO came with this A-Piller   888o

Im sure it is useable! ::)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on April 11, 2021, 08:16:16 PM
made an A piller

Made the various parts, CSM'd them together,  did some body work on it , made a mold.
 
Nothing beats a new part with gel coat!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on April 11, 2021, 08:21:46 PM
clamped in place  ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambobuilder on April 12, 2021, 08:20:25 AM
Very nice!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on April 12, 2021, 04:36:05 PM
And then there are other days.....................

I'm sure that any other builder on this forum that is building a LP640 is extremely pleased with the help that you have posted during your redo.  Kudos to you.  Thanks
01

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on April 15, 2021, 05:33:23 PM
Very nice!

thank you!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on April 15, 2021, 05:38:18 PM
And then there are other days.....................

I'm sure that any other builder on this forum that is building a LP640 is extremely pleased with the help that you have posted during your redo.  Kudos to you.  Thanks
01



Hopefully my build thread can be a help to someone.   Nice t-shirt! lol
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on May 16, 2021, 08:52:38 PM
Not quite finished with making interior pieces but done for now as I want to work on the exterior over the summer months.

using the sun-visor bracket to hold the a-pillar in place

welded bracket with weld nut on back side
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on May 16, 2021, 08:58:42 PM
Built the front trim piece that goes around the OEM sunglass holder.\

attached the sunvisor
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on May 16, 2021, 09:30:11 PM
the back of the interior, tried to make it as oem looking as possible ::toothy

still have a lot to do but will circle back this fall
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on June 02, 2021, 08:43:51 PM
Out and about and was able to check out Dales build as well as see how he was doing after his tumble.  A great inspiration on so many levels !

now I need to get back on my build!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on June 21, 2021, 11:09:19 AM
Nothing like a REDO, had to cut and adjust the outer door skin one more time. Looking at a bit more work before I can have the skin ready to bond to the inner door.

Hopefully get the skin bonded by the end of the week!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: AdrianBurton on June 21, 2021, 11:22:02 AM
how are you planning to address the mods to the roof line and A pillar?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on June 21, 2021, 03:29:49 PM
how are you planning to address the mods to the roof line and A pillar?

If you look at the picture, the clamps are pressing into the upper out door skin to cause it to depress to much.  Once I finish the body work on the outer door skin, I still have to Duraglass the inner upper door to fill the void around the steel rod.  This will bring the level up.  Also the thickness of the 3m panel bond to be used in the final bonding process will have to be considered.   

If the drivers side is any indication of how it will go, it should be close, but most likely have to bring the roof up

Attached a couple of pictures of MM's car.  The key point for me is the width of the white section along the top of the door skin and how it meets up with front fender.  Im not sure how wide MM's white section is but the width on the REDO varies by 1/8 - 1/4 of an inch along the top of the door skin.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on June 21, 2021, 07:53:38 PM
I did this once already, but the first time the skin wasnt lining up good enough so REDO  ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on July 11, 2021, 07:34:16 PM
bonded the outer door skin today, yeah I used a few clamps  :LL:

but first dura glass the upper frame in place

then had to cut the door to bring it more in line with the qtr panel, CSM the outside then the inside.  :o
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on July 13, 2021, 10:19:18 PM
upper door to roof gap,  ::salute

going to sandwich dura glass with CSM

durglass

grind

2.0 oz of CSM

grind

Z-grip filler

sand

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambobuilder on July 14, 2021, 11:30:59 AM
Well done! Doors are easy...said everyone who has never built one.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on July 15, 2021, 04:12:37 PM
Well done! Doors are easy...said everyone who has never built one.

lol  well said! the doors have been a black hole for my free time.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on July 23, 2021, 10:56:07 AM
still working on the doors  :LL:

it never ends,   door skin sticking up higher and out more than needed

cut skin
adjust area by sweeper
clamp skin down and in
CSM
Duraglass
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on July 26, 2021, 09:14:48 AM
Dear God! my shoulders ache  :D
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on August 01, 2021, 08:31:13 PM
everyday I'm shuffling shuffling.

https://www.youtube.com/watch?v=rGPwmgmXBWg (https://www.youtube.com/watch?v=rGPwmgmXBWg)

everyday I'm sanding sanding  :)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on August 02, 2021, 12:13:01 PM
Tedious, yes; physical, yes; time line, too long; necessary, YES.  Patience, patience.  Too many wish that they had taken the time to make if right.  When the paint is in the gun, any defect is going to show.  The long hours will only be known by the master builder.  ::thumbup ::thumbup ::thumbup
01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Havemurci on August 03, 2021, 09:22:53 AM
Longboard sanding, the arm workout of champions! It will pay off in spades when the paint flows.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on August 10, 2021, 08:23:50 PM
had to CSM duraglass etc to fill some holes from the removal of the old engine bonnet mounting hinge structure.

Also had my son in town for a few days and way able to get a couple hours of sanding out of him  8)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on August 13, 2021, 08:30:30 PM
 ::usa

I could be at this awhile   :LL:

 ::salute
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on August 27, 2021, 10:02:13 PM
Well I blocked the body as best I could

Time for some featherfill G2!  I used a 5 stage Apollo HVLP. Started with a 2.5 mm tip and a D cap at 5psi and blew out a qtr in about 3 min  ::) 888o

Switched to a 2.0mm tip and C cap and 4 psi. So much better and smooth.  Using FFG2 and with no thinning.

The black shows every flaw.   8)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambobuilder on August 28, 2021, 09:07:09 AM
Looks like all that prep work paid off big time. Looks fantastic!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on August 28, 2021, 06:25:03 PM
Sprayed some FFG2 on the REDO.  Nice to see it in one color.

Black is a great color to ID areas that need some additional work.

Plan is to block and fix the obvious issues.

Then spray FFG2, block again then move to 2k primer.

FYI all the individual pieces are just placed on the car and not mounted  :D
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on August 30, 2021, 09:23:07 AM
Looks like all that prep work paid off big time. Looks fantastic!

thanks Dale!!, It sure is a lot of work.  with more ahead.  Really liking the FFG2 in black, no guide coat needed as it turns grey when you sand it.  Also every littlie issue is so apparent in the Black as it has sheen to it.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: AdrianBurton on September 13, 2021, 12:15:52 PM
that not even the same car!!!!! Good work man!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lp670mike on September 13, 2021, 06:08:38 PM
I’m not on much these days. Life has been busy but, I do stop in to check out builds from time to time. It has been an incredible transformation for sure. You do excellent work! You’ll have it finished in no time. Keep at it man
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: ★Murcie-Me★ on October 06, 2021, 11:44:48 PM
No new updates on your build?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on October 09, 2021, 09:49:15 AM
that not even the same car!!!!! Good work man!


Thanks Adrian!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on October 09, 2021, 10:02:50 AM
No new updates on your build?

Hey Michael,  I had to go get a Steroid shot in my right shoulder as I had a constant ache, which was reminiscent of a pain I had in my left shoulder 20 years ago and ended up having rotator cuff surgery.   

I took some time off to let it heal and doing some therapy to strengthen the right side.  I'm left handed and the right has always been weaker.

I go back to the Drs on the 26th of October,  its a lot better but still kind of f'd.

Started blocking the car with some new blocks  https://linearblockingtools.com/ which seem to help as they are easier to hold on to. 
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on October 09, 2021, 10:11:05 AM
 ::salute
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: 01Lambiero on October 09, 2021, 12:09:10 PM
After the finish sanding and the prime and sanding, and the base coats, and the clear coats  :CSS :CSS :CSS ::thumbup ::thumbup ::thumbup..........what color have you chosen?

01
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on October 30, 2021, 08:37:31 PM
After the finish sanding and the prime and sanding, and the base coats, and the clear coats  :CSS :CSS :CSS ::thumbup ::thumbup ::thumbup..........what color have you chosen?1

nior sure maybe white or gun metal grey
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on October 31, 2021, 07:30:45 PM
got a second shot in the shoulder

Finally finished sanding the first application of FFG2 and fixing some body issues

Ready to spray again!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on October 31, 2021, 07:41:06 PM
Second application of FFG2.

Really dialed my gun in and it flowed a lot better with minimal orange peal
no reduction 2.0 tip and a D cap with 4.9 psi on a 5 stage turbine.

Used about a gallon
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on October 31, 2021, 08:05:36 PM
FFG2 cover most of the pinholes but a few remain.  Using evercoat metal glaze ultra to fill these

Thought this blocking 180 grit could be used but even with 80 the FFG2 clogs the paper up a bit

Lines and panels really coming along with this blocking

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambobuilder on November 01, 2021, 08:41:51 AM
All that detailed work will pay dividends in the final paint. Great job. Thanks for posting updates.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on November 02, 2021, 08:56:09 AM
All that detailed work will pay dividends in the final paint. Great job. Thanks for posting updates.


I have OCD issue, lol   its gotta look great or what is the point of all the work?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on May 23, 2022, 09:19:50 AM
After six month off, an MRI,  couple of steroid shots in my shoulder and some PT, I am back on the REDO.

A lot of rain this May in Western WA, glad to have some sun!!

High build primer,  a couple of body lines and to fix but over all pretty happy how it came out.

The primer blocks out beautifully!  Much less work than FFG2  ::thumbup
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambobuilder on May 23, 2022, 10:34:43 AM
Looks fantastic!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on May 25, 2022, 10:45:29 AM
Looks fantastic!

Thanks Dale!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on August 28, 2022, 07:55:30 PM
First attempt at vinyl wrap for the inner latches will be used for the front trunk release which is not visible.

Next attempt at wrapping should see a lot of improvement

 Definitely a better result than when using the chrome paint. 

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on September 07, 2022, 09:20:55 AM
Holy hell that was a lot of work!!! :LL:

But finally got the car painted.

Came out most excellent!!





Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: AdrianBurton on September 07, 2022, 11:53:37 AM
CONGRATULATIONS!!!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on September 10, 2022, 08:32:25 PM
CONGRATULATIONS!!!!

Thank you!  Its a mile stone for sure, glad to be done with the blocking
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on September 10, 2022, 08:41:18 PM
Cleaned up the crud from blocking on my brakes and suspension.  Pretty dirty

Used a little high heat clear to keep the rust at bay, not sure how long it will last but better than nothing.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on September 10, 2022, 08:54:30 PM
Using the 3m Trizact for wet sanding.

1500 grit
3000 grit
8000  girt  all with the DA, by the time you get to 8000 it is really pretty shiny.

Just a spray bottle and microfiber towel, very clean

then the perfect it 1 step with the purple pad.

I will never use a wool pad again!!

Result are impressive and so effortless, it is actually enjoyable  :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Tallon on September 25, 2022, 08:38:45 AM
Congratz sir, so it is balloon white?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on October 21, 2022, 03:18:57 PM
Congratz sir, so it is balloon white?

Thanks still have ways to go!!   

I tired a few test sprays with the Tri coat balloon white and it looked great, but to do the whole car would be a bridge to fa,r for the skills that I have. Next time  ?!?! :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on October 21, 2022, 03:47:45 PM
The REDO has been color sanded and is good for now!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambobuilder on October 22, 2022, 08:17:55 AM
Looks amazing. I know that is a big task.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on October 23, 2022, 05:55:47 PM
Looks amazing. I know that is a big task.

Thanks, DA  Trizact and one step purple made it pretty easy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on October 23, 2022, 05:57:42 PM
Wasn't raining today but still chilly at 45 degrees,  The REDO outside.   
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on October 30, 2022, 07:49:15 PM
Back to the good times on the REDO ::toothy

cut, adjust, fiberglass, grind, cut and adjust fiberglass, grind, repeat ::)

Cant tell you how many times I did this on the just the passenger side A Piller :P
The piece finally sits flush with the rubber door gasket with no gaps  ::thumbup

Dialing in the interior pieces made from scratch a PITA :LL:

And still there is more to do  :o :o

 :LL: :LL:



Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Jets303 on October 31, 2022, 08:26:27 AM
Looks awesome! I am not looking forward to making those parts. Did you start with foam? Or flat pieces?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on October 31, 2022, 03:10:02 PM
Looks awesome! I am not looking forward to making those parts. Did you start with foam? Or flat pieces?

thanks!  it takes so much time to get these right

The A pillar i used thin Masonite board cvoer in laminate to get the shape and curve. 
To get an exact fit on the door opening at the roof I eventually had to add material to the inside and then use  40 grit disk to sand the outside to get a flush fit with no gaps.

I will add some pictures
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on October 31, 2022, 03:38:25 PM
used  thin Masonite/laminate for the A pillar

For the long A pillar piece Made the 3 pieces.  Then Fiber glassed together. One long piece from front to the rear window

From the part pulled from the mold, I have been refining to get the final piece to use in the REDO.




Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on October 31, 2022, 03:42:08 PM
for the other pieces I used foam
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Havemurci on October 31, 2022, 04:28:28 PM
Lots of tedious work in a small awkward area, most of it on your back while twisting and reaching hard to fit intricate pieces….good times! That's the detail that makes a quality build. Bravo!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on November 02, 2022, 11:44:00 AM
Lots of tedious work in a small awkward area, most of it on your back while twisting and reaching hard to fit intricate pieces….good times! That's the detail that makes a quality build. Bravo!

With an OEM sized build at least, one could acquire OEM replica parts.  Having to make custom pieces for the G28, then fiddling with the gaps and then attachment points ..... dear god!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on April 17, 2023, 06:16:57 PM
When you make the interior pieces from scratch, the progress in painfully slow!  :LL:
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: AdrianBurton on April 17, 2023, 09:50:31 PM
that is BEAUTIFUL!!!!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: ★Murcie-Me★ on April 26, 2023, 02:11:46 AM
Any updates? are you installing those interior parts or just teasing us LOL?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Tallon on April 27, 2023, 07:35:36 AM
Wow the door card looks awesome. I used to have oem cards that were going to be modified but frank/digibeam took them and never heard from him again.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on April 29, 2023, 07:15:43 AM
that is BEAUTIFUL!!!!!

thank you!!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on April 29, 2023, 07:18:19 AM
Any updates? are you installing those interior parts or just teasing us LOL?

Even with the Switch surround in his possession, we had to do a REDO on the opening to get it to fit.  Its an hour to 90 minute one way drive to drop them off.  GOt them back and will get them in after I gat back into town
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on April 29, 2023, 07:22:57 AM
Wow the door card looks awesome. I used to have oem cards that were going to be modified but frank/digibeam took them and never heard from him again.

Said to hear you didnt get your card back
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on September 04, 2023, 08:58:43 PM
Been a while since I been on here ..... but will not wait a year like Mr. Strickland  :LL:

Getting parts back from the Upholstery shop. Slow and Steady!!  More slow than steady.....this year  ::toothy
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on September 17, 2023, 10:17:21 PM
Driver door card.  Wasnt fitting correclty.

Had to REDO, and remove some of the fiberglass on the upolstered door card.  Then re-glued the leather.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on September 17, 2023, 10:24:23 PM
outer window sweep is OEM

inner sweep aluminum angles mounted to studs,  felt sweep attached to aluminum
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on September 17, 2023, 10:32:18 PM
Driver door card mounted, clearance is perfect, red light hooked up, door lock switch wired.

well that didnt take very long to do ::)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Aloha on September 17, 2023, 11:09:27 PM
Saw the post in FB group while I have this window open and was like whaaatttt? lols, glad it is you : )



Driver door card mounted, clearance is perfect, red light hooked up, door lock switch wired.

well that didnt take very long to do ::)
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on October 12, 2023, 03:22:43 PM
Plugging away

Next up finalizing the Dash
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on December 07, 2023, 07:55:51 PM
center console insert progress!

 ::salute
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on December 09, 2023, 05:19:18 PM
For the airbag cover I wanted a more OEM feel instead of fiberglass.  I played around with different liquid rubbers and after quite a few prototypes I arrived at a formula.

Came up with a pretty close color match to the OEM steering wheel using a certain number of drops of black dye, a number of scoops of thickening agent and X grams of A & B. Then added liquid hard plastic to the back of the cover for rigidity. 

The aluminum trim ring just needs to be welded at the ends.

A little trimming, good to go!
 ::salute
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Neils88 on December 09, 2023, 08:05:33 PM
That looks fantastic! Great job! How did you get the surface effect to match it all to the rest of the steering wheel?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on December 12, 2023, 10:45:29 AM
Neils 88, thank you it was a process

I made the outer portion in foam, Then CSM, and smooth finish with filler.

The plug was made a bit smaller than needed.

Took this piece to the upholstery guy and he covered it in a pebbly vinyl.

For the center piece I had purchased it from Cory on this site. 

hope that helps

Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Neils88 on December 12, 2023, 11:02:17 AM
Thanks for the details. I'll be eventually making something similar.

Lots of work, but well worth it!
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on December 12, 2023, 11:23:50 AM
Thanks for the details. I'll be eventually making something similar.

Lots of work, but well worth it!

yes it was a lot of work, but the hard rubber has a better feel than the fiberglass one.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Tallon on December 14, 2023, 11:46:30 AM
Looks great, you have an oem steering wheel?
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on December 14, 2023, 12:18:47 PM
Looks great, you have an oem steering wheel?

thank you,  It came out supper nice.  The steering wheel is OEM
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: Simple Man 2.0 on January 31, 2024, 06:34:09 PM
Dash is just about ready to take to the upholstery shop.  Lost track of how many adjustments that had to be made to the OEM sized replica dash to fit the G28.  Had to do some of them twice  ::toothy

The hole for the pod, both ends of the dash shortened, Flange along the front the dash the A pillar openings on each side, the center console openings. left and right side of the steering wheel, the buttonhole opening to the left of the steering wheel,  the airbag opening, the grab handle area.  Flanges on each end.
Title: Re: G28 - Simple Mans, Simple REDO of an G28 LP640
Post by: lambobuilder on February 01, 2024, 08:25:58 AM
Looks Fantastic. Lots of hard work but really shows all the effort you put into.