Thanks for the tips - I have my HID internals already, I need to start working on the custom housing. There are a few companies out there that retrofit an existing housing with HID but my issue is I need a custom housing :rolleyes:
I looked at different head light assemblies available off the shelf but nothing was close enough to what I had in mind. One of my cars is a Mini Cooper S, I have seen these lights used in a few different hot rods but just don't want something that recognizable on this car, the two beside each other in the garage would give it all away.
I may have something to post on the lights in the next few weeks, I'm still focused on the body...

Any pics on custom headlight housings?

HL renderings
 

I have been working on the headlight layout, testing a few ideas and started a final mock up for 3-d rendering. The lights are Xenon, HID and LED, the finish will be a mix of chrome and carbon fiber.
It may be hard to visualize but this arrangement looks promising when I put paper mockups of the parts with the car. Yes - makin' **** up as I go here - like I said, never done this before...

http://www.daemoncustomauto.com/DCA%...er%20front.jpg

http://www.daemoncustomauto.com/DCA%...t%20Render.jpg

Looks interesting. While the five light arc be LED turn signals? I love the lights on Audis and this reminded me of those.

The five light arc is actually Hella LEDayFlex DRL - I think thats exactly what they run on the Audis. The LED turn signals are the little donut with colored plastic extensions.
Its cool the rendering reminded you of the audi.:thumbsup:

back at it
 

I have been away enjoying some time off, back to work soon and I put in a little time on the GT.

Drivers side floor is in, and I had to fabricate some panels to close out the inside of the front frame at the back of the wheel well.

http://www.daemoncustomauto.com/dca%...0floor%20f.jpg

http://www.daemoncustomauto.com/dca%...%20out%202.jpg

http://www.daemoncustomauto.com/dca%...lose%20out.jpg

These are a few parts I have fabricated to close out the front frame pocket, more pics when they are trimmed and installed.

And, work has started on electrical and electronics. There's quite a bit of planning involved in the wiring so I am doing a bit of work with the lights.

Rendering:
http://www.daemoncustomauto.com/DCA%...er%20front.jpg

Electronics layout:
http://www.daemoncustomauto.com/dca%...c%20layout.jpg

And the start of the tails, first with the proper sized lights:

http://www.daemoncustomauto.com/dca%...rop%20size.jpg

And with incorrect size backup light but showing the correct housing:

http://www.daemoncustomauto.com/dca%...op%20cover.jpg

For both lights they will be in a custom housing with lenses. I am also working on the electrically adjustable/heated seats but no images of that yet.

Those lights are going to be awesome! I really like how much attention is being given to lighting throughout the auto industry. Not just with function but with aesthetics as well.

Where are you sourcing your lights from? I can never seem to find the OEM quality and brightness LEDs.

Which ones are you looking for? I have used a few different suppliers, I have an idea of what parts I want and as I come across them I pick them up. I have not come across a single source for components.

interior
 

I was planning on putting the rear floor pans in today, welded up a few pieces on the interior and thought I'd better fit the seats in before the floor gets finished. I set the seat all full height and all the way back so I know I have clearance later.

Before, some time ago...:
http://www.daemoncustomauto.com/int%201.JPG

Test fit:
http://www.daemoncustomauto.com/DCA%...ide%20view.jpg

http://www.daemoncustomauto.com/dca%...fit%20side.jpg

http://www.daemoncustomauto.com/DCA%...gn%20front.jpg

http://www.daemoncustomauto.com/DCA%...head%20clx.jpg

http://www.daemoncustomauto.com/dca%...test%20fit.jpg

This isn't the final upholstery, it will be redone later when we get to that point. I still have not decided on colors but it won't be grey.

Well, I guess the turn signal Hella LEDs and the turn signal ring. I was hoping you had found a single source. My problem is I want to be able to make my own turn signals or marker lights but I can't find the really bright square LEDs that OEM uses anywhere.

Thanks

The Hella LEDay line is available at Tire Rack dot com or direct from Hella, for most other LEDs try super bright led dot com. They have the square ones.

Pretty much sums up the weekend.

http://www.daemoncustomauto.com/DCA%...t%20Heater.jpg

http://www.daemoncustomauto.com/DCA%...p%20weeken.jpg

Put in a few hours installing front suspension and brakes to get final clearance checks and plan out hard line installation. Need a break from wiring diagrams.

http://www.daemoncustomauto.com/DCA%...20susp%20f.jpg

http://www.daemoncustomauto.com/DCA%...ake%206pot.jpg

Everything is coming together nicely :)

http://www.daemoncustomauto.com/DCA%...ce%20check.jpg

I like that wheel spinning shot. Very cool.

Fuel
 

Made a little progress on the fuel system today, the stock P1800 has a rubber stopper that the filler door held onto a filler pipe. It was bad for leaking fumes so I went with a new filler neck and gas cap - this cap has a push through filler so it does not have to be removed to fill the tank.

http://www.daemoncustomauto.com/P180...filler%201.jpg

http://www.daemoncustomauto.com/P180...filler%203.jpg

And I've completed the in tank EFI mod - this was a bit of work but its almost there. I will need to prep and paint the tank. I also went with an integrated fuel level sending unit that will put an end to the jumping fuel guage I had before.

http://www.daemoncustomauto.com/DCA%...%20Mod%201.jpg

http://www.daemoncustomauto.com/P180...%20Mod%202.jpg

http://www.daemoncustomauto.com/P180...%20Mod%203.jpg

This is the first P1800 tank to be modified for an in tank pump that I am aware of. It's missing the locking ring in this image, I still want to add in a few sumps just past the baffles inside the tank.

My hunt for a B8444S is proving discouraging. I understand Volvo takes them all back and rebuilds them, I have been told they are not manufacturing new ones?

The dealership wants over 10k for a new engine long block only. There are a few used models on ebay but its a 6k gamble.

No one has a Noble M600 tt for sale that I can find....unfortunately.

Hmmmm. If only there were a reliable V8 out there with after market support.


LS it is.;)

nice! You could always go with an aluminum 5.3 to save money. They make great power.

I'm not up on Volvo engine coding but is the turbo 5 cylinder any good? I'm betting it's ridiculous cost wise to build it even if it is a good engine.

Yes, the turbo 5's are good.
The b8444s is a 4.4l V8 designed by Yamaha for Volvo. It's the largest Volvo engine. Noble uses the same 4.4l design from Yamaha but they upgrade internals and add twin turbos for a few extra ponies in the M600.

I had my heart set on a purring V8, never owned anything larger than a 4.

I didn't like the finish on my gas cap and wanted to test the hydro dipping image transfer process on something small. This process can be purchased in home diy kits now.
Prep - base coat applied, good timer, hot water, activator and film.
http://www.daemoncustomauto.com/P180...20test%203.jpg

http://www.daemoncustomauto.com/P180...20test%202.jpg

http://www.daemoncustomauto.com/P180...20test%201.jpg

And finished product.
http://www.daemoncustomauto.com/P180...20test%204.jpg

Much better but, I will have my other pieces professionally done.

Looks good. I had no idea there was a DIY kit.

I think this one came from my dip kit dot com

maybe a vendor on the site sells them as well.

THis is going to be a crazy ride. Very impressed with ALL the fab work and engineering going into this "home built" project.

If you run a 5spd you will save probably 65lbs+ over a 6 manual transmission.
ie TKO600 vs T56 Magnum. The 5spd is also a little slimmer than the latter. I'm not sure how crazy you are going with the weight savings; however you could also run a small diameter clutch and lightweight flywheel shave an easy 20lbs+ there. If you go too wild with the weight of the clutch/pp/flywheel setup it could affect driveability a bit.... but it'll rev like crazy :lol:

^ Thanks for the tips!

I am working on the rear quarter panels now, I have to fabricate the arches and wrap the metal back onto the body. It actually looks like its going to work :) You should see the rear end (from the back) on this thing now!

http://www.daemoncustomauto.com/DCA%...rough%20in.jpg

http://www.daemoncustomauto.com/P180...0in%20side.jpg

The opening at the top of the rear quarter, near the divers door makes a perfect place for a scoop.

not so sure.
 

I am beating away on flares, rough work is coming out now but I'm not sure if its heading in the right direction.

http://www.daemoncustomauto.com/P180...0flare%201.jpg

http://www.daemoncustomauto.com/P180...0flare%202.jpg

I took a break from this to see if an engine would actually fit. So far the measurements are looking good. These are close to scale

http://www.daemoncustomauto.com/Medi...fit%20diag.jpg

http://www.daemoncustomauto.com/P180...s%20Render.jpg

http://www.daemoncustomauto.com/Medi...e%20w%20FR.jpg

What do you think of the work on the flares?

Hard to tell with the close up pictures. Only thing I would be careful of is to make sure they don't end up looking like the stuck factory flares on 4x4 trucks. I personally prefer when the flare flows with the fender of widened fenders.

I am thinking I will build new rear quarter panels. I don't like the flares.

There's a lot of rust and patch work in the current ones anyway...

Need 3 more hours in a day :)

Or I stop playing with pictures on the computer and get some work done...
http://www.daemoncustomauto.com/P180...with%20new.jpg

back at it?
 

September is always too busy - no time for toys, today I had a few hours to look at the GT again.

Some time ago I made these little close out panels to wrap the frame rails and tie into the sill:
http://www.daemoncustomauto.com/dca%...%20out%202.jpg

I finally got them in - this image is taken from under the front of the car looking at the floor near the drivers feet:

http://www.daemoncustomauto.com/P180...0connector.jpg

Now the front floor, frame and bodywork are all closed in, I have a piece the trim in there still but it came together pretty well.

I mounted my new mirrors:

http://www.daemoncustomauto.com/P180...9%20mirror.jpg

And started to work out the front wheel openings:
http://www.daemoncustomauto.com/P180...t%20fender.jpg

its great to see some progress again, i am still looking for one myself, have even been thinking of doing the wagon version too, did you decide on a motor yet? i have been reading a lot on the t5 motor but it may be hard to sort wiring and rwd trans for it, it will more than likely be an ls1 or derivative as they make great power and performance parts are abundant, i have an ls6 in my nova and its great! good luck with the build:thumbsup:

I was planning on ordering an ls3 at Christmas - something came up and it may have to wait. The layouts I have done are based on the LS engine, fuel pump is set up for LS and everything just seems to line up so nicely for one. A V8 is total overkill but...

I like turbo's and considered a T5, but the work would be in making a FWD or AWD engine run a RWD transmission in inline layout rather than transverse has to be considered. It can and has been done.

One very popular version what at Sema - very nice execution!
http://stadium.weblogsinc.com/autobl..._amazon_04.jpg

Let me know when you start yours!

oh i will, there will be build pics too! these will be like 69 camaros soon! lol, my nova is up for sale but nearly wrote it off today!! on the highway at 130km/h when the steering wheel started wobbling like crazy then a grinding of aluminum sound! managed to get it pulled over across 3 lanes in rush hour, i have a set of (old) 3 piece racing wheels and 12 of the 36 rim bolts had sheared and the wheel came apart over 10"or so in length like a buckle and was hitting the grease nipple of the lower balljoint, scared the crap outta me and these wheels will be scrapped, which means delaying the sale to get new wheels to sell the car, no way i could sell it knowing what could happen, ! all the bolts in all wheels were replaced last year after i found a few sheared off but i cant trust them anymore, if a few more had gone the whole wheel would of fell apart and its scary to think of the consequences!!

scary **** - what kind of wheels?

they were old replicas of gt40 wheels, still dont know whats causing the new bolts to break though?

Are they the aluminum or grade 8 bolts?

they are either 8.8 or 10.9 grade metric 6mm

6x1.0 bolts in grade 10.9 or 12.9 then the torque should be 10-12 ft/lbs

you may want to verify torque values if new bolts are continuing to shear

thanks for the info, i will check the torque as i am sure it will be more than that! but there is a gasket between the parts and you need to pull on the bolt to get it to close the gap, and i'm sure 10-12 ft/lb wont do that, i will go check later,

Here is a good write up, in the example they use 15ft lb on M6 hardware. http://www.stanceworks.com/forums/sh...ad.php?t=26614

Most 3-piece wheels are sealed with silicone, so your set up may be different.

This is what mine look like:
http://www.daemoncustomauto.com/COR/...nstruction.jpg

that info is great thanks! now i will stop hijacking this great thread!:thumbsup:

rear bias
 

I've been on a bit of a break, doing what I can to research engines and forced induction. After a few weeks deliberating I picked up an iron block 5.3l engine. I did this because I am learning on this project, have never opened an engine before and decided a turbo project would be the most fun and best opportunity for me.
http://www.daemoncustomauto.com/P180...test%20fit.jpg

The 5.3l is very common here so if I happen to make an explosive error another won't be hard to find. I got my hands on a very good one and it fits!

http://www.daemoncustomauto.com/P180...0clearance.jpg

http://www.daemoncustomauto.com/P180...haft%20clx.jpg
Steering shaft clearance

http://www.daemoncustomauto.com/P180...0clearance.jpg

I am trying to keep the weight behind the front axle so I can attempt to maintain decent balance front to rear.

http://www.daemoncustomauto.com/P180...urbo%20clx.jpg

The turbo's are going to be tricky to squeeze in there, but I've got a few ideas.

http://www.daemoncustomauto.com/P180...test%20fit.jpg

http://www.daemoncustomauto.com/P180...ee%20check.jpg

The alternator has to move, I have to find an accessory drive that will allow me to keep A/C and move the alternator low.

:D

http://www.daemoncustomauto.com/P180...20assembly.jpg

Wow, the motor looks pretty high? I have the LS in my P1800 build, and it is actually lower than the original B18 4cylinder, and the factory LS oil pan is still above the body rockers. Do you have it that high for a reason?

high in relation to the body, maybe,
high off the crossmember no,
high in terms of centre of gravity, nope...

I have changed more than just the engine, keep stopping by for updates!