Protege5: Harder, not Smarter!

Finished rebuilding the turbo, its back together after soaking 4 days in vinegar. Now I gotta finish wiring my megasquirt...I hate electronics :(
 


Glueing the back piece to the front with...wait for it...over 9000 clamps.









Removed 7 pounds off the dash bar.







Primer


Paint

My dremel's motor died about 1/3rd of the way doing the final trim on the hatch. (I'd run it for about 5 hours straight today) RIP my good friend... :'(
 
It looks like you got rid of the dash pad/covering and the center console. You are dead serious about shaving weight.
 
It looks like you got rid of the dash pad/covering and the center console. You are dead serious about shaving weight.

Absolutely my last 3 months I'm averaging 48 mpg for all tanks combined. I'll be taking it to the scales pretty soon and we'll see what I'm down too now. I'm thinking its under or very close 2100 dry now.

This thing going like banana's on on-ramps. (wrc) especially with these grippy tires
 
Cool, a bit crazy but cool. 48 mpg! Thats about 20mpg better than my average tank.
 
Have you considered carbon fiber for your weight reduction process or was it cost prohibitive?
 
Have you considered carbon fiber for your weight reduction process or was it cost prohibitive?

Considered it yes. For about 12 seconds. The cost to build the parts in full carbon would be utterly ridiculous. Several thousand per hood/hatch. (on the other hand, using carbon for the final 1/2 layers mainly for looks would be...expensive yes, but not out of reach)

I did however pick up several yards of carbon last week, just to experiment with on some small interior pieces and/or final layer over fiberglass.
 
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Sorry if I missed it but what's the weight difference between your stock hatch and the fg one?
 
Sorry if I missed it but what's the weight difference between your stock hatch and the fg one?

Newest hatch with the inner seal weighs in a tad under 9 pounds. Totally sturdy, no flexing at all, adding the lexan/rivets will add 2 pounds maximum, probably more like 1.

Stock hatch is 48 pounds.
 
Having measured the gap between the fenders and my tires as I went inside after working on the hatch all day. 3.5 inch gap on the rear, 2.5 on the front.
I'm gonna order new eibach springs. Then I was off trying to determine the best spring rates to work with...

First off, after driving my car around like it is I have developed a superhuman ability to withstand bone shattering vibrations, insane banshee wailing and sweltering heat with no A/C. It is often my pleasure to take passengers along purely for the joy I obtain from watching the wild looks in their eyes as they survey their doom. I then help them buckle up with the harness while assuring them we won't actually be needing to use it to save us today...probably.

I then start the engine up, the car begins to shudder violently and hum as my rock hard engine mounts do absolutely nothing to dampen the powerful FS-DE powerplant. Better yet, when they attempt human interaction while we are in actual motion, lets just forget the fact that we can hear EVERY rock, pebble, stick, boulder, rock, pebble and rock WACKING the underside of the car, or the multitudes of pebbles being gobbled up by the sticky hankook tires and then repeatedly bashed against the pavement dozens of times per instant. Or it could just be the fact that their is an actual hole leading through the firewall right into the engine bay, yes...a hole, where your pansy air conditioning used to rest. Or it could be the deafening notes of the totally unmuffled in any way corksport exhaust bellowing my defiance to the rest of the cars ahead of me.

I smile with uhidden glee as they are shaken to pieces and deafened, while fearfully peering over at my speedometer (the one that's ziptied to..."the dash") attempting to discern whether or not we are in fact exceeding the speed limit or if this is the way the car is always like. So where were we? Oh yes...stiffer springs should be no problem. In fact, I think that's on my list of things to do this year. I can't wait to give you a ride.
 
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Beautifully written. A story of triumph. A victory under scrutiny through the eyes of a fellow passenger. Cheers to you weight junkie, preserver of gas. Hopefully one day, I will be lucky enough to ride in your steel death-trap
 
Some moron managed to whack my gas tank...door? cover? whatever you wanna call it. Unbelievable as I park literally in the farthest space I can find EVERYWHERE I go.

Anyways, I was thinking about making it up in carbon for fun last week...so I guess I really will make it up now. Yay motivation.


Weighing it...cuz...ya know...gotta make it lighter. ;)








Drilled out the spot welds for the inside hinged section.




Claying it up for the mold






Ready for PVA coating



I keep puttering around with my new hatch trying to make it fit best. I'll tell ya, I really enjoy making fiberglass parts. I realllllly dislike trying to fit them to the car. Tedious work but I got it looking pretty damn nice now.

I'm gonna get some canned paint this week and paint it up with my spray gun, then I got a new sheet of lexan to rivet on. I'm gonna try a new method for shaping the lexan to try and get a better looking edge.

Keep on zooming!
 
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