Since adding the roof rack, I have been meaning to make a more rigid spare tire hold down than 2 crucified bungee cords.
Started with a an extra mounting bracket that came with the roof basket and a scrap piece of 1/8" flat steel.
Measured and cut to length.
Center holes marked and punched. Pilot hole drilled and then finished with a step bit.
Plate mounted to bracket, center hole drilled and then bolt welded in place.
Bracket painted and mounted to rack. Scrap tubing added to rack to prevent metal-metal contact.
So I finally had a little down time this past weekend and I was tired of the spoiler taking up room on my workbench, so I decided to start working on it again to get it finished up. In order to fill the transition gap and make the contour flush with the roof line, I decided to use some kind of foam material.
After a failed attempt using Great Stuff, I just epoxied some styrofoam house sheathing to the existing spoiler.
Styrofoam shaped and contoured.
Before adding some fiberglass, I applied some duct tape over top so the fiberglass resin doesn't eat through the styrofoam.
A few layers of fiberglass added.
After some sanding and shaping of the dried fiberglass, Bondo body filler is added to fill gaps, holes and make the contour nice and smooth.
Then more sanding....
and more sanding....
and MORE DAMN SANDING!!!!
THE RESULTS...Before/After
After the first few coats of sandable filler/primer.
This stuff really does a good job of filling in small scratches and really highlights any imperfections.
I am letting this fully dry (~4hrs) and then will fill in some small pitting, holes and some small blemishes later tonight.
Will hopefully get some final sanding and put final coat of paint on tomorrow.
Stay tuned for the final product!
Love your work dude! It gives me the motivation to start my custom wing!
Thanks! Its a lot of work, especially all of the body work. Take your time, be patient and dont cut corners. In the end it is all worth it it! Especially being able to say, you did it yourself from scratch!:encouragement:
FINAL WAGON CUSTOM SPOILER
After a trial fit before final paint of my last spoiler progress, I decided to get out the fiberglass and bondo yet again in order to fill the blank space in the middle between where the existing stock panel meets the roof line on the edges. After having the spoiler mounted, it just looked like it should be one full piece with a nice taper and even transition to the roof line. Therefore, on to the pics...
Used stretched fleece again in order to get straight edge and a rigid foundation to fill gap.
Taped for protection, Getting a straight edge and Fleece with resin
Bondo and Sanded
The previous stage and final versions compared in primer
Final after new coat of Trim and Bumper paint (sorry for the glare, its just that shiny)
Looking back at the progress from the very start of construction
I should be officially done with this after mounting it tomorrow. Im letting it fully dry overnight and will try and get some pics of it mounted posted up tomorrow.
And for those wondering and who have asked before: NO I WILL NOT MAKE YOU ONE!
Bam, as you stated that space in the stock panel may be to allow for removal of rain, but I found out another reason it is designed that way:
DOH! :nightmare: And I thought the final design looked sooo good too!
Once my anger subsides, I will get out the grinder and bondo and figure out the best solution to the "binding" problem I now have with the current design. :mad: SOAB!:mad:
Yep, I just had to walk away! Im leaving it as is up thru the weekend, then will take some measurements then take it off and throw (errrr I mean) lay it nicely back on my workbench!
looks pretty good man! once you finalize and fix the binding problem, maybe vynl wrap it??? carbon fiber??
Emissions and prob a motor swap will be next on the upgrades. Ive been driving the wagon on and off for a month or so since the last time I had problems and the same thing that I posted earlier about spark plug in #1 cylinder, happend again!? Knocked the damn plug out this time, so not sure if it will even hold a new plug. Not sure why this keeps happening and so random but I am going to try a thick washer and a new plug and attempt to go get an emission to keep it legal. Then I may pull the head and try and see whats going on. There is no visual damage to top of piston but something is for sure hitting the bottom of the plug. I have run a magnet down inside the combustion chamber to maybe fish out a piece of a ring or something (even though there is no weird noise and the car runs fine up until the plug comes out) The symptoms dont really match anything that is (or is not) consistently happening.
Im by no means an ASE mechanic and not really into the idea of throwing a lot of money into diagnostics, tear down/rebuild of the stock motor. This is just an excuse to do the inevitable motor swap, just a bit sooner.
Now just doing the research on which b series to use considering bang for buck and modifications vs overall satisfaction once done. Biggest thing im doing now is researching cable to hydro conversion since I have a 98 Spec R LSD tranny that I have been holding on to for years that I would like to use. Keep cable and just use an Innovative or Hasport conversion Kit, or do the extra work and convert to complete hydro?
So you can see, Ive got lots Im considering at the moment. I hate to say, the spoiler has gone back on the damn workbench for now.
Here's a pic of the damage to the month old NGK from cylinder #1:
If that would of happened to me, somebody would of been wearing as a hat due to throwing it life a boomerang and not looking where it is going.
RBWdriven u had me crying laughing down here n FLA... ive done that same thing .... i remember spray tinting tail lights and i got disturbed and got a run in it ( i punched out the tail light) the person that interrupted me took off running ...
LoL
Yep, I just had to walk away! Im leaving it as is up thru the weekend, then will take some measurements then take it off and throw (errrr I mean) lay it nicely back on my workbench!
very nice progress on your wagon ..... basket with tire looks great ...
Its been too long, but I had some time this evening, so getting back to the wagon.
Gonna fix this damn spoiler if it kills me!
After a bit more measuring, I trimmed down the area at the front of the spoiler that was too thick.
Masked off the area underneath where the spoiler mounts and layed down a layer of fiberglass and resin to get the exact contour of the roof line.
Covered with plastic and then weighed it all down to get an exact contour as it dried. (Sorry no pics :disturbed:)
Here it is with fiberglass dried still with plastic on top. Plastic removed on right.
Another angle before trimming edge on left. Edge trimmed on Right
Looking down the seam of roof line and hatch door space.
Another angle showing matching roof line contour.
Its tight, but now allows for the hatch to fully open! :encouragement:
I will continue to work on the cosmetics and overall fitment with a lot more blending, sanding and bodywork. Hopefully get it done this weekend, time permitting.I will post pics when its finally done and mounted without any issues.
Also, got some MAJOR mods planned in the coming month, but dont wanna jinx myself on a few deals in the works. I will post up the details/updates when things are final.
Been doing tons of searching and reading on various forums and Ive been slowly acquiring all of this over the past month in plans for the swap:
Still have a few misc pieces to acquire, and have to read up again and again on wiring upgrades/swapping in order to make the b work in the wagon. I know its doable, but gonna approach it one wire and connector at a time. Still haven't found an idiot proof "Wiring a B-series in a wagon for dummies (with pics)" but have a lot of notes I need to consolidate. If anyone knows of a step by step tutorial, share the link.
Working on getting the wilwood big brake kit installed. This was not a must, but was one of those things i ran across and couldn't turn down. Prob a bit overkill for a daily driver, but then again, will add a little extra stopping security to my daily drive, plus looks good filling up the space behind the 16" rotas. Found out the hard way that the previous owner had swapped to DA spindles/knuckles/brakes. Got a set of OEM Dx spindles and will be swapping them out soon in order to finish the Wilwood install.
Big ups and thanks to FakeJDMEF8 and Bam-Bam for all of their help and guidance! :encouragement:
I will make a separate post on the brake install which will include a Honda spindle stamp identification guide that I pieced together in order to solve the "what spindles do I have" mystery.
loooks like a nice collection of parts you have there....
i have to say the BRAKE UPGRADE for me was my favorite .... cant tell you the number of times its saved my neck...!!!
Comments
Since adding the roof rack, I have been meaning to make a more rigid spare tire hold down than 2 crucified bungee cords.
Started with a an extra mounting bracket that came with the roof basket and a scrap piece of 1/8" flat steel.
Measured and cut to length.
Center holes marked and punched. Pilot hole drilled and then finished with a step bit.
Plate mounted to bracket, center hole drilled and then bolt welded in place.
Bracket painted and mounted to rack. Scrap tubing added to rack to prevent metal-metal contact.
OEM mount used with a few washers and wingnut.
DONE!
So I finally had a little down time this past weekend and I was tired of the spoiler taking up room on my workbench, so I decided to start working on it again to get it finished up. In order to fill the transition gap and make the contour flush with the roof line, I decided to use some kind of foam material.
After a failed attempt using Great Stuff, I just epoxied some styrofoam house sheathing to the existing spoiler.
Styrofoam shaped and contoured.
Before adding some fiberglass, I applied some duct tape over top so the fiberglass resin doesn't eat through the styrofoam.
A few layers of fiberglass added.
After some sanding and shaping of the dried fiberglass, Bondo body filler is added to fill gaps, holes and make the contour nice and smooth.
Then more sanding....
and more sanding....
and MORE DAMN SANDING!!!!
THE RESULTS...Before/After
After the first few coats of sandable filler/primer.
This stuff really does a good job of filling in small scratches and really highlights any imperfections.
I am letting this fully dry (~4hrs) and then will fill in some small pitting, holes and some small blemishes later tonight.
Will hopefully get some final sanding and put final coat of paint on tomorrow.
Stay tuned for the final product!
Thanks! Its a lot of work, especially all of the body work. Take your time, be patient and dont cut corners. In the end it is all worth it it! Especially being able to say, you did it yourself from scratch!:encouragement:
Wooden tray is my favourite :encouragement: Well done!
After a trial fit before final paint of my last spoiler progress, I decided to get out the fiberglass and bondo yet again in order to fill the blank space in the middle between where the existing stock panel meets the roof line on the edges. After having the spoiler mounted, it just looked like it should be one full piece with a nice taper and even transition to the roof line. Therefore, on to the pics...
Used stretched fleece again in order to get straight edge and a rigid foundation to fill gap.
Taped for protection, Getting a straight edge and Fleece with resin
Bondo and Sanded
The previous stage and final versions compared in primer
Final after new coat of Trim and Bumper paint (sorry for the glare, its just that shiny)
Looking back at the progress from the very start of construction
I should be officially done with this after mounting it tomorrow. Im letting it fully dry overnight and will try and get some pics of it mounted posted up tomorrow.
And for those wondering and who have asked before: NO I WILL NOT MAKE YOU ONE!
Next time you're driving in the rain at speed, note the water blowing off the back glass. I suspect that's why.
Nice work, Paul!
Bam, as you stated that space in the stock panel may be to allow for removal of rain, but I found out another reason it is designed that way:
DOH! :nightmare: And I thought the final design looked sooo good too!
Once my anger subsides, I will get out the grinder and bondo and figure out the best solution to the "binding" problem I now have with the current design. :mad: SOAB!:mad:
looks amazing though
Yep, I just had to walk away! Im leaving it as is up thru the weekend, then will take some measurements then take it off and throw (errrr I mean) lay it nicely back on my workbench!
Im by no means an ASE mechanic and not really into the idea of throwing a lot of money into diagnostics, tear down/rebuild of the stock motor. This is just an excuse to do the inevitable motor swap, just a bit sooner.
Now just doing the research on which b series to use considering bang for buck and modifications vs overall satisfaction once done. Biggest thing im doing now is researching cable to hydro conversion since I have a 98 Spec R LSD tranny that I have been holding on to for years that I would like to use. Keep cable and just use an Innovative or Hasport conversion Kit, or do the extra work and convert to complete hydro?
So you can see, Ive got lots Im considering at the moment. I hate to say, the spoiler has gone back on the damn workbench for now.
Here's a pic of the damage to the month old NGK from cylinder #1:
LoL
very nice progress on your wagon ..... basket with tire looks great ...
Gonna fix this damn spoiler if it kills me!
After a bit more measuring, I trimmed down the area at the front of the spoiler that was too thick.
Masked off the area underneath where the spoiler mounts and layed down a layer of fiberglass and resin to get the exact contour of the roof line.
Covered with plastic and then weighed it all down to get an exact contour as it dried. (Sorry no pics :disturbed:)
Here it is with fiberglass dried still with plastic on top. Plastic removed on right.
Another angle before trimming edge on left. Edge trimmed on Right
Looking down the seam of roof line and hatch door space.
Another angle showing matching roof line contour.
Its tight, but now allows for the hatch to fully open! :encouragement:
I will continue to work on the cosmetics and overall fitment with a lot more blending, sanding and bodywork. Hopefully get it done this weekend, time permitting.I will post pics when its finally done and mounted without any issues.
Also, got some MAJOR mods planned in the coming month, but dont wanna jinx myself on a few deals in the works. I will post up the details/updates when things are final.
Been doing tons of searching and reading on various forums and Ive been slowly acquiring all of this over the past month in plans for the swap:
Still have a few misc pieces to acquire, and have to read up again and again on wiring upgrades/swapping in order to make the b work in the wagon. I know its doable, but gonna approach it one wire and connector at a time. Still haven't found an idiot proof "Wiring a B-series in a wagon for dummies (with pics)" but have a lot of notes I need to consolidate. If anyone knows of a step by step tutorial, share the link.
Working on getting the wilwood big brake kit installed. This was not a must, but was one of those things i ran across and couldn't turn down. Prob a bit overkill for a daily driver, but then again, will add a little extra stopping security to my daily drive, plus looks good filling up the space behind the 16" rotas. Found out the hard way that the previous owner had swapped to DA spindles/knuckles/brakes. Got a set of OEM Dx spindles and will be swapping them out soon in order to finish the Wilwood install.
Big ups and thanks to FakeJDMEF8 and Bam-Bam for all of their help and guidance! :encouragement:
I will make a separate post on the brake install which will include a Honda spindle stamp identification guide that I pieced together in order to solve the "what spindles do I have" mystery.
STAY TUNED!
i have to say the BRAKE UPGRADE for me was my favorite .... cant tell you the number of times its saved my neck...!!!
can't wait to see em installed!
Gives new definition to stops on a dime.
I should have stated that a fuel filter with a b&m fuel pressure gauge and personal wheel with a boss hub (not pictured) Thx! I hope to be adding the smell of burnt rubber on cue with the added hp and lsd equipped spec-r tranny.