So every project has a part where you say “crap, that was way harder/more time consuming than I expected”.
For this project, it was the sleeves : cut some tube, drill some holes, f&@kin’ nailed, right?
Yeah, nah. I basically screwed my self by not making all of the sleeves the exact same length, which meant that the jig was of limited usefulness and I had to put a bunch more brain power into every one.
So that’s how I spent my morning.
I also juggled the door intrusion bars around so that three of them are a tight fit, and then made a new one for the 4th spot so that it is also a tight fit. Previously they were all a tight fit minus two angle-grinder cuts. Not sure how much this really matters, but I now know that it is as good as it can be.
Forgot how to sharpen drill bits for a while there… Dunno what I was doing wrong, but couldn’t get them to cut AND not tear the corners off. Came good after too many tries, very weird.
Made a small bungle with the lower intrusion bar bolts on the driver’s side. Basically, I wanted to put the bolts in vertically to make it harder to drag your leg across the bolt heads, but had to angle them so that I could actually drill the holes - I should have angled them inward and I would have achieved my goal better…
Got it right on the passenger’s side…
About to try to work out how to make the dashboard fit around the cage, then it all comes out again to make & fit the roof diagonal, Sainz bars and maybe an under-dash bar.
