90 SJ Build

Joined
Jun 15, 2018
Likes
3
Location
Pennsylvania
#1
So a few months ago, I purchased a project sn sj hull for this winter. I am in the process of sanding down the engine bay for reinforcement and de foaming the rear tray to re foam and add foot holds. I know w weak spot on these old hulls is the midshaft design as it is smaller and more prone to failure due to vibration. I have read threads where two of the bolt holes on the newer, larger midshaft style line up with the old threaded inserts, the other needing to be moved out. My question is while my tray is open, is it feasible to move a single insertion order for it to line up and epoxy it in place? In which case I would gain more possibilities for midshaft setups, whether OEM or aftermarket.
 
Joined
Jun 15, 2018
Likes
3
Location
Pennsylvania
#4
Some more pics. Foam is out. Sealing the bond line with thickened epoxy. It’ll cure nicely while I am away on a Colorado ski trip, at which point more sanding will be done to ready it for 1708 Biax reinforcement. Trying to decide whether or not to build a wider tray once refoamed, or just put in footholds. I am a bigger guy at 6’3” so a wider tray/stance appeals to me. Anybody with any thoughts?
 

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Joined
Jun 15, 2018
Likes
3
Location
Pennsylvania
#5
Did a repair on the bottom prior to laying down reinforcement. Came out well, just need to sand, smooth, and feather in. Project coming along slowly but surely. Also got my ebox cleaned up and ready to drop in, have a 61x to go in. Just need to replace the crank seals, hone and new rings. The final thing I want to eventually do is mod the hood.
 

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Joined
Jun 15, 2018
Likes
3
Location
Pennsylvania
#7
Finally able to get some more work done, been a busy past month or so. Foam will be cut soon. Filling old exhaust holes in, will cut new ones as the tray will be widened and lowered. Got a custom aluminum exhaust tube from RAD Dudes, should look pretty good!
 

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Joined
Jun 15, 2018
Likes
3
Location
Pennsylvania
#8
Some more progress. Started measuring, cutting, and test fitting foam for the tray. Hopefully should be able to 5200 all fittings back in and rebuild the tray in the next week or so.
 
Joined
Jun 15, 2018
Likes
3
Location
Pennsylvania
#13
Everything 5200, should be cured by the time I am able to work on it again between work shifts. Then the wide tray can begin to take shape with lots of glassing. Most recent US Composites order should be here shortly.
 

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Joined
Jun 15, 2018
Likes
3
Location
Pennsylvania
#15
Final side pieces cut and ready to be glassed in. Some more sanding, glass the pieces in, more sanding and then a final few layers of s-glass in the entire tray area for final reinforcement. Hope to reinforce the pole mount area quick before final body work starts for painting.
 

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