Nice job, I need to do the same on my car when it gets its bodywork sorted.

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GT4DC Events Co-ordinator
1996 ST205 UK

Extremely common to find the sills like this...
occurs when using a 2-ton jack without a piece of wood or similar to protect the sill.
It is now an MOT advisory if the sill is damaged liike this.

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Vice Chairman
1990 White UK Celica ST185 - Project DTM
1997 Cream BMW R1200C (as seen in James Bond "Tomorrow Never Dies")
2005 Jaguar X-type 3.0 Sovereign AWD Automatic
Blood Bikes - https://www.freewheelers.org.uk/

Well I havnt updated for a while on here, sorry. After alot of measuring and cutting and welding I have finally got the rear cage in place. I am at a cross roads now...do I go with my Evolution hybrid build, or go for an all out rally car...well only I can answer that question, I am torn between the two, I guess time will tell, but I am keeping it on hold until I have made my mind up.

For those wishing to have a go in building your own roll cage, this is a pretty terrific web site

http://www.metalgeek.com/static/cope.pcgi

Removed the little interior plastic support brackets, it leaves a much cleaner looking suspension top.



A template made for the strengthening plates



Plate made from 3mm steel





starting to jig the cage in



starting to weld.....this is the first thing I have really welded apart from minor parts and practice



a bit more



sub frame bolts



sub frame tie bar



a bit more



nearly there



finished for the time being



decisions to make now.

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ST205

Seeing as how you've gone down the half-cage route my vote would be to build the car in fast road / trackday spec. It wouldn't look quite right as a rally car with a half cage. You can tell I'm a stickler for detail My 2p!

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Don
GT4DC Chairman
1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

Good looking project! Also top marks for building your own cage....our life would be sooooo much easier if we could weld....

The subframe bracing is the one thing i wish we had on our cage....ahh well live and learn. It's only ever going on tarmac anyway

If I was going to go full blown rally car I would finish the rest of the cage and do the full thing.

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ST205

Getting there slowly



The shell prep has taken longer than I thought it would, although in the mean time I have been learning to melt aluminium and make cast parts.......harder than it sounds with mixed results.

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ST205

seen you casting progress on the celica club looks interesting what sort ofthings have you been casting. have you melted much more than just the metal lol

I was going to cast an alloy alternator bracket, but I cant get the recipe right, I need to add some copper but I cant get the mini blast furnace hot enough to melt it....and aluminium alloy on its own bends too easily...at least the types I have tried thus far.

I will be making some new radiator top support brackets and perhaps a bracket of two for various swirl pots, header tanks etc keeping the shapes simple

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ST205

Sounds familiar, my solution was to shower lots of dosh on it to speed things up but need to take a breather now!

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Don
GT4DC Chairman
1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

I don't have lots of dosh to throw at it, plus I want to do as much as I can myself. It's the challenge I have set myself, the only things I don't want to do is spray it and media blast it as setting up equipment etc is just too expensive. Although I am sure I will find one or two jobs I just can't do, rebuild an engine I might leave to the pros.

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ST205

A bit of a catch up.......copied from the past

Today is a good day.

Definitely a great day.

At last I have put colour to car and I must say it looks f'in brilliant, I so love the colour. It goes on very well, is very forgiving and is the perfect colour, love it, very happy bunny today. Well chuffed.......and it's only the engine bay, imagine how happy I cam going to be when I paint the topside I will be smiling so much the top of my head will fall off

[url="http://smg.photobucket.com/user/nialusa/media/imagejpg1_zpsf6b946f5.jpg.html"][/url]

Only the first layer, a small amount of flating to do, then more colour.

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ST205

A small bit of progress today.

Fitting the front coilovers

[url="http://smg.photobucket.com/user/nialusa/media/Celica%20Rebuild/P1010839_zps325269fc.jpg.html"][/url]

Took a bit of fettling but its all sorted now

[url="http://smg.photobucket.com/user/nialusa/media/Celica%20Rebuild/P1010849_zps030bc291.jpg.html"][/url]

rear coilovers fitted

[url="http://smg.photobucket.com/user/nialusa/media/Celica%20Rebuild/P1010842_zpsb7a8c4f4.jpg.html"][/url]

[url="http://smg.photobucket.com/user/nialusa/media/Celica%20Rebuild/P1010843_zps9e6a99d5.jpg.html"][/url]

as you can see, i dont have much space to work in...need to build myself a bigger garage.

[url="http://smg.photobucket.com/user/nialusa/media/Celica%20Rebuild/P1010845_zps9a7faa48.jpg.html"][/url]

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ST205

The engine is about a year or so away. interior next along with electrics and braking system.

Well, its on its own wheel at last (the other three i had to borrow )

Its alot lower than i remember it

[url="http://smg.photobucket.com/user/nialusa/media/Celica%20Rebuild/P1010852_zps7c76e8c2.jpg.html"][/url]

its alos alot easier to move around :thumbsup:

[url="http://smg.photobucket.com/user/nialusa/media/Celica%20Rebuild/P1010855_zpsdaa29de4.jpg.html"][/url]

interior next....oh joy, not looking forward to the next lot of work at all, maybe i will take a break for a while

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ST205

A whole lot of fun today, i still hate fibreglassing things. Whos daft idea was it to install a roll cage???? the top half of the plastics that frames the window will get flocked, the lower half, after a lot more work will get painted a high gloss black, along with the front door lower sections and the bottom half of the dash, dash inserts will get painted a silver.

[url="http://smg.photobucket.com/user/nialusa/media/Celica%20Rebuild/P1010862_zps79717ab2.jpg.html"][/url]

[url="http://smg.photobucket.com/user/nialusa/media/Celica%20Rebuild/P1010860_zpsc2342d37.jpg.html"][/url]

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ST205