Frame Painted

The Air Ducts were Removed and all welds Completed, next the Frame was Undercoated and 2 Pac Painted Black.
Re-assembling the Front End was Straight Forward but aligning the Motor Fixing Holes was another matter, the Frame had moved During Welding so a Little setting was required, 10mm Bolts in 10mm Holes is perhaps too fine a tolerance.

Fully Welded Frame and Engine Cooling Ducts

The frame has been fully welded, Go Eamon!
 
Initially Fibre Glass ducting was fabricated but quickly kicked to the curb in favour of folded aluminium.
Not only will they feed cooling air to the engine but serve as comfortable arm rests too.

The 25X50mm RHS through the length of the chassis has holes for the fuel and brake lines. The holes are at 250mm centres (300 max allowed) This opens into the engine bay from the tank area in front of the passengers feet. 

Gemini Brake Disk and BMW Caliper (Widened)

The cobbled up pipe notcher on the lathe to maintain consistency of the angles and the jig to mill the "O" rings for the calliper. The jig has a 7mm nipple machined to drop the widening plate onto so the "O" rings align with the calliper. (8 "O" rings in total ). The depth must also be correct to match the recessed "O" ring section in the calliper which is different on each side of the calliper. There needs to be 20% crush on the "O" ring so one side is .8mm and the other 1.2mm to match the BMW part. I used a 7/16" end mill.  Again all this can be purchased from TPC, but as I have no money and a shed full of machines and I'm surrounded by clever friends in the trade I can move forward.

Steering Rack and Shaft

The steering column is ED Falcon pre air bag and a Sierra coupling to the rack. (Tripod Cars. TPC)
Andrew at TPC uses a Toyota unit and can supply all the components required for the front end and steering to suit his chassis including the "A" arms.
I made mine due to budget restraints but if I had the money, they would have come from TPC. I used DN20 Sch40 SMLS pipe Grade 350 and 4140 round bar for the top threaded piece to the top ball joint. That also required a 17mm thread which you won't find on the shelf at the hardware. The bushes are out of an early Landcruiser but again...TPC and make your life easy.
I made the rack mounts using some of the escort parts and 6mm plate.
The bush and bearing at the bottom of the column have been replaced with better material and a 1" self aligning bearing and housing as the column tilts and extends.

Front Suspension

I machined aluminium spacers to simulate the Wishbone bushes during the build so I could weld beside them, in the photo's it's set up with min caster and about correct camber. The top ball joint taper still needs a final ream in the Gemini upright to suit the Landcruiser ball joint, that's why at times if you look closely the top "A" arm angle looks exaggerated.
The suspension is non parallel unequal length and when at ride hight has a low roll centre. 

Let's Make Sparks.