Still failed a warrant so instead of making seatbelt adjuster covers I started taking apart the front end. Couldn't remember if there was a way to remove the bolts without taking the trigger wheel/harmonic balancer off. So tapped it off. Is there a way?
Next I wanted to swap the cast exhaust manifold with a m52 stainless one. The main reason for this is the cast ones that were on it don't have an O2 sensor bung. Luckily for me one of the mates removed the old manifolds.
The next photos show the purge setup I used for welding on some extra stainless fittings to the stainless manifold.
Argon going in through the bottom, all holes taped and covered apart from the fittings.
Argon is heavier than air so you want the purge venting through the top of the part to make sure it is full of flowing argon.
I usually run a flow rate of 2lpm or less while welding. I do alter this depending on the size of the outlet of the part.
This was rushed and i don't intend on keeping this exhaust manifold for too long. The part wasn't as clean as it could be but you get the idea.
Being an exhaust it isn't completely necessary to purge it. It'll just be a bit ugly, not as smooth and not as strong(not by much).
The tube thickness of the manifold was about 1.2mm and the fitting was about 2.5mm thick. Unsure exactly what each material was. They seemed to weld like 304 or 316
Welded with 1.2mm 316L wire at about 58 amps. 3 second slope down and a post gas time that's just long enough to keep the tungsten covered while it has color. Like i mentioned earlier I was in a rush and I could've gone lower on the amps, longer on the slopedown and spent some more time getting comfortable
All up this took 45 minutes. I haven't measured anything so I hope it fits
I designed some under tray things a while ago and got a couple profile cut. Thinking up a tidy, and easy to remove way of mounting it to the bumper and body now. It sits just behind the lip not under it
Currently I'm mid way through removing the front suspension. Control arms are getting all new ball joints including the meyle hd outers. Offset lower control arm bushes (lcab) are also going in. The lcab is definitely one of the reasons the car was handling so terribly. The old ones had nearly torn completely apart
Also going to swap in all the m3 bilstein and H&R gear.
The badges and spoiler have been removed. Turns out the spoiler is genuine (i'd assumed it was a rep). It's developed a crack in the lower part because it had a screw attached in the wrong place. So that is getting repaired as well. Undecided if i want to keep the spoiler or sell