Rocky Mountain Club B5

Discussion Forums => Modifications => Topic started by: ianacole on January 28, 2007, 10:17:39 PM

Title: What do you do when you can't find a part?
Post by: ianacole on January 28, 2007, 10:17:39 PM
Why, make your own of course!!!

Disclaimer: Yes, I know I suck at welding and I need to clean my garage ;)

I purchased some new mirrors - lightweight CF racing mirrors.  What I failed to realize at the time was that I had no easy way of mounting them.  After taking off my stock mirror and housing, I was left with this:

(http://www.rmcb5.com/modules/gallery2/d/15631-2/IMG_3954-sm25.JPG)


After some deliberation, I bought some steel in anticipation of making some sort of mount.  Some how, this mirror is going to attach to this steel and my car:

(http://www.rmcb5.com/modules/gallery2/d/15641-2/IMG_3957-sm25.JPG)

So, what's the best way to start a new project?  By buying new tools!!  Ran down to Harbor Freight and picked up a 36" metal brake and a metal band saw:

(http://www.rmcb5.com/modules/gallery2/d/15635-2/IMG_3955-sm25.JPG)
(http://www.rmcb5.com/modules/gallery2/d/15638-2/IMG_3956-sm25.JPG)

After some thinkin', some cuttin', and some bendin', I ended up with this:

(http://www.rmcb5.com/modules/gallery2/d/15644-2/IMG_3958-sm25.JPG)

And the test fit:

(http://www.rmcb5.com/modules/gallery2/d/15647-2/IMG_3959-sm25.JPG)

Looked good, so it was time to tack the mounting bolt:

(http://www.rmcb5.com/modules/gallery2/d/15650-2/IMG_3960-sm25.JPG)

Once the bolt was tacked on, I had to drill the mirror mounting holes and the access hole for the adjustment screw.  Here is the final piece:

(http://www.rmcb5.com/modules/gallery2/d/15653-2/IMG_3961-sm25.JPG)

And what it looks like on (sorry 'bout the crappy first pic):

(http://www.rmcb5.com/modules/gallery2/d/15656-2/IMG_3962-sm25.JPG)
(http://www.rmcb5.com/modules/gallery2/d/15659-2/IMG_3964-sm25.JPG)

I'm pretty jazzed about the way it turned out.  I need to do the other side, then I'm going to have them powder coated black (probably flat).  I'll also be putting on some adhesive foam molding to keep wind out.  This was my first "major" fabrication for the car, and I think it turned out pretty well.  What do you all think?  And please, if you know of a company that makes blanks for mounting mirrors on the MKIV VW, DO NOT tell me.  I'd rather live in my own little fantasy world thinking I created something new and useful ;)
Title: What do you do when you can't find a part?
Post by: Docwyte on January 28, 2007, 10:19:30 PM
I never understood those tiny mirrors.  You won't be able to see $hit in them to check out who's behind you and where...

Regardless, nice fab job!
Title: Re: What do you do when you can't find a part?
Post by: ianacole on January 28, 2007, 10:22:23 PM
Thanks, since the car is being pulled off the road and converted to a race car, I only need minimal rear view to check for other drivers attempting to pass.
Title: Re: What do you do when you can't find a part?
Post by: jayryan on January 29, 2007, 06:47:50 AM
I think it's awesome.  :D
Title: Re: What do you do when you can't find a part?
Post by: 34k on January 29, 2007, 09:20:41 AM
Quote from: "ianacole";p="54514"
I only need minimal rear view to check for other drivers attempting to pass.


And hopefully there won't by many of THOSE!

Nice job Ian. Do you know where you're going to get it powder-coated? I need to find someone to do the intake manifold on my VR.
Title: Re: What do you do when you can't find a part?
Post by: Spicoli on January 29, 2007, 09:25:38 AM
Looks nice Ian.   Looks way better than the Duct Tape I was going ot suggest.  :lol:
Title: Re: What do you do when you can't find a part?
Post by: 92UrS4 on January 29, 2007, 09:38:56 AM
I'm with Jack on this one, I would have gone the duct tape route, but this will suffice. Nice job!
Title: Re: What do you do when you can't find a part?
Post by: Cole on January 29, 2007, 10:00:33 AM
So the real question is this: Do the new mirrors + fabbed mount still weight less than the old mirrors?
Title: Re: What do you do when you can't find a part?
Post by: ianacole on January 29, 2007, 11:28:18 AM
Quote from: "Cole";p="54524"
So the real question is this: Do the new mirrors + fabbed mount still weight less than the old mirrors?


You know, I haven't weighed it yet :lol: If worse comes to worst, I've got the prototype made - I'll redo them in aluminum if there isn't any weight savings.  The mirrors themselves are incredibly light.

Andrew - I'm not sure what I'm going to do for powder coating as of yet.  I was going to call Woody's Wheel Works and see if they can do these parts, and if not, if they know someone who will.  I let you know what I find out.

Thanks all!!
Title: Re: What do you do when you can't find a part?
Post by: Eric18T on January 29, 2007, 05:10:36 PM
http://www.powdercoatingspecialties.com/

They are afforable and do decent work. I have seen a few wheels powdercoated by them and they looked great.
Title: Re: What do you do when you can't find a part?
Post by: ianacole on January 29, 2007, 05:59:06 PM
Cool, Eric, thanks!!  I'll give them a call sometime this week (once I've finished both sides).
Title: Re: What do you do when you can't find a part?
Post by: 03Indigo on January 29, 2007, 06:01:00 PM
Ian, those I think those look great, job well done!!!!
Title: Re: What do you do when you can't find a part?
Post by: ianacole on January 29, 2007, 06:20:19 PM
:D

Weights

Stock:  1Lb 12oz.

New (sans powdercoating and weather stripping):  just under 11oz.

 :D  :D That'll be over 2 lbs saved.  May not seem like much, but every little bit helps.
Title: Re: What do you do when you can't find a part?
Post by: 03Indigo on January 29, 2007, 06:39:00 PM
if I were a race car driver, I would have about 50lbs that I could lose.....off  my belly ;)
Title: Re: What do you do when you can't find a part?
Post by: ianacole on January 29, 2007, 06:53:11 PM
Yah, me too  :oops:
Title: Re: What do you do when you can't find a part?
Post by: jayryan on January 30, 2007, 12:16:40 PM
Why doest his come to mind :lol:

(http://comics.com/comics/getfuzzy/archive/images/getfuzzy20366536070130.gif)
Title: Re: What do you do when you can't find a part?
Post by: gragravar on January 30, 2007, 12:18:19 PM
nice work on that mirror mount!  that will look done once the powder coating is done!
Title: Re: What do you do when you can't find a part?
Post by: RobD on January 31, 2007, 06:39:11 AM
Ian nice work.  I don't know many people that would buy their own brake and saw to fab a part like this.  I'm sure this is just the start of many other parts you will want to fab now that you have the ability fab things up.  Keep in mind that aluminum is about 1/3 the weight of steel so youe weight saving could be greater if you wanted to make the parts out of aluminum.

Being a steel salesdude I might be able to help you out on the alum sheets as well.

As for powder coating i know some guys that are in the business.  There is a company in Arvada (just down the street from RS Motorsports) named Focused Light.  There are 2 younger guys named Steve and Ben that run the show now and they have an Amada Laser for cutting steel but also have a couple of ovens they do powder coating with.  They are pretty reasonable too.  Phone # 303- 463- 5356.

If you are not in a hurry I have a trailer hitch for the Eurovan i wanted to get powder coated black as well.  I might be able to get them to swing a nice deal for me to coat everything free since I hook them up with Avs tixs every once in awhile and I have tixs to hand out right now!

Let me know what you think.

cell - 303-885-7682 if you want to talk about details (alum thicknesses powder coating etc.)
Title: Re: What do you do when you can't find a part?
Post by: ianacole on January 31, 2007, 08:23:31 AM
Hey Rob - THANKS!!  I need to get these done within the next couple of weeks as I need them installed prior to the Feb 18th autocross.  If that fits with your time frame, let me know.
Title: Re: What do you do when you can't find a part?
Post by: huevon on February 01, 2007, 08:18:35 AM
i know a guy who powdercoats on the side. he does a good job and he gives me a huge discount on parts!