hi Marty, thanks for the link, there were a few good tips.
It basically confirms how I would have done it pretty much. 
Why Ally? because if the bling factor of course!
 
No, I do actually need to be careful of weight, and I can work with the aluminium easier, once I can get some.
The only thing i'm not too excited about, the use of steel thread inserts. I had pictured though bolting and using nuts where possible.Hopefully some progress tonight and over the weekend.
 
 
 
 

one of the best parts playing with Matchbox and Hot Wheels was swapping the wheels and axles over...

just checking to see if anyone has a one piece tailshaft they'd be happy selling?
I have the gearbox but did not get a tailshaft with the car. Ideally closer to Geelong would be good, to save the posties back  :)
Yesterford supplied some new spring bushes, then I can refit the gearbox and dummy fit an adaptor.
Marty I think the anti tramp rods would be a good idea, and might fit them next strip down.

Deano, Great work so far. Not many people would set diff pre-loads up these days
 
I have gotten my local engineering shop to do inserts for a couple of aluminium fabrications. Not sure there are any 'do it yourself' kits around. If you go thick enough with the alloy could you thread it?
 
I'm not looking forwards to what is going to happen to to the costs of steel and aluminium in the near future!

I'm not looking forwards to what is going to happen to to the costs of steel and aluminium in the near future!

I'm not looking forward to the price of anything in the future, fuel, power, gas, rates.... Food even ...

Mark, most car belhousings are ally and are usually 10-15mm at the thread end. There's always helicoil to help, but if possible I would Tig a small ally block behind the hole so the threads go deeper and have more bite... If space allows..

Yep, with you Marty. Of course helicoils are a blessing
I try not to be a jack of all trades, cause I have enough trouble mastering the ones I attempt.

Thanks or the support Mark, but it may all still go t*ts up as they say, come the first roundabout or trafficlight GP.
Time will tell.
The idea of the van was to have something to play with, and learn some things I always wanted to, like welding.
I was to keep going until it stopped, but now it seems to have some drive now that its likely to go electric.
The 'jack of all trades' mentality will pare away as things get more serious, although I will find it less challenging on the sparky side than the pure fabrication.
 
Alli has gone up, but I tracked down a 400x 500 'offcut' in 16mm for about $200 (yes, ouch).
The idea of Helicoils is a bit weird, you thread into the alloy because you dont like threading into alloy.
I now have an EV engineer all worded up and booked for a chat tonight, but it seems positive in concept.
Making some cardboard mockups of the battery size, to see what might fit where. Rear springs are out getting a clean and paint, hopefully over the weekend.
It might be time for one of those youtube turbo heaters for the garage, as its getting too cold.

Very cool project Deano.
 
I thought I'd chime in on the benefits of the helicoil (I've used them a few times to repair threads in alloy).
 
The advantages for a non-repair situation are:
1) The helicoil "outer" thread is larger than the inner bolt thread (e.g. M10 for a ford bell housing), so will have more "bite" into the aluminum, making it stronger.
2) When taking the bolt in and out, you're not wearing out the aluminum, which as you'll know is much softer than steel and much more prone to cross-threading and galling.
 
Keep it up - watching this one with great interest :)

Hey Ash, good that another voice is onboard.
I've just never used them  before, but get your points and agree, they must be good.
 
I hope the adaptor plate doesn't have to be taken on and off too many times.
It will be good to mock it up and be able to see how much space is available for a coupler, and the clutch.
Then to decide on whether to keep the clutch or not, is a whole other discussion.
Sorry for posts without pics!

Look at all this forum chatter!

Am i right in believing your going to make this electric? or is it my post night shift less then 4hours sleep brain losing it.