Project Eclipse: Oct 28 Update

The rebuild continues at a slower and more detailed pace.

Now that the old header is out, we located the source of that nasty exhaust leak: a crack in the flex pipe.

Our suspension team continued to compress and disassemble the coil over system one by one to clean and repaint each strut.

The final bits of the rear end, mainly the sway bar end links are removed. As usual, they are siezed and will be replaced...

The grade 10 and 11 students continue to work under the car, tediously cleaning the undercarriage for undercoating...

...while other members of Car Club grind, clean and prep the rear end cradle for the first coat of paint:

With knuckles, control arms, trailing arms and rotors nearly prepped for paint, we can start painting the cradle before installing new hubs next week.

While the undercarriage continues its cleaning and coating, we will begin reassembly of the rear end subframe components and ready the coil overs, brakes, sway bar and other components for installation.

Car Club runs Tuesdays after school from 2:30 to 4pm. Drop by, meet Mr. Da Silva and the club members and check out Project Eclipse! New members always welcome! Come on out and discover team work, talent and student success!

Project Eclipse: Oct 21 Update

Now we slow down our disassembly rate and focus on some of the removed systems.

After showing students how and why brake rotors are turned, we resurfaced all four
and measured them with a micrometer to ensure they are reusable:

The headlight lenses are now finally removed:

...and while the Eclipse is low to the ground, today's crew

worked all around, and UNDER it removing rear bumper

bolts and continuing rust removal of the undercarriage. It's

a tough, tedious job, but our grade 9 and 10 crew are up for

the challenge!!!

Paying attention to detail during the rebuild is important, if we 

want to establish a good product. So as the rear end continues

to be rebuilt, our rebuild team details every bolt so it will function

without binding...

And while we continue to bead blast each part, our grade 9s

take on the challenge of disassembling the coil over system

for a refresh:

Car club continues next Tuesday, and is growing in membership

every week. Join us, or come on by and check out the rebuild!

Be a part of the rebuild. Be a part of student SUCCESS!

Project Eclipse: Oct 17 Update

Back at it, 17 Car Club members continued the teardown tonight and rebuild of the rear end along with a few other objectives.

First, we lifted the Eclipse to allow for the disconnection and lowering of the exhaust...

It looks like the aftermarket muffler and extension pipe had been welded
one too many times, so we may consider replacing the rough exhaust with
a new set of mandrel bent pipes with a stainless header.

Meanwhile, some students continued with the disassembly of the multilink
rear suspension...

...while others worked on removal of the hood and front fenders and
others started the tedious cleanup of the undercarriage for a layer
of undercoating before the rear end goes back in.

 

Finally, with parent teacher interviews a couple of hours away, we cleaned 

up shop and students headed home to fetch their parents. 

Many thanks from Mr. Da Silva for the dedication of our Car Club students!

Next week, we focus on reconditioning the undercarriage, continued work

on the rear end, and with fenders removed, we examine the physics of installing

the vertical door kit.

Project Eclipse: Oct 8 Update

Yesterday's car club objective was to continue the teardown, and remove the rear end
from the car.

After removing the rear brakes, we found that the parking brake cables were siezed into
the rear backing plates, so we decided to disconnect the cables up front in the car and
pull them through the body.

With the dozen or so student turnout, we worked not only in the car, but under and
around it removing critical subframe components.  We even worked on peeling away
the front bumper skin for access to other parts:

 

We continued working around the car, 

and had a three year auto student from grade 11

help get the rear end ready for removal.

And finally, we had lift off!!!

 

The rear end is off the vehicle and ready to be rebuilt...

 With the rear end to focus on, the Eclipse body can take a break

until we tackle removing the old exhaust next week...

 

In the mean time, our grade nine students continue to recondition other car parts,

including the rotors, which are being bead blasted, painted and resurfaced one by one:

 

Check back next week for more updates!

Project Eclipse: Starting the Rebuild

Well, here are a few pictures and words about the rebuild process...

First, it was hard to get our donor car off the ground. Its was barely
three inches off the ground in some spots...

Car club students figured out how to use three different floor
jacks to get it up enough for the side post hoist arms to raise
it off the ground! Good job crew!

Next, we had to remove those nasty old scratched rims...

Luckily, the tires have lots of tread left, so we will reuse them...

After being put through the bead blaster, the rims emerged 

paintless, with an original aluminum colour:

Then its off to paint. Our grade nine students have done a great

job with blasting and paintwork! Here's an old rim beside a

now reconditioned one:

Then each is finished off with the tire back on, and a custom

Bishop Reding graphic on the spoke. 

Next up, we will tackle the rear subframe. Our goal is to remove

and recondition it. Some of our grade tens are on it...

The coil-overs are out of each corner, and the brakes are off...

Once the emergency cables are removed, the trailing arm

bolts can be removed and the subframe, control arms,

hubs and brakes will be lowered from the car for

reconditioning and reinstallation. 

Check back soon for more pics on the Eclipse rebuild, 

or better yet, drop by and join Car Club at BR! 

Project Eclipse

Updated Objectives List on our BR Spirit Car!

SHSM and car club students are welcome to work on Project Eclipse so that we can
build a vehicle that can help promote student success at our school. 

The BR Spirit Car will also be available to promote special events on the school 
premises by serving as a media and interview point, where coverage of special events 
can be uploaded to the web throught the car's webcast capability.

Here are the details about the vehicle, and a status list of the rebuild:

Vehicle:

• 1999 Mitsubishi Eclipse
• 2.0L DOHC inline 4 cylinder engine (140HP, 130ftlbs)
• 5 speed manual transmission
• Front wheel drive, 2 door 4 seat coupe

Objectives:

• Full vehicle inspection - complete!
• Scan ECU and diagnose errors - complete!
• Recondition, paint and reinstall rims and tires- complete!
• Rebuild mechanical and undercarriage - complete!
• Remove and recondition powertrain- complete!
• Recondition halfshafts- complete!
• Replace wheel bearings- complete!
• Remove, recondition and reinstall rear subframe- complete!
• Remove, inspect and prepare front and rear bumpers- complete!
• Replace exhaust with new header, downpipe and muffler-complete!
• Assemble lowering kit- complete!
• Install lambo door system- complete!
• Rebuild exterior and prep for paint- complete!
• Tint windows and apply promo graphics- complete!
• Install carbon fibre spoiler-complete!
• Install short shifter-complete!
• Rebuild interior with custom dashboard and panels_ complete!
• Design and build rear skeleton for sound system- complete!
• Install sound system and automation- complete!
• Install webcast system with "hot seat"- complete!
• Install underglows- complete!
• Official launch- May 19th, 2016!!

Search the other Project Eclipse posts for constant updates on this initiative.

Come on out and support Project Eclipse!

See Mr. Da Silva in room 114 if you have any questions.