Project Eclipse: March 25 Update

It is after the March Break, and we are back at it in Car Club! Project Eclipse is well under way, and hopefully will have its outer shell painted by a community partner very soon.

Until then, we have assembled the transaxle back onto the engine with the clutch, flexplate, and flywheel.

The alternator and drive belt were installed, and although it was a tight fit, we were able to install the powertrain back into the Eclipse. After an unsuccessful lowering of the engine and transaxle in from above, we found it easier to install both components from below, then lift it into place.

With the rebuilt engine now back in, Car Club members were back on the outside of the vehicle as we prep the body to get it ready for paint.
We opted to weld shut three factory holes at the back of the Eclipse. They were originally used by the rear wiper arm, washer fluid reservoir, and broken power antenna.

Now that they are welded, students mixed up some body filler and began the process of filling and sanding the holes to match the body's contours.

In car club, we not only work on Project eclipse, but students also work on other small jobs. One senior student diagnosed his exhaust system leak using the hoist and a visual inspection.

Car Club is also an excellent opportunity for students to get caught up on missed work. Three of our senior automotive students practice the disc brake model before completing the review sheet.

Back at the Eclipse, senior Car Club members work on the tedious job of removing rust from the inner lip of the doors so they can be painted.

After the starter motor is installed, the clutch slave cylinder is cleaned up slightly and repainted. It will need a new hydraulic line fabricated to replace the badly corroded one.

Next, with the transaxle in and secured to its mounts, students remove the suspension yokes to make way for installation of both axle shafts.

And before this week's session ends, we have a chance to test fit the new header that we were able to get our hands on.  Shiny!!!

Well, it's time to clean up after another week of hard work. The BR Spirit Car sits quietly, another step closer to its rebirth!
See you next week!!!

Mr. Da Silva

Project Eclipse: March 11 Update

Hey everyone! As we head into March Break, the Car Club slowed its rebuild objectives of Project Eclipse as we finished most of the engine rebuild. It now sits ready to be hoisted and mated to the clutch and transaxle before it is lowered into place in the Eclipse.

What a difference from when it was first pulled...

Now in the meantime, senior Car Club students demonstrated their abilities by replacing disc brakes, touching up paintwork, and working on sound systems for the junior Car Club students to see.
By passing on these valuable skills to the next generation of kids going through the SHSM program at BR, the skill base in our students will continue to grow and excite students about success in the trades!

Now it's time to take a rest while students spend time with family during the March Break.
We will be back at it the following week, hopefully in time to check out a few goodies we have ordered to make the Eclipse cooler than ever!!

Have a safe March Break everyone!

Mr. Da Silva

Project Eclipse: March 4 Update

Sorry for the late post everyone, but here's the continuation of our BR Spirit Car rebuild.

While Car Club students continued on the Eclipse rebuild, we had some junior students help diagnose some electrical issues on a graduate student's sports car. His sound system was not functioning properly and we needed to get assess what has to be straightened out in order to make the amplifier work. Next car club will have us delve deeper into the repairs of the wiring so that the subwoofer can start to shake his car again!

This diagnosis is good practice, as we will be offering a NEW Mobile Audio and Electronics course for next year. Students who enrolled for this course will be excited to work with sound systems and learn to customize their vehicle in many cool ways, all while learning safe tool and work practices! We will definitely show off our skills next year when we rig the interior of the Eclipse with the coolest audio and video system ever!

Now, it was back to more sanding of the doors and rear fenders on the Eclipse to prep the body for minor body work before its paint job...

Again, with every large project, setbacks are no stranger...and we discovered THREE stripped threads on the Eclipse's camshaft bearing cap holes!!!
After teaching the class about the advantages of Heli-coils, Mr. Da Silva watched as one of the senior engine rebuilding SHSM students successfully repaired the stripped hole with a Heli-coil kit. Great job!!

If the stripped holes could not be repaired, the entire cylinder head might have to be thrown out and replaced! It's always a good idea to learn to be resourceful, so you can save money AND learn to fix problems as they arise! That's what learning is all about!

A few other Car Club students helped to reassemble the intake manifold and fuel rail assembly with new gaskets and O-rings, and now with a new paint job, the induction system is looking as sharp as the rest of the car.

Well, stay tuned for one more Car Club session before March Break. We will tackle the Subaru Impreza amplifier problem as well as get more of the Eclipse engine back together, with new gaskets and timing belt.
Keep those engines running, and we will see you soon!!!

Mr. D.