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.

Project Eclipse: Feb 25 Update

Car Club students are continuing on with Project Eclipse by focussing on the exterior shell as well as the powertrain rebuild.

With the engine and transaxle in different areas of the shop, each piece was cleaned, washed and dismantled to a point where they could be prepped and painted. Semester two's senior engine rebuilding class will work on inspection and reassembly of the engine's many delicate parts.The engine block now sits close by with a fresh coat of black while the transaxle takes on a new shade of aluminum.

During the drying process, other students take turns roughing up the Eclipse's exterior finish in preparation for its paint job.

Our senior students detailed some smaller engine accessories, from the alternator and pulley to the harmonic balancer.

Other students continued to resurface the engine's top end and the oil pan, while the fuel injectors and fuel rail were given some attention during the rebuild.

And while an engine plate takes a resurfacing, the engine block gets its pistons installed and connecting rods torqued to spec.

As the powertrain comes together, we will search for a community partner to contribute a paint job for our Bishop Reding Spirit Car. With every step we get closer in progress, the final goal becomes more and more exciting!
Check in next week to see how much closer we get!!

Project Eclipse: Feb 18 Update

Today Car Club members were getting used to their new semester course load, and a few less members attended to continue on the BR Spirit Car. With the present members working to some classic rock music in the background, we focussed on engine disassembly and the bodywork.

Junior and senior students worked together, separating the cylinder head from the 2.0 litre four cylinder Mitsubishi engine so that each piece could be reconditioned, painted and reassembled.

To try to curb the annoying issue of crushed adjuster bolts on the lambo doors, we decided to purchase grade 10 bolts to help minimize crushing of the adjustment parts. We don't want the cool vertical doors to fall out of alignment every time the door is operated too quickly.

While the front fenders were off again, another Car Club member lightly sanded some rusty spots inside the fender, then applied a cost of rust paint to help extend their lives.

At the other end of the car, one of the grade nines continue to rework some dents to even out the body contours.

We also had an opportunity to shampoo and degrease the transaxle, making it cleaner for it's later reassembly into the car.

The Eclipse now sits with a more familiar facade, given more panels are being installed. We hope by next week, the majority of Car Club will be focussed on sanding and smoothing the Eclipse's body. Soon enough, the BR Spirit Car will be looking for a fresh coat of paint before its powertrain is dropped back under it's hood!

Slow and steady wins the race.. We will catch you next week with more hard work on Project Eclipse!

Project Eclipse: Feb 11 Update

Car Club is back at it, and we are continuing Project Eclipse with a little more focus on the chassis as well as starting the dismantle of its power plant!

Our senior level Engine Rebuilding course has commenced, and the SHSM students have looked over the little four cylinder engine and are eager to crack it open. Along with some grade 9 and 10 Car Club members, we began to disassemble the 2.0 litre engine's external components to ready it for lifting onto a stand.

The external brackets and pipes are removed and reconditioned. The valve cover is removed and the camshaft components are disassembled and set aside in order.

The engine is now on the hoist and we examine how to remove the racing clutch in order to set the block and head on a stand.

Now off, one of our SHSM engine rebuilding students removes all gaskets from the valve cover in order to clean and sandblast it for a new paint job. Detail and presentation is key!














Another new entrant to our SHSM program uses his skills to clean and recondition cooling system parts...The new finish will add to the great detail of the engine under the hood:

 




















The engine covers are off and soon the timing belt and cams are removed. Smile, engine!






















Meanwhile, back at the Eclipse, some students continue to clean small bolts and other hardware to continue reassembling parts onto the outer body. This is a slow process, but worth the time.

We are trying to move further along the tedious job of reconditioning the car's outer skin, smoothing out dents and cracks so that the final paint job will gleam with minimal defects. This is currently the longest process of the rebuild, but with art and sculpture, patience yields results! So we'll keep at it.

Before the end of car club, some students get the wiper motor, painted wiper cover and hood all set into place. 

By continuing to test fit more pieces, we can see how the Eclipse is piecing together on its rebuild. It is absolutely crucial that all external pieces fit together as seamlessly as possible. 

One recurring issue we are having is the vertical doors. They are VERY sensitive! If they are bounced, or not lowered SLOWLY, they instantly pull out of alignment, and warrant a one hour removal of the fenders for readjustment. We decided to pull the adjusting bolts and find a higher grade steel replacement to minimize crushing of the adjuster when the door is closed too quickly.

The most important part of working as a team towards a goal, is sharing ideas and problem solving when necessary in order to reach that goal. The BR Spirit Car will be one great ride when we are finished! Check back soon for our next update!