Mark's 1G Winter Projects

[Mark Leasure]

Just got the passenger side door weight reduction done. I weighed the crash beam and it came to just a little over 12 lbs. I took out the electric window motor and it weighed as much as both mechanical crank setups combined. Not that they weigh a lot. I’ll post a pic as soon as photobuckets site starts working again. Drilling spot welds was easy, I just wrapped tape around a drill bit so it could not penetrate too far into the door. I used piano wire to break the adhesive bond between the crash beam and the door skin. Then an air body saw to remove the door metal and an angle grinder to cut the beam. It took around an hour and a half to get it all wrapped up. Not bad for that type of weight savings!
I also took the brake booster out, it was a little lighter than what I expected at around 8 lbs. I need to machine an adaptor bracket to fit up the other master cylinder I ordered.
So far so good!