83 Mondial QV - EV conversion project using Tesla LDU

I'm not proud. I know the quality of my welds. The mondial is at my friend's bodyshop and his lead tech has agreed to lay better beads for my welds.

I have considered upgrading to a 240V welder. It's one reason to consider putting an outlet on the wall next to my lift where the charger will eventually live.

 

Q: Are these fender badges "real" Ferrari badges or just "real enough"?
- Some previous owner stuck them to the front fenders of my Mondial and I pulled them off (cut off using string) prior to painting.
- I don't really love them so they won't be going back on my car.

They are made of metal (96-97grams on my kitchen scale) and are slightly curved to match the vehicle fenders vs being flat plates.

If they are legit though, I have no qualms about selling them off.
The alternative is to stick one on a gold chain and wear it around my neck for halloween.

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Q: Does anyone have a 3D scan of the front and rear spindles?
- I already know the distance between the two mount points for the caliper bracket because I have the stock caliper braket in hand.
- I'm specifically interested in knowing the distances:
a) in the z axis between the face front face of the caliper bracket mount point and the front face of the spindle (where the rotor rests)
b) the thickness of the caliper bracket mount point
c) the distance between one of the caliper bracket mount point centers and the center of rotation of the hub itself.


My Mondial is in the paint shop still and it's not as easy for me to take these scans.
Since the "complete" big brake kit I purchased had the wrong brackets and rear rotor hats and no replacement was forthcoming, I went in a different direction and am piecing together my own big brake kit from wilwood components. I have approx $4400 into new setup already but one benefit (for me at least), is that the rear parking brake it no longer a mechanically actuated drum an electronic servo controlled mechanism. All I need to do is make 6 brackets (2 for the front spindles, 2 for the rear spindles, and 2 for the EPB).

This piece of trick kit is ~$1200 by itself.
https://www.wilwood.com/brakekits/BrakeKitListRear?mincatdesc=Electronic%20Parking%20Brake%20Rear%20Retrofit%20Brake%20Kit

I won't send any brackets out for production until I confirm measurements on my own car first BUT if someone has these numbers (or a 3D scan), I can at least CAD up a rough estimate of what this looks like and save a little time.

 

It's been a few months since i posted but I didn't have much to report as my friend took my Mondial into his shop when things were slow, and then they got busy again. His uncle is now working on the car (one of the guys with all the old school steel working skills vs the "kids" who are better at working aluminum).

1) Easiest fix was in the back corner near the rear lights
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2) I knew the door sill plates had rust under them so this wasn't unexpected. Cancer seems to be on a single plane so the plan is to cut it back and weld the neplate in.
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3) I also didn't realize that the vinplate near the door latch was a plate covering another plate. The uncle removed it (I think it was riveted on) and found this bit of cancer to fix. Other side was fine.
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4) Now I know the front end was in an accident (this was not an expensive Mondial) because the car came with a Mondial 3.2 front bumper. Apparently the repair included a bit more bondo on the front passenger fender (tip was bondo vs steel). They'll add more sheet steel and fix this. We had a discussion and while the section of the repair will be more expensive than originally expected, its not a significant undertaking and they were already cutting/filling in the fender corner lights anyway. He's not making me a new fender NOR is he just slapping more bondo on there and calling it a day. I'm not going for Ferrari Classiche certification on this car so whatever.

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Since they are actively working on this car, I'll probably get it back by the New Years. After that, its all on me to get the car running

On the big brake kit front, my buddy started helping me CAD up the brackets necessary to make a big brake kit out of Wilwood components. What we learned is that the bolt holes for my chosen Wilwood calipers are only slightly farther out than the stock position so the bracket we need to fab will need to have the holes offset. I'll post pictures of the 3D print we'll make to test fitment but what this means is we'll have the calipers mounted 10 or 15 degrees higher than the stock calipers. In other words, if the calipers mount at 9 o'clock on the FR corner of the car when looking at the brake face, the Wilwood calipers will sit at approx 10 o-clock.

Pic of the rear. The little guy at 3 oclock is the electronic parking brake.
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We were originally going to make a banana shaped bracket with 2 holes to mount to the stock spindle and 3 holes for mounting the wilwood calipers so the same bracket can be reused for either side of the car (L or R). However, the delta in cost between 2x the same bracket and 1x each of the unique brackets from the chinese CNC house is $5 so... I'm probably not going to bother. If I shomehow break a specific bracket, I'll just order a new one from the same CNC house.

Total cost so far is $4540. The brackets (6x of them -- 2 front, 2 rear, 2 ebrake) will cost maybe $250. I'll also need custom SS brake lines which will run another $250 for 4 made locally. So $5K for my own BB kit. In hindsight, I could probably have saved $250 by not springing for the fancy black oxide coating (the surface bits will wear off but the slots will remain black and it prevents rust forming inside the rotor vent channels. The reality is I needed to hit $1K per jegs.com order to use a Q3-2024 coupon and I forgot I needed brake pads which would have helped me push over the $1K limit instead of springing for the fancier rotors). Oh well.

PS. Yes, my buddies uncle is fixing my booger welds

 

Oh, I also decided to go textured body color (azuro hyperion, or Corolla blue-gray as my friend called it) for that black stripe at the bottom of the door. I figured I should go this route if the front and back are going to the body colored as well (except for the very bottom lip of the 3.2 front bumper AND the exhaust valance at the rear which will now just cover my LDU support bracket.

 

Its Jan. We took my kid skiing for a few days, saw my mother-in-law, oh and I caught covid again. Sigh.

The good news is that while I was away, more progress was made by my friend's body shop. They found a bit more bondo than they expected (I wasn't worried, this was a bottom dollar Ferrari after all) but they added metal and welded things up nicely.

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This last one is a work in progress. You can see that they are starting to fill in the gap between the roof panel and the roof. It is curious though that some previous owner had skim coated bondo on the top panel. Dunno.
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