Latest on Clubman Rally Car - Seam Welding/Gussets

[checkyouout]

Here's a few pics of my project after the last few week's work.

I have now fully seam welded the chassis front to back and all panel joins on the car as well. As well as this I have fitted gussets to the engine bay. http://www.turbosport.co.uk/images/smilies/cool.gif

The repair work is complete on the petrol tank and spare wheel wells and I have also finished the repairs to the front floor pans. The spit I am using to rotate the shell has proved to be the most useful thing I have ever made. http://www.turbosport.co.uk/images/smilies/grin.gif

Welding left now is strengthening and seam welding the strut towers, a small repair to the chassis join (middle to back section), fitting the strut top strengthening plates, putting in the roll cage mountings and firewall, then fitting the new front panel and wings on. Then I'll let the cuts and burns heal up - not for a while yet then! http://www.turbosport.co.uk/images/smilies/wall.gif

The horrible coloured paint is anti rust stuff and will be overpainted.

http://media.turbosport.co.uk/2002/10/20021014222546621212.jpg
http://media.turbosport.co.uk/2002/10/200210142225467194.jpg
http://media.turbosport.co.uk/2002/10/20021014222546475346.jpg
http://media.turbosport.co.uk/2002/10/20021014222546556041.jpg
http://media.turbosport.co.uk/2002/10/20021014222546121146.jpg
http://media.turbosport.co.uk/2002/10/20021014222547765447.jpg
http://media.turbosport.co.uk/2002/10/20021014222547388638.jpg

[Gompo]

Still looking great mate, did you decide on what engine to go for yet?

[Sideways]

Looking good Andy http://www.turbosport.co.uk/images/smilies/smile.gif

That is such a cracking shell you have found there, I can't beleive how little welding you have had to do on it to get it to this state. http://www.turbosport.co.uk/images/smilies/grin.gif
It is worth plating over the small cut outs in the front chassis rails top & bottom, just past the anti roll bar mounts as this will help strengthen it up as these are designed to collapse in an accident so they are a weak point.

Which type of stut top reinforcing are you planning on using, the RS type or the Grp 4 ones?

Keep up the good work

Cheers,
Steve

[checkyouout]

Ey Up Greg,

Looks like the pinto is favourite at the moment - but you never know http://www.turbosport.co.uk/images/smilies/grin.gif

Recently I was nearly talked into putting a red top Vauxhall motor in it http://www.turbosport.co.uk/images/smilies/clint.gif easy power apparently. There's time yet.

Wish I could afford something wild like a cossie motor but I'm dreaming there and also the car is being built on a strict budget.

Cheers

Andy

[checkyouout]

Hi Steve,

Cheers for the words and the advise. good on yer. I'll now weld the crumple zones up as described. Thanks.

I'd got some RS tops to fit. Should I junk em and get hold of the Grp 4 ones then - Gartrac?

What you up then - website's quiet?

Cheers

Andy

[Sideways]

Hi Andy,

The RS tops ones are ok, but the Grp4 ones are bigger and slightly thicker metal. Gartrac can be quite dear but I know Phil Squires @ Rally And Competition Equipment (01782 518631) sells them at £35 a pair + postage.
Also worth puting some skids on the front chassis rail/floor where the front cage leg mounts, as these strengthen it up no end. Phil sells these also (& no, I'm not on commision unfortunately http://www.turbosport.co.uk/images/smilies/sad.gif )

Been mega busy at work lately, been out of the country on and off for the last three weeks, plus the misses has found my visa bill and seen how much money my AP racing brakes have cost me http://www.turbosport.co.uk/images/smilies/shocked.gif , so I've had to do some grovelling to get in her good books before I can get back in the garage again http://www.turbosport.co.uk/images/smilies/wink.gif http://www.turbosport.co.uk/images/smilies/grin.gif you know how it is...
but hopefully I will get in there soon and get some paint on it in the next few weeks.

Cheers,
Steve
www.the-yellow-peril.co.uk (http://www.the-yellow-peril.co.uk)

[mk2]

Its looking mighty good under there matey...When i welded up my mk11,I put double strut tops in, then strenghened up up like the rs..New towers etc. I was toying with the idea of a Shhhh, vaux motor also, but as i dunt rate vauxhalls, well ummm, it had to be the Pinto also...Just blown my 1st gearbox in 4 months....I feel really pleased.. http://www.turbosport.co.uk/images/smilies/grin.gif

[checkyouout]

Steve,

Looks like I'd better pay a visit to Phil then!

Sorry to hear about VISA bill and the missus. Been there - done that myself http://www.turbosport.co.uk/images/smilies/blush.gif

I don't know whether to strengthen the bulkhead like you have on your car. Does yours have spring hanger skids as well? I noticed from the web site that your wings are bolted on - is this just temporary or do you leave then like that for ease of changing - thinking about that first corner I take in mine http://www.turbosport.co.uk/images/smilies/shocked.gif Sorry about 20 questions again. Any idea what I should pay for a s/hand WCXM?

Cheers

Andy

[Sideways]

Hi Andy,
Be carefull when visiting Phil's place, cos I always come away spending more than I intended http://www.turbosport.co.uk/images/smilies/grin.gif + it doesnt help with the fact that I live 15 mins away and visit their place regularly http://www.turbosport.co.uk/images/smilies/grin.gif http://www.turbosport.co.uk/images/smilies/grin.gif

I think I will burn my visa bills infuture before the misses finds them http://www.turbosport.co.uk/images/smilies/wink.gif

No probs with the questions mate, Yes mine has the spring hanger skids, a worthwhile & easy mod, Phil sells these also http://www.turbosport.co.uk/images/smilies/grin.gif
Aye, the wings are bolted on for ease of changing them for when (not if!) I have an argument with the strawbales/tyres etc. I also use the mastic stuff on the flanges when bolting them on, however they are still welded onto the front panel.

I dont really know about the wcxm as its been a while since I brought one, I think I paid £50 for mine but it was in good nick, the touble is finding one that isn't bent, maybe Phil will have one, as they are regularly breaking rally cars for bits.

Blimey, at this rate Phil should be paying me a commision http://www.turbosport.co.uk/images/smilies/wink.gif http://www.turbosport.co.uk/images/smilies/grin.gif

Cheers,
Steve

[duncan]

Andy regarding the vauxhall engine conversion all the bits are out there to do this conversion but they do cost money.
trick parts that are needed are a manta sump modified pickup
bellhousing to fit ford gearbox. exhaust manifold to suit. also you will have to run a dizzyless setup and a magic box to control it.
the upside of this is redtop engines can be had for under £400 and with a set of twin 45's on should make 180+bhp and you will be able to thrash it all day http://www.turbosport.co.uk/images/smilies/grin.gif http://www.turbosport.co.uk/images/smilies/grin.gif
the otherside of this is you could get a very well sorted pinto for that money but it will be gutless below 3K were as the redtop will pull like a train from the word go.

there are a few of the special bits coming on the second hand market these days so the vaux conversion is making a lot of sense if it was me i think thats what i would go for.
see www.sbdev.co.uk (http://www.sbdev.co.uk) for info on the trick parts.
cheers
duncan

[Gompo]

I've been quite interested by the Toyota 16 valve 1.6 motor, it seems that a few people in Australia put these in their MK1/Mk2's, they dont push out great power but seem nice enough engines, probably pretty light, and not as sought after as much as XE's. XE would probably be the way to go though, but obviously the Pinto is a good tried+tested decent cheap engine..
Just realised, my bedroom (was my Mum's until recently) is a very similar colour to that pink stuff you have on your chassis rails http://www.turbosport.co.uk/images/smilies/sad.gif

Cheers, Greg.

[BigDave]

Good work that man!!

Nice Gusset by the way mate...!! http://www.turbosport.co.uk/images/smilies/wink.gif

[checkyouout]

Cheers Dave,

What you up to then? You've been quiet lately. http://www.turbosport.co.uk/images/smilies/confused.gif I've seen loads of enquiries on the web from you for Cossie bits. Have you got another project or somat?

I'd say I enjoyed fitting the gussets but you might get the wrong idea! http://www.turbosport.co.uk/images/smilies/laugh.gif

Cheers

Andy

[checkyouout]

Done a bit more this week (amongst keep running to the bog so progress a bit slow this week)

Dressed up and flattened the bulkhead lip before seam welding it.

http://media.turbosport.co.uk/2002/10/2002102121218637005.jpg

I've also seam welded the strut towers

http://media.turbosport.co.uk/2002/10/2002102121218612843.jpg

And fitted new strengthening pieces (the black things at the bottom of the towers) for the pan supports on both sides of the car. These were expensive for what they are (from expressed panels) I think buy then again they are needed apparently according to my rally preparation book.

http://media.turbosport.co.uk/2002/10/2002102121218414577.jpg

I've finished the repairs to the chassis where the centre joins the back section. I ended up cutting this out and having some chassis profile bent up for me at work to make it a good strong repair.

http://media.turbosport.co.uk/2002/10/2002102121218884742.jpg
http://media.turbosport.co.uk/2002/10/2002102121218395620.jpg

Also I've finished the repairs in the boot to the tank and spare wheel wells. These have been treated to a coat of seam sealer over the anti rust paint to prevent any further corrosion. http://www.turbosport.co.uk/images/smilies/laugh.gif

http://media.turbosport.co.uk/2002/10/200210212121869178.jpg
http://media.turbosport.co.uk/2002/10/2002102121218923870.jpg

Next job is to fit the chassis skids I've just acquired and to get hold of some Grp4 strut top plates and chuck them on.

Also I want to modify the front crossmember so I can get the rad further forward (and fit a bigger one in http://www.turbosport.co.uk/images/smilies/tongue.gif )

[Sideways]

Looking good Andy, coming along nicely now http://www.turbosport.co.uk/images/smilies/smile.gif

I still can't believe how good that shell is you found http://www.turbosport.co.uk/images/smilies/shocked.gif

Steve

[checkyouout]

To further strengthen the strut tops today I have added RS top plates (which should be on the RS shell anyway). I was going to buy some Group 4 top plates as these are a bit thicker and larger but I was told by a bloke from R.A.C.E. in Stoke that the standard RS ones are strong enough so as I had some kicking around the garage I've used them instead.

http://media.turbosport.co.uk/2002/10/20021030223459536297.jpg

Before welding I bolted the top plates to the strut towers to make sure they didn't move when I welded them up. I had also cleaned all the paint off both the inner wing and the top plates (they were secondhand) to ensure a good weld. In order to make them as strong as possible they were drilled loads of times and then these holes were plug welded.

http://media.turbosport.co.uk/2002/10/20021030223459391120.jpg


After this all the plug welds were dressed flat with a linishing pad then both top plates were seam welded round their outer edges before being coated in anti-rust paint.

[RSescorts]

Very nice Work Andy, http://www.turbosport.co.uk/images/smilies/clap.gif

Are you going for the Full gp4 welding/set-up??
(your not far away from that now i see)


cheers..................Ken

[checkyouout]

Thank you for the comments Ken. Much appreciated. Am I right in thinking you run a Mk1 Rally Car? http://www.turbosport.co.uk/images/smilies/cool.gif

Sorry to be a bit thick but I am not sure what the full group 4 set up is. http://www.turbosport.co.uk/images/smilies/blush.gif I am fitting tall turrets, the square ones (are grp4 ones round?). I'm not five linking it .... yet - daren't cut the floor pan! http://www.turbosport.co.uk/images/smilies/clint.gif but I will be fitting a panard rod.

In the next week or so I hope to have my chassis skids and rear spring hanger skids fitted and I am on the look out for a big gearbox tunnel at the moment. I'm fetching a roll cage tomorrow but it's only a six point one - I'm going to triangulate it to the rear turrets and through to the strut top pans though. WCXM is on it's way as well. I'm not arching the car either - at the moment anyway! http://www.turbosport.co.uk/images/smilies/grin.gif

Cheers

Andy

[RSescorts]

Hi Andy,
Are you Planning on Doing Historic Rallying?????

</font><blockquote><font class="small">In reply to:</font><hr />
I'm not arching the car either - at the moment anyway!

[/QUOTE]
How you going to put wide wheels on?????
you'll need them, but if your going to fit them later, run it with no bubbles then when you have an off you can fit them.

Grp4 is the top notch shell and running gear, and very expensive, http://www.turbosport.co.uk/images/smilies/wall.gif
you can prepare a shell to gp4 spec by using the book i think you already have, (Escort rally prep manual) http://www.turbosport.co.uk/images/smilies/wink.gif

Chassis rails and gussetts and strut tower&tops are a must.
but unless your doing Gravel (forest rallys) the shell doesn't take such a big pounding on Tarmac, and on the Loose you'll have a few heart stopping moments, and rear qtr wacks http://www.turbosport.co.uk/images/smilies/grin.gif
Pan hards are a pain to fit, i haven't done 4 link boxes but i'd
give it a shot rather than do a panhard rod, Round Turretts are grp4, thats why they are £60 but are they stronger than square ones????


I've got a MK1 and MK2 rally car, and Autocross MK2 which i'm sharing with my m8 next year for a few events.
but both Rally cars need work on them
MK2 is stripped and ready for new wings and paint job, (it was a droop snoot) was running Pinto soon Vauxhall.

MK1 is 1700x/f is good Strong needs new door but has Sunroof http://www.turbosport.co.uk/images/smilies/sad.gif this is removed and a steel plate is fixed in it's place, it looks crap with the Plate in, i will put a new roof on one day http://www.turbosport.co.uk/images/smilies/confused.gif

I also have lots of other bits and bobs in various stages of modification.

I see you weren't drawn to the Vauxhall XE engine, i have 2,

1 is kicking out 180bhp( almost standard) on 45 Carbs

the other has the biggest cams on hydraulic lifters, Double valve springs, titanium caps, big valves
252bhp on throttle heads, (not bodys) MBE 3d ECU, etc....

Going in MK2 after i kill the standard one http://www.turbosport.co.uk/images/smilies/grin.gif http://www.turbosport.co.uk/images/smilies/grin.gif http://www.turbosport.co.uk/images/smilies/clint.gif

Both engines are needing fitted, the standard one has a Dizzy fitted to the front of the exhaust cam, which allows clearance for the heat/bulkhead.

Cheers...............Ken