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Thread: GavinR's Mk2 Stage Car - DVY

  1. #41
    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Stage Car - DVY

    2003-2004

    Early in the year, DVY had gone off to Melvyn Evans for a general tidy up and came back painted in a lovely blue colour donated by a friend

    By the time the engine was sorted, it was too late for a shakedown rally, but we did Builth in Fly as we hadn't done a rally since Millbrook the year before

    Then, after quite a few laps of the local lanes, it was back to West Cork for the 25th Anniversary of that event. Seeded lower down at 90 we had a cracking 2 days rallying, DVY was running perfectly, and except for nearly rolling it into a ball on a flat 4th gear right hander and putting a tiny crease in the new paint job at the next bale chicane, we were very happy to finish 43rd overall and 6th in class out of the 150 entries. This was a lot worse overall but the same class position as in 2000 showing how many more WRC cars were running at the head of the field

    The only time DVY used to lift a wheel was in Ireland due to the softer springs


    After that I entered the Chieftan Sprint at Longcross in May, winning my class easily and set 3rd FTD behind Steve Broughton (of SBD) and his friend double driving their 1700cc Vauxhall powered Westfield, which had as much power as I did

    Nice pic from the Sprint


    But Millbrook was cancelled in 2003 and with the court case and working in Bristol instead of London since July 2002, money was a bit tight, so DVY stayed in the shed for the rest of the year

    In 2004 things weren't much better, and even though David and Richard offered to help with the expenses for West Cork we decided we couldn't afford to go, so it was May 2004 before DVY came out again

    There was no need to tax her, so I did a few laps of our 9 acre field to make sure everything was running perfectly


    Then it was off to Millbrook where we bumped into Cath Woodman for the first time in years, who was co-driving for Windy on his first ever Stage Rally

    After a good battle all day, Windy and Cath finished 19th / 3rd while we were 22nd / 6th only really setting good times in the afternoon when I'd remembered how to drive

    And the usual jump shot


    Soon after Millbrook, Carrie and I sat down and made the difficult decision to sell DVY, the mortgage being more important than having 2 rally cars (FLY will never be sold ) and I joined Turbosport as part of trying to sell her

    The price was £15k and we had a few people round, one in particular I remember was looking for his first rally car, but after I took him for a ride up the main road to the local garage, turned round and came back drifting round the corners flat in 4th, he decided DVY was too quick for him

    A few months later and still no buyers, Carrie put an ad on British Rally Forum asking for offers for all or parts of DVY and after a few calls, Rupert Lomax came round one Friday afternoon in August, liked what he saw and came back 8am Saturday morning with £8k and helped us remove the engine, gearbox, seats, harnesses, exhaust, radiator, fan, etc and took her home

    In October that year he entered his local forestry event, the Cambrian Rally, and was leading his class before his John Hardman Vauxhall engine had problems (I said he should have bought the Cossie )

    And a pic of Rupert on that event
    GavinR

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  2. #42
    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Stage Car - DVY

    2005-2007

    When Rupert had bought DVY, he had mentioned doing the Barbados Rally Carnival next summer and sure enough he was there - DVY now painted to mach his Plant Hire business


    In August, Rupert entered DVY on the Ranges Stages at Trawsfynydd and came 1st overall

    Then in October he was back out on the Cambrian Rally, this time retiring after a nasty encounter with a tree stump


    After this we heard a lot of rumours about how the damage was so bad that Rupert had to re-shell DVY, but when I phoned him in February 2006, he said it hadn't been that bad, just needing a new wing, door skin and a bit of panelbeating to the roof

    I'm not sure if Rupert and DVY did any more rallies between then and late 2007 when DVY had been modified to run in the Historics with a Warrior Pinto and proper AP brakes, no roof scoop, etc, and was out on the Track Rod and Cambrian Rallies - this pic is from the Cambrian
    GavinR

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  3. #43
    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Stage Car - DVY

    2008

    In early January I had a text from a friend saying they'd seen DVY on eBay and a link was put up on TS as well

    Rupert had always talked about building a Mk1 and he had finally got round to it, taking everything off DVY that would fit a Mk1 and selling DVY as a shell on eBay



    Carrie had left in Jan 2007 so I wasn't worrying about money as much and I decided to try and get DVY back

    After speaking to Rupert, I was happy DVY was as good a shell as when I'd sold it to him - he'd cut the bulkhead to fit the Vauxhall, fitted some extra bars to the cage, strengthened the panhard rod mount and fitted proper tank stands in the boot - he thought she would go for £3.5k, I thought more like £5k for a shell in that condition, but I bid £6k as it was DVY

    A few other people were bidding as well, and at the last second an Irishman bit £6k as well but lost out as I'd bid earlier

    When I collected DVY, Rupert had dug out some of the bits he'd removed to make DVY into a forest car - the original 300/120 Bilstein inserts which DVY was built with, some TCA's and compression struts, the dash clocks and steering column

    DVY then sat at my place in Wales for a few months and I fitted enough bits to make her rolling, and then was put into storage at my parents house while I moved to Bristol

    By October I'd finished all the events in Fly and brought DVY back to Bristol to be painted

    Before - took me hours to remove all the stickers and clean all the adhesive off


    After


    And they painted the engine bay as well - Fly's original Pinto was just fitted to get it out of the way - it won't be staying


    Today I've been rebuilding my other very narrow atlas, tightening the diff, fitting new shafts and very long wheel studs - I'll have to run thick spacers to clear the coilovers

    Looks like I'll have a busy winter getting her ready for some rallies next year
    GavinR

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  4. #44
    Racer 4drmatt's Avatar

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    Re: GavinR's Mk2 Stage Car - DVY

    another cracking read?

    so what is the plan for the car?

  5. #45
    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Stage Car - DVY

    Quote Originally Posted by 4drmatt View Post
    another cracking read?

    so what is the plan for the car?
    Plan is to rebuild to similar spec as before for Tarmac Stage Rallies - next year DVY and FLY will have to share engines and gearboxes though
    GavinR

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    Racer Decade Plus User PERKY's Avatar
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    Re: GavinR's Mk2 Stage Car - DVY


    Great read
    Spectated on many of the Welsh events you mentioned back in the 90's early 00's.
    Keep us updated on the progress

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    Re: GavinR's Mk2 Stage Car - DVY

    Quote Originally Posted by GavinR View Post
    Plan is to rebuild to similar spec as before for Tarmac Stage Rallies - next year DVY and FLY will have to share engines and gearboxes though
    That'll be fun again

    Give us a shout if you need a hand when doing any swaps proir to events

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    Re: GavinR's Mk2 Stage Car - DVY

    brilliant thread best of luck getting the car back together

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    Way too much free time Decade Plus User Retromotorsport's Avatar
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    Re: GavinR's Mk2 Stage Car - DVY

    " One man and his Car "

    there ya go Gavin, thats the title for the book, you've got a best seller there

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    Re: GavinR's Mk2 Stage Car - DVY

    Great read Gav

    Look forward to seeing DVY back in action
    Screaming 1300 mexico rep

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  11. #51
    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Stage Car - DVY

    I've been making slow progress on DVY due to having to work a few weekends, but last weekend I got the front calipers and discs built up

    I'd bought the calipers with blank lugs as they are cheaper like that and spent a few hours maching them with the help of my landlord Mike's metalworking machines

    I also fitted a probe for the tripmeter and a heavy duty quick rack from Barney





    GavinR

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  12. #52
    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Stage Car - DVY

    I'd bought some Wilwood Spot Calipers a few weeks back to try and make a proper mechanical handbrake but they looked a bit difficult to mount so I made a template out of cardboard and gave it to Mike

    A few days later he'd cut 2 of these out of 3mm plate with his plasma cutter

    I welded them onto the axle today and everything fits nicely




    And the diff is now nice and tight after I added a couple of shims

    This week my brake pipes will arrive, hopefully a pedal box and some wiring bits and pieces (I've got most of a standard Mk2 loom so it shouldn't take much) and I've got a few days off before Christmas so it should all come together quite quickly

    And I've entered the South Downs Stages at Goodwood next Feb in her so I'm got something to aim for now
    GavinR

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    Re: GavinR's Mk2 Stage Car - DVY

    Excellent read and its cool that you got the car back

    looking forward to seeing it finished and back out

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    Re: GavinR's Mk2 Stage Car - DVY

    Quote Originally Posted by GavinR View Post
    And I've entered the South Downs Stages at Goodwood next Feb in her so I'm got something to aim for now
    Need a navigator Gavin?

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    Mechanic JonSegger's Avatar
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    Re: GavinR's Mk2 Stage Car - DVY

    Quote Originally Posted by GavinR View Post
    ....And I've entered the South Downs Stages at Goodwood next Feb in her so I'm got something to aim for now
    I'm entering that one too... so I've also got something to aim for....

  16. #56
    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Stage Car - DVY

    Quote Originally Posted by JonSegger View Post
    I'm entering that one too... so I've also got something to aim for....
    It'll be good to see you out again

    I had a few days off last week and have been making slow progress - not as much as I'd hoped as everything seems to be taking twice as long as it should - various holes in the bulkhead I need had been welded up including the large hole all the wiring goes through and my extra clutch cable tube (specifically designed to miss a cossie manifold) had been cut off flush and filled with weld - after about 3 hours of drilling, grinding and welding everything was back to how it used to be

    I couldn't find a complete escort wiring loom in my shed but I found about 2/3rds of one so I spent a couple of days modifying and extending it to fit and its now installed


    All the lights work and the wipers and washers, but not the indicators and I refitted the rear spoiler and number plate to make her look more like a car



    The axle's all fitted with the calipers and brake pipes and rear suspension


    And the front brake pipes are done, just got to mount the reservoirs properly and fit the pedal box, hydraulic handbrake, etc
    GavinR

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    Way too much free time Decade Plus User Retromotorsport's Avatar
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    Re: GavinR's Mk2 Stage Car - DVY

    Getting there Gavin, but remember to take the 25th off, i got told off once for being in the workshop Christmas Morning

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    Re: GavinR's Mk2 Stage Car - DVY

    Quote Originally Posted by Retromotorsport View Post
    Getting there Gavin, but remember to take the 25th off, i got told off once for being in the workshop Christmas Morning
    Gary - I thought you said I could pop mine down to you at Christmas?

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    Spanner Monkey Arieke's Avatar
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    Re: GavinR's Mk2 Stage Car - DVY

    A Nice read

    I would love to come and watch. Hate living in belgium :s

    Ford Taunus Going RS2300 16v with 48s!!!

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    Re: GavinR's Mk2 Stage Car - DVY

    Nice to see her coming back together. You'll have to change/add some pictures to you sig soon

    re-applied for my competition licence at the weekend

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    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Stage Car - DVY

    Quote Originally Posted by Tazman View Post
    Nice to see her coming back together. You'll have to change/add some pictures to you sig soon

    re-applied for my competition licence at the weekend
    Good as you're on the Entry List now

    Got some more done over the New Year...

    Made another Fly Off Handbrake out of a standard one and a small bit of 4mm plate for the locking mechanism (the standard part is too hard to drill through)


    Bolted it inside with the hydraulic cylinder and the other handbrake


    And the pedal box (thanks Clint ) now fits perfectly after jacking out the dent in the bulkhead, so the brakes are all plumbed in now


    And I spent a few hours drilling holes in the engine bay so everything fits in the same place and I fitted the air horns & electric fan - wired them up and they work , bolted the reservoirs in place, cut a large hole for the throttle cables, fitted the ignition modules that trigger the coils and the headlights are in as well


    Next weekend, Dave is coming down to help swap the engine and box from Fly
    GavinR

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    Re: GavinR's Mk2 Stage Car - DVY

    Looking good Gav. Do you think you'll have it all done in time?

    Paul

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    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Stage Car - DVY

    Quote Originally Posted by Paul C View Post
    Looking good Gav. Do you think you'll have it all done in time?

    Paul
    Plenty of time

    Dave came down Friday night and we spent a very successful Saturday working on Fly and Dvy

    Starting in the morning with the engine, box and dry sump tank and pipes in Fly, by lunchtime it was all out

    Then the afternoon went even better, fed the oil pipes through from the boot to the engine bay (still full of oil and attached to the tank), dropped the engine in, got the gearbox lined up on the jack, I tilted the engine just the right amount, asked Dave to push and it slotted straight in, without any of the usual pushing and shoving

    Then I drilled new holes for the gearbox mount through the floor (I think the original gearbox mount went to Jon with the first sequential box), while Dave fitted the starter, flywheel cover plate and clutch cable plate and we called it a day at 4:30 so Dave could get home at a sensible time

    So big thanks to Dave for giving up his Saturday to help me out
    GavinR

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    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Stage Car - DVY

    Sunday I decided I would start at the front and work through to the back of Dvy, finishing everything as I went

    So now the engine bay is 99% finished, just needing to seal the bulkhead where the oil pipes pass through and run the large cable to the starter, fill and bleed the brakes, but everything else is done, even the rad is full of antifreeze






    The interior still needs some work - pedals, gearstick, gauges, cut out switch, seats, harnesses, etc


    And the boot needs a bracket for the dry sump tank, the battery and the fuel tank from Fly
    GavinR

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    Re: GavinR's Mk2 Stage Car - DVY

    getting there
    keep at it

  26. #66
    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Stage Car - DVY

    oo definately looks weird without the stripes!! Am all ready to help put them on next weekend!

    carrie
    GavinR

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    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Stage Car - DVY

    Got a couple of hours in this evening and fitted the throttle pedal

    I was going to put Fly's clutch pedal in Dvy but I'd been worried for a few events about it twisting as I press it, and the new pedal box had come with a brand new clutch pedal, so I started with that and fabricated an identical one - they're offset so the clutch cable runs inside the manifold and doesn't melt



    I also filled the brake system with fluid and pumped the pedal until fluid came out of the bleed nipples and left it like that, just need to do it properly when everything else is done
    GavinR

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    Re: GavinR's Mk2 Stage Car - DVY

    Good work Gav. i might pop along to Goodwood to see your battle with Jon!!

    Paul

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    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Stage Car - DVY

    The plan for this weekend was to get DVY running, and at 8pm tonight she was running

    Still got a long list of jobs to do before Goodwood and a few evenings work this week before the MOT next Saturday

    Finishing touch to the engine bay - a nice Ralloy strut brace


    A lot of progress inside - fitted the extra gauges, made a panel for the cut out switch, clipped the fuel pipe and battery cable to the tunnel and fitted the gearstick and display. The seating position needs a bit of work though


    And the boot with Fly's fuel tank and pumps, mounted on the tank base that Rupert had fitted. Battery needs bolting down and a bracket making for the dry sump tank
    GavinR

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    Mechanic JonSegger's Avatar
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    Re: GavinR's Mk2 Stage Car - DVY

    Jeez you don't hang about do you...! Excellent work.

    Looks like we're working to the same project plan... I also had mine running at the weekend and am planning to MOT it on Saturday.

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    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Stage Car - DVY

    After a busy week, DVY was finally ready for the MOT so I trailered her over to Melvyn's and she passed without any trouble

    Then I went to see Carrie and Guy who spent the rest of the day helping apply the stripes and we got both sides done

    Back home today I did the roof and took some pics and DVY now looks like DVY again, not just a plain white Escort





    Still a few jobs to do before the rally, including lowering the rear by about 3" and the front by 1", and David might appreciate a seat as well
    GavinR

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    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Stage Car - DVY

    THATS MORE LIKE IT - YAYYYYYYYYYYYYY

    carrie
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    Pit Crew Decade Plus User merp0's Avatar

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    Re: GavinR's Mk2 Stage Car - DVY

    That looks the part now

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    Re: GavinR's Mk2 Stage Car - DVY

    Very nice indeed, it certainly looks the part
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    Way too much free time Decade Plus User Retromotorsport's Avatar
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    Re: GavinR's Mk2 Stage Car - DVY

    Well done mate

  36. #76
    Racer Decade Plus User Joe-Tait's Avatar

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    Re: GavinR's Mk2 Stage Car - DVY

    Looks great Gav
    Screaming 1300 mexico rep

    http://i26.photobucket.com/albums/c139/gsijoe/untitled-21.jpg

  37. #77
    Bodger Tazman's Avatar

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    Re: GavinR's Mk2 Stage Car - DVY

    Quote Originally Posted by GavinR View Post




    Still a few jobs to do before the rally, including lowering the rear by about 3" and the front by 1", and David might appreciate a seat as well
    Yeah think a seat might come in handy

  38. #78
    Mechanic lee 1's Avatar

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    Re: GavinR's Mk2 Stage Car - DVY

    Looking good

    Good luck for the rally

  39. #79
    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Stage Car - DVY

    I'd been having a bit of a nightmare with the seats - when I went for the MOT I'd just bolted my seat to the seat rails but it was too high and too close - the homologated seats I've bought have nice alloy subframes but this adds a couple of inches to the height and they only just span the seat rails so I can't move the seat back

    So the only solution was to remove the rear seat rail and bolt directly through the floor, with large plates to spread the load and some spacers to allow for the uneven floor, my seat was finally in the right position and the harnesses fitted on Saturday before I had to stop and go pot collecting at the Midland Speed Awards night

    Sunday I sealed up the front and rear bulkheads around the oil pipes, bolted in the plumbed in Fire Extinguisher and made a decent battery tray

    Tonight I finished off the battery mount with some solid clamps, and mounted the 6 Fire Extinguisher nozzles - 2 in the footwells and 4 spread around the engine bay - for Irish events you need FIA Homologated Extinguishers so I've gone for some Zero 360 gas ones (I don't trust foam )

    Then I drifted slowly home in the Scorpio Estate, finding some nice quiet roads with virgin snow on them

    Tomorrow night I should have the pull cables fitted and hopefully the passenger seat, harnesses and hand held extinguisher

    We're seeded Car 7 on Saturday, just ahead of a genuine RS200, and Jon Segger is at 16
    GavinR

    http://www.turbosport.co.uk/signaturepics/sigpic2999_8.gif

  40. #80
    Bodger Tazman's Avatar

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    Re: GavinR's Mk2 Stage Car - DVY

    Quote Originally Posted by GavinR View Post
    Then I drifted slowly home in the Scorpio Estate, finding some nice quiet roads with virgin snow on them
    Sweet

    I'll get to play with my Impreza one day

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