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Thread: And now for something completely different, Rover Sd1 Stage rally car

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    Spanner Monkey

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    And now for something completely different, Rover Sd1 Stage rally car

    Hi all, here is my new stage rally car project, I am intending to build her on a budget but wewill see how that goes.

    Spec is ever evolving, but the V8 is staying, has to stay at 3500cc so I can get her logbooked, I am not sure what will be happening with the rear axle yet as parts such as LSD's and CWP's are rare as. Front suspension is as Rover intended, but Bilstien coilovers, Compression struts and eccentric top mounts, rear suspension again depends on axle choice, she may get six linked yet. Gearbox......well it will have to be a T5 as they are direct fit from a TVR, but I would maybe likle to get hold of one of those Glebe S/Cut Dog boxes. Engine, well I have already got some Omega pistons, group "A" rods and a Cross bolted block. Next on the shopping list will be a cam, lifters, some heads and to top her off, either Quad dell'ortos or throttle bodies.

    Anyway, some pics..............






    Thats gotta go............

    Gone......and staying gone till the cage is fitted..........

    Sound deadening removed..............

    Some wheels I have aquired.............








    Spot weld drilling......my favorite [xx(]

    Roof on for a trial fit, not being final fixed until the cage is welded in...........

    Thats better, "Moonroof" gone [8D]

    The stripdown continues......

    Wiring loom out......

    Impressive amount of droop/travel.......

    This cage is only a mock up, bought very cheap but won't be the finished item, I am having an exact replica of the Group A cage built eventually..........





    Some pics of the rot spots in the bulkhead, had a weigh up yesterday and I will definitely treat it to a bulkhead panel........



    At least the inner wings and chssis rails are all sound........

    The underside is extremely good..........


    started removing the bonnet, then took the drivers front door off, and this happened!..........


    So finally back down, doors off etc.........







    Aerial hole filled.........

    Fuel filler filled.........

    As this is the set up I intend to use.............

    And finally, the big one, cage done, really pleased with it.....................


    Last edited by Sunbmw; 25-07-2010 at 20:01.
    I fear understeer...

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    Spanner Monkey

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    More pics................

















    I fear understeer...

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    Pole Position Decade Plus User morcheen's Avatar

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    i would fear the understeer for you too
    my mates workmate used to rally one in the early 90's.these pics are from the chobham stages,he was understeering all over the place !



    i like your alfresco garage
    Last edited by morcheen; 25-07-2010 at 20:58.

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    i remember watching bob fowden across epynt on many occasions, sound was magic and oversteer was aplenty. also tony pond as i recall ? keep at it

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    Lovely job. Keep the updates coming.

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    great stuff, i remember when SD1 was considered the bees knees, keep the updates coming, with the right set up and V8 grunt theres no need for one to be an understeering monster

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    Spanner Monkey

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    Thanks guys, will be trying to get the welding done then get some paint on her as, as you can see, she resides outside at the mo (garage is on it's way). I intend to replicate the Computervision livery on it.

    Watch this space............................
    I fear understeer...

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    really interested to see this one coming along. had a few of these in the 80's and 90's. with decent shocks and springs they handled like a go-kart.
    the sound of it in the forests will be amazing

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    Mechanic bodger rogers's Avatar

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    i love it! this cars gonna be proper 80's cool just try not to wrap it around a tree like tony pond did.
    if it aint broke, break it!

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    Mechanic bodger rogers's Avatar

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    Re: And now for something completely different, Rover Sd1 Stage rally car


    this looks nice

    good luck with the build mate
    if it aint broke, break it!

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    always had a real soft spot for the old SD. Cant wait to see it burning up the road!!!

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    Can you just make a nice touring car instead like that Texaco one

    It looks class
    Screaming 1300 mexico rep

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

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    nice work mate

    good to something different

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    Well, productive day and a bit, got most of what I wanted to done, then ran out of welding gas! "Oh bother!" i said [:p].

    Anyway, pics as usual............

    Firstly, fit this...............



    In this hole here........





    Offered up for a trail fit before welding....







    Stitched in..........



    Purists will note that I haven't really done it the "Factory" way, by unpicking all the spot welds and re-spot welding it in, instead I hav just fitted part of the panel and stitch welded it in to match the rest of the seam welding, it also over laps at the bottom where it meets te chassis rails effectively double skinning it for added strength..............





    I also wanted to finish off doing the seam welding on the underside, so I can get some paint on the inside, not one for welding upside down................











    Last, but not least, when I ran out of gas, I attacked a job that I had been avoiding, drilling the original seat mounting brackets off.........

    I fear understeer...

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    Spanner Monkey

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    Update guys, been very busy, holes in bulkhead welded.............



    Note that I have also welded the holes for the heater pipes, that won't be returning!

    More seam welding..........





    Anyone like to guess where the exhaust may be exiting from?..........



    Right here...........



    Note that the welding isn't finished, tis was the point where me gas ran out!






    Some bits of extra cage that I wanted to add, I should have asked the cage guy to do it, but it was too late when I picked her up......





    Tacked in place..........



    Welded.....





    Another few bits............







    Now i'm happy.........







    I also picked these up this week, reputedly genuine NAS lamps, no covers though but hoping to drop on some more..........







    The welding here is crap, the problem is, at the factory, this joint is Braized, well I don't have the facility to re-braize it, so I have welded it, but because of the impurities, the weld looks awful, nothing some of Isopon's finest won't sort out.......





    Dressed up, ready to fill over........





    Spot welds........









    Little bead of sealer.......





    Coat of Grey primer to protect till next weeked when I hope to get some proper primer on......





    Handbrake plate............



    Pedal box strengthener..........



    I then found myself with a bit of time, so started on the doors, I weighed them first, WOW,..........

    Front door, a colossal 26kgs!



    Rear door, 18kgs!



    Those of a nervous disposition, turn away now...........



    down to 11kgs, more to come yet but polycarbonate wiow to go in so I reckon that will be final weight..



    3 more to do, not today though.
    I fear understeer...

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    Excellent project.....good to see something different !!

    There was quite a few of these in Scotland over the years....even a special shortened one......it was shortened to the same wheelbase as a Mk2 Escort !!

    There was also a Janspeed Twin Turbo race car....great when it went well & won everything but more often than not it would break down !!

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    Spanner Monkey

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    Quote Originally Posted by evodave View Post
    Excellent project.....good to see something different !!

    There was quite a few of these in Scotland over the years....even a special shortened one......it was shortened to the same wheelbase as a Mk2 Escort !!

    There was also a Janspeed Twin Turbo race car....great when it went well & won everything but more often than not it would break down !!

    Do you mean this one Dave......................



    I had chance to buy this car recently for not a lot of money, but at the time I had just started doing mine and was short of funds. Wish I had bought it now as it has some real trick bits and I could have used some of those bits in my car.
    I fear understeer...

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    I love the back door on that shortened version - do you think it inspired the RX8

    Great project, and will certainly attract a lot of attention when it's finished.

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    TURBOSPORT SPONSOR Turbosport Sponsor evodave's Avatar

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    No......thats not the one I was thinking of but it was along similar lines.....I think Duncan Jaffray, a Hotelier from Banchory rallied it but I'm sure it just had 2 front doors & was like a 3 door SD1....I really need to dig out some of my old pics to see if I can find it !!

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    Pit Crew Decade Plus User MK1_Oz's Avatar

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    Well impressed mate. Looking forward to seeing this one finished.

    My old man rallied an SD1 in the mid 80's (white with green roof - must find some pics - same as his Mk1 Twink in my avatar). He had a fibreglass tail gate and bonnet. He also used second hand tyres from the Audi Quattro works rally team which, as a teenager, I thought was awesome!!

    I remember he got the thing up on two wheel around a tight right hander (I have the pic somewhere) that resulted in the front strut mount cracking to buggary. Cannot remember if he had seam welded like you but he certainly added some strengthening work after that!

    Good luck with your build!
    1970 Mk1 Escort Tarmac Rally Car

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    Spanner Monkey

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    Thanks for the kind comments guys..............

    Having managed to wangle my first Saturday off for months a few weeks ago, I put all the pieces in place to get the car painted underneath, engine bay and inside.

    Trailer was loaded, sand blaster booked and all looked rosy, I took the car to the blasters in glorious sunshine which I was sooo glad about, then dropped her off instructing them what bits to do, and what not to go near.

    Dinner time loomed and they called me to go and collect the car, which I duly did, excited at the prospect of some bare metal to spray.

    However, my exitement was dulled slightly, they had made a cracking job of the inside and engine bay..............but then had ran out of sand [], they usually have 10 tonnes on stock but were awaiting delivery, but they only charged me 50 so I suppose I can't grumble.

    The upshot was though, I had to manually clean the underside, this was no mean feat, as this car is caked in waxoyl (I supoose I shouldn't moan about that, it is the waxoyl that has kept the shell in such good condition) and this subsequentlyset me back a good 4 hours.

    In essence, I can't help thinking that I rushed the rest of the job, the shift I work, I don't get to see my partner in the week, so when I request a weekend working on the car, it doesn't go down awfully well, then when It was going to run into Sunday night, I was properly in the dog-house.

    Anyway, I got her done, but not the best job I could have done, main thing is, it is sealed from the horrible damp weather we are having at the moment.

    Here are a few piccies as usual...........





























    Doors painted................















    So, now Been beavering away for a few weeks, sourced a 4HA axle from a Jaguar breakers in Wrexham, then set about the shell modifications to 4 link and make the turrets for the twin shocker set up I intend to use.

    Lots of cutting, fabricating and welding has ensued, but I am only a fraction of the way there yet, as there is extra strengtheners and plating to firstly work out where they will need to go to stop the whole lot just ripping out of the shell, then secondly, make and fit them.

    Anyway, some pictures to whet your appetite..............

    Bit of technical working out where the turrets need to go.........



    Attack!..........Attack!.........



    Nice big hole...........





    Rolled some turret bodies up out of 2mm steel..........





    Tacked in place..........





    Made the turret top plate from 3mm steel..........





    I have then decided to brace the turrets, and tie them to the base of the cage, this brace will transfer some latteral load to the cage from the struts, and also add some more stiffnesss to the rear of the shell............











    And finally, the damper units I am going to use are Escort Group4 Magnesium items, these are just mock ups for now, just to get an idea of open/closed lengths etc.......



    I fear understeer...

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    Nice project good to see something different

    Not good to see that speedline has become a painting stand for your door!! Is it off an evo?

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    I'm liking this
    67 TVR VIXEN V8

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    your cracking on well. nice work that!
    1970 Mk1 Escort Tarmac Rally Car

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    Some inspiration. THis one was probably one of the first around. Built well before British Leyland did the works Rovers.

    Is yours to be a gravel or tarmac car?



    1970 Mk1 Escort Tarmac Rally Car

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    Excellent pics there Sir, thanks. The car will probably be used on mainly Tarmac single venue events, but this is the first car I am building with the capability of being a forest car too, so making her strong as well as light(ish!). I used to just build light Tarmac cars, but fancy a trip into the woods one day..................

    I have been invited to go have a nosey around, and a drive of a genuine factory built rally car, I want to get some pointers as to how they 4 linked the rear end properly, I have a very early CCC with some pics in there of a works car, and it shows where the links are etc, but I need to see where they have strengthened the shell to suit.

    Watch this space................
    I fear understeer...

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    Pole Position Decade Plus User david_white's Avatar

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    Thats coming along great, will look stunning when its done. Great attention to detail.

    I too have a soft spot for these SD1s, my dad had them for ages and I watched them in touring cars back in the day. I remember Tony Ponds one too.

    When you are bored with it I'll take it off your hands and build a bastos touring car replica

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    Spanner Monkey SHIFTYrs2k's Avatar

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    I am really impressed with this build and your dedication here mate, well done
    An SD1 was the 1st car I ever drove...well sitting on my dad knees on morcambe beach steering that is

    Look forward to seeing her progress, all the best with it

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    Few nice detail shots here, not sure how relevant, but very nice.

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    Duck Re: And now for something completely different, Rover Sd1 Stage rally car

    hi there could you tell me where you got your roll cage from many thx rover sd1

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    Spanner Monkey

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    Well guys, been beavering away, and getting somewhere...not very fast.

    Firstly, got the rear turrets finished off...............







    Then moved on to the linking arrangement for the axle, please bear in mind that this is mostly guess work, I was hoping to go have a look at a proper car that has the 4HA under it, but had some idea so just freestyled it.............

    Holes for link boxes.......



    Link boxes made.......







    Now then, for the link bars to fit, they fit to the piece of the shell tghat is upright where the back seat usually is, this is fairly thin steel, so I have plated it with 2mm steel, and tied it to the shell by removing the embossed parts and welding through, i'll let the pics do the talking........









    Then welded some link bar brackets I made........





    Then I had to remove some of the boot floor to accomodate the watts linkage.........



    Then filled it in...........



    (Thats finished off now by the way)

    Then started on the watts towers......





    Since then I have strengthened all the towers, fully welded everything, drilled etc. next on the agenda is dipping and painting...........watch this space.
    I fear understeer...

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    Just read this all the way through....you are doing a cracking job...I spoke to a guy who was rallying one at race Retro this year and had a good look inside etc...its nice to see something different being done...

    Good Luck and keep the pics coming,

    Russ.

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    1970 Mk1 Escort Tarmac Rally Car

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    Nice fabrication there, well done!
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    Re: And now for something completely different, Rover Sd1 Stage rally car

    Sweet I used to love the SD1 years ago at the time it was my dream car Fabrication and ideas on this project are spot on
    When I grow up I will have a MK1 Escort

    I must be all growed up now then and paying for it!

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    Thanks for the kind words fellas....................

    A quick update from the extended weekend, got plenty done, including having a bit of a move around so I can get at her a bit better, and make a start on her sister (spare shell)..............

    I used the crane lorry from work, and used the oppertunity, whilst I could get properly underneath, to take some pics.............

    Axle now connected with all the link bars (not bolted or spaced up yet)............









    Twin dampers again, however, I only have two at the minute, so to attach the axle, I have used one each side.........





    Some underside pics, as you can see, next job is to fabricate the watts bars...............





    This pic gives an idea of how I have tied the strengthening plate to the shell............





    Fully floating car!



    Finally, erm...........I was gonna say beauty and the beast, but neither are particularly beautiful at this moment in time!

    I fear understeer...

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    Keep the faith and keep the pics coming...

    Russ.

  41. #38
    Pit Crew Decade Plus User MK1_Oz's Avatar

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    I am loving this build. Good memories!!!! Great work.
    1970 Mk1 Escort Tarmac Rally Car

  42. #39
    Spanner Monkey

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    Sooooooooooo, I have had yet another super productive couple of days, whilst I am waiting for some hardware for the rear (rose joints etc for the watts bars), I made a start on the front, so, I had decided a long time ago that I was going to run compression struts, but it took me till Friday to source some, then I had to fab some brackets up, and I was fairly pleased with the results, I also took the time to strengthen the area as much as I could............

















    I also had been bidding on a "Cheetah" subframe on ebay, basically, it allows the engine to be lowered and moved back, well, I got out bid.......twice in two weeks, so make of that what you will, so, I studied the pics and decided to make my own.

    Firstly, remove the middle of the subframe...........





    Chop the middle section down..........



    Weld back in place..........



    Fill the gaps.............



    Done......(well, nearly)





    Note that I haven't re-affixed the original eninge mount brackets (albeit down and back) as I think I am going to chassis mount the engine, and also, I want to dry sump it, so I will leave the engine positioning till I suss that out.

    Then just trial fitted the struts to see what kind of castor and camber I might hope for.....







    Lets hope for more good weather so progress stays strong
    I fear understeer...

  43. #40
    World Champion Decade Plus User exboyracer's Avatar

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    Re: And now for something completely different, Rover Sd1 Stage rally car

    Looking good
    http://escort.accelerator.org
    1968 MK1 Escort 1300GT
    1969 'Big Wing' MK1 Escort
    1972 MK3 Cortina 1600XL
    1984 Sierra XR4i
    And other junk I don't like to talk about!

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