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Thread: The new Racecar Shell

  1. #1
    Mechanic max0815's Avatar
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    The new Racecar Shell

    As some of you have seen if been racing a 4 door Escort together with my Dad. The shell we had to build up the car wasnīt the best as we got it because it had several accidents and bad repairs before. So we build it up and started to race with it. At the while we searched for a good 2 door shell to build a real lightweight and strong shell as we can drive the other one. So we searched for about two years and have seen many expensive crap. The we finaly saw a good two door shell, standing on a jig and nearly complete. The price was good so we took the trailer and bring it home.
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    Last weekend we started to take all parts out that are still mounted and checked out the repair work. The front panel and the left wing are death but the rest looks solid with a bit of work.
    The Target with the shell will be Hillclimb and Slalom. Build up on base of the German rules for Group H. The Book with the regulation is very big and you have the look after many things when you build a car. We can strip the car down to 710 kg, thatīs gonna be a hard target.
    We will work on the shell every few weeks and plan to use it in 2013 with the parts from the 4 door.
    This week I had some time and started to get rid of all sealing and stuff on the inside. And we plan to arche the body. But I think forest Arches are wide enough for our use. They are the first parts we need so if anybody has a set up on sale give me a pm.
    So I hope with the knowledge from you guys here itīs going to be a real good escort.

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  2. #2
    World Champion Decade Plus User caprimentle's Avatar

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    Re: The new Racecar Shell

    looks good, not that much rot, be good to see the transformation your gonna make
    its not dead till it's buried!


    T.I.T engineering. "Feel the power!"

  3. #3
    Mechanic max0815's Avatar
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    Re: The new Racecar Shell

    This week was the first week I have time to work on the shell again.

    First goal will be to get all the underneath sealing and coat off. We started to drill out all the unnecessary panels mountings and stuff.
    A lot of dirt and a lot of rust between the panels
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  4. #4
    Spanner Monkey

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    Re: The new Racecar Shell

    nice project, guessing youre near Karlsruhe if my memory of german plates serves me right?
    keep the pics coming..

  5. #5
    Mechanic max0815's Avatar
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    Re: The new Racecar Shell

    Today did some stuff: cut most of the rust parts off, tomorrow we gonna weld. Bought the a pillar panels the stut tops. And I made some panels by myself. There are many holes to weld up.
    And it take some time to plan the stuff like the rollcage with the german regulation
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    2012-08-24_11-42-43_345.jpg

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    Bodger Lilljebjorn's Avatar

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    Re: The new Racecar Shell

    Soon I will have my race car shell up on the jig as well!
    Great job mate.

  7. #7
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    Re: The new Racecar Shell

    good work going on there,looks like a good shell

  8. #8
    TURBOSPORT SPONSOR Turbosport Sponsor evodave's Avatar

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    Re: The new Racecar Shell

    Nice shell !!

    Keep the photo's coming as work progresses !!

  9. #9
    Mechanic max0815's Avatar
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    Re: The new Racecar Shell

    yesterday I started with making the panels fit. My Dad started welding on the floor inside. But after an hour of welding the gas was empty. Saturday afternoon no chance to get some gas. So we only fit the panels in and made everything ready.
    Tomorrow iīm going to drive to a metal company and order the circle and ellipse patches to weld the floor.

  10. #10
    Mechanic max0815's Avatar
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    Re: The new Racecar Shell

    Done some work the last weeks.
    Today I was thinking about the right look
    IMG_2706.jpg
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    These are the biggest problems I see at the moment
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    The inside is nearly finished. I hope to weld the seat mounting in over the weekend.
    The gearbox tunnel will stay till the gearbox comes in. On top Iīm going to mount a Scorpio gear shift gaiter
    IMG_2700.jpg
    IMG_2691.jpg
    IMG_2701.jpg

  11. #11
    Mechanic max0815's Avatar
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    Re: The new Racecar Shell

    Hereīs some update about my project.
    I was a bit lazy the last months but this is what happend.
    Seat rails after german regulation
    IMG_2939.JPG
    A small tunnel for the kat. The regulation says no work on the floor over the door steep so only a small tunnel
    IMG_2977.JPGIMG_2935.JPG
    The inner arches are done and I cut some metal on the inside
    IMG_2944.JPGIMG_3055.JPG
    Today I started to make the rear Turrents
    IMG_3058.JPGIMG_3059.JPGIMG_3060.JPG
    and tested some acid to get it to a bar shell
    IMG_3056.JPGIMG_3057.JPG

    I hope that the mountings for the rear anti tramp bar arrive to the next weekend that I can finish the rear axle stuff

  12. #12
    Mechanic max0815's Avatar
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    Re: The new Racecar Shell

    Done some work the last few weeks.

    Rear Turrents are in. Take a bit of time as we done it the first time ever. And finished the seatbelt mounting rod between the towers too. Also made a Alu panel to close the boot between the turrents. I have to make the boot complete airtight as we have the gastank in there.
    IMG_0003.JPG
    Yesterday we took the front panel of too replace it. Now Iīm going to derust all the parts behind the front panel and repaint them
    IMG_0006.JPG
    And started to work on the doors.
    IMG_0009.JPG
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    The rear panel got cut to for the exhaust and a underfloor wing
    IMG_3087.JPG
    We bought a 52" english axle from a capri to match the arches with 8" rims. The reason for the english is that we have 2 lsd for it and I think we donīt break it with our lightweight 1,3xflow car.
    I cut all the mountings and gonna blast the axle to derust it.
    IMG_3097.JPG

  13. #13
    Mechanic max0815's Avatar
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    Re: The new Racecar Shell

    A little Update on here. I want to save weight on the car so the headlights with all the mounting and stuff are quiet heavy. I liked the idea of grahambīs fiesta on here with the fake headlights. But Over here you have to run E certified headlights. So i searched on Ebay about some bike headlights. Made some alloy brackets and a fake headlight.
    2013-01-25_16-55-05_964.jpg
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    But the finished grill will be squared headlights because nobody over here want to have squared grills.

    Now Iīm waiting for parts. Order stuff from Ireland and found a guy over here that make me a small alloy fuel tank and a custom radiator

  14. #14
    Mechanic max0815's Avatar
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    Re: The new Racecar Shell

    Havenīt updated this for a while but here is how it looks like now:
    DSC_0013.jpg
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    I seld painted the inside the last weeks
    Attached Images Attached Images

  15. #15
    Pit Crew rwd2ltrfiesta's Avatar
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    Re: The new Racecar Shell

    very nice buddy

  16. #16
    Bodger

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    Re: The new Racecar Shell

    naaa? Wie läuft's??

  17. #17
    Mechanic max0815's Avatar
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    Re: The new Racecar Shell

    Fertig geworden. Ich such gerade ein Fahrwerk.

    Been ready. Searching for a suspension setup.

    http://www.turbosport.co.uk/showthre...=170941&page=2

  18. #18
    Spanner Monkey

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    Re: The new Racecar Shell

    good looking shell and good progress

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