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Thread: GavinR's Mk2 Rally Car - FLY

  1. #1
    Pit Crew Decade Plus User GavinR's Avatar
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    GavinR's Mk2 Rally Car - FLY

    I bought FLY in Feb 1991 as a Road Rally car - built from a std Mk2 1600 Sport and a Mk1 Stage Car, I ended up with a 2.0 Pinto on a 38DGAS, Mk1 3.0 Capri Front Struts / Brakes, RS2000 gearbox, 4.4 LSD English axle and a 6 point cage.
    18 months later, the shell disintegrated and FLY was reshelled into a tidy 1300 Auto shell, seam-welded & strengthened, same running gear but now with a Bias Pedal Box, Hyd H/Brake and Xr3i vents on the rear axle.
    Aug 1993 saw my first Stage Rally, at Millbrook, with a more powerful engine, and that winter the shell was Turretted and 5-linked with slipper springs.
    After a couple more years of Road Rallies, I concentrated on the Stages in a different car and FLY would get dragged out of the shed a couple of times a year to do a rough stage rally (Twyford or Kune Tune (below))

    and the annual outing on the Preston Road Rally...

    Spring 1997 at Twyford, now with a floating narrow Atlas, 5 speed Quaife and twin 48 Webers, the shell split along the floorpans as the front chassis rails bent upwards more than normal, the gussets bending the bulkhead, so the shell was straightened on a jig and reinforced with 3mm plate on the floors and bulkhead and the cage multipointed.
    Still doing the odd Road Rally - here on the Swan (Reading) - and yes we did get through the ford OK


    Summer 1998 on the Kune Tune, a rod went through the block and the engine was taken to HT (who were looking after my N/A cossie by then) for a basic rebuild, which saw Roland change the cam and extensively port the head without charging any extra and FLY had about 180bhp.
    November 2000, my wife and I moved house to West Wales, fitted Split 48 Dellortos and competed on the Cilwendeg.
    After a few years of competing on selected events and selling the Stage car in Aug 2004, 2005 has seen a few more Road Rallies - Carpetbagger (Devon) in January, Ystwyth Rally (Aberystwyth) in February, Classic Tracks (Llanybydder - 4th O/A) and Eagle (Newtown) in May, Dafydd Richards Memorial (Lampeter) in Oct and Preston (Norfolk) a few weeks ago (below)


    Current spec: Strengthened Auto Shell, 6 point Roll-Centre cage multipointed to A & B pillars, 170 bhp 2.0 Pinto on Split 48's built by HT Racing, 5 speed Quaife Gbox, Princess 4 pots on 2.25" Adj Bilstein struts, bias pedal box, Xr3i vents at the back on 4.6 ZF LSD Baby Atlas, 5 linked and turretted on Bilsteins and std 1300 slipper springs, Alloy Fuel Tank, etc
    Project for 2006 - build up my spare shell as the current one is getting tired

    GavinR

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

    Great read there Gavin... and shows the reason for these threads, as a lot people know you did a bit but now they know the history

    So keep us all updated as you rally around the hills and dales.

    And has that car still got Steves (S&C) alternator on it?

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    Racer Decade Plus User tim's Avatar

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    Re: GavinR's Mk2 Rally Car - FLY

    agree wit gary a good read there and a nice bit of history there

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    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Rally Car - FLY

    Quote Originally Posted by retromotorsport
    And has that car still got Steves (S&C) alternator on it?
    Yes, 55A Bosch one bought off him in 92 & still working perfectly
    GavinR

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

    Quote Originally Posted by GavinR
    Yes, 55A Bosch one bought off him in 92 & still working perfectly

    He said its out of warrenty 'specially as you've been driving it through rivers

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    Re: GavinR's Mk2 Rally Car - FLY

    Great pictures love the one with the steam as you go through the Ford

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    Re: GavinR's Mk2 Rally Car - FLY

    Great stuff excellent action shots, nice seeing them still gettin very well used LOL
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    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Rally Car - FLY

    Just heard I've got an Entry for my next Road Rally - Rali Bro Caron - 18th/19th Feb
    Run by Lampeter DMC, starting under 5 miles from my house
    Booked an MOT for tomorrow - hope they don't find too much for me to do
    GavinR

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    Re: GavinR's Mk2 Rally Car - FLY

    Quote Originally Posted by GavinR
    Just heard I've got an Entry for my next Road Rally - Rali Bro Caron - 18th/19th Feb
    Run by Lampeter DMC, starting under 5 miles from my house
    Booked an MOT for tomorrow - hope they don't find too much for me to do
    Good luck matey for the mot and the rally, just keep it out of rivers this time

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    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Rally Car - FLY

    MOT passed

    Just got a few things to do to Fly before the next event - including doing a club 12 Car in Newtown the Thursday before the rally in my Mk1 mexico
    GavinR

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    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Rally Car - FLY - Rali Bro Caron

    We had a great night on the Bro Caron last Sat night - Fly ran faultlessly in freezing conditions and apart from a minor indiscretion near the end we didn't have any problems, my wife was back in the hot seat calling the bends beautifully

    Lampeter DMC had organised a 100 mile route of tight twisty tarmac lanes mainly to the south of Lampeter, made more interesting by patches of ice on the hills and under the trees, which led to a few near misses with the scenery

    75 cars started including 16 Mk2 Escorts - seeded car 38 we were lying 38th at the halfway Petrol halt, but made up some time in the 2nd half to finish 23rd overall after being held up slightly by the Sierra XR4x4 seeded one car ahead of us

    The rally was won by last year's winner local man Gary Davies, this year in a freshly built light blue 4 door 1.3 Ghia Mk2, c/w square headlamps, chrome bumpers, 1.3 badges..... oh and a 2.4 dry sumped Pinto and Proflex suspension all round

    Plenty of pics on http://www.bg-photosport.co.uk and http://garyjonesrallypics.co.uk

    Near the end, there was a control about 30 yards before a very tight hairpin slot left and although I threw it in as fast as I could, we just nudged the bank on the outside and had to reverse out before carrying on with 1 spotlight pointing at the hedges. Luckily, at the next control was Melvyn Evans, who runs the garage where I get my MOT's done, and his wife straightened the spotlight while he signed our sheet.
    As all the lights were still working, we were quite surprised to find the amount of damage incurred when we pulled up at the finish...



    Looks like I'll be busy with the hammer next weekend


    The previous Thursday, we'd gone up to Newtown to try one of their evening 12 car events, driving my in-law's Mexico historic rally car for the first time, currently on permanent loan to us

    Having bolted a couple of spot lights on during the day and managed to melt 2 ignition packs when the coil shorted out we weren't having a good day, and then after filling up with Petrol a few miles from the start, the Mexico refused to fire up.

    Luckily a friend of ours, who was also competing, came to help us and we bump started it and I managed not to stall it all evening.

    The route was 50 miles of lanes around Newtown in heavy rain, and after losing 10 minutes along with 4 other crews helping a stranded Golf GTI back onto the tarmac after he'd got it sideways and balanced the car with the front blocking the road and the rear hanging over a ditch, we were pleased to emerge 2nd overall

    GavinR

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    Re: GavinR's Mk2 Rally Car - FLY

    superb thread! and nice car!!!! nice to see one being used and not polished

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    Re: GavinR's Mk2 Rally Car - FLY

    OOHH Ouch

    And a husband and wife team Great stuff

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    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Rally Car - FLY

    Now with Cosworth power for a month or so

    As my next rally is the Classic Tracks on Sun 28th May I thought I'd better take the engine out and investigate the cracks around the heater bubble and also the many cracks in the boot floor around the panhard rod tower, whilst also hammering the front wing back into shape

    Seeing my old N/A Cossie motor sitting at the side of the garage (where its been since DVY was sold in Aug 2004) and having sold an old Range Rover on eBay for more than I expected, my wife and I decided to bolt it into FLY and have a bit of fun



    Only problem is that the Cossie's dry sumped and the Pinto isn't but by Easter weekend I'd gathered all the bits I needed to make it happen - Ralloy Dry Sump Tank, 12.5m of 3/4" Braided Hose, extra Oil Temp and Water Temp gauges and 10l of Valvoline Racing Oil - and my friend Dave from Newtown came round on the Sat and then back on the Sunday & stayed to Monday to help out

    Anyway I spent Friday welding the boot floor - after removing the fuel tank there was a large crack above the chassis rail where it had been flexing over the years due to the panhard rod and a small crack round the bottom of the turret so this was all plated and a whole new spare wheel well fabricated to hold the dry sump tank



    Saturday saw a large plate from the gearbox tunnel to the heater bubble after flattening the lip (there was an 8" crack underneath here - no wonder we used to get wet feet after driving through fords ) and also a couple of smaller plates round the strut tops / bonnet hinges and moved the clutch cable hole 1.5 inches towards the tunnel to get the cable inside the exhaust manifold

    By Sunday afternoon Dave had finished the boot (fuel tank back in, moved the batteries to make way for the dry sump tank, rewired the fuel pumps so they both run together, oil pipes heading through the car and the engine was going in with Carrie (my wife) as chief crane operator while Dave and I guided it in. Everything looked good until the dry sump pan hit the steering rack before the engine mounts were at the right height. An hour and a half later we had welded 3mm plates to the XM end of the mounts to raise it up by an inch and it was bolted in



    Monday morning we finished off the dry sump pipes while Carrie fitted the K&N's (easier with smaller hands), fitted the electric fan, larger rad and expansion tank, wired up the Lumenition ECU and relocated the washer bottle, fitted the exhaust and starter and poured fresh oil over the cams so they would turn easier

    After lunch we though it'd be a simple 10 minutes to get the oil flowing round the system and fire it up - but unfortunately my usual technique of drivig the dry sump pump with an electric drill didn't work as there was too much air in the system. Next plan involved an old wet & dry vacuum cleaner on the pipe but that didn't have enough suction either so plan C was hatched - if you can't suck it, blow it

    With Dave's finger blocking the oil tank breather, myself pressurising the dry sump tank from my air compressor, Carrie waited expectantly at the front and finally we had oil coming out
    Back on with the pipes and the drill and the engine had oil pressure at last, took the plugs out so it could crank over with no compression, pressed the starter button and with a loud clunk, my pinto's 24v inertia starter jammed solid in the flywheel

    While I changed this to a large inertia one, Dave and Carrie went to park a few vehicles in the other shed as we were heading out as soon as FLY was running. New starter in, cranked over lovely, plugs back in & fuel pumps on, a few pumps on the throttle, it cranked over a few times and fired up just like that, and sat there idling perfectly

    Dave couldn't believe that he missed it actually firing up after spending most of the weekend helping me getting the engine installed, but big thanks to him for all his help

    After a quick petrol stop we headed up to Newtown, Carrie and I in FLY with Dave following in his '97 1300 Colt. Driving quite gently only using part throttle and revving to 6000 as the Quaife Clubman box isn't really designed for 240bhp, we still had the biggest grins for years, apparently Dave reached 95 in places trying to keep up



    P.S. Anyone got a Quaife Pro going cheap, any condition?
    GavinR

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    Racer Decade Plus User tim's Avatar

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    Re: GavinR's Mk2 Rally Car - FLY

    did u win a virtual road rally the other week, saw somthingi in motorsport news and wasnt sure if it was you or not?

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    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Rally Car - FLY

    Yes that was me, won the first round of this years Internet Table Top Rally Championship popcorn:

    For those of you who don't know, a Table Top Rally just involves plotting a route defined by cryptic navigation on a map - you get marks based on how accurate your route is

    For more info see http://table-top-rallying.org.uk/
    GavinR

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    Racer Decade Plus User tim's Avatar

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    Re: GavinR's Mk2 Rally Car - FLY

    congratulation mate

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

    Nice to see your still playing Gavin, wheres the pics of the grins though!!!

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    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Rally Car - FLY

    Thanks - Im sure we'll force ourselves to have another play in it this weekend so will take some photos & maybe even an in-car video
    GavinR

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    Re: GavinR's Mk2 Rally Car - FLY

    Nice one, looks like your gonna have loads of fun with that
    customcarbon.co.uk

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    Re: GavinR's Mk2 Rally Car - FLY

    Good to see you bought a quality dry sump tank off Roy at Ralloy and not a cheap pretender.Your car looks very similar to mine (unarched yellow 2.1 pinto)the main difference is my Missus would not be seen dead in my garage never mind helping me with the car.It may be because last time I built a Rally car 15 years ago I rolled it with her in it while testing it for the first time.
    Looks like it will be a bit of a beast with that motor in ,keep it between the trees .
    Skids

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    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Rally Car - FLY

    Finally got confirmation late last night of my entry for the Classic Tracks Daytime Road Rally on 28th May so just a couple of jobs to do this weekend...

    Remove Cossie, dry sump pipes and tank, and fit Pinto back in

    Fit new inserts to the front struts and raise the suspension height

    Try and make the LSD work like an LSD again

    That should keep me busy
    GavinR

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    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Rally Car - FLY

    Got the Pinto in and running Sunday as planned and investigated the diff some more after some advice from Fossie and extracted it on Monday night, stripped it down and found the splines had stripped out of the friction plates, hence no LSD

    Strange thing is, I had the axle rebuilt 18 months ago and the same problem was discovered
    After a few more conversations with Fossie, we came to the conclusion that this is probably happening because it is set up so tight - I ran the axle for 6 years on the back of my stage car without a single rebuild, when it was first built it was set to 90% locked as far as I can remember which worked perfectly on tarmac stages but now doing Road Rallies there must be more pressure on it
    It had been built with thin shims to get it that tight so Fossie suggested trying some wavy plates instead which I received from him this morning and took a day off work to bolt it all back together

    Finished it this evening, tried it with a torque wrench and it slips at 95 lb ft but I expect this will loosen a bit when I drive it at the weekend

    Roll on the Classic Tracks - I'm seeded 14th out of 75 entries, should be a good event as long as the weather holds - the organisers are concerned about the state of some of the tracks being used but they say they'll run it as long as the tracks are passable
    GavinR

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    Re: GavinR's Mk2 Rally Car - FLY

    wicked i might pop down to have a watch, hope the weather holds out, as it was nice last year, r u goin to have a crack on the thousand lanes

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    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Rally Car - FLY

    The organisers have been round the route earlier today and recommend a large can of WD40 and some wellies but say the event is definitely on

    More rain forecast for tomorrow morning but should be nice on Sunday

    Bit different from last year when it was very dusty but I'll get my chunkiest tyres on and hope we get round without too much trouble pray:

    Not sure what the next event will be - see what happens on this one first
    GavinR

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    Re: GavinR's Mk2 Rally Car - FLY

    good luck have a good skid

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    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Rally Car - FLY

    It turned out nice for Sunday, the sun shone all day, the tracks were very slippery in places and some of the fords quite deep, but Fly performed faultlessly and we finished 10th

    The first couple of sections were very similar to last year with the addition of a very slippery slalom through a cowshed (about 6 inches deep in cow percy: ) and the tracks were in reasonable condition

    Got onto a few more slippery sections, having passed various cars changing punctures, slid into a bank on the next section and the marshal at the end confirmed we had a front puncture
    Next section was 2 miles, 6 minutes on a normal tarmac road, changed the puncture and made it in with 2 seconds to spare thanks to some speedy work by Carrie and I

    Couple of sections later, steeply downhill round a couple of square corners, locked up and stalled it trying to stop for a codeboard, bump started it, couldn't reverse back to it so made Carrie get out and run 100 yds back up the hill to get the board

    Lying 14th at halfway, I wished I'd put the suspension up higher as the ruts got deeper, didn't quite make it round a tight downhill hairpin left and touched the bank on the outside, couldn't reverse out so had to wait for 5 spectators to help push - stopped on the next link section cos of a bad vibration - rear puncture this time where a rock had pierced the reinforced sidewall. Took us a bit longer to change but we knew we had plenty of time so it didn't matter.

    Post event pics




    Spent a few hours cleaning Fly yesterday - can't see any damage or bits hanging off
    GavinR

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    Racer Decade Plus User tim's Avatar

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    Re: GavinR's Mk2 Rally Car - FLY

    weldone gavin, the escort looks how it should look

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    Re: GavinR's Mk2 Rally Car - FLY

    boy does nt she look dirty, he he, i was watchin by the ford, was wicked fun, i put entry in for 1000 lanes rally, i sitting in navigators seat tho, as i building a road rally stage mk2 myself, also my bro is building one too (welshdiffsniffer)
    pics of his in restorations and projects

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    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Rally Car - FLY

    Big congratulations to my wife, Carrie, on her first Road Rally win last weekend on the Classic Lanes Novice Rally



    First time she's done a Road Rally with anyone else apart from myself, they even beat all the Semi's and got a nice pic in MN

    I managed to see them at 4 points during the night and they were by far the quickest crew out there
    GavinR

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    Re: GavinR's Mk2 Rally Car - FLY

    i saw that is MN this morning, congratulations Carrie

  33. #32
    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Rally Car - FLY

    After a quiet summer since the Classic Tracks, I was just getting ready to take Fly off the road for the winter as the tax runs out at the end of the month and we're moving house so money's a bit tight for a few months.

    Then I had a last minute call to drive on the FireFly Road Rally last weekend in Wrexham. Richard (who drove Carrie to victory earlier this year) has been navigating regularly this year and had been let down at the last minute by his driver.

    We spent a fraught 45 minutes scraping through scrutineering due to the scrutineer wanting us to prove the mechanical handbrake worked pray: - having run Fly with rear discs for 14 years this was the first time I'd ever been asked to do this - most scrutineers check you have cables fitted and leave it like that - but we managed it by making the cables so tight you could hardly move the car.

    After this bad start, the first section got us nicely warmed up - 1/2 mile down a lane, slot left into 20 acres of grass fields and follow arrows for the next mile including a man made jump!



    We dropped 3 minutes which turned out to be 5th quickest on that section which set us up well for the rest of the night. At the petrol halt we were 8th overall and 1st Semi-expert by a couple of minutes from 2nd in class.

    We set off on the second half and Fly started misfiring a bit over 4000 rpm - not much fun when there are some rather steep hills around - and then I managed to flatten the exhaust cutting a hairpin a bit too tight but we still finished 9th overall and 1st in class which now means Richard has to run as an Expert!

    The "no handbrake rule" in North Wales means some pics are a bit boring though!



    Just got to unflatten the exhaust and investigate a crack that has appeared in the chassis at the same place and Fly should be ready for next year!
    GavinR

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

    And the old girl (and man) still keeps winning .. good on ya Gavin

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    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Rally Car - FLY

    Just a quick update...

    I was out as Course Car on the Eagle Road Rally in Newtown back in November, after welding up the chassis, changing the exhaust and fitting a new clutch, Fly ran faultlessly, except for spluttering out of a deceptively deep ford on a farm track. The next farm track I slid off into a gently sloping field, performed 5 or 6 spins before managing to get pointing the right direction and then got bogged down trying to get back onto the track - gave the 15 spectators something to do though as they pushed me up the hill

    Just entered for the Bro Caron in Lampeter at the end of Feb and got an MOT booked for this weekend. In March, Fly's booked in to the bodyshop for a general tidy up and probably a respray ready for the Sprint Championship in April
    GavinR

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    Tyre Wall Terry Decade Plus User 4parajon's Avatar

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    Re: GavinR's Mk2 Rally Car - FLY

    What a great read that was, top drawer mate, congratulations to you and the missus

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    Racer Decade Plus User tim's Avatar

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    Re: GavinR's Mk2 Rally Car - FLY

    always a gud read this thread

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    Re: GavinR's Mk2 Rally Car - FLY

    Quote Originally Posted by GavinR View Post
    Just a quick update...

    I was out as Course Car on the Eagle Road Rally in Newtown back in November, after welding up the chassis, changing the exhaust and fitting a new clutch, Fly ran faultlessly, except for spluttering out of a deceptively deep ford on a farm track.
    That ford was a bit deceptive wasn't it, caught a fair few boys out I was out navigating in an orange mk2 http://www.vidmatt.co.uk/Eagle06/EagleRoadRally2006.wmv , we got water in the electrics and lost about 12mins when the car cut out but at least we made a nice splash for the camera Cracking event though
    Last edited by Andy Rich; 18-01-2007 at 01:01.

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    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Rally Car - FLY

    Nearly ready for the Bro Caron now, passed MOT at the second attempt after patching the sills and floors in a few places - I've had Fly so long now its getting a bit rusty in places

    I'm Car 25 out of 90 tomorrow night with Carrie on the maps as usual. Gary Davies, the winner for the last 2 years, is Car 1 in his Group 4 4 Door Mk2
    GavinR

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    Pit Crew Decade Plus User GavinR's Avatar
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    Re: GavinR's Mk2 Rally Car - FLY

    Well not one of my best events

    About the first competitive junction of the night, incredibly tight hairpin slot right at Give Way (on Road Rallies you've got to Stop at all GW's so no chance of throwing it in), cut it quite tight, reversed back and the exhaust hit the road I'd just come out of , bending it rather.

    Carried on as it didn't sound much louder but wouldn't rev much over 6k and by halfway it was backfiring through the manifold which had cracked under the stress, so called it a night rather than cause any PR complaints!

    Gary Davies came 1st Overall for the 3rd year running with Mk2's 2nd and 3rd as well

    Now just stripping Fly down ready to go into the bodyshop next weekend
    GavinR

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    Re: GavinR's Mk2 Rally Car - FLY

    What a cracking read that was

    Having not been a TS member that long I'm still trawling through 1000's of threads and that is definately one of the better ones!

    A big well done to you and your missus

    Rover.

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