Road Rally MK2 4 Door (XE powered)

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  • lukem30
    Spanner Monkey
    • Jul 2012
    • 408

    Re: Road Rally MK2 4 Door (XE powered)

    Yes fella, seems to work well.

    Comment

    • redhf
      Spanner Monkey
      • Jan 2006
      • 479

      Road Rally MK2 4 Door (XE powered)

      Yes looks well.

      Comment

      • lukem30
        Spanner Monkey
        • Jul 2012
        • 408

        Re: Road Rally MK2 4 Door (XE powered)

        Repairs have started





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        • freddy686868
          Pole Position
          Decade Plus User
          • Jul 2010
          • 4689

          Re: Road Rally MK2 4 Door (XE powered)

          Originally posted by lukem30
          Repairs have started





          I was waiting for the update. She's looking good and You'll be a pro at wing changing soon.

          Did the wing offer up straight away?

          Comment

          • lukem30
            Spanner Monkey
            • Jul 2012
            • 408

            Re: Road Rally MK2 4 Door (XE powered)

            Already had a chat about the above in work John.

            Couple more good pics from pembrey



            Comment

            • lukem30
              Spanner Monkey
              • Jul 2012
              • 408

              Re: Road Rally MK2 4 Door (XE powered)

              She's painted, and entry has gone in for another rally down Pembrey - rally cwm gwendreath.




              I replaced a leaky core plug and found a big air leak on the inlet manifold so I had to replace the gasket. It's running spot on now, can't wait to get out and give it a run.



              On the modification front I decided to fit some new 300 70 long Tarmac inserts. Reason being, I could never identify what rating my inserts were as they weren't stamped with numbers, and at the last rally my understeer reared its head again, the inserts were the only Unknown.



              When I tried to fit the new inserts into the m10 threaded hole at the bottom of the leg I couldn't get it to line up, upon closer inspection I found that the tube of the leg was bent so I had to replace that too. I found it odd that the bent tube was on the passenger side (which I didn't hit down pembrey) so who knows how long it has been bent. I also suspect that the insert was jamming in the leg due to the bend and could be the cause of my understeer. I'm waiting on a new spring seat so I can go out and try it.




              Last edited by lukem30; 24-01-2016, 22:47.

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              • lukem30
                Spanner Monkey
                • Jul 2012
                • 408

                Re: Road Rally MK2 4 Door (XE powered)

                Last thing was to swap the castle nuts on the steering arms for nylocs, as the split pins had siezed when i needed to change the steering arm quickly at the last rally.

                Comment

                • onecamohv
                  Pit Crew
                  Decade Plus User
                  • Jun 2012
                  • 1159

                  Re: Road Rally MK2 4 Door (XE powered)

                  where did you get the new tubes? they look like a nice job! did you just cut the old one off at the hub and but weld the new one on? will it be strong enough?

                  Comment

                  • lukem30
                    Spanner Monkey
                    • Jul 2012
                    • 408

                    Re: Road Rally MK2 4 Door (XE powered)

                    Originally posted by onecamohv
                    where did you get the new tubes? they look like a nice job! did you just cut the old one off at the hub and but weld the new one on? will it be strong enough?
                    I got the tube from Peter Lloyd rallying, but I am told they get them in from rally design. They come with the bushes and seals already fitted which was handy.
                    I ground the welds off the original tube, then cut it shorter and smashed it out of the hub with a drift, tapped the new one in and welded either side of the hub. Should be strong enough as the original was only welded on the one side.

                    Comment

                    • onecamohv
                      Pit Crew
                      Decade Plus User
                      • Jun 2012
                      • 1159

                      Re: Road Rally MK2 4 Door (XE powered)

                      ah cool thats what i was wondering, nice job!

                      Comment

                      • lukem30
                        Spanner Monkey
                        • Jul 2012
                        • 408

                        Re: Road Rally MK2 4 Door (XE powered)

                        We had another eventful day at Rali Cwm Gwendrath on Sunday. It was wet, miserable and cold, to be expected for February in Wales I suppose. We were seeded at car 40 and looking forward to a challenging day.

                        Stage 1 - Stage 1 didn't go well at all. We got stuck in some traffic very early on, not long after our intercom failed, and just after that we went off the road and got stuck in the grass. After a top job by the very few people standing there we got the car back out just in time to take a stage maximum, and we were OK to continue the rally.



                        Stage 2 - after our problems on stage one we really backed off a lot to get round as the stage was very slippy. We took no risks and got round with no dramas, which was nice.

                        Stage 3 - it was drying out slightly by now so we started to build the pace back up, all went well and the car felt a lot better in the drier conditions.



                        Stage 4 - we started off well and came out immediately in traffic, but pretty soon into the stage the gearbox gave up and we lost 3rd/4th gear, and we could only get second with a big struggle. So with only 1st and 5th gear we retired.



                        Last edited by lukem30; 09-02-2016, 20:56.

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                        • lukem30
                          Spanner Monkey
                          • Jul 2012
                          • 408

                          Re: Road Rally MK2 4 Door (XE powered)

                          Meaning as the box broke it gave me an excuse to try this



                          Which I expect will keep me busy for a while.

                          Comment

                          • lukem30
                            Spanner Monkey
                            • Jul 2012
                            • 408

                            Re: Road Rally MK2 4 Door (XE powered)

                            Phase 1

                            Plate has been test fitted and holes marked up



                            Rather than make a spigot extender I've taken the bell housing off the gearbox and sent it off for machining. 15.5mm to be removed from the the bellhousing flange and dowel holes re drilled.

                            Comment

                            • alladdin
                              World Champion
                              Decade Plus User
                              • May 2005
                              • 9248

                              Re: Road Rally MK2 4 Door (XE powered)

                              does the xe require a longer input shaft compared to pinto etc ?

                              Comment

                              • lukem30
                                Spanner Monkey
                                • Jul 2012
                                • 408

                                Re: Road Rally MK2 4 Door (XE powered)

                                Originally posted by alladdin
                                does the xe require a longer input shaft compared to pinto etc ?
                                Yes, it needs to be extended by over 20mm

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