Sunbeam Tarmac Rally Car

[rallysunbeam]

Re: Sunbeam Tarmac Rally Car

I don't think you will ever get a perfect fit with F/G arches. I fit mine as flush to the body as possible, then glass the inside of the extention onto the extended inner arch. That way adds stength and helps water proof and stone protect under the arch. I also fill the outer so you cannot see the rivetts but I know some like to show the fixings.... Personnal choice. One thing I did on the last car was to fill the area between the outer skin and the trim panel with expanding foam. Added loads of strenth to the main panel for next to no weight increase. Means you have more trouble if you come to weld it though. Has to be one of the last jobs, but definatly saved the main panel on more than one occasion.

Love the sound of your car, I had a Corolla GT with the 4AGE engine in it years ago and loved it. Unfortunatly I cannot run to a sequential box (though it is on my wish list) for mine and have a new Quaiff SCCR type 9. Get some picture of yours up on here, would love to compair..

Cheers
Kev

[Timmy tosser]

Re: Sunbeam Tarmac Rally Car

Hello. Car is in a shed 3 hrs up the road from me sitting on a bench at the moment, at the earliest of stages yet!! a sorry sight to be honest....(",).. I'll try and root out a few pics of it here later on!! Yeah the fiberglass seems to make sense when you look at the things that may happen, plus don't fancy spending 500 quid on a set of alloy ones to leave them welded into a round bale of silage on a stage some day!! Has the large tunnels from engine bay to back axle and is also turreted and 5 linked....long way to go yet...(",)

[iano]

Re: Sunbeam Tarmac Rally Car

Could i ask the cost of having the shell dipped and where it was done i live in Herts

[rallysunbeam]

Re: Sunbeam Tarmac Rally Car

Yes Mate no problem.

There is 2 main places, One in Dudley called SPL, You have to deliver the car to them and collect it. Cost is around £1000 then for a further £1500 they electro coat it that gives it modern day car rust protection.

Then there is the people I used, Enviro-Strip (UK)Ltd (Tel: 01827 284333) in Tamworth (Midlands). I cannot speak more highly about these people, They collected the car in a covered trailer, kept me informed through the whole 3 week process, e-mailed me the odd picture of what was happening to the shell, Delivered it back to me (with a photo, file and DVD of the whole process, personallised on my car), coated in an etch 2pack primer for £1100. Fantastic company I would very highly recommend. Service is world class..

Hope this helps.
Kev

[rallysunbeam]

Re: Sunbeam Tarmac Rally Car

This is the Video Enviro-Strip gave me when the shell came back:

Kev

[mario r h santos]

Re: Sunbeam Tarmac Rally Car

After reading this thread from top to bottom I felt I had to congratulate you on all your effort to build this car.

I'll keep waiting to know more about your developments.

It's becoming a fantastic car.

Good luck,

Mário Santos.

[rallysunbeam]

Re: Sunbeam Tarmac Rally Car

Well another productive day in the Garage: Although the N/S sill is the better of the two, I wanted to strengthen it and make sure of no isues in the future.

Two adantages to making your own sill
1) I made the lower (flat section) from 3mm sheet for added strength and the upper part in 1mm.
2) It's a damb site cheeper to get a sheet of metal than a complete sill.

The disadvantage is it takes a bloody long time and (with my ability) will never look as good as a preformed panel (Good job its a rally car and not destined for show grounds).



Anyway, here is a few more pictures for the post.

[rallysunbeam]

Re: Sunbeam Tarmac Rally Car

Had a few hours on the car again yesterday and tidied up a few bits, holes in the floor etc, and started on rebuilding the floor, Afraid the pictures are not as good as before as I tried just using my phone instead of a decent camera:





This is the front section where I fitted the sill stand. A little concerned I made a mud trap. So this is to resolve that









This is where I cut all the rear floor away to redisign the boot, for the internal tank. Still a fair bit to do here,

[stitchmotorsport]

Re: Sunbeam Tarmac Rally Car

coool project always good to read somthing differant

[rallysunbeam]

Re: Sunbeam Tarmac Rally Car

Time for an update. The lady of the house has gone away for the weekend, so I get to stay in the garage untill sleep insist's I come in. The upshot is the following pictures:

[vataman]

Re: Sunbeam Tarmac Rally Car

Nice to see something different

[rallysunbeam]

Re: Sunbeam Tarmac Rally Car

Another productive day in the garage.

More strengthening for the suspension mounts. I want to make sure I get the best from the FF axle.



And at last I can start filling in the boot area.





So much easier useing card to make a pattern.





Nice to get to a point where I can be thinking where to place bits.

[rallysunbeam]

Re: Sunbeam Tarmac Rally Car

The circle attachment arrived for the plasma cutter on Saturday, so I just had to try it out. Therefore as I wont be using the petrol filler it was the ideal curcle to cut.

[rallysunbeam]

Re: Sunbeam Tarmac Rally Car

The new fibreglass dash arrived yesterday so I thought I would prefit the dials. This will need to be adapted to fit around the roll cage and flocked before final fitting. Dials look good though. Need a carbon centre panel to reach down to the tunnel for the other bits. If anyone knows wher I can get one at a reasonable price please let me know. I think I will end up modifying an escort one...

Hope you like:

[rallysunbeam]

Re: Sunbeam Tarmac Rally Car

Had to spend a bit of time cleaning the garage today so only had a couple of hours to spend in the car. I used the time to make brackets and prefit the fuel pump assembly. Means I could weld the retaining nuts to the shell etc.







I sent this in a txt message to a mate who replied saying simply "CAR PORN"!!!!!