Sunbeam Tarmac Rally Car

[rallysunbeam]

Re: Sunbeam Tarmac Rally Car

Next update and a few more pictures. I have carried on filling in the boot area:



The off side area of the boot suffered from the tin worm quite a bit, so it took quite a bit of cutting to clear it out.





As this is the petrol filler side it is doubles skinned. Double the area for the rust to gather. I have cut the majority of the inner skin away and attached the new boot plate to it for strength.



I have also started on the Off side wheel arch. This was totally rotten to putting Grp 4 arches on meant cutting high and removing all the bad stuff.



Those wondering what the green cable is. I threaded it through the box section and intend to run all the cables for the boot area through it.

[rallysunbeam]

Re: Sunbeam Tarmac Rally Car

Not sure if people are not interested because it's not an escort but seems I am the only one looking at my thread. Is anyone interested? Is it worth continuing?

[novadave]

Re: Sunbeam Tarmac Rally Car

Definately continue, love watching these build threads.

[rallysunbeam]

Re: Sunbeam Tarmac Rally Car

Thanks, nice to know I am not talking to myself.!!!

[Paul C]

Re: Sunbeam Tarmac Rally Car

Yep, i'm here reading as well! Its a nice change to follow a build thats still RWD and not an Escort. Keep it coming

[MCURZON]

Re: Sunbeam Tarmac Rally Car

I read anything with the word Rally in the title!

Look forward to seeing your progress.

Matt

[patby]

Re: Sunbeam Tarmac Rally Car

5 years since my last post but I am looking at your thread with interest . Have my own Sunbeam in the garage needing lots of work and you are giving me an idea of what needs to be done to it.
Please keep reporting your progress as even if I dont comment I enjoy watching your progress.

[jonsey]

Re: Sunbeam Tarmac Rally Car

I'm reading. Keep the updates coming.

[shuvitsideways]

Re: Sunbeam Tarmac Rally Car

I'm looking too!

[rallysunbeam]

Re: Sunbeam Tarmac Rally Car

Thanks folks for the support. Will keep the post updated as I get further along. Unfortunatly I am on night shift now for the next 4 nights so it will have to be me designing the wiring on a PC. I will build it from scratch but intend to hide as many of the cables as possible to keep it neat. The idea is to have a bank of circuit breakers on the center console (When I can get my hands on a reasonably priced carbon one). The other things to go on there will be the main isolator, Fire pull a fuel guage and volt meter (Racetech to match the rest). Plus my have to mount a light switch there for the standard lights, (not sure yet) as well as spot lights etc...... Will keep you all updated as I go.

[rallysunbeam]

Re: Sunbeam Tarmac Rally Car

5 years since my last post but I am looking at your thread with interest . Have my own Sunbeam in the garage needing lots of work and you are giving me an idea of what needs to be done to it.
Please keep reporting your progress as even if I dont comment I enjoy watching your progress.

When you do work on it, Definatly get a spit, All this would be a nightmare without it.

[rallysunbeam]

Re: Sunbeam Tarmac Rally Car

Hi,

As I am working stupid hours this week and cannot get in the garage I thought I would post some back pictures of the rear end developement.

I knew from the start I wanted to run a better axle than the std Lotus item and the Atlas from a Cortina with the lugs on the top gave the idea replacement. All the options of CWP and Fully Floating made it the natural choice. I have already posted pictures of that but how to mount it was going to be a challenge.

Where to place the Turrets (having never done it before was an interesting challenge). I asked about but no-one could tell me how to determin where to mount them. In the end I made it up at what I thought was logical (Looks right now so, fingeres crossed when I drive it first time). Basically I put the axle on stands, took out the rear window and drew a virtical line, up both sides with a spirit level, from the center of the drive shaft. Then placed a piece of wood across the whole width of the car and dropped a plumb line down to the inner arch to find the middle of the turret. I used modified Escort turrets.





I had aleady cut most of the boot away which made it easier to see. (the old axle looks a bit tired).

I then bought the plasma cutter and what a difference. This shows the axle in place with all the new linkages.





Obviously the big whole where the boot was would be an issue, a bit noisey and cold to drive. I wanted to mount an internal tank and stiffen up the back end, so built the frame to weld in. Few things to notice, The down legs are extended an extra 15mm to mount a tank guard, I fitted a threaded bar to add a tow hook and manufactured weld in spacers to fill the box section for mounting a redesigned bumper hanger.







Looks good with the Guard on and nice and strong.

As with all development there is the odd issue... The back of the axle was way to close to the front of the tank guard and the diff cover wasnt on yet. I had to take it out and modify the tank enclosure by moving the centre guard stay internal of the tank frame. It gives me an extra 25mm of clearance.

[rallysunbeam]

Re: Sunbeam Tarmac Rally Car

You will notice a safety devices Roll cage in one of the pictures above. I have used the removable diagonal cross section for make the brace between the turrets but have decided to build my own cage. Therefore I am gonna sell on the cage. I can easilly manufacture a new diagonal for it. If anyone is interested or knows anyone who is PM me please. Guess in the end when the time comes if I have not sold it then it will go on E-Bay..

[Timmy tosser]

Re: Sunbeam Tarmac Rally Car

Keep up the good work... I'm reading away at your posts.... My own sunbeam build feels like its in high reverse... Good to see somebody getting somewhere!!!

[rallysunbeam]

Re: Sunbeam Tarmac Rally Car

Hi, Been a week or two of work and no chance to get in the garage, and therefore no progress.

Had plans of a full day on the car today but things seem to have been stacked against me. Got all prepped up to carry of with the wheel arch and found I had run out of Gas....... So plan 2 make a part I have been planning for a while, (not needed yet but I have the bits in so......), meant using my mini lathe, buy I had to fix it first. Almost said sod it and worked on the house, but I dont get enough time in the garage and I was not gonna waste the day. Took a couple of hours to manufacture the parts to fix the lathe. Its only a model lathe but suprisingly useful.

I contacted Cossymax from on here a while ago. He recently built a Sunbeam with an S2000 engine in it (interesting thread on here). I saw a part on his radiator that I needed and was interested where I could get one. Unfortunatly it was a one off part he had made and was not a stock item anywhere. I need to connect the inlet manifold coolant breather to something or blank it off.

I have had the radiator a couple of years. I think it was a return (I assume because they put the lower hose connection in the wrong place) cos I got it for a song and is ideal for me.



The Fan switch is a standard part with a 22mm x 1.5mm pitch. It's this area I needed to make a part for. I bought a lump of alloy hex bar from E-Bay and a couple of taps and made this:









The 2 brass fittings are for this unit and the inlet manifold, Unfortunatly the 1/8th NPT tap has not arrived yet. But here is is fitted.