Jersey E30 rally car rebuild

[martinpallot]

Re: Jersey E30 rally car rebuild

Spent all bloody day doing the stupid anti roll bar, As usual when you buy something that isnt meant to fit - it ends up damn dificult making it fit. But I got there in the end and it appears to do its job. good thing with this is that there are different stiffnesses available at only 19 quid a pop. The only problem now is that the brake fitting for the calipers just hits the tip of the ARB blade a fair bit before full lock is reached. No matter what fitting I use there doent seem to be a way around this, so looks like I have a decent excuse to go for some 300mm discs!




Will hopefully fab up the bracket for the battery and the header tank tomorrow. After that I can send a load of bits off for blasting before I paint them.

[exboyracer]

Re: Jersey E30 rally car rebuild

Looking good there

[martinpallot]

Re: Jersey E30 rally car rebuild

Been cracking on with the car these past few weeks. although it feels like nothing much has been done its taking forever to do all these little jobs. Also been been out shopping as you can see.....



Sierra blade type roll bar kitalong with all sort of odds and sodds. This looks like it will work, the blades need chopping and angling in to make the overall width at the tips 4" narrower (never realised sierras were that wide!) The turrets supplied will be used as a base but chopped about a lot as they weigh more than the roll bar itself atm



Made some plates for the gear lever area and the rear bulkhead fittings





After sitting in the car making brum brum noises for a couple of hours I wasnt happy with the brake and clutch pedal position, I choped the pedals up which has given me 2.5" more leg room and a better overall angle for my ankles, feels much more like it should be.




Overcame the problem with the airbox, this took about 3 days to do and im never doing it again. I made a plate to the shape of the area I cut out, made a mould from it, trimmed it. Ground through about 3mm of the carbon layer and countersunk the lot so that it would sit flush, then just glassed it in. Light skim of filler and some satin black and it looks like it came out the factory like that lol. I decided to lob off the carpy glass pipes to the airbox and use some trimmed down standard ones. this exacerbated the clearance problem slightly but got rid of the nasty 30 sharp angle at the joint between the airbox and the TB's.



Finally, binned the old oil coller with the push on fitting and jubilee clips in favour of some proper -10 jobbies. Still awaiting the fittings for the oil filter housing from turner motorsport.

Nowhere near as far as I wanted to be with it tbh and theres deffinately no rallying for me this years as both time and the rally car fundare quickly drying up, But hoping that if its done by Christmas I'll have a good few months to get used to it properly until the first event!

[martinpallot]

Re: Jersey E30 rally car rebuild

Had a busy couple of days, managed to fit the flywheel and clutch, followed by the box yesterday. today I fitted the diff and took measurements for how much I would need to cut and shut the propshaft, needed a whopping 35cm taking out of it! I then made the carrier for the centre bearing. Its heavier duty than I would have liked, but I figured it needed to be able to hold the bearing steady when the prop is spinning at a fair rate of knots. At least this way its one component i shouldn't have to worry about breaking.

I then moved on to making the second gearbox mount. I was advised by Elite to fit one at the front of the box to take the weight and another at the rear to steady it. As this is the evo2 box the drive flange is much further back, meaning that any vibrations from the prop over a long period of time could put more than desired amount of stress on the lugs at the front of the box. hopefully this will keep it in check.

[martinpallot]

Re: Jersey E30 rally car rebuild

Photos which go with the above posts:

[gorilla1q]

Re: Jersey E30 rally car rebuild

Very confused about why the pics wont show

You need to use the uploader at the moment mate the sites having a few problems with external picture hosts or something (such as photobucket)

Loving the car by the way

[martinpallot]

Re: Jersey E30 rally car rebuild

Very confused about why the pics wont show

[martinpallot]

Re: Jersey E30 rally car rebuild

Bit more progress to report today. Painted the bits I welded onto the front end

Then had to engineer a solution to the internal clutch slave cylinder. I know I probably wont need to bleed it unless the box has been off, but thought I better make up some extended piping so that if need be I dont need to take the box off just for that.

And the outside

Got some nice PTFE hosing and fittings for the fuel lines (This might be the first car I have that doesnt smell like a petrol station inside!) Also an MSA fuel sampling kit.

Fresh 4 plate and 30 degree ramp angle diff ready to go in its home

and after much sweating and cursing in my greenhouse/garage where the temperature measured a beautiful 28 degrees I got the engine in. The catch tank im using is mounted on the L/H chassis leg.

Now I need to get the bellhousing fitted along with the box. I also have a slight problem in that the carbon airbox fouls the bars going to the strut tops. Annoyingly only by about half an inch or so, but it does mean that the flange wont bolt up to the inlet, rendering it pretty useless for now. I'm in the process of devising a solution but will hold back on showing progress until I sort it, If you dont see anything reported there may be a carbon airbox going cheap

[Tristan]

Re: Jersey E30 rally car rebuild

pics , Martin?

[martinpallot]

Re: Jersey E30 rally car rebuild

Bit the bullet and ordered one of these off ebay from Hong Kong, it was very cheap and I'd heard mixed reviews but thought what the hell. Supposedly they are of varying quality and its pot luck whether you get one with the internal trumpets or one without. Luckily, the one that turned up had the trumpets. I got on to fitting to the engine, the only minor problem was that the holes to bolt it to the TB's needed opening up slightly but other than that, nothing major.

Here is it fitted


On the bottom side I needed to drill a hole for the BMW temp sensor to fit, the ICV piping fits straight on as you can see, the Other fitting you can see is the one which ussualy sits under the trumpets on the alloy plenum and goes to the head with the standard arrangment, somewhere in between it goes to the plastic oil sperator. This isnt a very good design in that if I were to plumb this straight to the head the box would end up full of oil constantly, not a massive deal with the alloy chamber as it has a fitting which allows the oil to drain back into the sump, but this doesnt. I've got a small catch tank so will plumb this in between the plenum and the head, and fit an 8mm fitting onto the drain hole in the bottom of it to allow it to drain back into the sump. This way the box should never have oil in it and I can ditch the plastic separator.



I also purchased the H&H 'Alpha N' Vanos and DME chips to run it for the time being until I get my arse round to getting it on proper management.

[whitevandan1985]

Re: Jersey E30 rally car rebuild

Some nice fabrication going on and to high standard to.

Keep up the good work!

[supereightyfour]

Re: Jersey E30 rally car rebuild

The threads act as really good stress raisers, if you have the thread wound all the way in you can almost reduce this risk to zero, but out goes the adjustability. The load goes up greatly as you wind the rod end out as well. The differences in joint design mean that a rod end eye can distort from bending and the spherical element can seize.

I had a quick google and this guy talking about the loading these joints are deigned for in his opening paragraph says "if rod ends are used in any other manner, the load ratings published in catalogs are meaningless"

But if you had a whole season with no problem and the rod end still has full movement then it's probably Sufficiently Sized.

[Graham]

Re: Jersey E30 rally car rebuild

I know its a slightly different concept, but given that the standard balljoint is 15.5mm at its thickest point, why would the 5,8ths bolt replacing it be any weaker?

perfect logic if you ask me

[martinpallot]

Re: Jersey E30 rally car rebuild

Interesting and I value any input, im no expert and do things via trial and error (Not the best way to do it, I know lol) If I hadnt done a season on them without issue I would be running into the garage and re-working them. I know its a slightly different concept, but given that the standard balljoint is 15.5mm at its thickest point, why would the 5,8ths bolt replacing it be any weaker?

[supereightyfour]

Re: Jersey E30 rally car rebuild

just make sure the rod in is plenty big enough and there -PROBABLY- wont be an issue

Fixed for you.

Dont worry ive done my maths

Ok, if you're happy, I'm happy.

I figured, eyeballing it really, that a 5/8" thread wouldn't be enough. Any tarmac action with grippy tyres is going to be putting a lot of force through a component that wasn't designed to take it. Lower suspension links carry greater forces in the horizontal plane than the upper links too so it's really the worst place to use them. Deliberately introducing it permanently as though it's an improvement is a mistake.

Use an on-board camera though eh?