Jersey E30 rally car rebuild

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  • martinpallot
    Bodger
    • Dec 2010
    • 86

    Re: Jersey E30 rally car rebuild

    Frustrating day in the garage today more than anything, rear arms were dropped off from the powdercoaters. these were an experiment to see if im happy with the finish. Im chuffed with how they turned out. The problem came when I went to press the e30 325 bearings in - they were clearly too big. The arms came off a facelift 325i so I immediately thought I had the wrong bearings. however once I measured the bearings and the hubs with the verniers I realised I appeared to have 323i trailing arms. The good thing was that I could still go five stud with these as they use the same bearings as e36 compacts, the annoying thing is that I couldnt use the brand new genuine 1 series drive flanges and bearings that I bought. This meant I had to piss 200 quid up the wall to buy compact bearings and some compact drive flanges :roll: Moral of this story is measure your bearings before you start spending money on your arms!!!



    Over the weekend I modded the rear beam. lifted it almost 40mm up to correct the rollcentres, this brought about the usual problems of the diff carrier, top of the beam and trailing arm brackets hitting the body. will need a combination of panel beating and chopping and welding to rectify. I also ordered high tensile bolts to chassis mount the diff so this is tomorrows job





    Chopped the spare wheel well out as I was going to fit a flat floor anyway and because it made the next job easier. I cut out the turrets and made some new ones, wanted them to look fairly standard which I think they do. They are 35 mm higher than standard , will get some 2 way avos made with rose joints top and bottom.







    I'm Not happy with the rear cage legs for two seasons, they mount on the arch tubs which is very flimsy and the position of the harness bar is such that the harnesses point upwards with the seats in their current position, will get some roll cage tubing ordered and re-do them to pick up at the turrets.

    Comment

    • Graham
      TURBOSPORT SPONSOR
      Turbosport Subscriber
      Turbosport Moderator
      Turbosport Administrator
      • Feb 2006
      • 25214

      Re: Jersey E30 rally car rebuild

      good stuff, i tried a beam that went really high up into the body, but found it was no good because the trailing arms were hard on the chassis rails, although you wont be running wheels as big as mine and thus might not be trying to get it as low on the suspension if you see what i mean
      sigpic
      https://www.facebook.com/penguinmotorslimited?ref=hl

      Comment

      • martinpallot
        Bodger
        • Dec 2010
        • 86

        Re: Jersey E30 rally car rebuild

        Got the rear seat area and the chassis members notched for the beam and rear arm reinforcing tubes - amazing how many issues moving the beam 40mm causes!







        Also started planning how im going to tie the diff to the chassis, going to use use this alloy spacer between the beam and boot floor and weld a tube between the turrets going down to a reinforcement on the boot floor.



        Its all going very slowly at the moment -these jobs seem to take forever!

        Comment

        • martinpallot
          Bodger
          • Dec 2010
          • 86

          Re: Jersey E30 rally car rebuild

          Progress report for the last week - cut the backstays out of the cage, they were heavy as fook, mounted on the arch tubs which have the structural integrity of plastic and the harness bars were in such a shite position that the harnesses would have pointed downwards towards the seat - big order of tubing on its way from custom cages. Also bought a tube notcher from demon tweeks - best hundred quid I ever spent!



          Drawing some inspiration from the more upmarket safety devices cage I decided to make the backstays mount on the turrets but in a slightly neater fashion than chopping 2 big holes in the rear bulkhead so this is what I came up with, pictures speak for them themselves, you can also see the rear strut brace which ties to the boot floor and provides the diff mountings









          All on captive nuts for easy fitting and should be as strong as an ox. Just need the tubing to arrive

          Comment

          • martinpallot
            Bodger
            • Dec 2010
            • 86

            Re: Jersey E30 rally car rebuild

            Some more progress....

            Diff mounts done


            front strut brace


            cage and bulkhead


            brackets and anchor points for the fuel tank, wheel well also plugged


            Comment

            • martinpallot
              Bodger
              • Dec 2010
              • 86

              Re: Jersey E30 rally car rebuild

              long overdue update at last!

              there has been progress - although not a massive amount on the shell itself - sneak peak at the new rear axle which is in hiding under the old shell - i would have taken a proper one but couldn't be bothered to pull the thing out. Its an e30 one with a custom blade type arb mounted under it, e30 arms with e34 inner and outer flanges, e46 300mm rear discs with and powerlite 4pot calipers with an internal handbrake mechanism



              new diff to go in the axle - this was a bit of a nightmare - its an e28 m5 diff with an e46 m3 3.62 CW&P e28 LSD unit which I though would be easy to 4 plate - unfortunately the large case diffs don't have space to fit 4 plates in by simply machining 50 though off the end plate and omitting the spacer - this needed 3.5mm taken off the end plate and the inside of the basket - this meant that the oil channels needed machining back in too. The holes for the crown wheel bolts also needed taking out to 14mm for the m3 ring gear. all new bearings and seals, a lick of paint and a breather welded into the back plate and I should have a theoretically bullet proof diff. Got 4 porsche 930





              I also needed to put a dome in the boot floor as the combination of raising the beam and the large diff meant there was a lot of interference - the brackets at the end of the diff bolt to the tubes through the boot floor to support the heavy bugger. I tied the front chassis mounts for the diff into a plate with a captive nut on the rear seat area where the brackets for the seat belts used to be.




              Then added a bar into the cage which pics up on these - should stop he whole thing ripping the floor to pieces in the (hopefully) unlikely event of a diff failure



              made a rather unconventional handbrake



              Strengthened the front end a bit



              bent up the anti roll bar and welded some brackets to hole the thing on



              made the removeable front jacking points up



              got hole of a rod of polyurethane - after much cursing managed to turn the thing into something resembling some engine mounts. These are to replace the the mk2 escort type ones I used previously. These are wider and harder so should cope with the weight of the s50 better. Now I need to make up some new plates for the motor and dummy fit it for welding together.



              Pedal box now assembled - I had the front and rear suspension powdercoated and this was done at the same time.

              Welded up the copious amounts of holes in the rear firewall too



              Thats it for now - going to be taking a week off in February hopefully to get it all in paint - then it should fly!

              Comment

              • headbolt
                Bodger
                • Jan 2010
                • 171

                Re: Jersey E30 rally car rebuild

                love the handbrake design proper thinking outside the box hope it works ok for you am sure other people may take up that idea

                Comment

                • exboyracer
                  World Champion
                  Decade Plus User
                  • Nov 2003
                  • 6740

                  Re: Jersey E30 rally car rebuild

                  Fantastic work , love the handbrake

                  1968 MK1 Escort 1300GT
                  1969 'Big Wing' MK1 Escort
                  1972 MK3 Cortina 1600XL
                  1984 Sierra XR4i
                  And other junk I don't like to talk about!

                  Comment

                  • david_white
                    Pole Position
                    Decade Plus User
                    • Nov 2004
                    • 4831

                    Re: Jersey E30 rally car rebuild

                    Brilliant work. Love the quality of fabrication and the amount of thought that goes into it. Those rear arms are works of art too.
                    Keep the updates coming..

                    Sierra cosworth turbo race car
                    QMN saloon car championship

                    RETRO Motorsport

                    Comment

                    • Toymex
                      Pit Crew
                      Decade Plus User
                      • Jan 2004
                      • 1337

                      Re: Jersey E30 rally car rebuild

                      Stunning fab work ,i wish i could weld like that

                      Comment

                      • Group4_Mark2
                        Pit Crew
                        Decade Plus User
                        • Dec 2004
                        • 1782

                        Re: Jersey E30 rally car rebuild

                        Welding is superb. I wish mine even looked remotely like this. Anyone willing to do a welding and fabrication tutorial with some videos
                        To finish first, you must first finish

                        Comment

                        • ColeJersey
                          Tyre Kicker
                          • Feb 2013
                          • 30

                          Re: Jersey E30 rally car rebuild

                          Great Fab work.. keep going!

                          Comment

                          • mista weava
                            Mechanic
                            • Sep 2005
                            • 992

                            Re: Jersey E30 rally car rebuild

                            I can't believe the work put into the previous shell was wasted.
                            www.rallycarsforhire.net

                            Comment

                            • martinpallot
                              Bodger
                              • Dec 2010
                              • 86

                              Re: Jersey E30 rally car rebuild

                              Update time

                              Have got the car painted underneath and inside. Fuel system is finished and the suspension is in. Narrow rear 2 way shocks to clear the big CV joints from AVO have arrived but not yet fitted as they forgot to include the upper spring seats. Have bolted on all the bits to get it rolling and made the brackets for the brake calipers front and rear.

                              Currently prepping the bodywork for paint. Hoping to get the main body done next weekend so that I can basically get the car built minus the exterior panels and move enough parts out of the way to allow me to prep the things like wings bonnet, boot and doors.














                              Comment

                              • PaulAlex
                                Pit Crew
                                Decade Plus User
                                • May 2006
                                • 1551

                                Re: Jersey E30 rally car rebuild

                                Lovely looking machine

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