Martins 2nd attempt at a rally car build

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Re: Martins 2nd attempt at a rally car build

Postby martine30rally » Wed May 09, 2012 10:37 pm

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!

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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.

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Its all going very slowly at the moment -these jobs seem to take forever!
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Re: Martins 2nd attempt at a rally car build

Postby mef » Wed May 09, 2012 10:58 pm

Very neat welding! well done! I assume you are having to be careful how far you go with such mods in respect of the 1st shell and it's outcome?

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Re: Martins 2nd attempt at a rally car build

Postby martine30rally » Thu May 10, 2012 6:46 am

Thanks, yes I definately need to think twice before I get too grinder happy on this one!
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Re: Martins 2nd attempt at a rally car build

Postby martine30rally » Thu May 17, 2012 11:59 pm

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!

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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

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All on captive nuts for easy fitting and should be as strong as an ox. Just need the tubing to arrive
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Re: Martins 2nd attempt at a rally car build

Postby Tris-m3 » Fri May 18, 2012 9:41 am

Very nice work mate, that should be strong as fook! :D
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Re: Martins 2nd attempt at a rally car build

Postby martine30rally » Wed Jun 06, 2012 12:21 am

Some more progress....

Diff mounts done
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front strut brace
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cage and bulkhead
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brackets and anchor points for the fuel tank, wheel well also plugged
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Re: Martins 2nd attempt at a rally car build

Postby Tris-m3 » Mon Jun 11, 2012 9:36 am

Nice work mate. It's got to be time for paint soon??
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Re: Martins 2nd attempt at a rally car build

Postby hsr2.6 » Mon Jun 11, 2012 10:37 am

Maybe the august hill climb :lol:
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Re: Martins 2nd attempt at a rally car build

Postby Dan-valver » Sun Jul 15, 2012 9:12 pm

Any update on this Martino?
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Re: Martins 2nd attempt at a rally car build

Postby Tris-m3 » Thu Aug 23, 2012 3:06 pm

Is this progressing anymore Martin? Or have you taken it apart again!? :lol:
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Re: Martins 2nd attempt at a rally car build

Postby martine30rally » Thu Aug 23, 2012 5:08 pm

It has progressed to an extent - still plenmty to do though, half the rubberoid is stripped off the bottom now, have gone to a large case e28 m5 diff so this has required various modifications slight changes of direction in some areas. Will update towards the end of next month as have other various things going on that are taking priority!
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Re: Martins 2nd attempt at a rally car build

Postby martine30rally » Sat Dec 29, 2012 11:03 pm

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

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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

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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.

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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

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made a rather unconventional handbrake

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Strengthened the front end a bit

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

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made the removeable front jacking points up

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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.

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

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

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Thats it for now - going to be taking a week off in February hopefully to get it all in paint - then it should fly!
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Re: Martins 2nd attempt at a rally car build

Postby alan1272 » Sun Dec 30, 2012 12:34 am

blardy hell!!!
top fabbin' again!

you gonna have a hatch in the dash in case the hyd handbrake cylinder needs attention?
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Re: Martins 2nd attempt at a rally car build

Postby gartrac » Sun Dec 30, 2012 12:02 pm

Some of the text seems to have been chopped by the images

I should have a theoretically bullet proof diff. Got 4 porsche 930


I take it you are using porsche 930 CV joints on the driveshafts, if you want to make the driveshafts bullet proof you can replace the inner cages available here, this is the only part of the joint that fails

http://www.prolinx.biz/Driveshaft_prices.htm

Is the width of the 930 joint going to be a problem or is there enough plunge to accommodate it, I know they will fit the splines on the M5 shafts, from memory the standard BMW joint is 32mm wide and the 930 is 40mm wide, or are you having custom shafts made

Once again nice fabrication work

Peter
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Re: Martins 2nd attempt at a rally car build

Postby is-si » Tue Jan 01, 2013 12:05 pm

Nice work Martin 8) , Interesting to see a big diff going in, presumeably made possible by the drop gears in your box. Did the E34 flanges require turning down to fit thru the E30 bearing?
Should be a roller soon. But is very time consuming stuff, i understand that regular posting can become hard.
Cheers
John
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