106 Rallye Register Forum

106 Rallye Register Forum (http://www.106rallyeforum.com/forum2008/forum.php)
-   Irish Members Cars (http://www.106rallyeforum.com/forum2008/forumdisplay.php?f=128)
-   -   Irish Rally Car Build (http://www.106rallyeforum.com/forum2008/showthread.php?t=77904)

Dieseldave 27-12-2010 08:49 PM

Irish Rally Car Build
 
Ive been getting a lot of info and buying a lot of parts on here lately
so I decided to do a build thread of my rally car.

This is the donor car I picked up in London on the way back from a
trip to the 'Ring. It had some nice parts like a 4 branch,spare rims with
A048's bucket seat etc.

http://i17.photobucket.com/albums/b8...europe/106.jpg

I then sourced a non sunroof gti shell.

http://i17.photobucket.com/albums/b8...allyCar051.jpg

Some seam welding.

http://i17.photobucket.com/albums/b8...allyCar064.jpg

http://i17.photobucket.com/albums/b8...allyCar065.jpg

http://i17.photobucket.com/albums/b8...allyCar066.jpg

Seat rails in.

http://i17.photobucket.com/albums/b8...allyCar079.jpg

http://i17.photobucket.com/albums/b8...allyCar069.jpg

http://i17.photobucket.com/albums/b8...allyCar068.jpg

Dieseldave 27-12-2010 08:58 PM

http://i17.photobucket.com/albums/b8...allyCar067.jpg

http://i17.photobucket.com/albums/b8...allyCar089.jpg

http://i17.photobucket.com/albums/b8...allyCar092.jpg

In primer.

http://i17.photobucket.com/albums/b8...allyCar076.jpg

http://i17.photobucket.com/albums/b8...allyCar077.jpg

And Two coats of VW Candy white from the Mk5 GTI.

http://i17.photobucket.com/albums/b8...allyCar080.jpg

http://i17.photobucket.com/albums/b8...allyCar081.jpg

And a few coats of the clear stuff.

http://i17.photobucket.com/albums/b8...allyCar100.jpg

http://i17.photobucket.com/albums/b8...allyCar099.jpg

http://i17.photobucket.com/albums/b8...allyCar088.jpg

http://i17.photobucket.com/albums/b8...allyCar096.jpg

http://i17.photobucket.com/albums/b8...allyCar097.jpg

http://i17.photobucket.com/albums/b8...allyCar091.jpg

http://i17.photobucket.com/albums/b8...allyCar090.jpg

Dieseldave 27-12-2010 09:13 PM

A new OMP 6 point cage.

http://i17.photobucket.com/albums/b8...allyCar102.jpg

http://i17.photobucket.com/albums/b8...allyCar103.jpg

Finished in matte black

http://i17.photobucket.com/albums/b8...allyCar105.jpg

http://i17.photobucket.com/albums/b8...allyCar106.jpg

Grip tape and covers over wishbone holes.

http://i17.photobucket.com/albums/b8...allyCar095.jpg

http://i17.photobucket.com/albums/b8...allyCar094.jpg

http://i17.photobucket.com/albums/b8...allyCar098.jpg

Dash cut to fit around the cage and then flocked.

http://i17.photobucket.com/albums/b8...e/DSC01891.jpg

http://i17.photobucket.com/albums/b8...e/DSC01904.jpg

Engine out of the donor car.

http://i17.photobucket.com/albums/b8...e/DSC01880.jpg

http://i17.photobucket.com/albums/b8...e/DSC01881.jpg

New genuine water pump,timing belt,cables,clutch etc.

http://i17.photobucket.com/albums/b8...e/DSC01911.jpg

http://i17.photobucket.com/albums/b8...e/DSC01913.jpg

http://i17.photobucket.com/albums/b8...e/DSC01914.jpg

I was lucky enough to track down a genuine cup car box and shafts after a guy
upgraded to sequential.

http://i17.photobucket.com/albums/b8...europe/fd6.jpg

http://i17.photobucket.com/albums/b8...europe/fd7.jpg

Bolted together and ready for in.

http://i17.photobucket.com/albums/b8...urope/fd14.jpg

http://i17.photobucket.com/albums/b8...urope/fd13.jpg

http://i17.photobucket.com/albums/b8...ope/106007.jpg

http://i17.photobucket.com/albums/b8...ope/106008.jpg

Dieseldave 27-12-2010 09:24 PM

Full set of Group N mounts.

http://i17.photobucket.com/albums/b8...ope/106001.jpg

Full set of Proflex poly bushes.

http://i17.photobucket.com/albums/b8...BLOCK001-1.jpg

http://i17.photobucket.com/albums/b8...allyCar107.jpg

Some new Group N Billies.

http://i17.photobucket.com/albums/b8...e/DSC01948.jpg

http://i17.photobucket.com/albums/b8...e/DSC01946.jpg

http://i17.photobucket.com/albums/b8...e/DSC01949.jpg

I got some second hand Spoox mounts and modded my wishbones.

http://i17.photobucket.com/albums/b8...rope/gh005.jpg

http://i17.photobucket.com/albums/b8...rope/gh006.jpg

http://i17.photobucket.com/albums/b8...rope/gh007.jpg

http://i17.photobucket.com/albums/b8...rope/gh014.jpg

Dieseldave 27-12-2010 09:37 PM

Kiwi on here sorted me with a set of cup car hubs,big difference over standard.

http://i17.photobucket.com/albums/b8...rope/gh001.jpg

http://i17.photobucket.com/albums/b8...pe/gh003-1.jpg

http://i17.photobucket.com/albums/b8...rope/gh004.jpg

Studs and nuts.

http://i17.photobucket.com/albums/b8...europe/fd8.jpg

New read discs and yellow stuff pads (to be changed for Ferodo's)

http://i17.photobucket.com/albums/b8...urope/fd31.jpg

http://i17.photobucket.com/albums/b8...forsale041.jpg

Some more nice bits..

http://i17.photobucket.com/albums/b8...e/DSC01882.jpg

http://i17.photobucket.com/albums/b8...e/BLOCK023.jpg

http://i17.photobucket.com/albums/b8...e/DSC01928.jpg

http://i17.photobucket.com/albums/b8...e/DSC01930.jpg

http://i17.photobucket.com/albums/b8...e/DSC01929.jpg

http://i17.photobucket.com/albums/b8...e/DSC01931.jpg

http://i17.photobucket.com/albums/b8...e/DSC01908.jpg

http://i17.photobucket.com/albums/b8...e/DSC01907.jpg

Aeroquip lines for the brakes.

http://i17.photobucket.com/albums/b8...e/BLOCK024.jpg

http://i17.photobucket.com/albums/b8...e/BLOCK025.jpg

http://i17.photobucket.com/albums/b8...e/BLOCK033.jpg

http://i17.photobucket.com/albums/b8...e/BLOCK029.jpg

http://i17.photobucket.com/albums/b8...e/BLOCK030.jpg

http://i17.photobucket.com/albums/b8...e/BLOCK027.jpg

Garry.M 27-12-2010 09:45 PM

looking good ! Alot of hard work there . ,,,if your going to be rallying then you might want to re-think your suspension.

Dieseldave 27-12-2010 10:03 PM

I will be going with rear Proflex to start with when its all up and running.
At this stage I just want to get it on the road and I can upgrade as I go.

Aero catches and boot clips fitted.

http://i17.photobucket.com/albums/b8...e/DSC01885.jpg

http://i17.photobucket.com/albums/b8...e/BLOCK034.jpg

http://i17.photobucket.com/albums/b8...e/BLOCK035.jpg

http://i17.photobucket.com/albums/b8...e/BLOCK031.jpg

KAM racing system

http://i17.photobucket.com/albums/b8...e/BLOCK026.jpg

http://i17.photobucket.com/albums/b8...e/BLOCK032.jpg

Twin fans,one will be on a dash switch and the other as normal.

http://i17.photobucket.com/albums/b8...BLOCK001-2.jpg

http://i17.photobucket.com/albums/b8...BLOCK002-2.jpg

Starting to look like a car at last :)

http://i17.photobucket.com/albums/b8...BLOCK003-2.jpg

http://i17.photobucket.com/albums/b8...BLOCK004-1.jpg

http://i17.photobucket.com/albums/b8...BLOCK006-2.jpg

http://i17.photobucket.com/albums/b8...BLOCK007-2.jpg

French style plates with an Irish number.

http://i17.photobucket.com/albums/b8...BLOCK008-2.jpg

http://i17.photobucket.com/albums/b8...BLOCK009-2.jpg

http://i17.photobucket.com/albums/b8...BLOCK010-2.jpg

Dieseldave 27-12-2010 10:19 PM

I'm running braided fuel lines inside the car so the fuel filter had to
be moved. I modded a diesel filter bracket from a MK2 Golf.

http://i17.photobucket.com/albums/b8...forsale039.jpg

http://i17.photobucket.com/albums/b8...forsale022.jpg

6mm OMP alloy sump guard.

http://i17.photobucket.com/albums/b8...urope/fd17.jpg

http://i17.photobucket.com/albums/b8...reakers010.jpg

http://i17.photobucket.com/albums/b8...reakers013.jpg

Torque Link for BE box. Mount on floor yet to be reinforced.

http://i17.photobucket.com/albums/b8...reakers011.jpg

http://i17.photobucket.com/albums/b8...reakers012.jpg

A big shout out to Garry M who hooked me up with this porn after a lot
of searching.

http://i17.photobucket.com/albums/b8...Picture050.jpg

http://i17.photobucket.com/albums/b8...Picture051.jpg

http://i17.photobucket.com/albums/b8...Picture052.jpg

http://i17.photobucket.com/albums/b8...Picture053.jpg

http://i17.photobucket.com/albums/b8...cture043-1.jpg

http://i17.photobucket.com/albums/b8...cture044-1.jpg

http://i17.photobucket.com/albums/b8...Picture054.jpg

Wrapped the manifold.

http://i17.photobucket.com/albums/b8...reakers008.jpg

http://i17.photobucket.com/albums/b8...reakers009.jpg

Saxosteve 27-12-2010 10:32 PM

Very Nice Dave,

Looking very good! The AP brakes are very smart!

shenparbitch 27-12-2010 10:35 PM

nice build.... SPLENDID stoppers....

welshpug 28-12-2010 11:20 AM

shiny shit :D

your rear brake pads are in the wrong way BTW, the L shaped bar is meant to be on the trailing edge of the pads :)

curl666 28-12-2010 12:04 PM

Cracking car build!

I had the shiny clarke racing jack for christmas, as seen in a pic or 2 :)

Steven Gault 28-12-2010 07:53 PM

looking good.. hope to see her out soon

Dieseldave 31-12-2010 06:15 PM

The one thing I was never happy with was the bolt in cage and when
the guy who came to buy my track car mentioned he was looking for a cage
I jumped at the chance to sell the one from this car.

So back to square one.

http://i17.photobucket.com/albums/b8...reakers038.jpg

http://i17.photobucket.com/albums/b8...reakers043.jpg

http://i17.photobucket.com/albums/b8...reakers046.jpg

http://i17.photobucket.com/albums/b8...reakers047.jpg

Few pics of the track car..

http://i17.photobucket.com/albums/b8...rope/track.jpg

http://i17.photobucket.com/albums/b8...europe/dfh.jpg

http://i17.photobucket.com/albums/b8...europe/dfg.jpg

Dieseldave 31-12-2010 06:29 PM

So off I went and bought this lot from Custom Cages.

http://i17.photobucket.com/albums/b8...omCages018.jpg

http://i17.photobucket.com/albums/b8...omCages020.jpg

http://i17.photobucket.com/albums/b8...omCages021.jpg

And fitting began

http://i17.photobucket.com/albums/b8...omCages025.jpg

http://i17.photobucket.com/albums/b8...omCages023.jpg

http://i17.photobucket.com/albums/b8...omCages024.jpg

http://i17.photobucket.com/albums/b8...omCages027.jpg

http://i17.photobucket.com/albums/b8...omCages028.jpg

http://i17.photobucket.com/albums/b8...omCages030.jpg

Ever wonder how you weld the top of the cage?

http://i17.photobucket.com/albums/b8...omCages031.jpg

http://i17.photobucket.com/albums/b8...omCages032.jpg

http://i17.photobucket.com/albums/b8...omCages033.jpg

http://i17.photobucket.com/albums/b8...omCages034.jpg

http://i17.photobucket.com/albums/b8...omCages035.jpg

And thats pretty much where its at now..

dunc 31-12-2010 06:32 PM

Nice work :) I really need to learn to weld!

Dieseldave 03-01-2011 06:11 PM

Updates from today.

http://i17.photobucket.com/albums/b8...Picture001.jpg

http://i17.photobucket.com/albums/b8...Picture002.jpg

http://i17.photobucket.com/albums/b8...Picture003.jpg

http://i17.photobucket.com/albums/b8...Picture004.jpg

http://i17.photobucket.com/albums/b8...Picture005.jpg

http://i17.photobucket.com/albums/b8...Picture007.jpg

http://i17.photobucket.com/albums/b8...Picture006.jpg

shenparbitch 03-01-2011 06:30 PM

looks good buddy.. brings back a few stressful memories of doing my cage though!!! haha

Lewis 05-01-2011 01:28 PM

That is looking very good mate - cage is tip top!

Misspiggy 05-01-2011 01:42 PM

that cage is lush...dare i ask how much??

ash w 05-01-2011 02:39 PM

that cage is awsome, nice build dude

Dieseldave 06-01-2011 12:40 PM

Cheers guys,check out custom cages website for pics and prices.

I bought one for this and my buddys Mk2 Escort so got a deal on two.

Lewis 07-01-2011 01:22 PM

Around 1500 for the kit IIRC.

Colin 07-01-2011 04:21 PM

Looking really good Dave, envious of the gearbox!!!

Just a quick one and I hate to be a Buzz Killington... But you have the fittings on your Hydro handbrake the wrong way round, the smaller fitting at the front is the pressure out. From the bias valve it needs to go to the rear (bigger fitting) and then the line runs to the back of the car from the smaller fitting. Hope that helps and keep up the good work!!!

Dieseldave 08-01-2011 05:43 PM

The cage only cost me 800 euro cash.

Colin, both fittings on the handbrake are the same size and marked In and Out.
If you think about it,the fluid flows in the front and when you pull the lever the piston
moves back and forces the fluid out the rear.

I tig welded the cage as its stronger and neater looking.Still another few hours
in it and then prep for paint.

http://i17.photobucket.com/albums/b8...Picture010.jpg

http://i17.photobucket.com/albums/b8...Picture020.jpg

http://i17.photobucket.com/albums/b8...Picture018.jpg

http://i17.photobucket.com/albums/b8...Picture013.jpg

http://i17.photobucket.com/albums/b8...Picture017.jpg

Wayne D 08-01-2011 05:43 PM

Looks great Dave, can't wait to see this when it's finished...

welshpug 08-01-2011 05:55 PM

naah, the handbrake is wrongly plumbed in, its from the bias valve to the rear port, and the front port to the back brakes.

check the wilwood website!

scottmmw 09-01-2011 12:27 AM

cage looks the nuts, cant wait to see abit more progress!

c_robinson 15-01-2011 03:57 PM

couldn't see for sure but looks like you didn't weld the underneath of the seat rail mounts, that's a big thing for scruts after the wyedean 07 death.

Otherwise looking damm good

Lewis 15-01-2011 06:39 PM

That welding is so nice mate, really well done!

Colin 15-01-2011 07:00 PM

Quote:

Originally Posted by c_robinson (Post 740386)
couldn't see for sure but looks like you didn't weld the underneath of the seat rail mounts, that's a big thing for scruts after the wyedean 07 death.

Otherwise looking damm good

Charlie can you explain abit more? Bit concerned. As in fully welded round the tube rail?

c_robinson 16-01-2011 12:42 PM

http://i17.photobucket.com/albums/b8...allyCar069.jpg

http://i712.photobucket.com/albums/w...allyCar069.jpg

You need to weld ALL THE WAY around the plate and the box section. It's not easy and it's not going to be particularly pretty but in the UK atleast it has to be done, no questions!

The death on the Wyedean 2007 was reportedly caused by seat rails not welded all the way round, resulting in both rails snapping on impact!!!!

Dieseldave 16-01-2011 03:43 PM

It has been fully welded on my car,all the pics were taken at different stages of work so they are not
an exact guide of the work that has been done.

c_robinson 16-01-2011 03:48 PM

good work, seen far too many seat rails left un welded all the way round and pulled up at scrutineering.

Build looks really nice

Colin 16-01-2011 09:42 PM

Thanks for the that Charlie, my rails are OK albeit tube and not box section, just I didnt know about the Wyedean accident and it alarmed me lol.

rorz 17-01-2011 12:29 PM

nice build so far bud keep it up

Dieseldave 26-02-2011 09:29 PM

Some more updates

I came across these advertised and had to have them,they are for a 206 cup car
but were never fitted to a rally car.

http://i17.photobucket.com/albums/b8...e/europe/s.jpg

http://i17.photobucket.com/albums/b8...e/europe/F.jpg

http://i17.photobucket.com/albums/b8...europe/g-1.jpg

http://i17.photobucket.com/albums/b8...europe/ADF.jpg

I got a cup car clutch cable and group A hub nuts from Skip Brown

http://i17.photobucket.com/albums/b8...ope/mk2014.jpg

The cage in primer

http://i17.photobucket.com/albums/b8...rope/dbf12.jpg

http://i17.photobucket.com/albums/b8...rope/dbf14.jpg

http://i17.photobucket.com/albums/b8...rope/dbf15.jpg

http://i17.photobucket.com/albums/b8...rope/dbf16.jpg

indigorallye 26-02-2011 09:52 PM

Nice!
Thanks for those pics too ;)

Dieseldave 26-02-2011 10:24 PM

No problem Mike,you have it all ahead of you now.

I got it painted today, very happy with the end result.

http://i17.photobucket.com/albums/b8...rope/awer1.jpg

http://i17.photobucket.com/albums/b8...rope/awer2.jpg

http://i17.photobucket.com/albums/b8...rope/awer3.jpg

http://i17.photobucket.com/albums/b8...rope/awer4.jpg

http://i17.photobucket.com/albums/b8...rope/awer5.jpg

http://i17.photobucket.com/albums/b8...rope/awer7.jpg

http://i17.photobucket.com/albums/b8...urope/awer.jpg

http://i17.photobucket.com/albums/b8...rope/awer8.jpg

A close up of the door bars

http://i17.photobucket.com/albums/b8...rope/awer6.jpg

shenparbitch 27-02-2011 09:15 AM

nevermind the doorbars.. "amii 25" has some superb airbags....

indigorallye 27-02-2011 09:29 AM

Think you will need spacers for the 206 rims too.

blakeyrallye 27-02-2011 10:21 AM

out of interest, how much did you pay for the hubs mate?

Dieseldave 27-02-2011 07:04 PM

I got the two hubs second hand for 200 pound. Mr. Brown wanted 258 each.

Mike.. The wheels came off a 106 GTi road car and had no spacers.

Wayne D 27-02-2011 07:50 PM

Car looks amazing mate, coming along really well. Hope to see this at some stage when you have it up and running.

Dieseldave 07-03-2011 09:36 PM

Just a few small updates.

I stripped out all the loom for electric windows,locking,heater,alarm etc.
Nice bit of weight in it too.

http://i17.photobucket.com/albums/b8...dave/loom4.jpg

http://i17.photobucket.com/albums/b8...dave/loom7.jpg

Griptape fitted to floor

http://i17.photobucket.com/albums/b8...dave/loom2.jpg

http://i17.photobucket.com/albums/b8.../picbits17.jpg

Plumbed in extinguisher mounted behind the navi seat

http://i17.photobucket.com/albums/b8.../picbits19.jpg

Started to make up a switch panel for the dash.

http://i17.photobucket.com/albums/b8...pe/picbits.jpg

http://i17.photobucket.com/albums/b8...e/picbits1.jpg

As the dash now needs to go into possition at an angle to fit around the cage the 3
mounting lugs were hitting off the bulkhead on the way in so I had to make room for them.

http://i17.photobucket.com/albums/b8.../picbits18.jpg

Lewis 08-03-2011 08:30 AM

This is really nice mate - I like the way even though it's a rally car you're still doing it properly and making a nice job of it. The attitude of most is ''oh it's a rally car mate so doesn't matter how it looks!'' Lazy fuckers! :p

scottmmw 08-03-2011 09:28 AM

looks really neat mate, i like your centre switch section, i have an idea of doing something like that too!

Nazor 08-03-2011 10:23 AM

Really disliking you at this stage Dave - after reading down through this :( jealous!

Trying to get a BE setup sorted for my 106 rally car - One Question - How did u get the GrpN mounts to work with the BE Box?? surely if they are GrpN they are for a MA setup - did u modify it?

blakeyrallye 08-03-2011 01:47 PM

Quote:

Originally Posted by Lewis (Post 749907)
This is really nice mate - I like the way even though it's a rally car you're still doing it properly and making a nice job of it. The attitude of most is ''oh it's a rally car mate so doesn't matter how it looks!'' Lazy fuckers! :p

if a rally car isn't prepared properly then you'll find yourself never finishing a rally due to unreliability!!

Dieseldave 08-03-2011 09:31 PM

Thanks for the kind words gents.

I think Lewis was refering to the cosmetics not the build quality.

Quote:

Originally Posted by Nazor (Post 749918)
Really disliking you at this stage Dave - after reading down through this :( jealous!

Trying to get a BE setup sorted for my 106 rally car - One Question - How did u get the GrpN mounts to work with the BE Box?? surely if they are GrpN they are for a MA setup - did u modify it?

The top gearbox mount on the battery tray is the same for BE or MA,the difference is with the bracket on the box itself. The lower mount wont fit,you need a torque link like above.


All times are GMT. The time now is 01:30 PM.

Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2018, vBulletin Solutions, Inc.