Irish Rally Car Build

[Dieseldave]

I made a jig from my old struts & uprights to position the steering arm.





And started to fab the new setup.











Struts built up with all the new parts including custom 12" springs from Faulkner









Spring caps were 1 part that was NLA so I had these spun up





I had these top spacers machined too. (spring cap here was home made to keep things moving)

[welshpug]

nice work Dave! I see there's a thrust bearing under the top cap too, is that to take some of the load away from the Spherical bearing in the top mounting?

What kind of steel do you use for the sheet?

[Dieseldave]

That's how the bearings are done on the C2 and they have a spherical top mount so I decided to use them also.

Steel for the steering arm? Just standard 2mm Mild steel, plenty strong enough when boxed in.

Another thing that was always in the back of my mind during events was the shafts/CV joints.

If was common in the early days of the C2 R2 that they would brake the outer joint where it
tapers down and Citroen upgraded these on the R2 Max and offered it as an upgrade for the R2.

I sourced some Max shafts and below you can see the difference.

Max on the left



Max on Bottom





And to make it work, new C2 R2 Max uprights, flanges and bearings from Cit Sport







Note the hub center has a bigger flange on it to allow spacers to be run.

[welshpug]

ahh that explains why it isn't a standard peugeot/citroen part when the bearing and the carrier is.

[Dieseldave]

Correct, plus any of the large cars or commercials with the bigger spline are 5 stud.

Studs etc changed over from my old uprights

[Cris B]

Looks very trick, nice work Dave

[Dieseldave]

Of course the 'box had to be converted to hydraulic clutch and the easiest option was to go
with this Wilwood pull type to replace the cable. I didnt want to get into modifying the 'box or
cutting up the clutch fork and the Wilwood cylinder works well in my MK1 Golf.



I welded a off stand onto the gearbox mount to carry the end of the cylinder.
I also fitted a dry break connector into the braided line.

[infamous aidy]

it's good to see more progress dave, i love how original you kept the saxo but i also love how you are doing some out of the box thinking on how to do stuff. i'm in the middle of trial fitting the engine again now i've moved the mounts and i'm looking into the clutch now.

i already made a bracket to mount a willwood cylinder but i'm having trouble with my release bearing. something just doesnt look right on it so i am tempted to run a GRT hydraulic bearing but its not a cheap option.

[welshpug]

still using a BE box Aidy?

[infamous aidy]

Yes mate. I think you commented on my Facebook post on the 306 group about the bearing and how it should fit. there is what feels like a lot of slack and i wasn't convinced by it. unfortunately GRT aren't currently replying to my messages.

Also my release bearing is missing one of the tiny little ears that help it pull back from the clutch

[welshpug]

ahh yes, I'm just fitting the BE4 box this evening with a new bearing so I can take a picture for you then.

[jools]

From looking at the boxes together I think there is no more slack on the clutch bearing between the be3 box and be4 box, rather the clutch fork on the be4 box with a ball joint pivot allows the bearing to move around more. The be3 arrangement is a lot better.... that said when installed the clutch works fine

[Dieseldave]

Originally Posted by infamous aidy

it's good to see more progress dave, i love how original you kept the saxo but i also love how you are doing some out of the box thinking on how to do stuff.

Cheers Aidy, With cars like the Saxo its more difficult, time consuming & more expensive
to go original than buy and fit available parts.

I did look at hydraulic release bearings too but they were silly money.



The budget Hispec 6 pot calipers finally made way for these Alcon 4 pots. They are the modern
day equivalent and have the same piston sizes etc as the S1600 Saxo so I expect them to perform
as well.

You may also notice I got a new camera lense & I'm trying my hand at arty stuff











The next hurdle was to have brackets made to mount the callipers.

I spoke to my machine shop about what was required but not been a car guy he
couldn't get his head around what I was at so I made a mock up for him.







And 2 weeks later he handed me a pair of sexy Aluminium brackets

[Dieseldave]

[Dieseldave]

Front corner built up

[infamous aidy]

That's a very clever bit of brake pipe routing dave. ii may have to steal that idea too!

just to save me going back through everything, what bar did you use for the front ARB?

[Dieseldave]

That idea is copyright.

25mm CDS tubing with solid bar hammered up the ends (100mm odd)

[Dieseldave]

These cams fitted to the top bolt of the struts/pivot allow for quick camber adjustment.
the three 8mm holes are are different distances from the 12mm hole so you set the desired
camber at the middle hole and then + or - 20' in each direction.



These sleeves were not in my head and I didn't know they were missing until I built
the Saxo so I pulled them out of an old head and fitted them.



New custom plug leads that actually fit the head correctly



Coil pack remounted as it was fitted to the old brake linkage



I also fitted clasps to the airbox to allow fast removal for access to the steering arms, injectors,
fuel lines etc without having to remove the 8 trumpet bolts.

[infamous aidy]

Originally Posted by Dieseldave

That idea is copyright.

25mm CDS tubing with solid bar hammered up the ends (100mm odd)

if i can't make the the derv roll bar fit i'll be looking into that then.

[Dieseldave]

Back down on all four's again, brakes bled & alignment done ready for a shakedown.

[Cris B]

Nice photos

[indigorallye]

OMG.

[Dieseldave]

Originally Posted by Cris B

Nice photos

Cheers Cris, I'm enjoying playing about with the camera.

Originally Posted by indigorallye

OMG.

Did I do something wrong?

[indigorallye]

Did I do something wrong?

Absolutely not.

[Dieseldave]

Yeah... I knew I did nothing wrong

[LeeThr]

The only thing you've done wrong is you've made me really want to get mine built so I can go drive it in Anger

[Alanapone]

I like the camber adjusters Dave. Do they rotate the bolt which has a lobe on it to adjust the camber or move the bolt in and out to adjust? (Does that make any sense?)

[welshpug]

no, they just push the bolt in/out in the slot on the strut, its a straight M12 bolt, a nice positive location having the 8mm bolt stopping it sliding.

similar to the arrangement shown here on the satchell setup which uses the same hub carrier, but this one relies on the clamping force of the bolt to stop the cam from turning, which to be fair so far it does just fine, Dave at satchell did say you could use a square washer with pre-set holes if you know what camber settings you wanted but so far we hadn't found that they ever moved.

[Dieseldave]

Thats OCD porn right there.

[welshpug]

Stuart's handiwork is quite something isnt it.

[Alanapone]

I see. It does look like a really solid way to do it and I guess it stops the bolt from turning and throwing the camber setting out.

Stuarts work is pretty spectacular as well!!

[shenparbitch]

Wishbone/compression strut bolt should be the other way up .... ����


Thank you btw....

[indigorallye]

Originally Posted by shenparbitch

Wishbone/compression strut bolt should be the other way up .... ����


Thank you btw....

I spotted that too

[Dieseldave]

Some more upgrades after the standard plastic fuel rail let me down.
I was never a fan of the original push on fuel fittings anyway.