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Old 13-11-2017, 02:26 PM   #101
Cris B
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Quote:
Originally Posted by shenparbitch View Post
Rad mounting technique looks familiar ����
Ha ha! I knew you’d done something similar.

I looked for your photos but couldn’t find them on Photobucket so freestyled it
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Old 18-11-2017, 10:53 PM   #102
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Satchshift fitting

Back in 2012(!) when I bought Danny's Quaife'd BE box off him it came with a Satchshift. At which point I sold my MA version and cracked on with the then project car which was the 16v White S2 Rallye. The thing was that in doing this car, I'd welded in a trimmed down version of the stick gator mounting plate so I didn't have one and I'd forgotten that. So the starting point for fitting the Satchshift to this car was to make a bit of tube.

I'd not made a tube out of flat sheet before but I found a paint tin that was the right diameter so used that as a form to bend the steel around. Ended up with this - it's pretty much round



Did the necessary prep, which included blanking the original gear lever hole and welded bit of formed tube in.



Now having fitted a number of Satchshifts over the years any one who has also done it will know that it is enough of a faff to bolt the bits onto the bulkhead with the interior stripped and an empty bay, but it's really a two person job with the car assembled. To remedy that I welded nuts onto the bulkhead so no spanners are needed - just a hex key

I also don't know how the shell was used previously as it had the cutout and drilled holes for the upper pushrod gator, but the other holes weren't drilled which was a bit weird



All fitted:



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Old 19-11-2017, 12:12 PM   #103
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Good work.
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Old 19-11-2017, 08:44 PM   #104
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Did the S1 shell not have the 2 captive nuts for that pedal box brace? They are in my 106 & Saxo.
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Old 19-11-2017, 09:13 PM   #105
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only one captive nut there on an S1.

been helping to do some very similar work on a Red S1 rallye too.
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Old 19-11-2017, 11:39 PM   #106
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Pedals

Bought some Motamec pedal covers, but they weren't a great fit and being thinner alloy that say a set of Sparco's decided that they needed to be modified:



Bit of time shaping them:



Did all three:



Drilled the pedals and welded nuts onto the back to simplify fitting. Bit of matt black to tidy them up...



Mounted

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Old 24-11-2017, 12:13 AM   #107
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Finally managed to get the paperwork sorted and it arrived back from the DVLA this week.



14(!) registered previous keepers which means that there's some significant gaps in my knowledge
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Old 25-11-2017, 11:35 PM   #108
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So suspensions on, steering is connected up. Question has anyone else had any issues with getting the tracking right with Tommy's steering arm kits? I've basically zero'd all of the adjustment out of them and I still have quite a bit of toe in. Without shortening the arms I'm going to have to use thinner lock nuts or something similar to make these work Any one else have any issues?



Chucked the wheels back on and rolled it outside for a wash, it was very dirty but it's given me a chance to clean up some of the mud off the bits I need to tidy up. It's clearly been run without wheel arch liners for quite a long time and now the dirt is gone, it's clear that there is tar residue all over the place.

Rear beam on this car has been properly slammed, too low for my liking...

Any way the reason for getting it rolling was to turn it around so I can do the engine swap out of the Maxi into the Rallye more simply. Once the engine and box are in I can letterbox the bulkhead into the scuttle.
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Old 26-11-2017, 04:54 PM   #109
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Never had an issue on Mike's with the arms. I'd imagine once weight of the front end is in the arms will pinch in and a true toe setting can be set.
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Old 26-11-2017, 11:02 PM   #110
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Quote:
Originally Posted by dunc View Post
Never had an issue on Mike's with the arms. I'd imagine once weight of the front end is in the arms will pinch in and a true toe setting can be set.
Cheers Dunc. I think I need shorter springs so maybe with a completely different setup I'll get it dialled in right...

Before I scrapped the silver GTI I chopped this out:



This was because I had realised the I'd was going to put the EW back in the Maxi so I'd need to repair the cut out I'd put into the chassis and I'd need a donor section. Now when I've been working on the Rallye, I'd come to need to buy a pair of the chassis reinforcement plates.

Turns out this is the last one that 106 Parts had for sale:



By sheer luck I have a pair:



Drilled the four spot welds and with some careful work with the slit disc on the welds and we have two ready to fit...

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Old 08-12-2017, 07:53 PM   #111
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Footrest is in. It was a mission, but second time lucky on the welded in captive nut mountings. Should make it nice and easy if I decide to run carpet and gives me more confidence than the threaded rivet inserts.

Powder coat is bolloxed. Cracked and peeled off as it was bent to shape to fit the footwell. I’ll get it blasted to key it in and then either epoxy it or get it powder coated again.
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Old 09-12-2017, 09:53 PM   #112
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Fantastic progress pal! What is the end intention for the car? I thought initially it was a daily, but there's some pretty fancy parts going in!
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Old 10-12-2017, 08:52 AM   #113
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It’s supposed to be a run about

Just a fancy one
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Old 11-12-2017, 01:36 PM   #114
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Thumbs up

Going to be doing the same for a passenger footrest in mine.

Will you be mounting a small dry cell battery to the rear of the footrest?
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Old 11-12-2017, 04:35 PM   #115
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Quote:
Originally Posted by westwell_22 View Post
Going to be doing the same for a passenger footrest in mine.

Will you be mounting a small dry cell battery to the rear of the footrest?
Yes that's the plan. I did that on my white s2 previously but wanted a more secure mounting this time around. The s1 and s2 floor pans are different shapes too.



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Old 11-12-2017, 06:26 PM   #116
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Whats the plan for the car long-term? Anything MSA related? As there clamping down on putting the battery behind the footrest. If it's not in the rules yet it will be soon but it will need to be behind the back of the occupants not in front.
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Old 12-12-2017, 07:20 AM   #117
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Thanks for the heads up. In that case I will likely put it on the bulkhead behind the passenger seat... I intend to allow an interior to be refitted to road rally rules. Liverpool Motor Club just sent out an email to members about a new version coming out for some light festive reading so I might take a look over the holidays.

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Old Today, 11:15 PM   #118
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Engine's swapped over time to cut the scuttle...



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