Irish Rally Car Build

**Dieseldave** · 27-12-2010, 08:49 PM

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.

I then sourced a non sunroof gti shell.

Some seam welding.

Seat rails in.

**Dieseldave** · 27-12-2010, 08:58 PM

In primer.

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

And a few coats of the clear stuff.

**Dieseldave** · 27-12-2010, 09:13 PM

A new OMP 6 point cage.

Finished in matte black

Grip tape and covers over wishbone holes.

Dash cut to fit around the cage and then flocked.

Engine out of the donor car.

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

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

Bolted together and ready for in.

**Dieseldave** · 27-12-2010, 09:24 PM

Full set of Group N mounts.

Full set of Proflex poly bushes.

Some new Group N Billies.

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

**Dieseldave** · 27-12-2010, 09:37 PM

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

Studs and nuts.

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

Some more nice bits..

Aeroquip lines for the brakes.

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.

KAM racing system

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

Starting to look like a car at last

French style plates with an Irish number.

**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.

6mm OMP alloy sump guard.

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

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

Wrapped the manifold.

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

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.

Few pics of the track car..

**Dieseldave** · 31-12-2010, 06:29 PM

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

And fitting began

Ever wonder how you weld the top of the cage?

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.

**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.

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

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

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.

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

The cage in primer

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.

A close up of the door bars

**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.

Griptape fitted to floor

Plumbed in extinguisher mounted behind the navi seat

Started to make up a switch panel for the dash.

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.

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!

**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

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!

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

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.

27-12-2010, 08:49 PM	#1
Dieseldave 106 RALLYE REGISTER MEMBER Join Date: Sep 2008 Location: Sligo,Ireland Posts: 1,592	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. I then sourced a non sunroof gti shell. Some seam welding. Seat rails in. Last edited by Dieseldave; 15-12-2012 at 11:33 PM.

27-12-2010, 09:13 PM	#3
Dieseldave 106 RALLYE REGISTER MEMBER Join Date: Sep 2008 Location: Sligo,Ireland Posts: 1,592	A new OMP 6 point cage. Finished in matte black Grip tape and covers over wishbone holes. Dash cut to fit around the cage and then flocked. Engine out of the donor car. New genuine water pump,timing belt,cables,clutch etc. I was lucky enough to track down a genuine cup car box and shafts after a guy upgraded to sequential. Bolted together and ready for in. Last edited by Dieseldave; 27-12-2010 at 09:13 PM. Reason: Automerged Doublepost

27-12-2010, 09:37 PM	#5
Dieseldave 106 RALLYE REGISTER MEMBER Join Date: Sep 2008 Location: Sligo,Ireland Posts: 1,592	Kiwi on here sorted me with a set of cup car hubs,big difference over standard. Studs and nuts. New read discs and yellow stuff pads (to be changed for Ferodo's) Some more nice bits.. Aeroquip lines for the brakes. Last edited by Dieseldave; 18-03-2013 at 12:15 AM. Reason: Automerged Doublepost

27-12-2010, 09:45 PM	#6
Garry.M WHOOPS! MEMBERSHIP JUST EXPIRED Join Date: May 2004 Location: Hatton , Peterhead Posts: 1,574	looking good ! Alot of hard work there . ,,,if your going to be rallying then you might want to re-think your suspension. __________________ 2011 SMRC Class C winners 2007 STRC Championship winners* 2008 MSA National Asphalt Championship class B9 winners 2005 Highland speed championship class A1 winner 2006 STRC Class 1 winners

27-12-2010, 10:03 PM	#7
Dieseldave 106 RALLYE REGISTER MEMBER Join Date: Sep 2008 Location: Sligo,Ireland Posts: 1,592	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. KAM racing system Twin fans,one will be on a dash switch and the other as normal. Starting to look like a car at last French style plates with an Irish number. Last edited by Dieseldave; 27-12-2010 at 10:03 PM. Reason: Automerged Doublepost

27-12-2010, 08:58 PM	#2
Dieseldave 106 RALLYE REGISTER MEMBER Join Date: Sep 2008 Location: Sligo,Ireland Posts: 1,592	In primer. And Two coats of VW Candy white from the Mk5 GTI. And a few coats of the clear stuff.

27-12-2010, 09:24 PM	#4
Dieseldave 106 RALLYE REGISTER MEMBER Join Date: Sep 2008 Location: Sligo,Ireland Posts: 1,592	Full set of Group N mounts. Full set of Proflex poly bushes. Some new Group N Billies. I got some second hand Spoox mounts and modded my wishbones.

27-12-2010, 10:19 PM	#8
Dieseldave 106 RALLYE REGISTER MEMBER Join Date: Sep 2008 Location: Sligo,Ireland Posts: 1,592	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. 6mm OMP alloy sump guard. Torque Link for BE box. Mount on floor yet to be reinforced. A big shout out to Garry M who hooked me up with this porn after a lot of searching. Wrapped the manifold. Last edited by Dieseldave; 03-01-2018 at 02:16 PM. Reason: Automerged Doublepost

27-12-2010, 10:32 PM	#9
Saxosteve WHOOPS! MEMBERSHIP JUST EXPIRED Join Date: Feb 2007 Location: ..on Boost. Posts: 612	Very Nice Dave, Looking very good! The AP brakes are very smart!

27-12-2010, 10:35 PM	#10
shenparbitch 106 RALLYE REGISTER MEMBER & ThunderCnut Join Date: Aug 2006 Location: wisbech Posts: 1,766	nice build.... SPLENDID stoppers....

28-12-2010, 11:20 AM	#11
welshpug 106 RALLYE REGISTER MEMBER Join Date: Mar 2006 Location: cwmcarn Posts: 4,912	shiny shit 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

28-12-2010, 12:04 PM	#12
curl666 WHOOPS! MEMBERSHIP JUST EXPIRED Join Date: Nov 2007 Location: South Wales Posts: 7,268	Cracking car build! I had the shiny clarke racing jack for christmas, as seen in a pic or 2

28-12-2010, 07:53 PM	#13
Steven Gault WHOOPS! MEMBERSHIP JUST EXPIRED Join Date: Jul 2010 Location: N Ireland Posts: 87	looking good.. hope to see her out soon

31-12-2010, 06:15 PM	#14
Dieseldave 106 RALLYE REGISTER MEMBER Join Date: Sep 2008 Location: Sligo,Ireland Posts: 1,592	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. Few pics of the track car..

31-12-2010, 06:29 PM	#15
Dieseldave 106 RALLYE REGISTER MEMBER Join Date: Sep 2008 Location: Sligo,Ireland Posts: 1,592	So off I went and bought this lot from Custom Cages. And fitting began Ever wonder how you weld the top of the cage? And thats pretty much where its at now..

31-12-2010, 06:32 PM	#16
dunc Mike's Mechanic Join Date: Mar 2004 Location: Macclesfield, Cheshire Posts: 10,301	Nice work I really need to learn to weld! __________________ dunc been there, done that... got trailered home!

03-01-2011, 06:11 PM	#17
Dieseldave 106 RALLYE REGISTER MEMBER Join Date: Sep 2008 Location: Sligo,Ireland Posts: 1,592	Updates from today.

03-01-2011, 06:30 PM	#18
shenparbitch 106 RALLYE REGISTER MEMBER & ThunderCnut Join Date: Aug 2006 Location: wisbech Posts: 1,766	looks good buddy.. brings back a few stressful memories of doing my cage though!!! haha

05-01-2011, 01:28 PM	#19
Lewis WHOOPS! MEMBERSHIP JUST EXPIRED Join Date: Jun 2006 Location: Bucks Posts: 3,967	That is looking very good mate - cage is tip top! __________________ 106 Rallye - Never ending WIP....

05-01-2011, 01:42 PM	#20
Misspiggy EAST MIDLANDS GROUP LEADER Join Date: Sep 2009 Location: Shepshed Posts: 1,131	that cage is lush...dare i ask how much?? __________________ [CENTER][IMG]http://i456.photobucket.com/albums/qq289/misspiggy1988/sig1.jpg[/IMG][/CENTER] [COLOR="Red"]10% discount to all RR members at constella.co.uk :) just email us for a paypal invoice to get th discount :) [/COLOR]

05-01-2011, 02:39 PM	#21
ash w Banned Join Date: Oct 2009 Location: south molton, devon Posts: 1,944	that cage is awsome, nice build dude

06-01-2011, 12:40 PM	#22
Dieseldave 106 RALLYE REGISTER MEMBER Join Date: Sep 2008 Location: Sligo,Ireland Posts: 1,592	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.

07-01-2011, 01:22 PM	#23
Lewis WHOOPS! MEMBERSHIP JUST EXPIRED Join Date: Jun 2006 Location: Bucks Posts: 3,967	Around 1500 for the kit IIRC. __________________ 106 Rallye - Never ending WIP....

07-01-2011, 04:21 PM	#24
Colin FREELOADER! 85+ posts still not joined :-( Join Date: Dec 2006 Location: Banbury Posts: 96	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!!!

08-01-2011, 05:43 PM	#25
Dieseldave 106 RALLYE REGISTER MEMBER Join Date: Sep 2008 Location: Sligo,Ireland Posts: 1,592	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. Last edited by Dieseldave; 08-01-2011 at 05:43 PM. Reason: Automerged Doublepost

08-01-2011, 05:43 PM	#26
Wayne D IRISH REGIONAL LEADER Join Date: Jun 2004 Location: Monaghan,Ireland Posts: 1,084	Looks great Dave, can't wait to see this when it's finished... __________________ [IMG]http://i16.photobucket.com/albums/b1/wayne_douglas/Sig2009.jpg[/IMG] 106 Rallye Video [url]http://www.youtube.com/watch?v=qYEWnCiGOHw[/url]

08-01-2011, 05:55 PM	#27
welshpug 106 RALLYE REGISTER MEMBER Join Date: Mar 2006 Location: cwmcarn Posts: 4,912	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!

09-01-2011, 12:27 AM	#28
scottmmw 106 RALLYE REGISTER MEMBER Join Date: Jun 2009 Location: cleveland Posts: 1,625	cage looks the nuts, cant wait to see abit more progress! __________________ Northern saloon car champonship build.

15-01-2011, 03:57 PM	#29
c_robinson 106 RALLYE REGISTER MEMBER Join Date: Sep 2006 Location: cheltenham Posts: 1,096	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

15-01-2011, 06:39 PM	#30
Lewis WHOOPS! MEMBERSHIP JUST EXPIRED Join Date: Jun 2006 Location: Bucks Posts: 3,967	That welding is so nice mate, really well done! __________________ 106 Rallye - Never ending WIP....

16-01-2011, 12:42 PM	#32
c_robinson 106 RALLYE REGISTER MEMBER Join Date: Sep 2006 Location: cheltenham Posts: 1,096	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!!!! Last edited by c_robinson; 16-01-2011 at 03:51 PM.

16-01-2011, 03:43 PM	#33
Dieseldave 106 RALLYE REGISTER MEMBER Join Date: Sep 2008 Location: Sligo,Ireland Posts: 1,592	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.

16-01-2011, 03:48 PM	#34
c_robinson 106 RALLYE REGISTER MEMBER Join Date: Sep 2006 Location: cheltenham Posts: 1,096	good work, seen far too many seat rails left un welded all the way round and pulled up at scrutineering. Build looks really nice

16-01-2011, 09:42 PM	#35
Colin FREELOADER! 85+ posts still not joined :-( Join Date: Dec 2006 Location: Banbury Posts: 96	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.

17-01-2011, 12:29 PM	#36
rorz REGISTERED FORUM USER - NON MEMBER Join Date: Jan 2011 Location: wirral Posts: 34	nice build so far bud keep it up

26-02-2011, 09:29 PM	#37
Dieseldave 106 RALLYE REGISTER MEMBER Join Date: Sep 2008 Location: Sligo,Ireland Posts: 1,592	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. I got a cup car clutch cable and group A hub nuts from Skip Brown The cage in primer Last edited by Dieseldave; 24-12-2012 at 10:01 PM. Reason: Automerged Doublepost