Irish Rally Car Build

[Dieseldave]

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]

In primer.





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





And a few coats of the clear stuff.

[Dieseldave]

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]

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]

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]

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

[Dieseldave]

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]

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]

Very Nice Dave,

Looking very good! The AP brakes are very smart!

[shenparbitch]

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

[welshpug]

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]

Cracking car build!

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

[Steven Gault]

looking good.. hope to see her out soon

[Dieseldave]

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]

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]

Nice work I really need to learn to weld!

[Dieseldave]

Updates from today.

[shenparbitch]

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

[Lewis]

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

[Misspiggy]

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

[ash w]

that cage is awsome, nice build dude

[Dieseldave]

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]

Around 1500 for the kit IIRC.

[Colin]

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]

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]

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

[welshpug]

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]

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

[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

[Lewis]

That welding is so nice mate, really well done!

[Colin]

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]

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]

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]

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]

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]

nice build so far bud keep it up

[Dieseldave]

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]

Nice!
Thanks for those pics too

[Dieseldave]

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]

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

[indigorallye]

Think you will need spacers for the 206 rims too.

[blakeyrallye]

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

[Dieseldave]

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]

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

[Dieseldave]

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]

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]

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

[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?

[blakeyrallye]

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]

Thanks for the kind words gents.

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

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.