[trackday_prep] Track Toy Preparation To Msa Rallying Regs.

[Mad Scientist 106]

I think this really wants to be in the major projects section but I can't post in there, so its here for now.

 

As some of you know, myself and Sorrentopete have recently acquired a 1990 205 1.9gti, with 90000ish miles and no history what so ever! It cost the princely sum of £0. Actually it cost a £50 donation to Children in Need but you can’t count charity…..mate! Thanks Jon! We will look after her!

 

The idea is to turn the car into a track toy, however, we will be building it to MSA rally regulations so we can get the car log booked for rallying. Whether we rally it or not remains to be decided, but it will make the car more attractive to buyers if we sell it on. It will also mean the car is a lot safer as a track toy.

 

Its all thanks to Pete that we got hold of this, as he was on here at the right moment. I think he would have had it to himself had he not already got 2 complete GTIs and a barn full of spares. What it does mean is that I now have a matching drive to Pete, and we are both lowering the tone of the street!

Having borrowed a trailer (thanks Dai) we set off to pick the car up from Leeds in the pouring rain the Sunday before last. On arrival, it was sat down the side of the Jon’s house in a pretty sorry state. It was covered in moss and pine needles, with 4 flat tyres. It also would not start (unsurprisingly) as it had not been used in well over a year. The tax expired in January 2007. Thinking we could push it onto the trailer, we gave it a go only to find the brakes were well and truly seized. Still undeterred we managed to tow it to the front of the house and winch it on. Two hours later it was on my drive, and I headed back to return the trailer and have Sunday dinner at the GF’s parents house.

 

The next day on returning from work it was dry and not too cold so I set about stripping her! (the car that is!) I got the interior out to find the rear quarter windows had been leaking for some time, causing some mild surface rust in the rear drivers side footwell. There was also a leak through some of the seam sealer on the bulkhead, causing some tin worm in the passenger front footwell. Apart from this, the shell seemed fairly sound, with no rot externally. All good so far.

 

Next thing we did was stick a decent battery on it and try and start her. To our surprise it fired up first time, warmed up normally and sat idling perfectly. The engine sounded pretty good, with no rattles or knocks. Still good thus far!

 

The following weekend we really got stuck in. The rest of the interior came out…….literally all of it. All that remains is the pedal box, and that is only there until I get the brake lines and master cylinder off. I also got the fuel tank and exhaust off for a good poke around underneath. All the wiring is out, and the engine is partially stripped ready for removal.

 

Amazingly, under the car is in very good condition, with only some minor surface corrosion. The only bad rot is the passenger front inner wing, which needs cutting out and replacing. Not a major problem.

 

The plan for next weekend is to get the motor and box out and strip the suspension. I will then be left with a bare shell on axle stands.

 

We will be removing all the seam sealer, seam welding the shell and sorting the inner wing and other rot, before re-sealing and painting the interior and engine bay. From there its going to be cleaning, replacing and bolting everything back on! It also needs a sunroof plate! Not much to do then! Easy!

 

The plan is the following “mods”:

 

Full roll cage (probably bolt in)

FIA bucket seats

6 point FIA harnesses

Plumbed in extinguisher

Polycarb windows and heated front screen

New standard brakes all round

Bilstein suspension (or similar)

Eibach front springs

New bushes all round (some oe, some polybushes)

Fuel and brake lines in car

Brake line rear bias valve

Fuel swirl pot

Relocate battery to rear footwell

Group N top mounts

Group A rear beam mounts

Partial rebuild of engine (depending on what I find)

Full gearbox rebuild

 

Plus, I expect, many other bits as we go along.

 

I’m hoping to get 200bhp/ton out of this which should be more than fun around Oulton.

 

Anyone with any advice, please post away. Similary, if anyone knows of good suppliers for the parts I have listed, let me know. I have done the usual searches but its still a minefield. I am particulary keen to hear from anyone who has recently done the inner wing or plated a sunroof.

 

Pictures to follow……….left the camera at my mates at the weekend.

 

Wish us luck!

 

Pete (and SorrentoPete!)

 

[BusEngineer 7]

I went round to see this the other day and i can honestly say pete works fast!!

It was a pile of bits when i got there

The plans for it sound fantastic tho

As for what i was saying when i was round pete about the floorpan in the one on my drive, the passenger footwell is shot through but the piece behind the drivers seat that is ribbed is sound if you want to cut it out for yours, you are more than welcome fella. In the meantime enjoy, and im sure ill be round sorrento petes at some point to check your progress

PS- enjoy that underseal

[welshpug 1,623]

nice project! good way to approach it IMO, just hope you get it completed in time to avoid the 2009 regs.

Edited November 18, 2008 by welshpug

[Mad Scientist 106]

Busengineer: Thanks for the offer, i'll weigh it up this weekend and let you know.

 

Welshpug: Please tell me more about the 09 regs. I only have the 08 Blue book and have not looked anything regarding regs. up on the net.

[welshpug 1,623]

all I've heard is rumours I'm afraid, don't know how concrete the minimum weights thing is, but I do know that all cars will Require a "dry break" fuel sampling type fitting to be installed regardless of the Logbooking date.

Edited November 18, 2008 by welshpug

[Mad Scientist 106]

Just read what I could find easily, doesn't seem that there will be any problems, just a few tweeks!

[Peetypug 5]

Its about time you started this. If you hadn't you'd have forgotten a few things.

Like the massive spider we evicted that somehow managed to get on the back of my head

Anyway i have a cunning plan that i've been plotting while bored here at work.

This project may be getting a lot more ponies than 200 per tonne

[Mad Scientist 106]

Just trying to work out how to add pics................hopefully, this shows the car when we got it to my house:

 

http://i239.photobucket.com/albums/ff313/P...ey/DSC_0348.jpg

 

Result.........more pics to follow!

[Mad Scientist 106]

OK then, so here are some pictures as promised, but a bit of an update first!

 

Managed to get the locking wheel nut that had stuck off! I had to weld a socket to it in the end, one of Sorrentopetes to be exact!!!……see pic.

 

Also started to dig deeper into the rot in the inner arch, and its not too bad. Just needs a section cutting out and some new steel welding in. Hopefully I’ll get that done tomorrow, along with cutting and plating the other rot in the floorpan. Sunday is seam welding day!

 

 

The car as it was when we got it back:

http://i239.photobucket.com/albums/ff313/P...ey/DSC_0350.jpg

 

Interior:

http://i239.photobucket.com/albums/ff313/P...ey/DSC_0351.jpg

 

Partially stripped:

http://i239.photobucket.com/albums/ff313/P...ey/DSC_0361.jpg

 

ROT!

http://i239.photobucket.com/albums/ff313/P...ey/DSC_0365.jpg

 

MORE ROT!

http://i239.photobucket.com/albums/ff313/P...ey/DSC_0368.jpg

 

After a wash, with fairy liquid!

http://i239.photobucket.com/albums/ff313/P...ey/DSC_0371.jpg

 

And another!

http://i239.photobucket.com/albums/ff313/P...ey/DSC_0372.jpg

[Mad Scientist 106]

Forgot to add, the fuel tank is off now too, and there is nothing to worry about rot wise underneath, which is nice!

 

 

Getting emptier:

http://i239.photobucket.com/albums/ff313/P...ey/DSC_0386.jpg

 

Hired help (actually its free thank God!)

http://i239.photobucket.com/albums/ff313/P...ey/DSC_0447.jpg

 

Locking wheel nut adaptor!

http://i239.photobucket.com/albums/ff313/P...ey/DSC_0444.jpg

 

Inner wing:

http://i239.photobucket.com/albums/ff313/P...ey/DSC_0453.jpg

 

Treated rust:

http://i239.photobucket.com/albums/ff313/P...ey/DSC_0390.jpg

 

Special!

http://i239.photobucket.com/albums/ff313/P...ey/DSC_0406.jpg

 

 

Really getting into this now, so hopefully the momentum will continue.

 

Pete

[jackherer 543]

After a wash, with fairy liquid!

 

I know its only a track car but modern washing up liquid takes off more than T cut

[cybernck 400 1 Cars]

please work out how to add thumbnails before you continue!

 

thanks.

[Peetypug 5]

i'll show him how to do thumbnails first thing in the morning.

[Peetypug 5]

Edited November 22, 2008 by sorrentopete

[Mad Scientist 106]

Well, the engine and gearbox is out now thanks to Pete's help. Cheers mate.