My Indigo Blue Throttle Bodied 106 Rallye

[Track_Cit]

Yea once but the engine still needs setting up as its running uber UBER rich!

the steering wheel stuff sorta took a back seat tonight, as I picked up my bits from the coaters today. I took all the wiper motor assembly apart for coating as it was old and haggard looking. It was a bit of a mission to do but easy once you start re-assembling. I took lots of photo's so I remebered how it went back together, something I didn't do with parts on the Saxo so I learned a valuable lesson there! Looks way better now any, and will be protected from corrosion. Obviously couldn't do the motor bit so that'll just get a clean up. Also got the modded Satchshift plate back, looks sweet so I am stoked with that! FINALLY got it all in, and a cheeky video too.


Anyways here are the pics:

Blasted and coated - check!



Close up:






Finally fitted:



Video (viewable by link only too):

http://www.youtube.com/watch?v=U0PX2ePyk3s

[Track_Cit]

Some more updates...got some Megs quick detailer the weeked (great stuff) and gave the Rallye a good clean as it was minging from the journey over. I think Dave (the guy from work who helped bring it over) took great pleasure in driving the trailer through the biggest puddles of st ever on the back roads to dirty it up! So, whipped round and got it all nice and mint again - looks SO shiny when it's clean i love it!

Also got started to put the wiper linkages back together after giving the other bits a bit of a polish.

I will carry on with the lowering of the steering column later this week when the spacers arrive, so pics to follow.

My Dad also came over and helped me finish my garage lighting (well actually wired it all for me which was sweet), so now I can see properly and my photo's will come out a little better.

Here's progress so far:



New door bolts - better pic:






Clean again:








Wiper motor linkages starting to get back together:










That's all for now!

Lewis

[Track_Cit]

More updates tonight - finally got myself a crimp tool to do the Amp superseal connectors without spending £200 on the 'proper' one! So finished off my wiper motor set up tonight. Looks much neater now and will be waterproof now too. Just need to do the other side where it connects and it's done. Been working on my column too but that's not finished yet. Will stick up pics when done.

Here are the snaps anyways - not the best photo's in the world but you get the idea:



















That is all for now,


Lewis

[Track_Cit]

Cheers guys - almost there now!


Right few more updates tonight. I had a right fk about with my Satchshift due to the fact my gearbox selector arm only had one ball on it (no puns please!) but I managed to get around it, the hard way as is usual with my car at the moment. I must have the patience of a saint....

Anyways, I borrowed a big hammer and some snap on long punches from the Audi mechanic who I am mates with next door to where I work, and whacked out the roll pin holding the selector arm on. I then used the punch to press the ball out from the selector arm, drilled a 6mm hole and relocated it further up the arm. While I was at it I cut the bottom off as it's no longer required. It was also something i'd been meaning to do, but never anticipated actually getting the arm off....ever! So got that sorted, painted it, and refitted it. Makes a huge difference to the gear change, and now it's uber close and tight like it should have been form the start, if it wasn't for my ste selector arm! I removed the bottom ball that standard gear linkages use too, the one that's bolted to the gearbox. Gives a little more room to work under there with the excess metal out of the way.

I also removed the standard wheel speed sensor from the gearbox, and modified it to make a blank, and my STACK does not use this to take the speed reading. Just tidying up and removing stuff that's not needed.

And last, but by no means least, I picked up my new AST race suspension from Dan while I was down in Devon the weekend. I still owe him a bit of cash but he was kind enough to let me collect them while I was down so a huge thanks to him. Also had a good chat and it was funny listening to our birds comparing our obsessions with bolts and cars, very amusing it was! They also use different hubs to the one's I have, and work with tapered drive shafts. My hubs are meant for flat drive shafts, but i'm thinking of keeping these ones as they are way more beefy, and just getting some new shafts. One of the wheel bearings does feel tight as hell though so i'll need to replace that.

Getting there now chipping away at the last little (but painful) jobs!

Here are the photo's anyway:

[Track_Cit]

V8S said:

Hi chap - I sent you an email through your profile a couple of weeks ago. Did you get it?

Hi mate, no I don't think so? Try sending it to [e-mail] instead.

Thanks again lads. last few steps to get to the finish line now really. Need to swap the wheel bearings, get the top plates welded on for the suspension, then the exhaust then mapping. So a fair bit when you list it out. The most contraining aspect of this build is the fundage as you can imagine!

Drilled the post welds off one of these, and just need to get something similar welded onto the top plates to support the bonnet lifts, then that's that sorted:



like so:

[Track_Cit]

If it was working i'd love to mate, but I still have a fair few jobs until she's ready Maybe next time! Thanks for the props - do you have a blog on yours?

Pete, yes please dude!

[Track_Cit]

Well here is my quarterly update!

It is necessary to fit the turret top plates when using solid mounts, but one was presented with the problem of the bonnet props being in the way. I wasn't happy with the usual solution of chopping the plates around the bonnet props, or just doing away with them altogether, so I wanted do something a little bit different and incorporate the bonnet stay into the plate so to speak. Unfortunately I can't weld.......

Enter Stu, metalwork guru, cider drinking champion and generally all round top bloke! I asked if he could knock something up from my drawing which he said wouldn't be a problem. After a royal fk about with the courier, my plates finally arrived back from Stu, so a massive thanks to him again for his sterling work. As usual, perfect workmanship, and a super job all round. Big thanks to him again.

So I got them just offered up on the car to make sure they all fitted etc, which the did. Temporarily bolted them in place for welding, then I will get the turrets re-sprayed, then suspension back on. I also have to buy a new drive shaft, swap the hubs over and the other jobs still to do. Slow progress as usual but you know how i do things by now!

Here are the snaps of the process.

From inception:








To completion:













That's all for a while!

[Track_Cit]

Thanks guys.

What you need to realise is that it costs a st load of money to do these projects, this is why it takes so long to finish it. If I had more cash it would have been on the road long ago! Anyway, I don't like to rush things Also I enjoy the build up part of it.

Few more little updates.

I FINALLY got the bits of carbon off Bic that I was waiting on (they were waiting on materials), so I made a final piece for the STACK AFR guage, as the other bit was too small and looked gash. Also finished lowering my steering column, but there was an ugly gap between the dash and column so I made a nice bit of carbon up to fill said gap. Looks sweet and i'm pleased with it. Also whacked a bit of carbon vinyl on the door bars as I have some left over from pimping my tool box

Here are the results:















Hopefully will get the top plates welded and painted next, then I can get a new driveshaft, swap out the hubs and get the suspension fitted

That's all for now,

Lewis

[Track_Cit]

Hi guys, it's been a while since I updated here, so I thought I would post an update....i've sold her!


























Just kidding!

Finally got my exhaust made, also got the manifold ceramically coated to keep temps down in the bay, and also to freshen the manifold as it was looking a bit haggard. Here are the shots anyway:

(copy and pasted from another forum)


Very pleased with the exhaust, the workmanship is ace and it looks stunning fitted up. I need to adjust it slightly but I haven't fitted it properly, just hung the back box and centre section so will need finialising once I get the manifold back on (what an arse that is to do!) It's beautiful though, I will let the pics do the talking. Big thanks to Benji and Steve at TM Sport. It's very subtle yet rallye slag, just what I was after:






























Jobs left to do:

1) Rear external brake lines
2) New passenger side rear caliper
3) New drive shaft
4) Swap out the hubs off the AST's for my old ones with the pug sport studs in
5) Wire the wiper motor with ip65 connectors
6) Get the AFR wired in
7) Map it
8) Rape it!

Long term (if money / the wife allows)

9) Weld in cage
10) black wheels
11) Fuel swirl pot and pumps (may become a necessity but we shall see)

[Track_Cit]

Here is the manifold, just got it back yesterday and work was done by camcoat - very nice workmanship too, please with it

Right i was up half the night fitting the manifold back on as I couldn't wait! Got some nice pics of it too, and fitted up. Gotta say my Snap On tool collection is a god send with some of the real tricky to access bolts. Managed to get it on first time easy as pie, then realised the very bottom bolt under one of the primaries wouldn't tighten on as it's butted up against the underside of the tubing, so had to undo everything and re-fit, argh! Makes such a difference having the right tools for the job though. Took 4 hours to take it off using the halfords spanner set as they were too long to move around underneath, but got it on the loosened, then back on again once i'd nipped the troublesome nut up in just a couple of hours last night. Did get a tiny scratch on one of the pipes but never mind. Still looks sweet as! Cut my pinky to fk on the rad, those fins are sharp as hell lol!

Anyway here are the pics:

The whole manifold:




Close Ups:








New Studs and Nuts (didn't replace all of them as wasn't necessary):




Essential tool for the job:



Difference in finish between the ceramic coating and black powder coating on my suspension (the ceramic almost looks kinda bluey):




During Fitment:




Getting there.....the 'bd nut' is on the underside of the far right primary and is a fking mare to tighten. You have to nip it up gradually whilst moving the manifold onto the studs until it's all flush with the head, got there in the end though....the ole back is feeling it today mind!




All fitted up:







Oh, I also got myself a Costco membership through work (what a hellishly busy place that is) and picked up a jack as I was in need of one:








That is all for now!

[Track_Cit]

Thanks for the kinds words lads

It's getting there, money is tight so it's taking a while but hopefully almost there now!

[Track_Cit]

Thanks, they're real carbon with a vinyl overlay so lightweight! I can see how they may not be to everyone's taste though, but I like them!

[Track_Cit]

Thanks very much buddy!

[Track_Cit]

Gentlemen! Thanks for the kind words and apologies for the delay in updating things. I missed a recent update here as I couldn't find my thread But here they are:



05/09/2013:

Did a few more bits on this tonight. Lowered it down on the new suspension and fitted the rear caliper. It was so long since I took it off I couldn't hardly remember how the bd went back on

It's got mad camber yo, so need to adjust it a bit so it's not so extreme. The other side is even worse, looks like it's on air ride! Also my steering arms are at a seriously steep angle which I thought AST corrected on their motorsport struts, but it seems not - meh I was thinking of getting some rose jointed track rod ends and inverting the steering arms...just need to find a supplier!

Here are some shots anyways:









Steering arm angle - savage!




















18/11/2013:

Small update. Received my Rose Jointed Steering Arms from my boy Tommy Rallye, designed and made in Yorkshire, England, so thanks to him for these! Excellently made as I expected, cheers Tom.

They will be fitted upside down to combat this crazy steering are angle as per fig. 1 below:




And the new steering arms (yet to fitted obviously):






Detail of weld:




That's it for now. I need to drill out the holes in my struts to 14mm where the OEM Track Rod ends go through, in order to fit the new bolts.

To do list:

Re-fit wiring loom - took it out when I was going to sell the engine, going to be fun putting it back...not!
Fill with fresh oil
Replace Filter
Fill with Coolant
Get new battery as mine will undoubtedly be dead again (this is my 2nd - argh!)
Get new brake lines for the rear as I bought a replacement caliper and the damn thread is different and I don't know what it is so will need to take it to Earls when I can get a day off work in the week (not until next year now)Wire in AFR
Weld on strut top reinforcement plates and paint
Finish wiring in Wiper motor with fancy plug (a job I started ages ago but couldn't be assed to finish!)
Probably will need to empty the fuel out and start again as it's been sitting for a long time
Mapping

Drive, break, fix, repeat!

Think that's about it, hopefully I can get the damn thing ready for the summer now. I say this, but queue next year it'll still be in the same position!

[Track_Cit]

Otter Smacker said:

Top work as always OP

Tom's a decent chap, although not seem or heard of him in a long time - Has he still got his his lovely Rallye as pictured?

(Did later change the rocker cover design to Apples & Pears)

Aye he still has it, although he uses it strictly for track days now!

johnfm said:

Wow.

Awesome attention to detail.

One Point - what is the clearance from your throttle body trumpets to the scuttle panel?

It looks like 'not much' from the pics.

IIRC you want a certain minimum free air clearance from the mouth of a trumpet - or you will have restricted breathing .

It's not loads but it's more than it looks from the photo's. I think it will be fine to be honest, but time will tell once I get it mapped etc.

[Track_Cit]

LeeThr said:

Just stumbled upon this and had to leave a comment so I can keep track of the updates.

Stunning project Really hope to do something like this myself one day.

Thanks.

I am currently in the process of trying to buy a house and struggling to find somewhere in budget with a garage, and also struggling to find somewhere to store it so it may have to be sold. This will break my heart, but what can i do?

If anyone is interested (serious only) please email me.

Thanks.

[Track_Cit]

What it's worth in cash money doesn't nearly amount to what it's worth to me in terms of its sentimental value. I wanted one of these for years, and spent so long looking at them on the internet on lunch breaks at work, drooling over them when I got home, getting inspiration from Race cars etc. I nearly sold it last year and had a buyer for the engine, but couldn't do it - I actually cried! Sad I know, but it's such a sweet machine.

To give you guys an idea of cost, the engine alone cost me over £7k. Performance wise, once complete I think it would be comparable to a Westfield or the like, but the difference being it's a proper car and in immaculate condition too.

Breaking it would see me making the most money back on it, however, i'd rather take a hit and sell it complete to a caring owner who would finish it and use it. Who knows, in the future when I have my own garage again perhaps I could even track it down and buy it back.

[Track_Cit]

Thanks for all the kind words chaps.

Really it does pain me to have to even consider selling. The Mrs has been very supportive thus far, but the reality is as follows:

1) House with garage is affordable, but it would have to be in a horrible area and 'the boss' wouldn't have any of it.

2) House with garage in nice area would be over budget

3) Possibility of renting a garage (again most are in ste chav areas) which would leave me paranoid about it's vulnerability when I wasn't around. Also most of these garages have no power or water so not the most convenient, however, it is still an option I guess.


I still have it in my mind that I will keep her, and the Rallye but it depends on the above factors. If anyone of you wealthier fellas on here have a nice farm I could store it on where I know it would be safe and I could work on it (in Hertfordshire if possible) let me know. I would obviously pay for the service.

Failing that, if anyone is prepared to offer me a sensible figure for the project as a whole I may consider parting with it. When you look at the cost vs spec of a Caterham, then compare this, I would value it at around £11k I think. It's worth at least £15K in parts alone

[Track_Cit]

Krikkit said:

This. Even a wooden one isn't too expensive (and avoids planning permission) and would keep it out of the elements.

True, but finding house with that space and access is not an easy task. Plus you have the interim storage issue until said garage is erected.

To give you an idea we are looking at cottages, and generally even parking is a luxury, let alone a driveway to wash/work on the Honda and a Garage to store the Rallye! The boss wants to remain in this particular area, or not so far that she can't easily visit friends and relatives when we start a family. I wouldn't mind living in the sticks but then i'm an unsociable b*stard at the best of times!

mwstewart said:

Fantastic project and standard of work, something to be proud of.

You are doing the right thing by prioritising a decent house over the car. The market is generally rising at the moment so it is a great time to buy property. I'm not in exactly the same situation as you in terms of selling something I have, but I'm sacrificing driving the cars I have lusted over for the sake of securing my future. I think the bitterness of these sacrifice in the short term, will taste sweet later on

It is rising indeed, and unfortunately I live in a particularly desirable area and the prices are hideous here, unless you want to move into a dump, hence having to move further afield, but still within the catchment area so to speak. Still, I would rather have a nice house and buy a nice car down the line, than stay in an area where the market will remain stagnant, removing the opportunity to make any money on a sale in a few years time. A lottery win would solve all my problems, but sadly in life things don't work like that!

[Track_Cit]

Guys, thanks for the supportive comments as always

Update on the house front: We have exhausted the current list of gaffs that fall under the lady bosses 'acceptable' list, so I don't think it will going anywhere soon, which is good news for me!

Even if we do buy a place, I will still endeavor to hold onto the Rallye for all the reasons mentioned above. The problem with the type of properties we have been looking at, and generally prefer, is that they are little cottages on narrow roads with horrendous parking, and zero driveway to speak of (not even so much as a grass verge!) so keeping it 'on site' would be out of the question. I'm not fussed about keeping it outside, but it has to be kept where there is space to do so if that makes sense.

I have one pair of axle stands at present, and need to swap out the gearbox drain plug on the Honda for a magnetic type, which I hope to do the weekend, then crack on with this a bit more.

MrMoonyMan said:

Worst comes to worst I've got a garage (st.albans) I could move my long term project car out of to make sure you don't sell this!

MwStewart is right, a house should come first. But your car is so special and has just been made so well you really should do all in your power not to sell it.

You would spend every single day regretting it if you did!

That's very kind of you and something I may be interested in if necessary - I would obviously pay you the service! We'll see what happens.