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Author Subject: Daveyboy's Rallye Race car
daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline
Post #1001
clen666 wrote:
Cool

Where did you order the laminova from as I plan on getting one from merlin?

I'd also considered getting a fuel cell a while ago but didn't want the weight up higher than standard and didn't trust myself to cut the floor and not cock it up so will be interested to see your effort

Thumbs up


From Think Automotive in Isleworth, via Rich Walker as he gets them at a decent price. Good idea on watching me f*ck up the tank install first LOL
Given the choice I'd rather not use one, but the old man is giving me such a headache about safety that I bought it to make him shut up LOL

To be fair though it will be a properly sorted car once its all in, I will have to sort a fuel guage and sender though as I'm not arsing about dipping bits of wire in the tank between races to see if I have enough to make it through the next heat. Must resist buying the Stack Pro-Control one that has programmable presets to make the dial glow yellow, orange then red as fuel drops to a certain level! Cool

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 10th Jun 2011 at 03:52
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clen666

Seasoned Pro

Location: Co. Durham

Registered: 12 Feb 2009

Posts: 2,401

Status: Offline
Post #1002
Well you might as well get it now you've gone this far! Razz

Thanks for the heads up about rich, have you gone for the longest version of cooler?

________________________________________

Team 'unintentional rat look'
Posted 10th Jun 2011 at 03:56
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daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline
Post #1003
clen666 wrote:
Well you might as well get it now you've gone this far! Razz

Thanks for the heads up about rich, have you gone for the longest version of cooler?


Yes, well there is a bigger one, but thats for big V8s and Turbo applications and it's £500, way over the top for my car. He did spec the medium one at first until I told him I want my oil at 80-85 degrees. Thing is it pumps a lot more heat into the water system so you need a much more efficient radiator to cope. So I got on to Radtec and they ar going to knock me up a pair of twin core ally Rads, need to get a separate expansion tank sorted now as well.

EDIT, I obvioulsy only need one rad, the other is a spare in the event of the inevitable front end collision Wink

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 10th Jun 2011 at 04:01
Profile
clen666

Seasoned Pro

Location: Co. Durham

Registered: 12 Feb 2009

Posts: 2,401

Status: Offline
Post #1004
Yeah I thought the cooling system would need uprating after reading cosmics project thread. What temp thermostat are you going to run then?

Will you be integrating a water swirl pot into the cooling system? I've read they can be quite beneficial on race cars but unsure whether it would be unnecessary on the 306

________________________________________

Team 'unintentional rat look'
Posted 10th Jun 2011 at 04:22
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daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline
Post #1005
clen666 wrote:
Yeah I thought the cooling system would need uprating after reading cosmics project thread. What temp thermostat are you going to run then?

Will you be integrating a water swirl pot into the cooling system? I've read they can be quite beneficial on race cars but unsure whether it would be unnecessary on the 306


Thermostat will be changed for a lower opening temp one if I can find one. As for the swirl pot no plans as yet. I have gone up on the hose size from 32 to 38 to get a little extra capacity, and the runs will all be swaged ally tube with Samco bends. I figure the tubes will radiate heat and further aid the cooling. I'll also be adding a water treatment which helps to raise the boiling point while giving better wetting in the head and improved corrosion and silting resistance. In theory Wink

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 10th Jun 2011 at 04:35
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daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline
Post #1006
Right, I have finally finished my radiator contract so now I have a bit of spare time on my hands in the evenings (Only temporarily mind, I've possibly landed a contract welding up aluminium sub-frames for multi-axle stretched Humvee Limousines! Wierd) Anyway, I decided its time I sorted the sump, so I cleaned it up a bit, had a good old look at it and decided on how I'm going to box in the oil pick-up, first thing to do is knock up a tin box. That part was easy, next I had to make some room for it, this involved hacking out the existing aluminium sump divider with a plasma cutter. Unfortunately I skipped a test cut and due to the angle of the torch it cut out the baffle but also pierced an inch long slit in the base of the sump. Not a problem to fix as the TIG welder was still set up next to the bench so I just repaired the hole I had made (hate making work for myself, but at least I had the means to put it right) after that though I could see I had managed to spray a little molten ally into the front sump plug thread (If I did one again I'd put the sump-plug in to avoid possible damage, hindsight is ace right?) so rather than risk a dodgy thread, I welded on a AN-10 JIC male boss I had left over from something else I'm doing. I can get a cap for that that will effectively do the same job as the original plug but also happens to look cool.



I need to take some really careful measurements of exactly where the oil pump sits in relation to the sump, as it mounts on the block. This makes life a little difficult as the baffle box will be bolted into the sump and has to line up perfectly with the pump pickup. I will also be doing my best to fit in an oil pump chain tensioner after hearin a few horror stories and seeing how slack the chain is I want to do everything I can to stop it from flailing itself to death at 8K plus.





________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 17th Jun 2011 at 06:01
Profile
phillipm

Seasoned Pro

Location: Rotherham

Registered: 15 Oct 2006

Posts: 20,607

Status: Offline
Post #1007
's no wonder it's taking so long, you're making more jobs up than you fix LOL

________________________________________

- Bespoke rollcages/additions/adjustments. Half cages right up to complete custom spaceframes - MSA/FIA spec, CDS, ROPT, T45, etc - PM me
Email me!
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Posted 17th Jun 2011 at 05:02
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daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline
Post #1008
phillipm wrote:
's no wonder it's taking so long, you're making more jobs up than you fix LOL



Tell me about it Dry

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 17th Jun 2011 at 05:44
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phillipm

Seasoned Pro

Location: Rotherham

Registered: 15 Oct 2006

Posts: 20,607

Status: Offline
Post #1009
Zirconium discs? Yer cheapskate LOL

________________________________________

- Bespoke rollcages/additions/adjustments. Half cages right up to complete custom spaceframes - MSA/FIA spec, CDS, ROPT, T45, etc - PM me
Email me!
Custom-made polybushes available - need an odd size or fitment? - anything from batch work to one-off pieces.
Posted 17th Jun 2011 at 07:29
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daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline
Post #1010
phillipm wrote:
Zirconium discs? Yer cheapskate LOL


Bob nicks all the ceramic ones, and I could'nt be arsed to open up the shop to pinch them back Razz

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 17th Jun 2011 at 16:14
Profile
daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline
Post #1011
The oil pump chain tensioner arrived today, looks like a nice compact unit. Its like a spring-loaded plastic arm, and it should help to eliminate the chain slap that seems to be eating chains on the high RPM engines. All I need to do is assemble the bottom end to get the exact mounting location then weld a threaded boss on the inside of the aluminium crank case end casing. I will keep up the forum updated as to how this works out but if successful this could well be a very handy fix.

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 17th Jun 2011 at 20:54
Profile
daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline
Post #1012
I could'nt put it off any longer so I made a start today on getting rid of some of the rust on the Rallye. As I have it at this stage it would be a shame not to seam weld it, si I did a bit of that too.



It rained like f*ck on and off all day just to make life more enjoyable Dry





After a little welding... The bit that takes the longest is digging all the seam sealer out of all the joints so you can weld it.





Did'nt get it finished, so I chucked some rust killer on all the bits I had prepered to stop rust getting a hold of it again before I can come back to it.





Oh, and I got bored last time I was working on it, so I pulled the previous owners stickers off to leave this...

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 19th Jun 2011 at 23:58
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lotek

Seasoned Pro

Location: Berkshire

Registered: 04 Dec 2007

Posts: 6,107

Status: Offline
Post #1013
Cool
Posted 19th Jun 2011 at 00:54
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rallyeash

Seasoned Pro

Location: Devizes

Registered: 11 Dec 2006

Posts: 4,424

Status: Offline
Post #1014
really going to town on this, fair play!

________________________________________

230 hp 2.1 16v XU 205 rallye on jenveysHyper Project thread here
309 3dr K20 Type R
Posted 19th Jun 2011 at 00:56
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daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline
Post #1015
rallyeash wrote:
really going to town on this, fair play!


I'm doing it just in time, some of the rust is quite bad, especially in the area under the servo where leaks lift the paint. I can't wait to get all the shitty jobs out of the way so I can get onto just bolting in shiny bits LOL

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 19th Jun 2011 at 01:01
Profile
owain

Seasoned Pro

Location: Essex

Registered: 20 May 2009

Posts: 9,185

Status: Offline
Post #1016
Really quite some time ago (over an hour, maybe more) I decided to read back your thread from the start.

It took a long time.

RESPECT TO THIS THREAD AND YOU, SIR.

Makes me realise I know nothing, I'm off to be depressed somewhere, probably bed.

________________________________________

Membership expiring soon, get in contact on our new little forum project.
Posted 23rd Jun 2011 at 08:54
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daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline
Post #1017
owain wrote:
Really quite some time ago (over an hour, maybe more) I decided to read back your thread from the start.

It took a long time.

RESPECT TO THIS THREAD AND YOU, SIR.

Makes me realise I know nothing, I'm off to be depressed somewhere, probably bed.


Haha! Thank you, to be fair I started off just like you did, prepared to have a go, but not necessarily sure how to do it. Luckily I have facilities here to turn most of my failures into wins (eventually)

I just wish I had the money and time to move this thing along a bit faster, but it's moved on massively in the last month now Smile

Cheers for the kind words, I'll be looking forward to seeing yours in action sometime.

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 23rd Jun 2011 at 16:13
Profile
daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline
Post #1018
Fuel pumps and regulator arrived today, shiny Big grin

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 24th Jun 2011 at 16:45
Profile
daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline
Post #1019
Good progress today, all seams on front inner arches are seam sealer free and ready for welding tomorrow (If I'm not tempted to bugger off on the jetski that is :Cool

I also found in the scrap bin, some panels from an old welding set with some louvres pressed into them, these will be perfect for welding in to the sides of the turrets to help shift a bit of unwanted hot air from under the bonnet.

A few brackets and other unwanted lumps of metal got to feel the wrong end of my angle grinder today too Big grin

Will post up some pics tomorrow as and when I can be arsed.

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 26th Jun 2011 at 15:40
Profile
clen666

Seasoned Pro

Location: Co. Durham

Registered: 12 Feb 2009

Posts: 2,401

Status: Offline
Post #1020
Are you fully seam welding it or stitch welding (ie inch on, inch off)?

I've read fully seam welding can result in cracking, as some give is required with the forces involved

________________________________________

Team 'unintentional rat look'
Posted 26th Jun 2011 at 05:18
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daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline
Post #1021
clen666 wrote:
Are you fully seam welding it or stitch welding (ie inch on, inch off)?

I've read fully seam welding can result in cracking, as some give is required with the forces involved


Fully on the chassis legs, turrets and bulkhead area, stitches on the floorpan, sills and boot floor. I'm not expecting cracks on a circuit car, if it was doing forest rallying maybe Unsure

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 26th Jun 2011 at 15:39
Profile
devere

Senior User

Location: Saxtead

Registered: 16 Dec 2008

Posts: 810

Status: Offline
Post #1022
Shoul still ideally only be stitched. the chassis still needs a certain amount of fex, as it is under great stress on hard cornering, be it on the track, or in the forest. It would crack if full welded all along even on a normal road.
Posted 26th Jun 2011 at 15:51
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daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline
Post #1023
devere wrote:
Shoul still ideally only be stitched. the chassis still needs a certain amount of fex, as it is under great stress on hard cornering, be it on the track, or in the forest. It would crack if full welded all along even on a normal road.


It's mostly done now so we'll see I guess won't we? Personally I think distortion from weld heat input and shrinkage or just plain old poor welding quality through insufficient preparation (removing all paint, seam sealer and any zintec or boron coatings that may be present)is more likely to be the cause of cracks, there will be no give in a stich welded seam, just less shrinkkage stress to start with. By careful placedment of the welds and keeping them balanced, distortion and stress should be minimal. Time however will tell Wink

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 26th Jun 2011 at 16:10
Profile
berger

Seasoned Pro

Location: Bathurst

Registered: 26 Oct 2008

Posts: 1,068

Status: Offline
Post #1024
daveyboy wrote:
devere wrote:
Shoul still ideally only be stitched. the chassis still needs a certain amount of fex, as it is under great stress on hard cornering, be it on the track, or in the forest. It would crack if full welded all along even on a normal road.


It's mostly done now so we'll see I guess won't we? Personally I think distortion from weld heat input and shrinkage or just plain old poor welding quality through insufficient preparation (removing all paint, seam sealer and any zintec or boron coatings that may be present)is more likely to be the cause of cracks, there will be no give in a stich welded seam, just less shrinkkage stress to start with. By careful placedment of the welds and keeping them balanced, distortion and stress should be minimal. Time however will tell Wink


Will last forever being wheeled around your yard/garage. LOL Razz

________________________________________

Bang'in 7 gram rocks!
I have one gear, GO!
Posted 26th Jun 2011 at 16:40
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clen666

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Location: Co. Durham

Registered: 12 Feb 2009

Posts: 2,401

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Post #1025
LOL fair enough, hope its ok, I'm sure it will be, just going off what I have read from other places

________________________________________

Team 'unintentional rat look'
Posted 26th Jun 2011 at 18:09
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