My to do list.

This is a list I sent to Mark today. When we were working on his car he'd do the same for me so that I could figure out what we needed to do that night, and what I could do during the day to make night go easier. Anyhow, I decided to really go off and create a pretty lengthy to do list. Hope to get to the part that says, After Cage, by Thanksgiving. So, here it is. With a few things missing.

Pre-Cage
Remove windshield
Clean glue and paint from roll cage mounting structure
Grind sunroof to flat surface.
Make patch material from 20 gauge steel to fill
Gut doors
Clean as much glue and tar residue from interior to prep for paint
Remove fuel tank, lines, pump, etc.
Remove brake lines
Drill out spot welds and remove old spring seats from shell
Clean dash.
Cover dash in felt and patch holes with carbon fiber pieces with holes drilled for switches, and gauges
Install roll cage, except front strut tower supports
Install seat mounting brackets

After Cage
Install new brake lines and brake balance bar
Install new fuel lines inside
Install fuel pumps and fuel filter into spare tire mounting area.
Install fuel cell and filler.
Wiring harness for electrical items in rear

Construct and install rear beam.
Hopefully JVAB rear beam will be available by this point.
If not put back in stock beam, welded diff
Install JVAB Brakes or Sierra XR4X4 rear discs/calipers
May have to modify/fabricate brackets to the STA's for the rear coilovers.
Install JVAB front brake kit and route lines to it.
Finish running fuel lines to fuel rail/fuel pressure regulator.

At this point the car should be running and driveable. Turn it around in the garage as it's time to start up front.

Remove - intercooler, upper intake manifold, exhaust manifold, exhaust, turbo, radiator, oil filter, most coolant lines, coolant reservoir, power steering low pressure lines, power steering pump, alternator, turbo feed line off block and spin on oil cooler.

Install alternator in relocated position and the power steering pump using JVAB mounts or Ranger mount.
Mount new coolant expansion tank.
Fabricate a front crossmember (make sure it's in front of and above bottom of radiator) to hold power steering and oil coolers.
Mount oil and ps coolers
Install spin on remote filter adapter to block.
Fabricate mount for remote oil filter kit and remote oil cooler thermostat and install
Run lines (AN-10, AN-8) between above.
Plug spot or install a sensor into turbo oil feed off block.
Install Radiator, swirl pot, and run coolant lines.
Install Cossie intercooler, rotated upper intake, throttle body, and silicone hose between two.
Install exhaust manifold, turbocharger, turbo feed line (off oil filter adapter), turbo return, and silicone hose to intercooler.
Fabricate mount for VAM (like a MAF in Subaru) and run hose to turbocharger and mount a filter.
Install downpipe and fabricate exhaust system
Install and run wiring for boost gauge, water temp sensor, fan switch, oil temp sensor, oil pressure sensor (also on oil filter adapter), and fuel pressure sender.
Maybe change the oil, install new plugs, and maybe plug wires. Fill coolant and such. Fire the son o bitch up.

Figure out mounting for front bumper skin. May have to fabricate brackets.
Install sunroof patch.
Put doors back onto car
Install a seat of some kind (prefer some junk since it still has no windows.)

Take to Colorado Springs on a trailer to drop to Keeney's for body work. Bring whaletail, cossie arches, and picture of the large single rear cossie window. Have them paint interior, exterior, finish work on rear window, bondo siding holes, mount whaletail and arches.

Pick up from Keeneys.
Cut and install Lexan in all side windows.
Get new windshield installed.
Install real seats, dashboard, gauges, switches, harnesses, etc.
Fabricate another crossmember for front mounting point for skid plate.
Make a skid plate.
Take car to CORE and beachball on second run.
Start stripping new shell.

---

Grant Hughes

Damn, looks like you'll beat me to a running XR by a bit. Maybe I can still beat Skye....

At the rate I'm going, I should EASILY be able to put antique plates on the car before it's ready.

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Andrew Steere
Lyndeborough, NH
KB1PJY

Yeah, but I don't have to repair a bunch of rust, am not doing the shell stripping or glue, or seam welding everything right away, so I didn't have as much to do as you. And as I was telling Mark, we'll hopefully finish this list at the end of Spring.

Moving overseas post graduation is looking more attractive and possible all the time as well. Number of actual rally events done will be minimal. Hill Climbs and maybe 1-2 rallies a year is all I'll really be doing to start out.

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Grant Hughes

fiasco Wrote:
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> At the rate I'm going, I should EASILY be able to
> put antique plates on the car before it's ready.

I hear ya. My checklist consists of the following:

Open beer.
Light smoke.
Stare at non-running car.
Drink beer.
Cry a little bit.
Repeat as necessary.

I'll get there one day.

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Brian Driggs | KG7KCA | PHX, AZ | 89 Pajero
alterius non sit qui suus esse potest

Brian, at least Steere is in NudeHamster where it gets stupid cold.

What's your excuse?

Put the beer down and get to work.

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Cheers
M.Samli
Phoenix AZ
Gaylant VR4
EVO III GSR (Stolen)


Rallies are no place for traitors

brian, you partying with us at prescott?

I don't want to jack Grant's thread too much, but yes, I will be partying with everyone in Prescott. As for my car, well, I'm a slacker. Been a LOT going on lately and heat just sucks the will to work right out of me. Fortunately, it's supposed to be in the lower 70s in Prescott with some light rain tomorrow. Wo0t!

My car will get there... someday. It's got to be running inside the next eight weeks if I'm gonna take it with me to the new place. !!

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Brian Driggs | KG7KCA | PHX, AZ | 89 Pajero
alterius non sit qui suus esse potest

Don't feel bad...Our XR has finished a few rallies and that still sums up our to do list. Except we substitute poorly running for nonrunning.

The other weekend as motivation we took the car out for a drive. That involved:

find empty clear 2 L bottle
rig it as a catch can for breather
drive car at max boost
grin like an idiot
giggle like a school girl
poor 1 quart of oil back in engine
open beer.....
repeat as necesary until the realization that rally cars are the coolest thing ever sets in again.

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Matt Smith

Racing in glorious black and red

My daily life is a Saab story (sold!)

I start at the top of the list and find myself wanting to do easier things. Like push new bushings into the new STA's instead of remove the windshield, which appears to be OG as the rubber seal is fucked badly. May just use the sledge method. Maybe I'll do the sunroof and cage feet cleaning instead. Better run and get some beer first. Sunlight is a wasting.

Paddy has it rough as he has no garage and is up in that one country above the US.
Moose and Brian have it rough as they live in the worst, hottest, most ghetto city in the US.

I think I found a wood burning stove for the garage. I was tempted to build a sauna outside the garage too but don't want to spend the money. That and the barrio boys would probably just destroy it.

---

Grant Hughes

NoCoast Wrote:
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> Moose and Brian have it rough as they live in the
> worst, hottest, most ghetto city in the US.

Heeeeey. It's not that bad. I was just talking about this with a fellow crew member on the way home from Prescott yesterday. It might be hot as fuck in Phoenix and miserable during the summer, but the winter is awesome and gives plenty of time to be working on cars when it's not miserable. Additionally, we've got how many rallies within reach? Gorman, Desert Storm, Prescott, Laughlin, maybe even Cog if one is feeling saucy, and I'm sure there's at least one or two that I am forgetting. This is a good location for rally, imo. I'd just like to see/do some forrest rally one day. Perhaps a trip to the PNW may be in order.

In any case, since Moose fried his motor this weekend, perhaps he'll have a "slightly" used water pump he would trade for a case of Guinness. Combined with my en route balance shaft eliminator kit and renewed excitement for rally, I should bve making progress on Betty (my Gaylant) soon. I've told myself I want to drive her to Laughlin.

Wo0t!

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Brian Driggs | KG7KCA | PHX, AZ | 89 Pajero
alterius non sit qui suus esse potest

Phoenix is convenient for rally for sure. But I can't stand the city. I spent quite a bit of time there in the late 90s. A few days from moving there actually in 1998. I always had fun there and loved being able to skateboard in the winter (which is when I usually tried to go down) but the summer sucked. We may come out to Laughlin again to spectate so maybe see you there.

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Grant Hughes

NoCoast Wrote:
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> We may come out to Laughlin again
> to spectate so maybe see you there.

Sweet! I'll be looking for you, then.

The summer certainly does suck out here, but I think it will be easier for me to tolerate next summer if I'm in a house where the AC works decently. I've had my fill of $300 electric bills and only being able to cool the house down to 85* or so.

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Brian Driggs | KG7KCA | PHX, AZ | 89 Pajero
alterius non sit qui suus esse potest