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XR V2.0 Build thread

Posted by phlat65 
phlat65
Sean Medcroft
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Location: Edmonds, Washington
Join Date: 02/12/2009
Age: Midlife Crisis
Posts: 1,802

Rally Car:
Building a Merkur


XR V2.0 Build thread
February 05, 2012 09:48PM
I am really not too good at tracking things and documenting stuff, so i will just put up a bunch of pictures of the build so far.

This car arrived here maybe a month after we destroyed V1.0 at Olympus. It was basically a roller with some interior left init. It was free!!



So I washed it, and cut the side windows



Here are the panels I made and welded in



We cleaned all the crap out of the interior. All that tar is hell...



Then I welded up like 30 holes in the floor

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phlat65
Sean Medcroft
Mega Moderator
Location: Edmonds, Washington
Join Date: 02/12/2009
Age: Midlife Crisis
Posts: 1,802

Rally Car:
Building a Merkur


Re: XR V2.0 Build thread
February 05, 2012 09:56PM
I wanted to get the seats a bit lower, and much closer to the tunnel, so I made some boxedue to the super wide center tunnel for the 4x4 stuff.



The ford book references a stump plate in the footwels, once you peel off the tar it is pretty obvious why, as the floor is fully perforated. So I made plates and welded them in. Here is with the seat mounts tacked in place for cage placement



One of the things that really bugged me was the width of the tunnel, especially near the gas pedal. You had to have your foot at an angle, and when you try to heel/toe your heel hits the tunnel, so I cut it out and widened it. You can see on the right how far forward the wide part was, they used to be even on both sides.



Thats pretty much it for the interior until the cage goes in.
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phlat65
Sean Medcroft
Mega Moderator
Location: Edmonds, Washington
Join Date: 02/12/2009
Age: Midlife Crisis
Posts: 1,802

Rally Car:
Building a Merkur


Re: XR V2.0 Build thread
February 05, 2012 10:04PM
IN the engine compartment, I welded up all the holes in the rails



Welded in the inserts for the JVAB sump guard



Welded in all the supports for the front skidplate mount, front bumper bar, JVAB tow hook and skid support plates



The next thing I wanted to do to the last car, but never got to it, was some better engine mounts. The engine really moved around alot, and being bolted to the front crossmember, made swapping the front crossmember a chore. I basically copied what Ford did, but used some Ford F250 4x4 front leaf spring bushings



I made all the plates, and had Derik Nelson weld them together.



Then I fabbed the motor mounts



Here it is all together

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phlat65
Sean Medcroft
Mega Moderator
Location: Edmonds, Washington
Join Date: 02/12/2009
Age: Midlife Crisis
Posts: 1,802

Rally Car:
Building a Merkur


Re: XR V2.0 Build thread
February 05, 2012 10:17PM
For the front Suspension, I am using a new version of the control arms and comp struts that Derik and I made for the last car. Had the ball joint holders machined out of 4130, 1.25 .120 wall tube, lots of gussets, non handed ect..



Here they are installed, I am proud of these!





In the rear, I am using the JVAB square beam, and Supra Diff



It was designed to use some poly bushings, but i had the last car solid mounted and liked it, so I solid mounted this one also. Here are the alignment pins and plates



Then I made the rear mount on the diff



For the rear suspension, William at TSS is making me some 4130 tube rear arms, rose jointed, adjustable for camber and toe. They are badass!!!


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phlat65
Sean Medcroft
Mega Moderator
Location: Edmonds, Washington
Join Date: 02/12/2009
Age: Midlife Crisis
Posts: 1,802

Rally Car:
Building a Merkur


Re: XR V2.0 Build thread
February 05, 2012 10:21PM
I am sure there is alot more, but that pretty much gets it up to date. Hoping fro Derik to start on the cage in 4 weeks, that will get it back to me end of march, then paint, and swap in the drivetrain, wiring, fab the side windows, underbody, and a few other things. Really hoping to be driving the car early April at the latest.



OK, back to work.....
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Tom B
Tom B
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VW Golf



Re: XR V2.0 Build thread
February 05, 2012 10:29PM
bknblk2
Tony Wood
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83 Citation "Oskar"


Re: XR V2.0 Build thread
February 06, 2012 08:40AM
THAT is a sexy beast...
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alkun
Albert Kun
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volvo 242


Re: XR V2.0 Build thread
February 06, 2012 10:03AM
Very nice Sean, thanks for sharing.
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NoCoast
Grant Hughes
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Location: Denver, CO
Join Date: 01/11/2006
Age: Settling Down
Posts: 6,740

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Merkur



Re: XR V2.0 Build thread
February 06, 2012 11:38AM
So, a car that has strong and fully adjustable front and rear suspension with a rear diff with lots of ratio options and stock to 1.2-2 way aftermarket clutch type diffs, four piston large vented front and rear brake options with modified pedal for adjustability, build weight of under 2500 pounds potential, 200-300 hp easily, super strong gearbox options with the T-5, and RWD. Sounds like a winner!



Grant Hughes
http://rally.build
Denver, CO
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phlat65
Sean Medcroft
Mega Moderator
Location: Edmonds, Washington
Join Date: 02/12/2009
Age: Midlife Crisis
Posts: 1,802

Rally Car:
Building a Merkur


Re: XR V2.0 Build thread
February 06, 2012 12:12PM
CHicken dinner!
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slidewayswrx
Patrick Darrow
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Location: Portland OR
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Swedish John Deere



Re: XR V2.0 Build thread
February 06, 2012 01:04PM
Your hard work is inspirational. After reading this thread the first time through I immediately went to work on mine. Got to keep that ball rolling

Blake, I'll see you tonight
William, expect a call
JV, expect a check
Al you've got a new message

and Sean, keep it coming. Your new build is already leaps and bounds above your previous, which was one of the cleanest builds in the NW.

Now I'm back to work



Zap zap my ass...
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BobOfTheFuture
Rob Russo
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240 wannabe, And suddenly out of nowhere, A VW.



Re: XR V2.0 Build thread
February 06, 2012 01:15PM
Wow that is nicely done. Way to go!



Enablers, All of you.
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john vanlandingham
John Vanlandingham
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Saab 96 V4



Re: XR V2.0 Build thread
February 06, 2012 01:45PM
Quote
slidewayswrx
Your hard work is inspirational. After reading this thread the first time through I immediately went to work on mine. Got to keep that ball rolling

Blake, I'll see you tonight
William, expect a call
JV, expect a check
Al you've got a new message

and Sean, keep it coming. Your new build is already leaps and bounds above your previous, which was one of the cleanest builds in the NW.

Now I'm back to work

Brian your T cam is in Portland, you might give me a call.



John Vanlandingham
Sleezattle, WA, USA

Vive le Prole-le-ralliat

www.rallyrace.net/jvab
CALL +1 206 431-9696
Remember! Pacific Standard Time
is 3 hours behind Eastern Standard Time.
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Aaron Luptak
Aaron Luptak
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Location: SLC
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Civic...



Re: XR V2.0 Build thread
February 06, 2012 02:24PM
/crosses fingers hoping to see a double-decker rear wing.

nice work!



KF7RWG
http://www.utahrallygroup.com
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slidewayswrx
Patrick Darrow
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Location: Portland OR
Join Date: 12/30/2006
Age: Settling Down
Posts: 379

Rally Car:
Swedish John Deere



Re: XR V2.0 Build thread
February 06, 2012 06:25PM
Quote
john vanlandingham

Brian your T cam is in Portland, you might give me a call.

When you say Brian are you talk to me, Pat??? Which one of us is losing it here?



Zap zap my ass...
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