XR V2.0 Build thread
Posted by phlat65
Sean Medcroft Ultra Moderator Location: Edmonds, Washington Join Date: 02/12/2009 Age: Possibly Wise Posts: 1,802 Rally Car: Building a Merkur |
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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Sean Medcroft Ultra Moderator Location: Edmonds, Washington Join Date: 02/12/2009 Age: Possibly Wise Posts: 1,802 Rally Car: Building a Merkur |
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. |
Sean Medcroft Ultra Moderator Location: Edmonds, Washington Join Date: 02/12/2009 Age: Possibly Wise Posts: 1,802 Rally Car: Building a Merkur |
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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Sean Medcroft Ultra Moderator Location: Edmonds, Washington Join Date: 02/12/2009 Age: Possibly Wise Posts: 1,802 Rally Car: Building a Merkur |
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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Sean Medcroft Ultra Moderator Location: Edmonds, Washington Join Date: 02/12/2009 Age: Possibly Wise Posts: 1,802 Rally Car: Building a Merkur |
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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Sean Medcroft Ultra Moderator Location: Edmonds, Washington Join Date: 02/12/2009 Age: Possibly Wise Posts: 1,802 Rally Car: Building a Merkur |
Patrick Darrow Professional Moderator Location: Portland OR Join Date: 12/30/2006 Age: Midlife Crisis Posts: 379 Rally Car: Swedish John Deere |
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/crosses fingers hoping to see a double-decker rear wing.
nice work!  KF7RWG 
http://www.utahrallygroup.com |
Patrick Darrow Professional Moderator Location: Portland OR Join Date: 12/30/2006 Age: Midlife Crisis Posts: 379 Rally Car: Swedish John Deere |
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