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Thread: Rally Rolla.

  1. #91
    BIG MEK buzz's Avatar
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    Is that Kevlar laid up and resin-ed in the same style you would normally do fibreglass ?

  2. #92
    Crash Test Dummy smee's Avatar
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    Quote Originally Posted by buzz View Post
    Is that Kevlar laid up and resin-ed in the same style you would normally do fibreglass ?
    Yes it is.

    Cut and layout fabric to ensure it fits.

    Layer of wax, then a layer of release agent.

    Put down some epoxy and then lay the fabric.
    Squeegee and roll to get epoxy through.

    Rinse and repeat till finished.

    I generally go a bit over on the fabric lengths.
    Sturgeon's Revelation (sometimes referred to as his second law): Ninety percent of everything is CRAP

  3. #93
    BIG MEK buzz's Avatar
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    Cool, I was wondering how you got it off after it set.
    How strong are you finding this kind of shield in practice?

  4. #94
    Crash Test Dummy smee's Avatar
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    I've had one on my Familia for the last 12 years and it has not missed a beat.
    I have reduced the number of layers on this latest incarnation to see how it goes.
    Slightly more protected than the familia one so hopefully less prone to rocks.

    The underbody on the familia is also too thick, so I have scaled it back on #RallyRolla also.
    No problems. When it wears slightly, I just scuff it up and paste some more epoxy over the top.

    I have found it is best to put a sacrificial layer over the good stuff to offer wear resistance and a little strength, although it does add to the weight.

    I'll stick a layer of Kevlar and then a layer of woven mat on the underbody and sill guards this week to add a bit of bulk and piece of mind.

    Fuel tank and underbody from the familia.

    This used Vinyl Esther resin and not epoxy.



    Sturgeon's Revelation (sometimes referred to as his second law): Ninety percent of everything is CRAP

  5. #95
    Crash Test Dummy smee's Avatar
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    This is what the underbody looks like after 12 years.

    Sturgeon's Revelation (sometimes referred to as his second law): Ninety percent of everything is CRAP

  6. #96
    BIG MEK buzz's Avatar
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    Cool, thanks. Certainly looks to be doing the job - the idea of a sacrificial layer makes a lot of sense.

  7. #97
    Registered User MWP's Avatar
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    Quote Originally Posted by smee View Post
    I still have a return line to fit to the tank.
    Bottom 2 lines feed pumps.
    Top line is return to tank, and next to that is the return line from the fuel rail.
    Slightly lower is input from tank..
    Fuel pumps will feed line to fuel rail.
    Tank is only 1 litre in size.
    Seems to have been working fine for competition Lotus vehicles, so thought I would try my luck.
    Surely the tank is designed like all other surge tanks though... ie, pick ups are off the bottom of the tank when its stood upwards (normal orientation).
    There isnt much point in running a surge tank at all if the pickups are not on the bottom.

  8. #98
    CNGAF rowdytoot's Avatar
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    Quote Originally Posted by MWP View Post
    Surely the tank is designed like all other surge tanks though... ie, pick ups are off the bottom of the tank when its stood upwards (normal orientation).
    There isnt much point in running a surge tank at all if the pickups are not on the bottom.
    This, I don't get it either.

    1998 MX5 - Ohlins DFV coilovers, Roll bar,15 x7.5 Konig Litespeeds, Mania Intake
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  9. #99
    Crash Test Dummy smee's Avatar
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    Quote Originally Posted by rowdytoot View Post
    This, I don't get it either.
    Seems to be working in these instances.

    I spoke with them and detailed what I required.
    They had a product they had used in competition that I thought would suit my requirements.

    Happy to be proven that it is wrong, and does not work.

    Surge Tanks

    Dual-Bosch-044-Fuel-Surge-Tanks
    Sturgeon's Revelation (sometimes referred to as his second law): Ninety percent of everything is CRAP

  10. #100
    Non Compos Mentos Gammaboy's Avatar
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    The obvious answer is they do 2 different configurations of tank - one laid over, with the pickups set up for such, and one stood up, with pickups to suit.
    "Where can we get hold of a Vincent Black Shadow?" "Whats that?" "A fantastic bike," I said. "The new model is something like two thousand cubic inches, developing two hundred brake-horsepower at four thousand revolutions per minute on a magnesium frame with two styrofoam seats and a total curb weight of exactly two hundred pounds."

  11. #101
    Registered User MWP's Avatar
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    Quote Originally Posted by smee View Post
    That link explains it all
    All good then.

    I gather you'll run one pump normally, and use the other as a backup?

  12. #102
    Crash Test Dummy smee's Avatar
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    Quote Originally Posted by MWP View Post
    That link explains it all
    All good then.

    I gather you'll run one pump normally, and use the other as a backup?
    Yep.

    Low volume pump into tank.
    Run one pump as prime, and the other as secondary.

    A bit of fabrication to create a sealed under floor area with a see through lexan port hole to show off the bling.
    Also a separate fluid port so the floor can be removed with compromising the connections through the cabin.
    Sturgeon's Revelation (sometimes referred to as his second law): Ninety percent of everything is CRAP

  13. #103
    Crash Test Dummy smee's Avatar
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    So, have done a little more with the fuel pump area.

    Fabricated a cover and viewing port with Acrylic so at least you can see what is hiding there.

    Last edited by smee; 13-02-16 at 10:34 AM.
    Sturgeon's Revelation (sometimes referred to as his second law): Ninety percent of everything is CRAP

  14. #104
    Crash Test Dummy smee's Avatar
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    So wire stripping has commenced.
    There is a wire, and in some case 2 for everything.
    Basic indicators, head and tail lights, horn etc retained.
    Lots has gone.
    PDM and switch being sourced from 10secrx7 to allow for no fuses or relays and to look schmich.
    Sturgeon's Revelation (sometimes referred to as his second law): Ninety percent of everything is CRAP

  15. #105
    Crash Test Dummy smee's Avatar
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    OK, been doing a little work behind the scenes.
    This is all that is left of the factory wiring loom.



    Last edited by smee; 13-02-16 at 10:35 AM.
    Sturgeon's Revelation (sometimes referred to as his second law): Ninety percent of everything is CRAP

  16. #106
    Crash Test Dummy smee's Avatar
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    New rear shocks and some wiring



    Sturgeon's Revelation (sometimes referred to as his second law): Ninety percent of everything is CRAP

  17. #107
    Crash Test Dummy smee's Avatar
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    OK,
    So things have progressed a little slowly of late.
    Other priorities.

    Some updates to what I have been doing.

    All new hubs and bearings installed.
    Some welding or protection of the spring seat on the rear arms
    Wiring now progressing.

    Electronic battery isolator



    Fuel level sender install.


    Fuel Tank and rear suspension.
    Rear suspension needs to be sussed to protect the hoses to the remote canisters.


    In tank surge tank pump.
    Was waiting on a laser cutter to manufacture the alloy donut which sits the pump in the original housing position of the factory fuel pump. The new pump is bolted to this plate and locked in by the screw cap and big o-ring.


    Front brakes and suspension.




    Tank wired and installed.



    Rear Brakes and suspension.

    Sturgeon's Revelation (sometimes referred to as his second law): Ninety percent of everything is CRAP

  18. #108
    aka SpaZdA (tm) mondo2000's Avatar
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    Have you sorted some adjustable rear spring seats?

  19. #109
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    remote reservoir canister placement is well um not somewhere i would want them

    but awesome rally rolla is still awesome
    Quote Originally Posted by zammo
    I'm the retard with the cockroach in my ear.

  20. #110
    Crash Test Dummy smee's Avatar
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    Quote Originally Posted by ZammoTheCockroach View Post
    remote reservoir canister placement is well um not somewhere i would want them

    but awesome rally rolla is still awesome
    True in regards placement.

    I spoke with Murray about placement, and he seemed to think it would work.
    If not, then they will be modified to remote hanging off the base of the shock.

    Rear beam is angled, and hides most of the canister. Bottom picture.
    Rear beam hides behind tank when under load on the road and I have wrapped them in Urethane to add more protection, as well as beefing up the remote line protection.
    I have stuck some flaps on in front of the tank to limit the stuff thrown up by the front wheels.

    Still looking for some adjustable spring seats.
    My call out to the fellow who rolled his BMW rally car last year with them fitted has gone unanswered.



    Sturgeon's Revelation (sometimes referred to as his second law): Ninety percent of everything is CRAP

  21. #111
    aka SpaZdA (tm) mondo2000's Avatar
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    Why does old mate make the rear dampers like that? It's like they're upside down, unsprung weight would be less if they were up the other way.

  22. #112
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    gravity and fluids naturally want to go that way
    Quote Originally Posted by zammo
    I'm the retard with the cockroach in my ear.

  23. #113
    aka SpaZdA (tm) mondo2000's Avatar
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    There's no air inside them dude, just oil and nitrogen separated by a floating piston. The floating piston will be inside the remote reservoir, which can be mounted in any orientation.

  24. #114
    Registered tax offender SuperDave's Avatar
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    Keep an eye on the placement of the reservoir on the rear beam, you might find that they will walk a bit with the twisting.
    My car
    Corolla
    Quote Originally Posted by Sketchy View Post
    Wait, I can have a coke bore in my backyard? Can I have a hooker bore as well?

  25. #115
    Crash Test Dummy smee's Avatar
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    Quote Originally Posted by SuperDave View Post
    Keep an eye on the placement of the reservoir on the rear beam, you might find that they will walk a bit with the twisting.
    I was thinking I might tack in some end plates to stop that.

    That or get some thick wall tube to act as a sort of cover which I can then slide the canisters in to.
    Sturgeon's Revelation (sometimes referred to as his second law): Ninety percent of everything is CRAP

  26. #116
    Crash Test Dummy smee's Avatar
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    OK,
    Been a bit slack of late, but have been doing some work on the Corolla.







    Test fit of esky lid representing radiator.

    Sturgeon's Revelation (sometimes referred to as his second law): Ninety percent of everything is CRAP

  27. #117
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    fukyeh
    Quote Originally Posted by zammo
    I'm the retard with the cockroach in my ear.

  28. #118
    Crash Test Dummy smee's Avatar
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    Switch box.

    Sturgeon's Revelation (sometimes referred to as his second law): Ninety percent of everything is CRAP

  29. #119
    Crash Test Dummy smee's Avatar
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    Dash Fitting and basic setup






    Sturgeon's Revelation (sometimes referred to as his second law): Ninety percent of everything is CRAP

  30. #120
    Crash Test Dummy smee's Avatar
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    This is where I am at with this one.
    Had a bit of a busy year with the SO's car and its competition dealings,



    Sturgeon's Revelation (sometimes referred to as his second law): Ninety percent of everything is CRAP

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