rally rebuild

[jdrally]

After a few years thinking om what to do with my car I have now taken the plunge and ordered many new parts for my car. I have just spent the evening taking out the parts to enable me to move the fuel lines and electrics as my new John Read Duratec has the fuel and exhaust on different sides. I have also ordered an axle, suspension and brakes from Rix engineering. Lastly I will install a Sadev sequential gearbox.

http://i937.photobucket.com/albums/ad213/jdrally09/IMG_1026.jpg
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http://i937.photobucket.com/albums/ad213/jdrally09/IMG_1025.jpg
http://i937.photobucket.com/albums/ad213/jdrally09/escort.jpg

[bluevan1]

nice one m8.
like ur car.
a just painted a mk1 without bubble archs with the same strip as ur s ...

[SHIFTY]

very nice mk1 you have there mate :cool:

I like the last pic...pmsl :D

[RS_Fiesta]

Take it your doing it up to sell going off the Pistonheads add?;)

[yellowcustom]

very nice colour scheme indeed on that car

[Andyc]

Very clean and tidy

[alancdavis]

Nice,,,,:) will the seat not be a bit high sat on the cross members ?

[jdrally]

Nice,,,,:) will the seat not be a bit high sat on the cross members ?
I am only little so need extra height

[jdrally]

Take it your doing it up to sell going off the Pistonheads add?;)
Just fishing.

[jdrally]

Some bits arrived today. Dry sump tank fittings and pipes with remote filter head, also teflon fuel pipe and fittings.
This weekend I will get some big bits :).

http://i937.photobucket.com/albums/ad213/jdrally09/drysumptank.jpg

[lee bishop]

looks a lovelly strong shell

[jdrally]

Had a great day yesterday. Left home at 3am (took me 5 hours) to drive to Rix engineering to collect my axle, brakes and front suspension.
Then drove 1 1/2 hours back to SWR Motorsport to coillect my Sadev gearbox.
Oh the joys of living in the west country.

Still coffee and munchies kept me going.

http://i937.photobucket.com/albums/ad213/jdrally09/IMG_1048.jpg
http://i937.photobucket.com/albums/ad213/jdrally09/IMG_1046.jpg
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http://i937.photobucket.com/albums/ad213/jdrally09/IMG_1042.jpg
http://i937.photobucket.com/albums/ad213/jdrally09/IMG_1041.jpg

[specialbuild]

Looks like it's going to be a very exciting car to drive!
Wish my xmas present pile looked like that!!
ian

[Hoogi]

Look like some trick front struts........or is it just me behind with the times :thumbright:

[mk11jon]

Is it my eyes or does one of your brake discs have more mounting holes than the other?

[jdrally]

Is it my eyes or does one of your brake discs have more mounting holes than the other?
One is for the front the other is for the rear.

[mk11jon]

Ah i see, ordered a kit for myself should be here tomorrow:)

[Fat Cat the Rat]

Mr Rix does some nice kit, should be fun to drive.:thumbright:

[jdrally]

OK, now have the axle assembled with the gp4 hubs and brakes and fitted to the car. Very happy with the width as it is 1.5" wider than my old one so now it fills the arches better.
I also spent 2 evenings sorting the Rix front suspension and hubs. It was a bit like competing on Krypton Factor but I think its ok now.
Dry sump tank with lines and fuel tank fitted so the boot area is finnished. Now I will work on the engine bay. Hope to be finnished this weekend.


http://i937.photobucket.com/albums/ad213/jdrally09/IMG_1065.jpg
http://i937.photobucket.com/albums/ad213/jdrally09/IMG_1067.jpg
http://i937.photobucket.com/albums/ad213/jdrally09/IMG_1068.jpghttp://i937.photobucket.com/albums/ad213/jdrally09/IMG_1064.jpg
http://i937.photobucket.com/albums/ad213/jdrally09/IMG_1062.jpghttp://i937.photobucket.com/albums/ad213/jdrally09/IMG_1061.jpg

[PaulC-grp4]

Hows this project progressing?

Nice shell looks very tidy.

[stevepmex]

I like that. Lots of nice bits there too.

[mike77cos]

Very nice work

[jdrally]

Been flat out in work recently so no time to do much in the garage. As yet I am still waiting for my engine, but have been assured it wont be long.
All I have managed to do is to fit the front suspension and brakes, fuel lines and dry sump pipes. This seems to be all I can do until the engine arrives.

http://i937.photobucket.com/albums/ad213/jdrally09/IMG_1096.jpg
http://i937.photobucket.com/albums/ad213/jdrally09/IMG_1097.jpg
http://i937.photobucket.com/albums/ad213/jdrally09/IMG_1098.jpg

[bobmk1]

That is a awesome piece of kit, keep up the good work ;)

[jdrally]

Must be Cristmas. After months of developeing and testing it seems JRE have finally satisfied themselves enough to build my engine.
Duratecs seem to be temperamental to get power out of by I have been assured that my motor will be the best yet.
Dyno time next Tuesday will see the results.

http://i937.photobucket.com/albums/ad213/jdrally09/Image0042.jpg
http://i937.photobucket.com/albums/ad213/jdrally09/Image0043.jpg
http://i937.photobucket.com/albums/ad213/jdrally09/Image0044.jpg
http://i937.photobucket.com/albums/ad213/jdrally09/Image0045.jpg

[jdrally]

Getting ready to rumble. Fitted with 8 injectors. Cant wait now.
http://i937.photobucket.com/albums/ad213/jdrally09/IMG_1271.jpg
http://i937.photobucket.com/albums/ad213/jdrally09/IMG_1269.jpg
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http://i937.photobucket.com/albums/ad213/jdrally09/IMG_1270_1.jpg

[bluevan1]

nice engine there u have.

[jdrally]

Engine on the dyno today. I am happy with the results of 280bhp and 195lb/ft torque @6,2000rpm. Torque spread good with 185lf/ft@ 4,000rpm and again at 7,500.
Clutch on order and then fitting will commence.

[PaulC-grp4]

Looking great - Whats the top right pulley up by the throttle bodies? Is that an electric water pump?!

[jdrally]

Looking great - Whats the top right pulley up by the throttle bodies? Is that an electric water pump?!
Thanks. It is just an idle pulley. The water pump is the black pulley with the 3 bolts, bit more clear in the photo without the head fitted.

[PaulC-grp4]

Thanks. It is just an idle pulley. The water pump is the black pulley with the 3 bolts, bit more clear in the photo without the head fitted.

I wasn't sure if i could see a hose / outlet on or near it. So why is the idle pulley is there ? It seems a long way away from everything else !

[jdrally]

I wasn't sure if i could see a hose / outlet on or near it. So why is the idle pulley is there ? It seems a long way away from everything else !
If you look at the side view you can see the water outlet near the water pump. Also the idler is there due to the water pump spinning the correct way (anti clockwise) and that there is an engine mount on the front of the block when used in fwd cars.

[jdrally]

I know what I am doing this weekend, and probably for the next few weekends.
http://i937.photobucket.com/albums/ad213/jdrally09/IMG_1291.jpg
http://i937.photobucket.com/albums/ad213/jdrally09/IMG_1292.jpg

[bal080]

Nice manifold!

[Xelr8]

That Engine & Manifold looks Awsome :cool::cool::cool::cool:

If you don't mind me asking how much does a set up like that cost?

[jdrally]

That Engine & Manifold looks Awsome :cool::cool::cool::cool:

If you don't mind me asking how much does a set up like that cost?
£12,500 plus vat.

[Xelr8]

Thanks for the info much appreciated :thumbright:

[Class]

Good on you mate, I like what you are doing. That'll be a load of fun and very competitive (Tarmac car I assume ?). Best of luck with it.

[jdrally]

Good on you mate, I like what you are doing. That'll be a load of fun and very competitive (Tarmac car I assume ?). Best of luck with it.
Thanks for the comments, yes it will be a tarmac car.
Here the latest photo of the engine installed. Was quite easy and the Ralloy engine mounts fitted very well. I have also cut a big hole in the transmission tunnel to allow fitment of the gearbox. Plus been sorting out the wires as a few things like oil pressure sensors, management are different to my old engine. Quite labourious work, but have plenty of excitement still.
http://i937.photobucket.com/albums/ad213/jdrally09/Photo0009.jpg

[SHIFTY]

Looking great, dont know if its been mentioned but what cc did you go for?

Im sure you will have lots of fun with new engine :cool: :D

[jdrally]

Looking great, dont know if its been mentioned but what cc did you go for?

Im sure you will have lots of fun with new engine :cool: :D
Hi Shifty,

I was looking at your lovely car also. fancy a swap, only joking.
I have decided to stay in the 2ltr class as some friends of mine have 2.4/2.5s and the axles, shells and gearboxes are taking too much strain. Not sure if I can keep up with the repair bills. The MSA have also limited the 2.5 class to the same tyre width as the 2ltrs, so I guess the torque advantage they have will not be so effective.
Heres a couple more photos of the transmission tunnel which I have had to cut to allow fitment of the Sadev sequential. I also have a bundle of wires to sort, oh joy.
http://i937.photobucket.com/albums/ad213/jdrally09/gearboxtunnel.jpg
http://i937.photobucket.com/albums/ad213/jdrally09/loom.jpg

[PaulC-grp4]

Looking good - your making great progress. Any goals for your first event in it?

[jdrally]

Looking good - your making great progress. Any goals for your first event in it?
Thanks Paul,

Will take my time to finish so I am hoping to have on the road by the end of March. I do have some co-driving duties on some rallies so hopefully the car will be rally ready for the TSH Stages in May. This rally is a very good event over 2 days in Cornwall based at Portreath. Only about an hour drive for me.

Last time I competed there I managed to come 3rd o/a, but was much younger then. At least I know the stages well, but my car now is a million miles away from what it was before, so I will take it easy on the first rally back in the drivers seat.

[SHIFTY]

Thanks mate :)

Nice one sounds good, bet your 2ltr will rev alot better than those stroker ones too :cool:

Keep up the good work, look forward to seeing her in action :cool:

[ajpmsport]

Thanks for the comments, yes it will be a tarmac car.
Here the latest photo of the engine installed. Was quite easy and the Ralloy engine mounts fitted very well. I have also cut a big hole in the transmission tunnel to allow fitment of the gearbox. Plus been sorting out the wires as a few things like oil pressure sensors, management are different to my old engine. Quite labourious work, but have plenty of excitement still.
http://i937.photobucket.com/albums/ad213/jdrally09/Photo0009.jpg
Been following your project with interest. LOOKS good... Nice to see your seat mounts, alot of controvicey (sp) this year about them. Awsome front bottom arms. Are you going to run air filters ? Looks tight to fit them on.
Keep the pictures coming.

[jdrally]

Been following your project with interest. LOOKS good... Nice to see your seat mounts, alot of controvicey (sp) this year about them. Awsome front bottom arms. Are you going to run air filters ? Looks tight to fit them on.
Keep the pictures coming.
I know what you mean about seat mounts. I first built this car in 1998 and all was ok then. But not used this car for many years now. I might get a local scrutineer to have a look, but I have seen alot worse on older built cars that still run today. I might get some modern tubes fitted while I can.
I have also spoken to JRE about filters and they can reduce the spacers by about 1/4 inch to allow filters and should not affect the power. But we will fine tune when one the road.
The bottom arms are well made items from Rix engineering and are fitted to Callum Duffy and Simon Mauger cars. Plus I can dial out the scrub radius which is a problem when fitting 15inch wheels. This should make it turn in better.
Still have plenty to do.

[PaulC-grp4]

Any more updates? just giving this one a little bump!

[jdrally]

Not much to report on. Friend of mine is making some adaptors for my filter head so I can fix the Stack oil pressure and oil temp senders in.
Bellhousing had to be machined to allow fitment of the centre hydraulic release.
So while I have been waitingt I have made up the fuel and dry sump lines for the engine bay.
http://i937.photobucket.com/albums/ad213/jdrally09/Photo0019.jpg

[jdrally]

I have removed the throttle bodies to allow me to fit the new dry sump lines and fuel lines. I first made a bulkhead plate to cover the old holes, but it will be unseen when throttle bodies and filters are fitted. Tomorrow will attack the wiring loom.
http://i937.photobucket.com/albums/ad213/jdrally09/Photo0021.jpg
http://i937.photobucket.com/albums/ad213/jdrally09/Photo0020.jpg

[auldy]

Looking very impressive mate!

What is the name of the colour the blue strip is? Looking for ideas for my mk1 and like the colour!

Auld

[jdrally]

Looking very impressive mate!

What is the name of the colour the blue strip is? Looking for ideas for my mk1 and like the colour!

Auld

Cheers Auldy.

Cars in Ermine with Olympic blue stripe.

[auldy]

Thanks very much mate

auld