Rally Mk1 Project

My first Mk1 was built supposedly as a Sunday driver and maybe a bit of track use. Since completion it's really only seen track use but is really a bit of a compromise. I now want a rollcage, coilover turreted rear suspension, etc

I bought this for the bonnet, doors, wipers, and a few extras:


But it was really in too good shape to cut up. So after 6months of sitting in the corner a fully "Rally build" has commenced. Hopefully will be a bit quicker and a lot better than the first build.

Sunday arvo was off with the doors, then this evening off with the front guards




A few nastys but a much better shell to start with than last time:

I spent most of Saturday building a spit to mount the shell - the local scrap merchant had a load of 75mm square galv tube which proved useful. I'll need to go back and get another length as I would like to add a bit more bracing to the uprights.



The shell is now pretty much bare:


Does anyone need 1600 suspension or diff (in Perth) - otherwise it'll be dumped next weekend!

sms sent

Saturday was spent on rust and body repairs:

First was the getting rid of the rest of the underseal:

(That's three dustpan loads)

This is the rust I spotted when I cut out the rear arches (this is the inside of the C-pillar):


This is my DIY sandblast unit:


10 minutes later (and a lot of mess):



Next was the jacking points. Both had been bent seriously out of shape and at some stage filled with bog. The main problem for me was this stoped the bubble arches from fitting the body:


A DIY slidehammer:


A bit of heat and 30 minutes of bashing and it's back into shape:


The passenger side wasn't as bad but after a tap with the hammer a big lump of bog fell out revealing:

(I wish people would treat rust prior to filling)

Anyhow thats all fixed now. As of Saturday night it looked like:



Then Sunday was the "Last Blast" Superkhana - So I took the white one out to remind myself why i'm doing this:



I really really need to get a decent LSD, and a better engine, and better gear ratios, and better seats, and...

Rust repairs - the ongoing saga:


Boot wells:


Turrets mounted:




and aligned:


Stitched welded the chassis rails:


and front suspension:


and started playing with the roll cage:






Happy new years for Saturday!

Paul.

I like the look of the bends on the cage, any chance of some closer photos of the bends themselves ? I didn't think the little hydraulic benders were capable of turning out goo bends without loads of crush.

quote:

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Originally posted by Phil

Great work Paul Gotta love a fast paced build thread

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You dropping a subtle hint Phil....[8~2]

Hi PAUL LOOKING REALLY GOOD did u get my last sms. news years day saw me start my twin cam restor,started welding now i have kevins welder [forcefeed v6capri] at the rear panels ps need more practice welding.[8~2]