Jono_Misfit goes rallying - Breaking breaker bars

[jonomisfit]

Next part of the plan has been enacted.

I traded my road car in today against a transit custom. Almost made me cry as I'd had it from new and it was a blast. Still, it'd gone for the greater good.

Van is pretty decent. Low mileage and pretty good condition. Drives nice too.

[grumpybadger]

Despite offering an opinion on the should I, shouldn't I post I've missed this progress until now.

Good for you for making a decision and then actually commiting to it.
Many don't.

I"m sure with your attitude to being prepared you'll do well.

Good luck with it.

[jonomisfit]

Thankyou. Much appreciated.

[jamesd1972]

Exciting stuff, along for the ride !
James

[jonomisfit]

Yesterday saw me head to knockhill for my BARS test.




The sole picture I took as I was a bit occupied.

It was a good experience. I was in a group of 3 and we got about an hour with their rally coach going through some key points on rallying, driving technique, things to look out for. Then it was 4 laps of the rally course (mainly wet, slippy, muddy, gravel strewn tarmac, with a few gravel bits thrown in) with feedback from the instructor, whilst driving standard was being aporaised, along with suggestions on techniques to practice.

Followed by the written test, which is based on key bits from the motorsport UK rules book, section R, rallying. This was OK, and was only about 20 questions.

Day was good, and they've stamped my licence application, so just need to send that off and I'll be licensed to stage rally.

Driving the laps yesterday has solidified I need a good dose of practice, and I should go get some 1 to 1 driver coaching so I start right from the get go.

[westbay]

Well done !

[jonomisfit]

Today was a busy day with a few trips out.

Notably the morris went to its temporary accommodation. First time in a long while that I've towed anything. Went well with no mishaps.





What didn't help was my plate for the trailer hadn't turned up, so I uses the one off the back of the transit.

After a bit of faffing about I got the trailer lined up reasonably and rolled it off the trailer straight into the storage container.





Plenty of room in it for storing rally car spares etc.

Then back, got the c2 into the garage and investigated clicking sound coming from the van. Which turned out to be the cv boot had popped off and ejected all the grease. Joys.

I found some grease and re filled then refitted the boot, but suspect the joint is now toast.




C2 has an mot next weekend, so will see what the tester makes of it, and what he finds needing fixed.

[jonomisfit]

The guy I bought the transit from got the driveshaft sorted, although with the cold spell its now shown the battery is weak and needs replaced.

The car went for its MoT and other than a few minor points it went through ok.

Right.. get it back out the garage

P1080322 by jono_misfit, on Flickr

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Battery was flat, so gave it a charge for a bit

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Then took it for a shakedown.

Went from my place over to the next village and back a couple of time to warm the car through. I didnt go as i was just sussing it out.

My thought.

Its loud, unsurprisingly so with no interior and a full rally exhaust. How loud.... well mrs_misfit commented that she could hear me from inside the house with house windows closed going over the hill and back.... pretty loud then.

Steering is very light, but when I got used to it a bit there was a reasonable feel

The tyres are toasted. They are mediums so are too hard really for the temp, but also feel old.

Brakes have no feeling to them whatsoever. They are very soft, have a lot of travel, and a lot of dead zone. One of the calipers is dragging a bit so needs looked at. I need to give them a bleed and see if that improves them a bit or not. Pads work from cold which I was surprised about. But even though they don't feel great they work well and stop the car nicely.

Handbrake is fun and works really well. it is however a bit too close to the wheel for me so I may tweak it a bit

Seat is too far back. I need to move it forward another 50-100mm I think.

Car is surprisingly soft. I felt less rattled about in it than I do in the road C2 VTS i bought.

Gear shifter is woeful. Utterly lacking in precission, so I suspect most of the joints in it are past their best.

Gearbox is nice and low ratio so the car pulls hard, but engine doesnt have much go till about 4000rpm

Diff pulls hard.


I took the car on a longer shake down, again not going hard, but I just wanted to check how things were on it. Did about 5 - 7 miles round the lanes pootling about and occassioanlly giving it some beans on the straights. There were a fair few rattles I need to look into coming from the front suspension and the middle of the car.

Put the car back in the garage and jacked it up and put on stands.

A look round shows the brakes are in reasonable condition standard C2 VTS so i'm guessin the brakes issue is sticky sliders.

Drivers
P1080337 by jono_misfit, on Flickr

passenger

P1080339 by jono_misfit, on Flickr

Strengthened wishbones, but the bushes look like they've seen better days

P1080341 by jono_misfit, on Flickr

Struts are AST5100 series single way adjustable, but still some pretty decent ones. A look shows they would have been about £3k new for the car set. I need to have a good look at them to see if they need a rebuild. Receipt in the file is from 2018 for a full rebuild so may well need a full re-do.

P1080342 by jono_misfit, on Flickr

All the joints seem good, however there is movement in something. Eventually tracked it down to this. The top mount spherical bearing has slop in it, a coupe of mm. Passenger side is the same, but a little less bad. Will need to replace.

P1080343 by jono_misfit, on Flickr

Passenger side

P1080344 by jono_misfit, on Flickr

Rear all looks in good condition, although have found the noise coming from the middle of the car. The fuel filter appears to have come away from whatever mount it was on, so will need to sort that.

P1080345 by jono_misfit, on Flickr

Exhaust also has a massive flat spot in it from where something hit it, hard. I may see about cutting it out and replacing it.

There are a few other bits to sort, notably where some cables are rubbing, bushes are getting a bit old. etc.

Oh, and some seats and belts..

And need to get the extinguishers serviced as well.

All in all, i'm pretty happy with the car. Should do me well.

[jonomisfit]

In the spares I got there are some more alloy wheels some of which need a proper refurb.

In between other things I thought i'd try stripping one back and seeing what it came out like.

Before (this isnt the one I started on but I began stripping before I took a pic)

P1080360 by jono_misfit, on Flickr

It looks OK from the front, but the back is heavily corroded. It also got a big bite from the rim.

after a couple of goes with paint stripper, its taken off the top coat, but not really touched the primer.

P1080361 by jono_misfit, on Flickr

inside post paint stripper

P1080362 by jono_misfit, on Flickr

And yes, that is a big flat spot on the wheel. Its not in good condition.

primed and given a couple of coats of white.

P1080363 by jono_misfit, on Flickr

a few more coats (and a few runs down the back face...

P1080366 by jono_misfit, on Flickr

It came out as I expected. No great. I'll have a think on it, but may buy another set of same alloys (they're Peugeot 207 gti / 206 CC alloys) then send them all off for stripping and re-powder coating in white.

[jonomisfit]

today was only short on the escort and rally car as I needed to sort some things on the road car... which I did, but only to find the topmounts are away and I need to replace them.

Anyway, i've been ordering bits up and crying at the further expense.

I bought some seats so fitted them.

P1080416 by jono_misfit, on Flickr

loads of room

P1080417 by jono_misfit, on Flickr

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I've pushed the codrive seat back about as far as I can. I can maybe get it a hole lower in the mounts by canting it back a bit but then i'll be up against how far back you head can be v's the roll cage hoop

P1080420 by jono_misfit, on Flickr

Extinguishers are out and boxed ready for sending for a service.

I'm awaiting a few more bits then will be on with prepping the car for use.

I still need to sort the wheels, so have contacted a refurb place to see what the costs like for a strip, straighten, and re-paint.

[stealthstylz]

I wouldn't bother straightening the wheels, just bead sealer the curse word out of them, balance them as well as possible, mark them up as the dodgy ones and run them on the back.

[jonomisfit]

The car runs on all standard bushing as far as I can tell, and much of it isnt in good condition.

I was going to drop the wishbones and swap the bushes out on them, however this is a french car..... it has got what I consider to be.... unusual bolt / nut sizes throughout and it turns out I don't have all the tools to remove.

I.e the ARB drop links are 17mm, the damper pinch bolt on the upright is 16mm, the bottom ball joint are 17mm, the pinch bolt for the bottom ball join I think are 15mm, the hub nut is 35mm. I have some buying to do.

The front ARB bolt was 19mm.. .which seems utter overkill for the loads in it,

state of the bushes

P1080421 by jono_misfit, on Flickr

Blasted and ready for rust killer

P1080424 by jono_misfit, on Flickr

treated and primed with etch primer

P1080425 by jono_misfit, on Flickr

baked, painted black, baked again

P1080433 by jono_misfit, on Flickr


new bushes

P1080422 by jono_misfit, on Flickr

Fitted

P1080434 by jono_misfit, on Flickr

I was going to replace the bushes in the rear beam as they are equally toasted.

dropped the rear dampers out, which are in good condition (top bolt 16mm in double shear, bottom bolt 22mm in single shear)

P1080426 by jono_misfit, on Flickr

then onto the rear beam

P1080427 by jono_misfit, on Flickr

except this needs a deep 18mm socket on to get off, which i don't have

P1080428 by jono_misfit, on Flickr

so that scuppered that job

impact marks on the exhaust

P1080429 by jono_misfit, on Flickr

free floating fuel filter, which I managed to re-secure to a bracket above it

P1080430 by jono_misfit, on Flickr

so onto another job.

The front cam cover gasket is leaking so need to replace it. Which was fine until.... one re-fitting one of the bolts went slack suddenly, and on trying to wind it back out again.

P1080435 by jono_misfit, on Flickr

Joys. So next time I need to take it back out and extract the broken bolt.

I went in at this point.

[jonomisfit]

I got the old bolt out. A couple fo blobs of mig on the top, then welded on a nut and it came straight out.

P1080441 by jono_misfit, on Flickr

I machined up a standard bolt to match the length and tip shape of broken one, then refitted

P1080442 by jono_misfit, on Flickr

then on to start fitting this.

P1080443 by jono_misfit, on Flickr

Satchell Engineering "Satchshift" replacement for this

P1080444 by jono_misfit, on Flickr

which is frankly abysmal... Maybe when all the bushes are new it works well, but mine is worn and so vague it almost unuseable. I'm surprised it hasnt led to a load of missed shifts.

The satch shifts arent cheap (~£360) but they are very good, and the quality of kit seems very high.

This ammused me.

P1080448 by jono_misfit, on Flickr

They arent a million miles different so should be fairly straight forward.

popped the cables off

P1080445 by jono_misfit, on Flickr

then took out the gear shift

P1080446 by jono_misfit, on Flickr

and cleaned it up

P1080447 by jono_misfit, on Flickr

this bit goes in first, on the rear most original shifter mount

P1080449 by jono_misfit, on Flickr

draw round for a hole to drill

P1080450 by jono_misfit, on Flickr

P1080451 by jono_misfit, on Flickr

marked up the centre

P1080452 by jono_misfit, on Flickr

X marks the spot

P1080453 by jono_misfit, on Flickr

drilled the floor, and also the heat shield

P1080454 by jono_misfit, on Flickr

Then cleaned up and painted the edges.

I put1 some strips of foam rubber on the lip that presses on the hole and bolted it down

P1080455 by jono_misfit, on Flickr

start stripping these bits out

P1080456 by jono_misfit, on Flickr

then a roll pin to knock out of the fwd/aft shift

P1080457 by jono_misfit, on Flickr

removed

P1080458 by jono_misfit, on Flickr

not sure if this is a standard thing or not, but there was a roll pin inside the roll pin, i'm assuming to make it less likely to come out

P1080459 by jono_misfit, on Flickr

start fitting the first piece of the shift, goes onto the ARB mount and a spare bolt hole at the back of the subframe

P1080460 by jono_misfit, on Flickr

also has a little bracket to bolt to the bulkhead

P1080461 by jono_misfit, on Flickr

P1080462 by jono_misfit, on Flickr

fitted the first shaft

P1080463 by jono_misfit, on Flickr

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I had to shim it with a few washers to get it set correctly

fitted the shifter

P1080465 by jono_misfit, on Flickr

it was at this point this went wrong....

The what felt like a secure pin, that I assumed was held in place inside the gearbox suddenly dropped into the gearbox. Ahhhhh. I think it was just stiction from the o-ring seal that had been holding it in place.

P1080467 by jono_misfit, on Flickr

I managed to fish it back out but it didnt feel right. After much moving it round and moving the cross gate I managed to get it back working so that turning it moved the cross gate back and forward. I had to go by feel and it was awkward to get in there. It also would just drop straight back down again if not supported.

P1080466 by jono_misfit, on Flickr

I spent a hour watching BE gearbox rebuild videos and it looks like what holds the shaft in place is the shift arm outside the gearbox and the little spring that sits under it.

How to get the new arm on without stripping the gearbox?

eventually I settled on drilling the centre (although this isnt the center as I couldnt get he drill in properly) and tapping it for a bolt

P1080468 by jono_misfit, on Flickr

I could then put the shift arm loosley in place, and use a nut and washers to pull it down, whilst pulling up on the bolt to stop it dropping out of position

P1080469 by jono_misfit, on Flickr

P1080470 by jono_misfit, on Flickr

What a pain in the backside, but got there eventually. As it took so long to do I ran out of time. Will pick it back up next weekend.

So much for a quick job...

[jonsey]

I have double roll pins on the selector shaft on my type 9 gearbox as they do like to snap when there is only one. I think you’re supposed to fit them with the splits 180° opposing each other.

[jonomisfit]

Thanks. I'll keep that in mind when I refit them.

[jonomisfit]

After much swearing I got the roll pin in.

I ended up taking the arm off again, getting the pin partly in, re-fitting it, then drivign it in the rest of the way with the air hammer set on low impact. A right pain for access to it.

P1080471 by jono_misfit, on Flickr

difficult to see, but i also got the second roll pin i, this time using a welding clamp. Taking care to anti align it to the first roll pin.

P1080472 by jono_misfit, on Flickr

connected the linkages and started greasing it up, but decided I didnt like the angle on the cross gate ball joints, so flipped the upper middle one after this pic. Put it at a much better angle and nothing fouls on it.

P1080473 by jono_misfit, on Flickr

set the gearshift up. What a difference. very positive engagement feels great!

P1080474 by jono_misfit, on Flickr

Sorted all the things I'd moved / disconnected

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extinguishers came back from service so fitted them

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I need to sort a bracket for the bias adjuster, plus I don't like the handbrake position so may well re-make the handle on it

P1080481 by jono_misfit, on Flickr

[jonomisfit]

I need to mount the brake bias adjuster. It used to be attached to the gear shift housing.. which is no longer there

P1080483 by jono_misfit, on Flickr

handy stud

P1080484 by jono_misfit, on Flickr

cut a piece of 3mm aluminium angle

P1080485 by jono_misfit, on Flickr

couple of holes and cut down

P1080486 by jono_misfit, on Flickr

a bit of cutting and drilling later

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fitted

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Then onto the rear beam. I watched a youtube video that showed the best approach on these was leave the full suspension assembled, then unbolt the beam bracket. SO all suspension back on again....

P1080490 by jono_misfit, on Flickr

Then undid the 3 beam beam mounts each side, which was very easy. E type toque bolts, but worryingly 2 on the driver side and 1 on the passenger side were fairly slack. SO have evidently loosened with time and rallyling...

Getting this out was a mare, and took over an hour on its own

P1080491 by jono_misfit, on Flickr

I was trying to press it out with by bearing press kit (bolt through centre etc.) but snapped a piece of 12mm stud as it wouldnt move. Eventually hammered a big screwdriver up the side of the bush, turned it cracking the plastic housin, then did that repeatedly round the edge. Eventually it then pressed out.

Cleaned up the beam bush housing casting

P1080492 by jono_misfit, on Flickr

then for the beam bush

P1080493 by jono_misfit, on Flickr

in

P1080495 by jono_misfit, on Flickr

then did the other side

P1080494 by jono_misfit, on Flickr

I've gone for "fast road" spec bushes, but if they move too much I may go for the harder compound ones.

I didnt have enought time left after the beam, so sorted rollcage padding

P1080497 by jono_misfit, on Flickr

P1080498 by jono_misfit, on Flickr

then continued on with removing stickers

P1080499 by jono_misfit, on Flickr

and cleaned up residue with tar and glue remover

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All ready for whatevewr graphics I decide to go for.

[jonomisfit]

I've been playing about in the livery editor in EA WRC game to try out that may be close to what I go for. Its based on the colour scheme the car is already in, and sort of based on some graphics I found on I can get from Ebay.

I used the C2 S1600.



Thoughts?

[Davey]

Other than the huge logo on the front bumper that looks suitably silly.

[jonomisfit]

My spending spree contintues. I've ordered a race suit, helmet, Head restrain, etc. which should be here in a few days.

Still working my way through a few odds and sods on the car though.

Thge wing mirror has been knocked off at some point and the stubs that the screws go into are all snapped off the mounting panel.

P1080502 by jono_misfit, on Flickr

I turned up a nylon stub

P1080503 by jono_misfit, on Flickr

I was going to glue it on, but figure it'll just snap at the join line, especially with the existing damage to the mounting plate. So i've drilled it from the back

P1080504 by jono_misfit, on Flickr

the counter bored the mirror to clear the bolt / washers

P1080505 by jono_misfit, on Flickr

goes on like so

P1080506 by jono_misfit, on Flickr

a test fit shows it works ok. So back to the lathe to make another one

P1080507 by jono_misfit, on Flickr

due to the damage under it I made the stub have a wider base so it spreads the load

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The top one is very thin material so I don't think does a lot for holding it all on, so i've left it out for now.

on the car

P1080511 by jono_misfit, on Flickr

worked well, but another hit on it will likely break the mirror beyond repair.

Fitted the harnesses and as it was a a nice day I took the car out for a shakedown drive. It went quite nicely and there a definitely less clonks than before, but still a couple more to sort. The new gear shift is epic. Nice and short, really positive feel, and really precise.

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I didnt do that many handbrake turns in the laybys....

In between other things I gave the spare set of alloys a quick run through the blast cabinet, then a sand down ready for a coat of paint to tidy them up a bit. The need full refurbs, but will do for now.

coat 1

P1080513 by jono_misfit, on Flickr

coat 2

P1080517 by jono_misfit, on Flickr

coat 3

P1080518 by jono_misfit, on Flickr

leaving to the side for a week to cure before I give them a laquer

P1080519 by jono_misfit, on Flickr


I spoke to a local scrutineer tonight. Really nice guy. I'm going to take my car round in a couple of weeks for him to look it over and advise if there is anything else I need to do before it can be used. I might also get the car onto a new passport at the same time and save any faffing next year.