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How To Build A Rally Car


altezzaclub

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ha! Unsurprisingly the tanks went for close to retail price when you factor in the compete lack of guarantee. Naturally Steve HAD to buy SOMETHING, and this became the victim!

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I think he only bought it for the mudflaps..  genuine.. original...  worth the $250 he paid for it!

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After trying to winch it on & finding the remote control batteries were flat, we swiped their mower petrol & Steve drove it up onto the truck. That was fine, except he was the only person who knew how to lower the Mothership's tray, and the Hiace slid back down if you took your foot off the brakes. In the end I climbed up into the cab & leaned over with a foot so he could get down and drop the tray, and much to everyone's relief we got it out of there after an hour of loading efforts.

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The last day was pumping out a couple of "nearly empty" dams.. Every farmer is having their dams re-dug and tidied while they are empty with the drought, and seeing the earthmoving man was on the main farm Steve grabbed him for a quick couple of days.  Except it takes a couple of days just to pump the water out! The floating 20L is holding the hose, Steve's caravan water pump is by my feet and the Honda genset is by Kobar, running through several tanks of fuel to get it dry.

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Then Steve had to lead the procession through the paddocks to where the farms join-

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..and build a tyre bridge to get them over the main highway!

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So, when I get back up in a week or so that should all be finished and we can concentrate on how to fit a large J160 6-speed into a small transmission tunnel without altering the body.

Meanwhile.. more gardening!

 

 

 

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Love it Mate !

Great pictures !

Quote

Some guys bought their Gfs along, although they tended to be a distraction..

I nearly split my cornflakes out whist reading that caption !

I'm a bit worried about those ramps you used to get the Hi-Ace on the back ?

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In amongst it we had the local car club come around for a visit, an interesting collection of cars.

Lovely selection of cars there.  My late brother had  Hillman like that !

Good heavens !  Chrysler, Hillman, MG, BMW, Rolla, Foulcan, Volvo, Merc,  Landy,   I can't see two vehicles from the same stable.  Does your club have a rule, one of each, or something ?

I'd give you more than one (1)

 image.png.b1ece14c2a32582d94297a2eeec56d26.png     if this website allowed it.

Cheers Banjo

 

   

 

Edited by Banjo
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  • 3 weeks later...

Ah, back home after a short trip up there-  We cut the engine mounts down and re-welded them, and started on the custom gearbox mounts made from KE70 sway bar mounts, urethane bushes and some 4mm plate. I'll get photos next time.

We pushed the Slowdeo 4WD ute with the blown head gasket down the driveway to the road and put on a sign saying $450!  If we can sell it for that we'll buy a Sam-Q remote for the 6-speed, otherwise we'll have to build one.  I've left the body un-touched so we can swap the cross-member, motor and gearbox with the mounts into another shell easily without chopping the floor up.

Kobar got stuck on the hoist for a few days with a collapsed front hub bearing, and they just got that going yesterday with a new diff locker too. Steve got the 4Ha of paddock disced up twice, lime & sulphur spread and a green manure crop planted all just in time to miss the rain!

He did find time to do the gravel khanacross in Mao!

1854966804_Maorally-X.thumb.JPG.14cc6e062798d0ba22f075387147720e.JPG

...and it was christmas so we needed christmas lights on the hangar!

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OK, found one of the new sump height, this is the lowest I'd like the sump without cutting the crossmember. Lowering it tends to make the gearbox more level without hitting the floor.

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The gearbox shifter ends up here, hard up under the floor for the same reasons as the low sump.  Options are to cut through the main crossmember of the floor, shown just above the bolt-holes in the shaft. or fit a really flat remote gear lever link, which is what we'll do. The mounts go on the angled faces where that 10mm bolt is, and we will hang the gearbox from up in the tunnel for more ground clearance.

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  • 1 month later...
  • 2 weeks later...

OK, so a trip or two back Steve ploughed a couple of hectares and planted a green manure crop. When I arrived up in Jan it was growing well, but suffering the drought-

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The solution involved a big handful of cash and an ex-Council diesel water pump. Not cheap, but a nice setup, pumping out the dam and covering about 2/3 of the crop.. 

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With another handful of cash it was powering irrigation sprinklers.

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In the workshop I found the usual chaos, this time the Landcruiser farm ute.

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I needed the rally car's gearbox mounts welding, and the welder was back at Kempi being fixed, so I cleaned the hubs and fitted new bearings. We took one hole of the dustcover for a Terratrip probe and I put the struts together.

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Then the next problem.. The bushes in the camber adjusters are for 15mm strut shafts, pretty usual, but Bilsteins are only 14mm, so it was awaiting new bushes to be made. The AE86 springs don't match any spring top, KE70, Corona or Celica, so we made custom ones there too.  Meh- forgot to photograph them, I'll do it this week.

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Edited by altezzaclub
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Steve had made a 40M long test vege garden and the smaller sprinklers were falling over, so we made a pyramid out of old waratah posts.

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Lewis said that was too complicated and found an old plough disc. I welded a post on that and we had the world's simplest stand..

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That was the only un-used disc in the steel dump, but there was a worn one so we welded extra feet on that for the third sprinkler.

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They will do the last part of the green manure crop too, its not hard to move them around while the big sprinklers are fixed in place.

While I was away Steve had cleared out the storage/junk shed part of the woolshed and moved the two spare cars out to a new home. Now we need to re-roof this one too!

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Then they stripped the timber cladding off the Woolshed North wall and fixed the rotted posts.

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The corner one was especially bad!

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Edited by altezzaclub
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The big job was fitting a plastic roof to make a glasshouse for growing seedlings-

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and it even has a wind-up wall!

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The electricity went off one evening and all the next day, and that's when I discovered there were no lamps or candles at Auburn Vale.  What sort of 1920s farmhouse is this?? I dug out a lamp and made sure it worked for next time!

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I'd moved one of Steve's farm cats down to Auburn Vale and she'd had kittens down there. Now I have them living under the deck outside my room-

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but that's preferable to what lives IN the room with me!

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..and if you're ever taking bets of centipedes versus redbacks, I can give you a clue..

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Anyway- back up tomorrow for another hit! Maybe get those struts done AND the gearbox mounts if the MiG is back.  No doubt there will be lots to do setting up the inside of the glasshouse too-

 

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  • 4 weeks later...

Well, another trip and yep, struts done...

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Of course they don't fit!!  The Sigma LCAs give it such a camber angle that the LCA balljoint runs out of angle.  I assume people who use them ignore that and let the droop limit be the balljoint jamming.  Anyway, another little problem to solve later, we'll see how it all sits with a motor in.

Ah.. hang on, assembling the flywheel & clutch shows the clutch plate has the wrong number of splines! ..and we need an Altezza slave cyl.  You can pay a lot of money for these, or find out which parts bin Toyota used and buy them for Coronas or Hilux or whatever!

The gearbox mount is welded up and ready for fitting, that will be interesting!

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A constant irrigation has grown the manure crop and taught a lot about plumbing!

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..and someone is going to be eating a lot of zuchinnis in a month's time!

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Steve's dad Pete took me to the Avalon Airshow for a week to look at the helicopters for sale. We spent an excellent day at the RAAF museum while we were there.

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So, Orange for a week, then back up to get that motor in!

 

Edited by altezzaclub
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Somehow I have never read this thread. Not sure how that came about. But spending the weekend in a Airbnb beach house in Blairgowrie with Mrs Parrot and three 14 yr old girls so I’m sure I’ll find some time to get educated about farms and stuff. 

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Haha!  Excellent Pete, so I can expect some clever ideas as we progress with the build......

The overall aim at the moment is to get it back on its wheels with the motor & gearbox in, some doors hung on it and some ballast in to see what the ride height is like.  I need to move the rear shock mounts to make the most of the Bilstein's travel, but I need an idea of ride height for that. So solving the 6-speed problems plus the 4AGE conversion problems plus random suspension modification problems are all part of that road..

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On 3/8/2019 at 9:11 AM, altezzaclub said:

Steve's dad Pete took me to the Avalon Airshow for a week to look at the helicopters for sale. We spent an excellent day at the RAAF museum while we were there.

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Ah you should have mentioned you were going to be down earlier. Could have sorted you on a guided tour of the maintenance hanger(life member of the club I'm with is head of maintenance there). Other than the p51 they had in for service, they are also building a mosquito from very few parts. In the museum itself, I'd have to say the Boomerang and the jet hanger would've been my favorites. 

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  • 3 weeks later...

Stu, we would've loved that!  next time...

Well, another trip, more work...  Into the Sigma LCAs....    they push the steering arm and strut out so far that the steering arm balljoint runs out of angle and the LCA with the steering arm on it can't match the angle of the face on the bottom of the strut. Alternatively, if you put the assembly together then the steering balljoint jams on the edge of its cup and that is the limit of suspension droop, and THAT won't be good for the balljoint. In the photo here the balljoint jams on the inner edge of its cup.

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We made a couple of wedges to fit between the LCA and the balljoint, so it tilts the balljoint and makes it more horizontal.

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This tilted the balljoint just enough to allow the strut to bottom out without the balljoint jamming in its cup.

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With the front suspension done we hit the rear arches. Without springs and shocks the axle goes right up and hits the body in several places at once, a wonderful design. With the 14" rims we needed to chop 75mm out of the top of the wheel arch and re-weld the inner and outer skins.

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We cut the arches off the front guards of one of the paddock Coronas and made those fit. They aren't a dead copy of the KE70 shapes, but now that they are trimmed, riveted, bogged and painted they look fine!

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Edited by altezzaclub
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More shiny goodness from SamQ for the back of the head, although we only wanted one outlet and plugged the other 3.

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We cut the steel bypass line to fit and cleaned all the water pump gear. The hose fittings were all corroded, but some bog tidied them up. Then we moved onto gearbox and thrust bearing problems..

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The difference in the wire clips shown on those thrust bearings shows how different the Altezza J160 box is. No other Toyota seems to have the same clip system.

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However it was one of several major problems involving the clutch stuff. Basically the Altezza crank sits about 14mm further out from the block, so on a 4AGE the gearbox input shaft doesn't go inside the spigot bearing, the thrust bearing carrier falls off the front of the input shaft tube, and the slave arm pivot can't stick out far enough to let the arm push the thrust bearing far enough forward.

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We're currently looking at the best way to move those three components forward. We only found this out after buying a slave cylinder (off another Toyota) but on Ebay they can't be determined if they're left-hand or RH, and of course it is upside-down on the J160... so useless!

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Meanwhile, the boss was there in my chair and wouldn't even let me have lunch!

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