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How To Build A Rally Car


altezzaclub

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I modified a rubber channel to fit under the new alloy radiator, then drilled a hole at the top of one side to be tight, and the other side to be slightly loose so it can slide under stress. Hopefully this will allow the front of the car to flex without flexing the rad as well. I'd already cut the front out to help with motor changes, and when I put the top strip back it it was reinforced so is stronger than the floppy stock one.

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These are the modified KE70 spring tops we made to keep the front springs in line and captive-

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Back outside, things are growing. The green manure crop is now waist-high, compared to this photo.

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A quick trip in Pete's R44 showed how patchy the watering was, and we now have even water over the whole area.

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The trial vege garden is producing, Steve has a regular run on Tuesdays to organic shops and restaurants etc up Armidale way, zuchinni, beans, silver beet, and beetroot.

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But the main course is in the glasshouse, 6000 seeds planted every two weeks, to be planted out in the main area when the green manure crop has been slashed & dug back in. All the Brassica family, brocolli, cabbage, caulis, kale.. for winter frosts.

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This requires farm machinery.. two gensets to run pumps!  Beautifully made, quiet and efficient.. except you have to check the oil each tankful of fuel, even tho' they're brand new.

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Just for interest we stripped the motor after it seized... A SOHC with a centrifugal cam-controlled exhaust timing that holds the valve open past TDC to regulate the max speed. The thing that was a carb is actually a fuel-injection system! The generator part is built-in to it all.  It ran again but didn't produce enough grunt, so we have a new larger version.

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Steve bought a Hino fridge truck, so we did a rubbish run before hitting it with the water blaster to clean it out.

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We tried to get the old decals off, but its a massive job, so it was pressed into service as it was, a milk delivery truck! New vinyls will come later.

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We turned the Dyna into a spray truck. Making the booms was easier than getting it mobile, it had been neglected for years.  The Nikki carb ran flooded all the time, and it took a day to swap enough parts to fix that, and now it only runs with the choke full out!  Some massive air leak somewhere, but we didn't have time to pull the manifold off and see if the missing bolts in the middle were important..  The little bit of "oil" left in the gearbox & diff was like grease, obviously not changed in the last 30years, the clutch doesn't free completely, the wiring will set fire to it one day and the starter solenoid is moody..

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Down at Auburn Vale the deck is half sanded/oiled. Its been in the sun so long it won't come up like new unless we sand 2mm off the top, but this will keep it protected.

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We patched the drinking water tank at the house too, some people were not keen about the red worms wriggling around in their glass. A quick google showed them to be bloodworms, the lavae of a non-biting harmless midge, but definitely off-putting.

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I vacuumed the tank dirt out too, and saw a brown snake escaping the water going everywhere by sliding under the blue car. A search showed it kept moving on..

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That got me looking at the concrete tank, 40,000L and not being used..

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however a look inside was quite daunting!

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I pulled the main plug and let the metre of sludge out, and when its dried we can get in with a shovel. However the big problem is the tree that is growing over the roof blocking the gutters...   I can put a roof over the tank again, but dropping that tree without hitting the roof, the cars or the power lines is something else!

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Anyway, AuntyCat, who I catnapped from Strathaven and bought down to A'vale, became Mothercat down in the shearers cottage where Steve's little bro lives. She bought two grown kittens up to the main farmhouse, where they seem to have made themselves at home.  Aren't cats clever!329657019_Ppetesfamily.thumb.jpg.0c9b12f1dea80099693a1dc1ba6fcc5e.jpg

A long break now, I've got to stay at home looking after cats & chickens while my mob are overseas, so it will be 6weeks before I get up there again.

We'll see what happens then...

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  • 4 weeks later...

While I've been working my way through endless lists of chores at home, Josh phones up.. He navigated for Steve for a while, then moved to Blaney, just out of Orange, and he's building an Evo 3 for the Orange Rally this weekend.  So i've had a couple of afternoons working on something completely different with about 4times the bhp!  Mind you, after seeing this clip, I'm sure you can get enough out of a 4AGE !

https://www.facebook.com/VHTRacing/videos/248299146008069/?s=100000342565571&v=e&sfns=mo

 

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  • 1 month later...

Woo! End of June, I better catch up!  So I came up way back in mid-May, with the faint problem that The Girls KE70 died on the way up!  Steve picked me up that night with the trailer and we stuck the car in the workshop. His dad, Pete,  was away for a few more days so his younger bro & I got stuck into the kitchen floor with a belt sander.

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In a frantic few days we sanded it all twice, filled it and sanded it again. We even painted the hearth!

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We finished it the day he arrived home, quite a surprise after a couple of decades with nothing once the carpet had been lifted.

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Auntie cat had two litters last summer, so The Dark Minx is quite big now, and all the new kittens are at the house.

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Minx's brother Sylvester is all grown up, and their three siblings are living with Steve's bro down at the shearers cottage.

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The new generation, another black & white, a grey & white, a ginger and two stripey tigers,   have a lot to learn!

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So we hit the farming-  first up was tweaking the Dyna design so the booms folded back properly and were supported when out. I think it sprays 6M of garden each side.

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The seedlings in the glasshouse were big enough to plant out, bigger than when this was taken,  but we had no machine to do it-

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The machine built for it let the seedlings fall over and ended up burying them rather than planting them-

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So we ran it along the garden to make the grooves

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and started planting brocolli..

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20,000 of them!!

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Well, actually it was done with the help of the usual starving Uni students!  Yeah, it was FREEZING cold!

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Then we hired a rotary hoe to see if it chopped the soil up finer. It did, but not before dropping the drive bolt out of a wheel, then having the engine cover chew the belt up..

Kennards were very good about it and gave us another weekend for free.  After that Steve bought a tractor driven one!!  Due this week sometime.

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There was still engineering going on, his little bro' was sowing oats and broke the harrows bar.

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We used a spare I-beam and reinforced the holes for shackles

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and always feeding out to do!  A $30k truck of feed doesn't last long, you burn 20cows in the herd every time to feed them.

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Steve's GF's Corona came back to have the heater fixed. We'd isolated it a few months back as it leaked, but -7deg mornings in Glen Innes were putting the strain on. I ripped the dash out, almost completely, and we put in another from a spare 'Rona... but it leaked too!  So Steve had the original fixed and out the dash came again, then all reassembled... and it leaked again!!

So that went back with the second one, and they said it was fine when tested, so we have two good cores and a leak from the heater control valve that dribbles inside the heater before dripping out! Then we spent a day converting it to an external tap under the bonnet from a KE70.. which leaked of course!!  So we swapped it for a better one which was fine!  ...until we moved the control slide and THEN it leaked!  So its gone back to Glen Innes with a slightly dripping control valve under the bonnet!  ..and I know a tremendous amount about how Toyota heaters work and how to get them in and out!

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I'd been working on the blue car on and off when I got time, the lack of compression meant a full head job, and it only got assembled completely two days back... and didn't run! Don't talk to me about 4AGE igniters, I'm quite allergic to them just now!  I'll update The Girls KE70 after this.

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Anyway, another new toy was a seeding machine. The old ones have a horizontal disc full of various sized holes so you can select the hole for a vege seed and a rotating brush slides the seeds over the hole. this put out the seeds too close together, so Steve ponied up over $300 for a better system. I haven't got a photo of it before I extended the handles so it could be used by an adult.

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The handles only join the chassis through two miserable rivets, and it was flexing all over the place until I put a couple of diagonals in down to the back wheel.  It has a vertical disc with cups that pick up a seed and drops it out through the wall to be planted, and you can tape over some holes to sort out the distance between plants. There are 6 discs for different sized seeds.

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Then we found as you push the force goes through the back wheel and lifts the front wheel off, so more mods were needed-

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Now it seems fine, and it planted a few thousand peas and beetroot yesterday.

 

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In the general chaos Lewis dropped his KE70 in saying it had a terrible vibration in the car and it had ruined the clutch. He'd just paid a mech to put new bearings in the driveshaft last year and it had never been quite right, then got much worse..  So up on the hoist and we found a driveshaft with sort-of OK front universals, a new center joint, and a completely dry & destroyed rear uni!  The clutch?? Well, the circlip slipped along the cable and it went all soggy, as KE70s do!

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"A rally car" you ask?  Ah, a desk for my desktop computer so I can read Parrots 4AGE manual while fixing the Girls KE70 in the workshop!  Next trip!! I promise!

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If you want broccoli and beetroot, why not just go to the supermarket and buy some.  They even have beetroot in tins!

Seriously though, do you have to deal direct with the big two, and are they as bad as you hear?

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All organic, so we never even wholesale it. There are lots of restaurants and small organic shops that will buy it, more than we can produce at the moment.  Give it a couple of years to get sorted out and we'll see how big it can grow. The next step is for Steve to work out a 12-month planting timetable and just see how it goes. Organic Certification is being done right now.

Tomorrow is Monday, so that means a late afternoon picking greens & packing them in the freezing wind, followed by picking greens frozen in the frost on Tuesday morning before he heads off in the Hino for deliveries..  I'm hoping to head home then and sit by the heater in Orange!

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  • 1 month later...

Well, another trip up and back, and its a quiet time for vege farmers. First was re-wiring the back end of the blue Isuzu truck that gets used almost every day. A couple of days had that through rego. Then onto the red truck..  Much heavier, it hardly gets used and suffers from blowing exhaust gaskets all the time. Nice truck-

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TERRIBLE motor design! I've taken the inlet and exhaust manifolds and the turbo off, all of which hide behind that chassis rail in the smallest space they could fit them into!

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While I was cleaning and sorting and freezing my butt off, we took time to modernise the workshop!

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So good!

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The chimney was a job, but man it sucks!

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Having run out of excuses it was time to put the motor in the rally car!

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I've forgotten most of what the hell I did years ago so it was a while getting all the front suspension tightened up and sorted out. We now have a shopping list of odd stuff to buy, and the last job for me was moving the shock mounts on the diff. Next week that can go in and we start plumbing electrics, fuel, brakes and on and on!
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On the way home I popped into Lake Burrendong, it dams the Macquarie River that starts in Bathurst, flows North of Orange and over to Dubbo and further North-West past Nyngan. There won't be much water getting out there, its at 5%...

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Then when I get home I find the wife has contaminated the garage! So now I either have a surplus Hoonicorn or Altezza, and both will be surplus later as The Girl is going to buy an i30 she reckons!

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  • 3 weeks later...

Another trip & more adventures!   Too many photos I didn't take as usual...  Anyway, the red truck was re-assembled and passed rego, so now it will sit in the shed until next year..  Too big to use for feeding out, too small to carry a useful number of cattle. We ran out of water in the big 22000L house tank, while there was only 6" left in it the endless frosts help blow a plastic line off and it leaked out. We moved the tank, put down more sand and fitted a new tap. The top had collapsed in so we took that off and inverted it again, its awaiting the next trip up. The snow put 6" of water back in it!

Ah, the snow, yes... after a week of freezing temperatures and high winds, the snow came for a couple of days. That week made the fireplace a great asset, I wouldn't want to be in the shed without it.  The snow did make driving between the farms fun however!

6pm as we close up-

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Outside its like this-

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and driving home is like this-6_15pm.thumb.jpg.75802b8701fb29c114a483418628a176.jpg

two days later its like this-

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and someone has to stand on the back of the truck feeding out hay every two days!

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Getting back up to the workshop was OK, the Council tractor cleared the hill. Steve had gone back after dinner in the Landcruiser, but could only crawl up using the locker.

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Things were still pretty chilly at the workshop-

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Anyway, we fitted the dizzy, found it was very close to the extractors so made a heat shield-

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The alty wouldn't clear the extractors either so we moved that to the other side, which meant lengthening wires. The heat shield is in this photo too.

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The diff had the shock mounts welded up and its back in.  Steve picked up a pair of wheel crawlers, those things the V8Supercars slip under the tyres to wheel a car sideways back into the pits, they just need a bit of cutting and welding to be made useful and very handy in the shop. The braided lines arrived, clutch and diff lines great, the fronts need a hard 90deg angle to keep them out of the stones. We've gone from Celica calipers on the back of the strut to Corona calipers on the front.

So next trip in Sept will be all wiring and planting I expect, spring is just around the corner.

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