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PhillipM
Samba Member
Joined: January 07, 2010
Posts: 595
Location: UK
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 Posted: Wed Jan 13, 2010 2:52 pm Post subject: Our off-road rail. |
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Copied and pasted this from another post, so any questions or expansions on it needed, ask away!
Well, here's our heap:
Specs
Builder: My mate Ed, it's all T45 aerospace grade tubing.
Wheelbase: 110 inch
Trackwidth: 85 inch
Weight: 780kg (1700lb)
Engine:
Make and Model: Originally a 2.1 VW engine ~ 70bhp, now replaced by Mazda Renesis Rotary engine, complete with 3 stage variable intake length system.
Displacement: 1300cc
Power: 268bhp
Fueling: Bosch 040 pump, 3 sets of staged injectors, sequential injection and ignition on DTA S80 Pro ECU.
Exhaust: 3 tube, Short-Centre Branch stainless headers, homemade, 2" primaries into a 7* collector and a 2.5" main system with two baffled boxes (noise regs again), there's a little more power to come if we can keep it quiet enough whilst dropping the baffles, working on it this winter...
Transmission Make/Model: Originally rebuilt but standard boxes, then replaced with Renault UN5 transaxle - 5 speed, 9" diameter differential + phophur bronze anti-flex bushes.
Driveline: Race prepped 930 CV's with 300M shafts, wilwood hubs, 2800lb Kennedy pressure plate, 4-puck Feramic clutch.
Brakes: CNC pedals, cutting brakes, Hispec 4-pots rear biting on 288mm discs, Wilwood 4-pots up front biting on 248mm discs, Carbotech XP8 ceramic brake pads
Steering: Home-made billet alloy jobbie.
Fuel: 5 Gallon aluminium tank with baffles + foam.
Front Suspension:
Type:T45 steel beam, 4" wider, +2" chro-moly arms, forged spindles, Glacier DX arm and link pin bushes.
Travel: 12 inches.
Shocks: Fox 2.0 coilovers with twin-spring setup and hydraulic rebound stops, poly-foam bump stops.
Rear Suspension:
Style: Beam with custom T45 2" wider trailing arms, poly bushed out, Glacier bushed inner, 300M torsion bars, additional second rising-rate torsion bars, plus coilover springs
Travel: 14 inches
Shocks: 2 x Fox 2.0 coilovers with twin springs, hydraulic rebound stops, plus 2 x Bilstien 5300 series smoothbody's, all remote canister, flutter valved.
Wheels: Home-made 15" and 16" steel wheels, 6-8" wide.
Tires: Fedima Extreme Competition, 195mm wide front, 235mm wide rear.
Lights: Regulation rear running lights + lots of carrots.
Gauges: Stack 10krpm tachometer, oil press/temp guages, plus data logging from DTA S80 ECU.
Seats: MotoQuip + Corbeau Fibreglass buckets, with 3" aircraft-style sparco belts.
Protection Full 10mm thick 7075 T6 underbody skid pans, T45 forward nerf bars, Clubman 500 side nerf rails, full MSA/FIA spec T45 safety cage, all panels are 1.6mm 5052 aluminium alloy, fire extinguisher system, 4mm thick ballistic-spec polycarbonate windows, T45 rear engine cage, MSA regulation (bloody huge) mudguards.
(Ooops)
OK, there's not as much VW left as there was when it was built, but it's still VW-based in my mind  |
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LeviMan2001
Samba Post Whore
Joined: April 11, 2009
Posts: 3855
Location: Alaska
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PhillipM
Samba Member
Joined: January 07, 2010
Posts: 595
Location: UK
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| Posted: Wed Jan 13, 2010 5:14 pm Post subject: |
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| That's after the alternator melted from the engine bay heat, few cooling issues when we first fitted it! |
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shano63 
Samba Member
Joined: October 06, 2006
Posts: 3596
Location: Stormville NY
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| Posted: Wed Jan 13, 2010 8:37 pm Post subject: |
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Your tires will last you for years keeping it in the air that much! Cool buggy, cool pics
_________________
63 T1 Ragtop Gulf Blue
08 Civic 5spd
22 Wrangler 6spd
78 F250 4x4 4spd
Chris
Take it as it comes-- Morrison |
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MAYHEM
Samba Member
Joined: January 30, 2006
Posts: 1813
Location: Warm and sunny coastal CT
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| Posted: Thu Jan 14, 2010 10:36 am Post subject: |
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Man, that looks like it would be a blast 
_________________
Greg
Model Citizen
| johnnypan wrote: |
| I digitize myself in the privacy of my own home. |
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PhillipM
Samba Member
Joined: January 07, 2010
Posts: 595
Location: UK
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| Posted: Thu Jan 14, 2010 4:30 pm Post subject: |
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| shano63 wrote: |
| Your tires will last you for years keeping it in the air that much! Cool buggy, cool pics |
They would if it didn't keep throwing them off the rims |
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SkooobaSteve
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Joined: March 23, 2005
Posts: 3152
Location: Dothan Alabama
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shano63
Samba Member
Joined: October 06, 2006
Posts: 3596
Location: Stormville NY
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| Posted: Thu Jan 14, 2010 7:16 pm Post subject: |
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| PhillipM wrote: |
| shano63 wrote: |
| Your tires will last you for years keeping it in the air that much! Cool buggy, cool pics |
They would if it didn't keep throwing them off the rims |
Beadlocks! 
_________________
63 T1 Ragtop Gulf Blue
08 Civic 5spd
22 Wrangler 6spd
78 F250 4x4 4spd
Chris
Take it as it comes-- Morrison |
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PhillipM
Samba Member
Joined: January 07, 2010
Posts: 595
Location: UK
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| Posted: Fri Jan 15, 2010 6:00 am Post subject: |
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| shano63 wrote: |
| PhillipM wrote: |
| shano63 wrote: |
| Your tires will last you for years keeping it in the air that much! Cool buggy, cool pics |
They would if it didn't keep throwing them off the rims |
Beadlocks! |
They're too heavy
We've stepped up to a 16" rim this winter and 7-ply kevlar sidewalls instead of the 3-ply nylon that were on the old tyres, so hopefully that should keep them seated this year.
Next job is a plate differential, but nobody does one for an old van gearbox for some reason 
So I think it's going to be a DIY effort. |
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2true
Samba Member
Joined: December 13, 2004
Posts: 1218
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| Posted: Fri Jan 15, 2010 6:28 am Post subject: |
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Looks Fun!  |
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vw (o\!/o) nut
Samba Member
Joined: January 02, 2006
Posts: 855
Location: Wisconsin - Where the men are men and the sheep are nervous.
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| Posted: Fri Jan 15, 2010 7:23 pm Post subject: Re: Our off-road rail. |
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Somebody is having WAY TOO MUCH FUN.
_________________
"Curiosity killed the cat, but for a while I was a prime suspect." |
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PhillipM
Samba Member
Joined: January 07, 2010
Posts: 595
Location: UK
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| Posted: Fri Jan 15, 2010 7:50 pm Post subject: |
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| We'll be having way more this year now it's on fresh tyres and a rebuild front end (she'd got a fair bit of play in the link pin bushes + uprights) |
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shano63
Samba Member
Joined: October 06, 2006
Posts: 3596
Location: Stormville NY
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| Posted: Fri Jan 15, 2010 10:08 pm Post subject: |
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I'd put up with the flats! That kicks ass!
_________________
63 T1 Ragtop Gulf Blue
08 Civic 5spd
22 Wrangler 6spd
78 F250 4x4 4spd
Chris
Take it as it comes-- Morrison |
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PhillipM
Samba Member
Joined: January 07, 2010
Posts: 595
Location: UK
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| Posted: Thu Mar 20, 2014 5:07 pm Post subject: |
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Forgot I'd started this, this thread is waayyyy overdue for a shedload of pictures and updates, bear with me and I'll dig the older stuff out  |
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PhillipM
Samba Member
Joined: January 07, 2010
Posts: 595
Location: UK
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| Posted: Thu Mar 20, 2014 6:26 pm Post subject: |
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Have an absolute picture overload from the last few years, I'll have to rewrite some text/story to go with 'em later:
Okay, waaaayyy to many photo's and nowhere near enough writing, but you get the idea! |
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PhillipM
Samba Member
Joined: January 07, 2010
Posts: 595
Location: UK
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| Posted: Sun Mar 30, 2014 1:24 am Post subject: |
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Car going back together and shiny new discs - clearance on the caliper is a little risky mind...
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Not All There
Samba Member
Joined: September 12, 2013
Posts: 20
Location: CT
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| Posted: Sun Mar 30, 2014 6:31 am Post subject: |
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| nice to see whats under the shell. looks like a blast |
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PhillipM
Samba Member
Joined: January 07, 2010
Posts: 595
Location: UK
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| Posted: Sun Mar 30, 2014 6:49 am Post subject: |
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| Well, weighed as it is there, it's 736kg, there's probably another 40kg on top of that with the rest of the bits and pieces + fluids, but we're aiming at a minimum of 350bhp, so it should be fun |
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PhillipM
Samba Member
Joined: January 07, 2010
Posts: 595
Location: UK
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| Posted: Wed May 28, 2014 4:05 pm Post subject: |
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Been slow going for a while due to other things getting in the way, but rear bonnet framework has taken shape (actually, half the ally skin is made and the lights mounted now, but I don't have a picture):
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PhillipM
Samba Member
Joined: January 07, 2010
Posts: 595
Location: UK
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| Posted: Sat Jun 14, 2014 6:17 pm Post subject: |
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Not being too happy with the temporary air inlets for the manifold and supercharger, and having a spare bit of billet from another project, Ed make a small mountain of swarf today and replaced the manifold one whilst I was swearing at the cam sensor (I had to make a plug for it, because we couldn't get a connector to fit it for love nor money):
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