Rallyho progress

[fiasco]

Here's what Luke, Jordan, Brett, Mike, Andrew, Ted, Breck, and Jeff did this weekend.

http://picasaweb.google.com/andrewsteere/Rallyho82507

http://picasaweb.google.com/38crew/SaabBuild

--Andrew

[Rallyho]

A HUGE thanks to Luke, Jordan, Andrew, Brett, Ted, Jeff and Breck for what in the light of day is a MASSIVE amount of work done over the course of 1 1/2 days:

Roof vents in
fr susp on
rear susp on
900 motor mounts and tranny cover on
side, rear and hatch lexan windows done
most of the body work, bondo, etc done
seat mounts done
harness mounts done
close in firewall holes done
door bar taco gussets done
dual master cyl/brake bias/brake pedal ratio mod done
complete rack-to-wheel steering shaft/universal/quickener/mount/quick-release system done
Hydraulic handbrake fab mostly completed and ready to finalize and mount
Various other little, time consuming or PITA stuff done and tied up.

Seriously, I spent 5 hours cleaning up a 2-bay garage that looked like it had been hit by a giant, metal shredding, Moxie & PBR drinking monster.

I felt like I did a bunch of running around, yessing and noing, parts hunting and "holding the other end" while all you guys worked your asses off.

Thank you. You guys rock!

[Geoff]

I wish I could have been there, sounds like a good time!

You coming over this way next weekend to get the car inspected?

[Luke]

Glad I could be of assistance. Thanks for being a great host Mike. Had a great time even with your kids jumping up and down on my air mattress at 7:30 am with darth vadar masks saying "use the force".

[Hans]

Looks like a fun weekend of wrenching/fabbing.

Q re: rear shock area -- looks like some of the cage was welded right over the top where the shock bayonet/nuts goes. Am I seeing that right? Are you using eyelet mounts somehow?

EDIT: Holy $h1tty usability, Batman -- Picasa sucks for linking. The photo in question is 100_1439.jpg
http://picasaweb.google.com/38crew/Saab ... 6961049250

[Jordan]

Yeah, honestly I think Mike is going to have to re think that area. We came up with lots of solutions for shocks, but all of them aren't really ideal ,as they all required either special tools or parts, and are probably not worth the hassle fo having the cage supported at that point like it is now. It is certainly not in its finalized state so I'm sure they will figure it out.

Just an FYI, that tube is open at the top after it passes into the trunk so there is still top down access to the upper shock mount.

[Luke]

The rear shock area does need some more thought. Reinforcing the upper mount which is a known week point is very good idea, but servicability in a rally car is also a big concern and it can be difficult to satisfy both needs.

Mike, in terms of the brake light switch which no longer exists on your car this is what I was thinking. Could be placed directly on the banjo coming off the master. It could also be placed on a banjo coming off the master for the handbrake if you didnt mind the brake lights also coming on when you yanked the handbrake. http://www.pegasusautoracing.com/produc ... RecId=5028[/url]

[Rallyho]

YEah, I need to do some head scratching on that rear shock thing.

I was looking at the pegasus book last night and saw those. If I do the banjo things up on the masters, they will need a banjo bolt, so might as well stick the brake lite switch there.

[Jordan]

Mike, where did you get your master cylinder CNC mounts? I didn't see them on the speedway website... at least not in the brake section.

[Rallyho]

Got them here
http://www.aa-mfg.com/

[Jordan]

Cool , found them, thanks.

[Luke]

They also have those neato double shear seat belt tabs. I've ordered a bunch of stuff from them, all their prices are cheap cheap.

http://www.aa-mfg.com/pdshop/shop/item.asp?itemid=622

[Geoff]

YEah, I need to do some head scratching on that rear shock thing.

Looking through the AA-mfg catalog, would something like this work for you?
http://www.aa-mfg.com/pdshop/shop/item.asp?itemid=863

[Rallyho]

I don't think so. The issue is that while I've made the rear upper shock mount integral to the cage, thus stiffer, the upper shock mount bolt must now be "dropped" down this long tube onto the shaft...well, to hold the shaft you need a hex key.

So we quick-fabbed some metal tubing with nuts at the top and the bottom, with the thought that a long hex t-wrench could go down inside and hold the shock to tighten.

this may ultimately work, but it's not a super elegant solution and I'm no sure if it will hold up.

so, I'm debating other ways of getting shocks in there.

[Geoff]

I've held Bilsteins that had rusted threads with calipers around the shaft, I haven't damaged one yet!

I think I saw somewhere once some socket tool that had a hex in the center and a socket around the outside where the hex stayed stationary and the socket would turn the nut. I almost think it was in the Eastwood catalog. I may be dreaming...

Could you change it to a dual-eyelet?