OFFICIAL: NicoClub's Rally 240SX, by Finnish Fury Rallysport

[Speedy7_7]

In that case would it be possible to reinforce them to increase longevity?

We would rather bend the control arm instead of the sub-frame. So we will leave them stock. And we would rather them bend than break, which is why we won't run aluminum ones.

[J14cm7]

We are also considering the cf wrapped cage, but it may be to costly and time consuming. I have 2 sq. yards of carbon fiber, so there will be some things I make out of CF, but I don't know if I can let $200 worth of CF wrap the cage, it just hurts my insides.

Well whether you do it or not who ever came up with the idea is an effing genius!

[nismofly]

If you do end up doing the CF I would assume you'd at least prime the cage underneath it to protect the metal?

Also that's what I figured with the poly.

[S13AL]

REAL carbon cage....

[Razi]

Won't that just shatter in a crash?

[Ajax]

I wouldn't expect it to shatter, and certainly my experience with carbon fiber is limited, but I can't imagine trusting my life in a roll-over to carbon weave and resin.

[J14cm7]

I wouldn't expect it to shatter, and certainly my experience with carbon fiber is limited, but I can't imagine trusting my life in a roll-over to carbon weave and resin.

Serously? its still a fully built and inspected steel roll cage. Just with CF wrap on the outside or maybe i misunderstood you statement.

[nismofly]

he was talking about the picture 2 posts above yours

[J14cm7]

Im sure that one is wrapped too. but maybe not either way its sexy
Modified by J14cm7 at 8:33 PM 2/25/2010

[Dill_XD]

No it is an all CF roll cage, Oakley Design makes them. It really the only company that does.

[IanS]

Ok, random updated. Can anyone tell I have ADD?

So I took some time, and finished up some of the stitch welding I wanted to do.



Then I cut out some more patches, and filled the rest of the holes in the floor pan.



Then I went through and cleaned all the areas where I had welded with marine clean, then sprayed them with metal ready. I will be doing the whole floor with POR, but I wanted to double coat some areas.





Then Cale and I went to town.





With paint drying, I decided to jump back onto my custom coils. Bought time I know right?

Cut down second strut tube, and cut out a cap.



I welded on the cap, then welded on the perch for the adjusting sleeve. Its not pretty, but I wanted to make them beefy.



Then I attached them with the wire wheel. I know they look like they are different lengths, but its just the picture.



I marine cleaned, metal readied, then hung them up.





Then I painted them with POR. Once they are dry, I will paint them yellow to match the rears.





And the project you have all been asking about.

I pulled the seal off the rack, and cut grooves into the piston. This way, air/grease can pass from one side to the other without causing resistance.



Then I welded up the 2 flow ports on the steel portion of the rack. I will use pipe plugs for the aluminum parts. In theory, you could just run a loop line between one port, and the other, and you wouldnt need to modify the piston. I chose not to do this, one for simplicity of parts on the car, but also, its one less thing to be ripped off.



Then I slipped the steering shaft back into the rack, and popped the worm gear back in. I can easily turn the worm gear back and forth easily with just two fingers. There is a lot less force involved. Tomorrow I will pick up some caps, and I can finish putting it together.



Just in time too. The steering rack on my daily driver S13 has been leaking for a while, and its due for a new belt. I may de power the coupe, and then modify the leaking rack for the race car. This way I can get a feel for the de powered rack before the car is done.

[Ajax]

Serously? its still a fully built and inspected steel roll cage. Just with CF wrap on the outside or maybe i misunderstood you statement.

I just meant that if its a full CF rather than just a wrap. I don't know- it might be just as strong/stronger than a full steel cage, but I still wouldn't feel comfortable.

[bllabong89]

Im not sure if you mentioned it before but what kind of welder are you using?

[Speedy7_7]

Im not sure if you mentioned it before but what kind of welder are you using?

It is a Miller millermatic 180, Ian picked it up brand new for around 900, it has been the greatest tool I could have imagined.

No it is an all CF roll cage, Oakley Design makes them. It really the only company that does.

A CF cage would not be safe in a rally situation. keep in mind, if/when we tumble this car we could be doing up to 130 mph on a gravel road. A CF cage would be fine for a road racing car, if they roll they roll across grass and asphalt. There is a very real possibility that we would be rolling onto boulders, trees, into rivers. CF is incredibly strong unless it is punctured by a small object, like a pointy rock. The steel can more effectively bend to absorb sharp objects, keeping the majority of the cage in tact while we finish rolling.

In 2007? I think, a good friend of Ian and I jumped a 1999 STI off a large boulder and landed the car on the roof on another boulder, right above the driver, the rock had pierced an 8 in. wide hole in the roof and was stopped by the cage cross above his head. He and his co-driver walked away, but if you look at the car, you would think they died. I will try to find pics of the car.

[IanS]

I decided to look for photos. In my search, I found this shot of Chris and I running a practice stage in 2006.



Another shot of Chris. Wish I would have been co-driving for this one. Once the 240SX is done, we will get around to bringing the CRX back to rally spec.



I will keep looking.

[lbreevesii]

Those pictures are awesome Ian.

Here is a question for you. How do you get into rallying? I mean its coming to the point that there aren't many roads to practice on, you've gotta have a beefy car(that aint no stock crx!), etc. I mean I've driven many dirt/gravel roads sideways, even spun out a few times learning the limits, but that's a long way from having a beefy enough car to actually learn with.

I haven't really looked into it(nor could I probably afford it) but is there a way to get into it without sinking tons of cash on a build like this and actually go do it without sponsorship, etc. ie: just to learn and have fun. Even if its going slow?

[CTGordon]

Actually that CRX was very much a budget build. Outside of the cage, seats, and other safety equipment, it was all stock.

I know that people at Rally America have said that they are focusing on building their grassroots rallies over the next few years. We can probably expect to start seeing more and more coefficient 1 events popping up all over the country. These are small, one day events that Joe Everyman (actually most rallyists fall into this category) can do, as the entry fees are usually ~ $150 rather than $900-1400 +.

Go to http://rally-america.com/ and http://www.nasarallysport.com/main/ They have all their national and regional events listed. I'd recommend starting out by finding the events near your area and volunteering to marshal for a couple of them at first. When you do, talk to everybody, ask questions, make friends. Rally is a life-long addiction. If you aren't already Travis Pastrana or Ken Block it's always best to ease into it, no matter what your enthusiasm/rage tells you to do otherwise.
Modified by CTGordon at 10:48 AM 3/2/2010

[SR20DET.240]

I know that this is not true rally racing but I have a couple of friends that wanted to do some cheap rally style racing with a CRX ( Not as modded as the one pictured) and they are doing rallycross. I also know that there are some rally HPDE's held at Summit Point in WVA. Not sure if there is anything like that in NC but here is a link to the SCCA rallycross.

http://www.scca.com/contentpage.aspx?content=47

Hope this is helpful.

[lbreevesii]

Looks like there's nothing close. 5 hours to the WV event, 7 to TN, 5+ to SC. The lemons car isn't very comfy for more than a couple of hours at a time and I don't have a truck/trailer to be hauling with right now.

Just talking, but lets just say I took the lemons car to an event. SCCA caged, racing seat(s), etc. Stock suspension, but with proper tires and wheels. Would it hold up?

As much fun as it would be, i'll be keeping my feet on tarmac for a while i'm sure. I really respect you guys. Rallying is right up there with F1 and BTCC in the awesome category. Love em or hate em, guys like Block, Pastrana, and their cohorts are doing amazing things for an amazing sport.

sorry for the hijack Ian. Keep up the awesome work. Wish I was getting half as much done as you. Also, you could always do a CF look alike vinyl wrap on the cage. Much cheaper!

Also as an aside to the rallying. I highly recommend that you secure the ends of the springs that hold the headlight bezels/buckets with safety wire or something. Ask me how I know.


Modified by lbreevesii at 8:57 PM 3/1/2010

[IanS]

Those pictures are awesome Ian.

Here is a question for you. How do you get into rallying? I mean its coming to the point that there aren't many roads to practice on, you've gotta have a beefy car(that aint no stock crx!), etc. I mean I've driven many dirt/gravel roads sideways, even spun out a few times learning the limits, but that's a long way from having a beefy enough car to actually learn with.

I haven't really looked into it(nor could I probably afford it) but is there a way to get into it without sinking tons of cash on a build like this and actually go do it without sponsorship, etc. ie: just to learn and have fun. Even if its going slow?

Check CTGordon's post. That is Chris (hi Chris ), and he is the owner of the punched out CRX, and he speaks the truth. I helped put the car back together after its first major wreck (previous owner, not an accident), and I can tell you its darn near stock. The engine, transmission, brakes, and control arms are all stock CRX SI bits. The suspension, is just stock struts/springs from a DA integra. Almost all of the money went into safety equipment.

As for getting into rally, all I can say is, just go. I ended up at my first rally 10 years ago, completely by accident. To guys like me and Chris, rally is less a hobby, and more of an addiction. Start out by showing up. Do course work, or hook up with a team and run service. The rest just kind of happens.

Rally crosses are also a great way to get your toes muddy.

PS, Chris, how was 100AW? I see you and Greenhouse took 1ic on Saturday. Hope you had a hell of a ride.

[CTGordon]

Looks like there's nothing close. 5 hours to the WV event, 7 to TN, 5+ to SC. The lemons car isn't very comfy for more than a couple of hours at a time and I don't have a truck/trailer to be hauling with right now.

I'm kind of jealous that you have 3 great events very close to home (in rally terms). I just drove 11 hours to and from Salem, MO last weekend. A month before that it was 13 hours to Atlanta, MI. Next up is all the way from Minneapolis to Seattle. Anyway, like Ian said, just go. Leave the lemons car behind, take the daily driver and volunteer, the rest follows. Get to know the lay of the land at stage rallies while honing your skills at rallycrosses.

Love em or hate em, guys like Block, Pastrana, and their cohorts are doing amazing things for an amazing sport.

Absolutely, these guys get huge respect from me. They are true class acts, and have brought a lot to the table to help with the hopes that this sport will not be dying in this country any time soon.

PS, Chris, how was 100AW? I see you and Greenhouse took 1ic on Saturday. Hope you had a hell of a ride.

Greenhouse can drive. The only other 2wd competition we lost to in the overall was Mr. Duplessis (no surprise there really), but he did let us come within a few seconds of him here and there. VanWay is really starting to pick it up too, kept us on our feet all day. That lucky bastard got to take a Sheriff for a ride on the press stage . The thing I enjoyed most, I think, was seeing the two 4th gen civic hatches and the CRX. May be some competition for Ol' Black and Blue when we get her back on the stages.

[lbreevesii]

I'm kind of jealous that you have 3 great events very close to home (in rally terms). I just drove 11 hours to and from Salem, MO last weekend. A month before that it was 13 hours to Atlanta, MI. Next up is all the way from Minneapolis to Seattle. Anyway, like Ian said, just go. Leave the lemons car behind, take the daily driver and volunteer, the rest follows. Get to know the lay of the land at stage rallies while honing your skills at rallycrosses.

Dang sure sounds like an addiction!

If I get a chance i'll head up to Summit point. Its about 5 hours and i'd like to check out the road course track. Lemons is running it now.

Maybe i'll get to go have some fun in the dirt up there sometime.

[Speedy7_7]

You can literally show up and walk into headquarters (usually a local hotel) and sign up to be a stage marshal. Marshaling is the best way to watch now-a-days. They are pretty strict about where spectators can go, but if you are a marshal, you usually end up on a random corner in the middle of the woods, at some crossroads, your only job is to keep people off the track, and you usually wont see anyone else. After the first rally car passes, if you aren't hooked, you are as blind and deaf as Helen Keller.

Back in the day (2000-2004), they used to let us run down the stage and post up wherever we wanted, then some people got themselves killed. Now they will cancel a stage if the spectators are not in the designated areas.

Remember to bring fuel.

Here are examples of the types of scenes you may see.

[CTGordon]

you usually wont see anyone else.

Cale, this seems to be changing rapidly. Remember how I was talking about the jump in spectators lining the stages from S*D last year to Ojibwe and then LSPR? I'd say it's grown by 15-20% so far over this year's S*D and 100aw.

There was a HUGE turnout for 100aw. I've been down there 4 times now and it was never like it was this weekend. The super-special alone was almost at maximum capacity. People were even throwing massive parties out in their cow pastures along the stages, some with half an acre's worth of tables it looked like, COVERED in food and booze, and that's where they stayed all day, from the first running of a stage in the morning, to the last at night (they were getting pretty darned... excited by the last time through).

Check out this KOMU-TV8 News coverage: http://www.youtube.com/watch?v=BwGp1A8K71U

I'm shooting to co-drive for a different driver at each of the RA National Calendar events this year. I'll have my report on your desk in August, but as of now I would expect the trend to continue.
Modified by CTGordon at 12:08 PM 3/3/2010

[bersh240]

Remember to bring fuel.

those spectator guides are the most useless things in the world.

any chance of an update ian?

[IanS]

those spectator guides are the most useless things in the world.

any chance of an update ian?

That wasnt a spec guide, it was our marchall book. It had maps for all the stages and entry points and such.

Sorry, no updates. Ive been stuck at work late every day this week. I will be getting out there tomorrow. All I have to do is throw a rear main seal into a Neon, and put the transmission back in and Im going to try and bail.

[gmac708]

Looking good Ian.

[lbreevesii]

You can literally show up and walk into headquarters (usually a local hotel) and sign up to be a stage marshal. Marshaling is the best way to watch now-a-days. They are pretty strict about where spectators can go, but if you are a marshal, you usually end up on a random corner in the middle of the woods, at some crossroads, your only job is to keep people off the track, and you usually wont see anyone else. After the first rally car passes, if you aren't hooked, you are as blind and deaf as Helen Keller.

Hahha nice simile. Hell man I've watched enough you tube vids and group B to be hooked on how awesome it is.

Maybe I will try to swing up to summit point sometime soon. Like I said, its a straight 5 hour shot up 81 from my house.

[Cbus240]

Wow. I just read this thread from the beginning to its current state, and all I can say is, I really want to learn how to weld now! haha seriously though, awesome job with all the fabrication/metal work man, you are definitely dedicated. Props for using POR-15 btw, I LOVE that stuff. Keep up the good work buddy, can't wait to see the end result!

[lbreevesii]

Ian has me wanting to learn to do better metalworking. I suck. My neighbor(who has been helping a bit on my project) has been giving me a few welding pointers that have made me a 10x better welder. It takes practice! It looks like ian progressed quickly as well. He too had a pro's help. haha.