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

[IanS]

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!

Ill show you fabrication.

**Update**

Sort of. I got the strut tubes painted up, and reassembled the front dampers reassembled. Im still waiting for one more part to finalize them, but you get the point.



Then I removed the tension rods from the brace. It required some cutting, as the bolts were seized. Since I had them out, I pressed the old bushings out, and installed the urathane ones.





And since I already had all the right stuff out, I grabbed my old S14 tension rods off the shelf and put urathane bushings into them as well. They are for sale if anyone wants them. The bushings are brand new, Energy Suspension. I had them left over because I had pillow ball rods in my S14.





When I removed my tension rod brackets, I tack welded some metal to them so they would retain shape.

I took some more square tube, and started building my own power brace. After welding the first cross bar, I removed the bracing.





Then I cut out some support plates to brace the inner bolt holes.







Then I played the "triangulation" game.







Then I ran out of gas for my welder. I hope to pick up some more this weekend so I can finish it. Id like to support the other side of the bracket with plates, and prep it for a skid plate mount.

Thats it for tonight. Ive got lots of time this weekend, so look for another update soon.

[IanS]

Another mini update.

Since Im still low on Argon, I worked on some other stuff.

I had installed caps into all the fluid ports on the body of the rack. I then sealed them with RTV. I did it last week without taking pictures. Now that they are dry, I installed it onto the rack.





Installing the preload bushing into the steering rack.



The spring pad.



Spring



And adjusting. I adjusted it so there is just enough load on the rack piston to keep it from moving side to side inside the tube. I may choose to tighten it later, once the rest of the suspension is installed, and I can give it a good shake.



Then I reinstalled the inner tie rods, and the one remaining bellows boot. I will have to order a replacement for the other side, as it was torn. I may choose to go with urethane boots.



Im very please with the way it turned out. I can easily turn the worm gear back and forth with 2 fingers. There is almost no effort involved. Im excited to feel it with tires on the ground.

New rack bushings installed.



I got the front subframe all cleaned up, and bolted the rack to it.



I picked up some bolts to replace the subframe bolts. They were small, and rusty. I sized up, then ground part of the head off so they rest flat against the fender plate.



Then I bolted the subframe in place. Look at all the pretty colors.





Then I grabbed the lower control arms. Cale knocked the nasty ball joints out of them, and pressed in some urethane bushings. I bolted them on.



Thats it for today. I hope tomorrow is more productive.

[J14cm7]

wow ian that project is really coming along. Thanks for posting so many updates it really helps people that dont necessarily know every part on the car and how it all works. keep up the good work and the updates.

P.S. when are you guys CF wrapping the cage lol

[CTGordon]

A little motivational for you, Ian, a little rally pronz if you will, from last weekend (since I hear you'd like to make 100aw next year). Very nicely edited with proper equal opportunity screen time for the 2WD cars. That's greenhouse and I starting about 2:14 (yes, a NEON, let the stage times speak for themselves...) he cracked me up he was so upset about our DNF on Friday.

http://www.youtube.com/watch?v=rjHOPZ_8xnY

[DMan II-40]

That video was cool. Ian I really like that power brace you made, and the skid plate thing is a good idea. Wish I could make s*** like that, don't have a welder.

[J14cm7]

I dotn know why but i was a little upset block ditched his subaru for a focus, It just doesnt seem the same.

[CTGordon]

I don't believe it was out of lack of loyalty. He said he wanted to go to the WRC, and Subaru no longer supports WRC efforts at this time.

[S13AL]

Is the engine bay going to stay white?

[Speedy7_7]

Yea, the engine bay and interior are going to be white. How long they stay white is left to mother nature.

[IanS]

I dotn know why but i was a little upset block ditched his subaru for a focus, It just doesnt seem the same.

Its not a focus, its a Fiesta. He wanted WRC, and Ford did what Subaru wouldnt.

Anyways, some more pictures.

Bolted one of the tension rods into the bracket to get the width right.



Cut out a template for the bottom



Copied to metal and tacked on.



And the other side.



Welded fully.



And the side plates.



Cleaned it up, hung it, and layed down some primer.



And then paint. It took me a few minutes at the store to pick a color. I looked at all the colors, then went with my guy and grabbed the brightest one I saw. This is the result.





I hope to get it installed tomorrow, along with some other front suspension stuff.

[J14cm7]

Its not a focus, its a Fiesta. He wanted WRC, and Ford did what Subaru wouldnt.

Obviously this is above my comprehension but I went on the WRC site and all it looked like there were was ford and citroen. When i think rally car i think subaru. Seems odd to me that subaru wouldnt do it but thats another thread.

[Didderson]

Mighty fine color my friend lol! Looks as good as it functions!

If that isn't the beefiest power brace i have ever seen... Yeah it's the beefiest heh. Still lovin' the build! Will you be picking up the pace a little w/ the season coming up faster?

[WI_S14_Goldie]

good s***...keep it up!

[IanS]

Obviously this is above my comprehension but I went on the WRC site and all it looked like there were was ford and citroen. When i think rally car i think subaru. Seems odd to me that subaru wouldnt do it but thats another thread.

No kidding. It shocked us all when Subaru made the announcement. Whats good, is they seem to be focusing on some lower levels of the rally universe. Which is good for us.

Mighty fine color my friend lol! Looks as good as it functions!

If that isn't the beefiest power brace i have ever seen... Yeah it's the beefiest heh. Still lovin' the build! Will you be picking up the pace a little w/ the season coming up faster?

As the temp climes, I will be able to get more and more done, plus I will be out there a little more.

[bersh240]

Its not a focus, its a Fiesta. He wanted WRC, and Ford did what Subaru wouldnt.

he drives both...fiesta for rally americafocus for wrc

and your making me want to buy a welder and learn to do stuffs.

[mRodiek]

Obviously this is above my comprehension but I went on the WRC site and all it looked like there were was ford and citroen. When i think rally car i think subaru. Seems odd to me that subaru wouldnt do it but thats another thread.

If I remember correctly, it was a financial woes.

[IanS]

he drives both...fiesta for rally americafocus for wrc

and your making me want to buy a welder and learn to do stuffs.

Weird, I thought they dropped the focus entirely in favour of the Fiesta.

Anyways, on to the update.

While I worked on other stuff, Cale worked on the front knuckles. He removed the dust shields, cleaned the bolts, replaced the slides, and installed the braided brake lines.



I got the subframe brace installed. I dont think we will be needing flash lights to work on the engine.





Then I pressed some fresh Moog ball joints into the control arms, and installed the knuckles. Along with the tension rods.





Then I put the tie rods back together, and the coo de gras the coilover assembly.



And with a wheel on, back on the ground. LOOK AT THAT RIDE HEIGHT.





With a fender on, just to show the gap. Im taking 4x4 status to a whole new level.





Now I know someone is going to say, "but there is no engine". Cale weights 260+ standing on the subframe, so that should bring it down. Nope not really.



Not enough. Im just south of 250, and I hung my weight out on the bumper support. The picture is from a different angle, but as you can see, it still has mad clearance. The best part is, I currently have the coils adjusted to the middle, with no spring preload. So I could go higher.

[chukidrifter420]

the custom coils look great man! I cant wait to see event footage of this! subscribed!

[Razi]

Epic height!Why'd you remove the dust shields though?Won't it keep as much crud out of your rotors as possible?

[IanS]

Epic height!Why'd you remove the dust shields though?Won't it keep as much crud out of your rotors as possible?

Thanks.

Actually its the opposite. The dust shields tend to hold rocks and stuff against the rotor. It makes wicked noise, and can groove the rotors.

[Razi]

Ahh makes sense.

Good to see the suspension coming together.

[S13AL]

jesus! the car is like a foot off the ground... I wonder what the back is going to look like.

[carps13guy]

your setup is looking more and more awesome every update. that power brace looks beefcake. and i dig the gloss white bay, very professional

[DizzyKitty]

OH!wow!subscribed!

I want to see this thing airborne!

[J14cm7]

Awesome ian. your ride height is the same as mine FML.

[IanS]

Ok guys, its time to figure out my colors. Help me pick a livery.

zeropost?cmd=fshow&id=2

Awesome ian. your ride height is the same as mine FML.

You wish you had this much clearance. I can lay under my car without a jack.

[RallyB13]

Weird, I thought they dropped the focus entirely in favour of the Fiesta.

This is the last year for the Focus. Next year will be the Fiesta for WRC.

[Onyxyth]

firstly, this build is awesome and it's one of the reasons I still lurk around here (I don't even have a Nissan, I drive an '85 Celica, hah)

secondly, have you considered making the tie rod ends double shear? A lot of the amateur rally guys do it because the single bolt simply breaks off.

here's an example


Modified by Onyxyth at 6:14 PM 3/9/2010

[bllabong89]

Are you upgrading the brakes? Those look stock correct? Also, are moog ball joints better than oem or remanufactured or just better all together?

[carps13guy]

moog are just better all together. they have been making balljoints forever. & i believe you can get them with grease zerks already mounted. btw if you didnt know you can replace your rear s13 LCA ball joints with b12 sentra ones instead of buying a new set of arms