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

[IanS]

I will drive the car, windows or not, it will move under its own power.

I smell determination.

Sorry thats just BO, no time to shower, gotta finish the car.

I did not take any pictures today, mostly because I was under the car the whole time.

I installed the driveshaft. For now Im stuck with the stock 2 piece unit because Im broke. It will be good enough for Omaha.

I filled the diff with gear oil, and the transmission, then I put the shifter back in.

I broke the bleeder screw off the slave cylinder while trying to bleed it. I got a new one, installed it, and got the clutch bled.

I installed the drivers seat, along with the steering wheel.

Then I drove the car. Alignment is all goofed up, and the engine is boggy, but it drives and feels solid. But there are problems. After taking it around the block, I tried to properly time the ignition system, but its way retarded, even at max advance. I apparently did not get the oil pump drive shaft in properly, FUN. That explains the lack of power. Easy enough fix, but ugh.

What worries me is a possible wiring ghost I picked up. On the way down the driveway I lost all of the cluster, except for the clock. No idiot lights or gauges, though the high beams light still works. Im guessing it has something to do with the connector I had to splice from the engine harness to the body harness near the ECU. IIRC those wires are for the cluster, so it would make sense. Im going to recheck it all. I heat soldered and heat shrinked all of them, but you never know.

The final issue is a tick that sounds like its coming from the head. With exhaust on it, and the car outside I was able to hear it better. Sounds to me like a dry lifter, though I forget how the SOHC heads are set up. I did flip the head upside down to clean the block surface, they could have leaked. I dont remember it having a tick before, and I didnt really touch the top end, so who knows. Maybe the lack of secondaries is to blame, and Im just captain paranoia. Either way, its on the bottom of my list. Ill figure the other stuff out first, and hopefully I can get some glass in it soon.

Hopefully I can get some of this stuff worked out tomorrow.

[lbreevesii]

Whats the rating on that fire suit? I love putting on one of my spare 3.2/1 suits and a helmet and hitting the back roads. the looks I get are great XD

Best of luck on the wiring. Hopefully you're better at that stuff than I am!

[IanS]

Whats the rating on that fire suit? I love putting on one of my spare 3.2/1 suits and a helmet and hitting the back roads. the looks I get are great XD

Best of luck on the wiring. Hopefully you're better at that stuff than I am!

Hmm, I think its 3.2/5, but I dont remember, and Im too lazy to go look. It is whatever rally america spec is.

[RallyB13]

Hmm, I think its 3.2/5, but I dont remember, and Im too lazy to go look. It is whatever rally america spec is.

For R-A, 3.2/5 is legal by itself, in a one-piece. 3.2/5 in a two-piece requires Nomex underwear. 3.5/1 is legal with nomex (3.3) underwear in either one piece or two piece.

Since I'm shaped oddly I either have to go for a one piece that makes me look like cookie monster, or a two-piece with nomex. I chose a two-piece 3.2/1 and Nomex.

ChumpCar requires the above + Nomex socks, SFI rated shoes, and SFI rated head sock (if you have facial hair, at least), and a full-face helmet (thankfully I'm one of the rare rally guys who uses full-face already, cause this s*** is getting expensive even without needing to buy a new one).

I got most of my stuff just before Nemadji Trail 1 (I co-drove for Jim Cox in the V8 S10) and borrowed a HANS. My Hutchens Hybrid Pro should arrive on Friday.

My 1.75" bender die arrived today, so when I get back from vacation after the ChumpCar event, the cage goes in...

[Tyler]

there is just something about a firesuit that makes you feel cool. i also find that at least for me it adds a certain level of confidence, i know its all mental but anything helps. i even wear mine at events that dont require it.

[RallyB13]

there is just something about a firesuit that makes you feel cool. i also find that at least for me it adds a certain level of confidence, i know its all mental but anything helps. i even wear mine at events that dont require it.

So true. I'm sure I'll get sick of it eventually, but for now I have to keep myself from dressing up in it just to walk around the house

Just came back from the garage where I fired up my home-made air over hydraulic bender for the very first time (got my dies in yesterday and finished correcting a piece I welded on backwards (oops, 5/8" steel plate is a PITA to cut with a sawsall, BTW). I bought the design from gottrikes.com and I'm loving it now. Bent a piece of 1.5 x 0.095 to 90deg, released, found 2 degrees springback, bent an extra 2 degrees and it lines up perfectly in a square. Much easier to be accurate than the ratchet-type benders I've used before. Time to start my own build thread now

[lbreevesii]

Heres a great read about fire suits. Even with a great one you don't have much time to get your a** out of a burning car. Remember kids, practice!

http://www.nasaproracing.com/proracing/suits.html

[IanS]

So true. I'm sure I'll get sick of it eventually, but for now I have to keep myself from dressing up in it just to walk around the house

Just came back from the garage where I fired up my home-made air over hydraulic bender for the very first time (got my dies in yesterday and finished correcting a piece I welded on backwards (oops, 5/8" steel plate is a PITA to cut with a sawsall, BTW). I bought the design from gottrikes.com and I'm loving it now. Bent a piece of 1.5 x 0.095 to 90deg, released, found 2 degrees springback, bent an extra 2 degrees and it lines up perfectly in a square. Much easier to be accurate than the ratchet-type benders I've used before. Time to start my own build thread now

Glad Im not the only one.

I wish I could have built my own cage. Next time, next time. Once the build thread is up, drop a link in here.

Heres a great read about fire suits. Even with a great one you don't have much time to get your a** out of a burning car. Remember kids, practice!

http://www.nasaproracing.com/proracing/suits.html

Actually Im really happy with the ingress/egress on my car. I thought the low roofline would make things tough, but even without a quick release hub I can slip out in a hurry, and I am by no means a flexible guy. Being 6' 2" and 230 lbs can make getting in and out of some stock cars tough.

Cant update much, been busy all weekend with my buddies wedding. I did get all the shoulder and submarine belts installed, as well as the lap belt for the drivers side. I just need to pick up some more bolts, and I can do the navi's side.

I also re did the distributer drive shaft, but managed to break my timing light before rechecking it, so I need to figure out a new light.

After staring at wiring diagrams for too long, Im pretty sure I have a ground issue that is killing the cluster. Hopefully I can work it out.

[King Ranzo]

Ian. This build is coming along epically. Can't wait to see this girl in action.

[S_chassis_FTW]

Wow you have gotten a lot done since i last checked! Great Job!

[IanS]

Ok, another update with no pictures. Sorry guys.

I figured out my wiring issue. It was loose plug going to the fuse block. It must have come partly unplugged when I hung the box under the cage. On first start I just had the box laying on the drivers floor. Everything works again.

I got the tailights and rear bumper installed.

I finished installing both seats, and all of the belts.

I will be working on it all day today. I hope to get the dash back in, and drive the car around a little more. I should also be picking up a new timing light so I can get that squared away.

[IanS]

Ok, I feel like you guys are going to riot if I dont drop some pictures in here.

I was checking to make sure I got the seat put back in the right spot. I forgot to mark the rails when I pulled them out. Im not making faces, thats just what I look like.



Got the dash put back in, along with the center console.



I tested to make sure I could still wear a helmet.



Moved the car outside since it was such a nice day. Got the rally computer installed. I still need to wire it.



And one of the fire bottles.



And the other fire bottle.



It looks so awesome with the interior back together.



Morgan trying out the co-driver seat. The harness are a little big on her.



Started getting the roll cage padding in. I dont have the money for new stuff right now, so I borrowed the padding out of Chris's CRX. His car is slotted for rebuilding once mine is done, so Im hopping he wont mind. The padding would have needed to come off to fix the cage anyway plus, I think it might be garbage, its really dried out. I think both cars will just get new stuff later, but this is good enough for Omaha. I love you Chris.

I ran out, because the CRX doesn't have as many cage tubes as my car, so I will need more anyway.





Then I pulled the car off onto the grass for some pictures. The front bumper still needs some tweaking.





I hate the "in between dirtiness" the car has. I would much rather it was just dirty as all get out.



I need to do something about the exhaust.



Besides windows, and few little things here and there, Im pert near ready.

[Razi]

Ok, I feel like you guys are going to riot if I dont drop some pictures in here.

Darn right!

I'm loving the interior!
The dash looks cool, I might do that if my black dash starts cracking someday.

[IanS]

I'm loving the interior!
The dash looks cool, I might do that if my black dash starts cracking someday.

Do what?

[Gcustoms]

amazing

[CTGordon]

I love how you left my No-Doz bottle in its holder on the computer.

You probably don't need the padding on the windshield bar, or up to the A pillar, only need it where helmets might hit while you are strapped in. Might make it cover more territory, but you probably just want it all over because it looks cooler.

[motoman399]

I'm loving the interior!
The dash looks cool, I might do that if my black dash starts cracking someday.

Do what?

it almost looks stripped of its padding, or flocked. but im pretty sure its just dusty. and the car is looking killer! keep it up man

[IanS]

I love how you left my No-Doz bottle in its holder on the computer.

You probably don't need the padding on the windshield bar, or up to the A pillar, only need it where helmets might hit while you are strapped in. Might make it cover more territory, but you probably just want it all over because it looks cooler.

How could I not, it fits so well in there, both physically and metaphorically. I think every log book should come with a 4 pack of redbull.

I was thinking about taking some off the wind shield bar, but decided not to cut it down. Its such a nice long piece. As for the stuff on the A pillar, I will keep because it'll save a noggin or two, plus it will cut down on helmet scratches. You cant hit your head on it while seated, but you sure can while trying to get in/out of the car.

PS, it totally does look cooler.

it almost looks stripped of its padding, or flocked. but im pretty sure its just dusty. and the car is looking killer! keep it up man

Looking back at the pictures, it almost looks like its covered in microfiber. Too bad its just dust as heck. Hmmmm, maybe something to try for later.

Ill be gone for the weekend, look for updates early next week, then pictures from Omaha. Everybody needs to come see how ugly this thing is in person.

[lbreevesii]

Looks sweet. Maybe I can get my cage done soon...

That looks pretty sweet with the dash in. Since i'm doing lemons mine is just going to stay dashless :-D

[IanS]

Looks sweet. Maybe I can get my cage done soon...

That looks pretty sweet with the dash in. Since i'm doing lemons mine is just going to stay dashless :-D

I was thinking about running dashless, but then I decided for the 2 pounds the thing added, it sure does clean up the inside nicely. Without a dash I always feel like I am driving around in a big noisy steel coffin.

[Razi]

Hahaha yeah I thought you flocked your dashboard, but it's just dust.

[IanS]

Well, the windshield is in, and the battery is rigidly held down.

All I need to do is cut out and install the lexan tomorrow, rap up some loose ends, and its off to Omaha.

[lbreevesii]

Looks sweet. Maybe I can get my cage done soon...

That looks pretty sweet with the dash in. Since i'm doing lemons mine is just going to stay dashless :-D

I was thinking about running dashless, but then I decided for the 2 pounds the thing added, it sure does clean up the inside nicely. Without a dash I always feel like I am driving around in a big noisy steel coffin.

haha I know what ya mean. If my dash had cracks I would have kept it, but its worth too much towards the budget

C'mon now its more like 15 lbs too.


Can't wait to see how it runs man. Its gonna be awesome!

[IanS]

haha I know what ya mean. If my dash had cracks I would have kept it, but its worth too much towards the budget

C'mon now its more like 15 lbs too.


Can't wait to see how it runs man. Its gonna be awesome!

Hahahaha, yah, I kind of felt bad about chopping up a mint dash to fit around the cage.

As for how its going to run, I predict it will be slow, noisy, and a boat load of fun.

[breadbox]

Woot, slow and noisy boats!

[IanS]

T minus 22 hours till Convoy rolls out.

[breadbox]

Did you ever build that manual rack or did you just get another one?

[IanS]

Did you ever build that manual rack or did you just get another one?

Its all manual, and it feels great. Steering effort at a stop is no worse than an old CRX, and you feel super connected when cruising.

[breadbox]

so what, you tore it apart and got that seal machined off, packed it full of grease and plugged the holes?

Really looking to do this. I might have a rack in my garage already.

[IanS]

so what, you tore it apart and got that seal machined off, packed it full of grease and plugged the holes?

Really looking to do this. I might have a rack in my garage already.

That is essentially what I did. Just make sure you set the preload on the rack correctly when you reassemble.