Insanity-74s ST205 Rally Hybrid build

Insanity-74

New member
Finally started to weld the roll cage in....man its taken alot of measuring, cutting, remeasuring, etc etc I cant believe how difficult it has been!!!! I collect the rest of the cage in a week or so when I can get time to go and get it. My poor welding machine has been working overtime, with 2.7mm thich steel its on full blast to get good penetration. looking forward to getting it all done.

cleaning up the standard rear suspension towers

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making a template for the reinforced suspension tower tops

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the fabricated tops

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Welding the cage together, getting it measured and cut to size

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its coming along nicely.....still think it will take a few years to finish, I work too slowly.
 

celigts

New member
So pumped to see more of this. This will be amazing when it's up and running. I need to do this type of restor on mine. So much rust :(

Quality looking work tho.
 

Insanity-74

New member
Thanks :) its a good job things are going slowly, one of my problems is I tend to rush things and it all goes wrong, its a good job I cant rush this.......prime example yesterday, taking out the rear side windows, spent about 2 hours cutting through the glue to get the windows out........with about 2 inches of glue left I thought "I'll just pull the window, the glue will let go"....well it didnt and the glass shattered. Luckily getting another shouldnt be too hard, but for the sake of 2 inches of glue I should have kept going with the hot cutter. I'm definitely not cut out for removing screens/windows...I will leave it to the pros when putting them back in. It took ages to vacuum all the broken glass out the shell and off the garage floor. :doh: :doh: :doh:

Filled in the standard aerial hole which is about all I have done this weekend.
 

Insanity-74

New member
A bit more roll cage done, what a pain to do.......But coming along slowly now that I have picked up the remaining bits.

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Also gives you an idea of the small amount of space I have to work in.
 

Insanity-74

New member
A bit more done today, the bit of the roll cage that ties in the rear sub frame bolts to stiffen up the rear end a little

Welded uprights to the sub fram bolts (that go under the rear seats

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Tied the two together

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I just need to add the triangulation to the rest of the roll cage, and add in the main hoop diagonal

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RallyX-GT4

New member
Dang, I'm really looking forward to seeing the progress... And, of course, am totally jealous. You've got quite the skills. Do you work with cars for a living, or is this just a hobby for you?
 

Insanity-74

New member
Thanks :) It is just a hobby, working with cars would be nice as a job, but there just isnt the money in it, maybe something I would like to do when I retire. I have however worked on cars more or less my entire life, and I have had my GT4 about 10 years. I used to pester my Dad when he worked on his cars (could never afford to take them to a garage so did all the work himself) so I guess thats where I picked it up from. I did train as an aeronautical engineer but most of what I have learned about cars I picked up from by doing, or by watching tutorial type videos on youtube :) :lol:
 

Insanity-74

New member
More or less finished the cage for the time being until I decide what I want to do with the car, either continue with the hybrid evolution build, or build a full on rally car...until I make my mind up I decided its best I put everything on hold.

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Insanity-74

New member
Small update. I had to remove one of the bars to make access easier. I have been dressing all the welds on the cage

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Its now primered up, the yellow is a high build primer. Just need to weld the last bar back into the cage.

all the interior seam sealer has now been removed and I have started priming the interior which will be painted the same colour that the outside will be. Once that has been done the cage will be painted black and I can start doing the custom interior parts.

it will then be sent off to get the bottom media blasted then I can start rebuilding 8)
 

Insanity-74

New member
I have been busy recently, but have found some time to spend on this project.

I stripped down the petrol tank

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gave it a good paint

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the obligatory walbro fuel pump

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all back together with some stainless steel bolts

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rejuvenated the fuel tank straps

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started rebuilding the rear axels

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managed to rescue the rear brake disc backing plates

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they came up well

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Found a product called Deox C which is great at getting rid of rust, bought the rear hub carriers up a treat

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and I got alot of bolts zinc plated

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and the door catches chromed

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things are starting to go back together now, the rear subframe and suspension parts are all half built, just waiting for the paint on the rear hubs to dry and cure and they can go back together, need some snap rings for the rear axels, then they can go back on. Rear diff can be completed tomorrow if I get time.
 

toayoztan

Moderator
Looking good!

What did you do to strip the Fuel Tank down?

I'm about to work on mine and get it coated too.

I was also thinking of taking it to a shop to get the inside treated and sealed.

Bryan
 

Insanity-74

New member
The tank was in pretty good condition to start with, on the inside the tank was near perfect, the outside I just attacked with a wire brush drill attachment, got rid of all the rust, then painted with POR15 although I think Eastwood paints are just as good if not better to work with.
 

Insanity-74

New member
Its been a while, but a bit of progress this weekend.

I got hold of an ST202 front bumper, an old knackered GT4 front bumper, both of which I have cut up to make into one. I also managed to get hold of a TOMs front lip which I think suits the car very well.

had to use the parts car to line the bumper up.



still so much to do and it seems like two steps forward one step backwards all the time. i might have retired by the time I finish this rebuild.
 
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