Insanity-74s ST205 Rally Hybrid build

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Re: Insanity-74s ST205 Rally Hybrid build

Postby Insanity-74 » Tue May 08, 2012 7:14 pm

Blasted and POR15 ed the diff carrier

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Also the seams were a bit FUBAR so I set about fixing those too (I did this a while ago before I started stripping the underseal off the car...sorry the photos are a bit out of sequence)

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Not perfect when I was done...but not bad

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I also had a go at blanking off the rear high level brake light

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I made a plate up ready to weld into place

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Unfortunately I got a bit carried away with the welder and ended up melting holes into it......so its in the bin and I need to buy a new boot lid (trunk lid to you guys :) )

A few minor parts painted up

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Inside the rear diff

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I will have to dismantle the rear diff so I will make a slide hammer to remove the shaft ends....I want to send the diff housing to get sand blasted so i can get it in as good a condition as possible for painting.
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Re: Insanity-74s ST205 Rally Hybrid build

Postby Insanity-74 » Sun May 20, 2012 6:20 am

Minor update.

Still scraping away at the underbody protection :doh: , although for a change of scenery I decided to start painting the bits I had already done with POR15 paint.

Wheel arch stripped ( sorry about the blurry photos, dont know whats going on with my camera at the moment.

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and then painted

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the rest of the underside of the car will be done the same....should keep the rust at bay for a good few years.

Roll cage is on its way 8)
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Re: Insanity-74s ST205 Rally Hybrid build

Postby Insanity-74 » Tue Jun 26, 2012 7:23 pm

Roll cage arrived...trial fit of the main hoop yesterday

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Re: Insanity-74s ST205 Rally Hybrid build

Postby rallygarage » Tue Jun 26, 2012 8:18 pm

You are very handy and neat. What are you planning for suspension and transmission. Technicaly that is what makes a rally car. You will have to buy that. Just about everything else you can fabricate. I like GT4OC fiberglass. The airbox is very cool but not necessaryfor rally.
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Re: Insanity-74s ST205 Rally Hybrid build

Postby Insanity-74 » Wed Jun 27, 2012 6:50 pm

As I am not going for an all out rally car I dont know what suspension I am using yet, it depends on my bank balance...a UK company called Avo will make me some custom coilovers to my exact specifications but will cost £3800, but they will be strong...or theres the BC coilovers option for less than half that....but I dont know how long they will last or what the quality is like.

Transmition wise I will just be using a more or less standard set up...might go for a carbon prop shaft but havnt decided yet....nothing more fancy than that.

Still not sure if I want to go for the rally look or sports car look? or a weird mix of both?

Time will tell.
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Re: Insanity-74s ST205 Rally Hybrid build

Postby Insanity-74 » Fri Aug 03, 2012 7:45 pm

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.
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Re: Insanity-74s ST205 Rally Hybrid build

Postby Meurz » Sun Aug 05, 2012 4:43 pm

Slowly > cutting corners and ending up with a shit result.

Looks good!
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Insanity-74s ST205 Rally Hybrid build

Postby celigts » Sun Aug 05, 2012 6:00 pm

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.
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Re: Insanity-74s ST205 Rally Hybrid build

Postby jaydog82 » Sun Aug 05, 2012 6:35 pm

Looking great.
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mine is the red one on the left

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Re: Insanity-74s ST205 Rally Hybrid build

Postby Insanity-74 » Sun Aug 05, 2012 7:18 pm

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.
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Re: Insanity-74s ST205 Rally Hybrid build

Postby Insanity-74 » Mon Aug 20, 2012 8:17 pm

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.
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Re: Insanity-74s ST205 Rally Hybrid build

Postby Insanity-74 » Wed Aug 22, 2012 6:04 am

Coming along slowly

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Re: Insanity-74s ST205 Rally Hybrid build

Postby WarTowels » Thu Aug 23, 2012 12:07 am

I look forward to your posts with pictures and I'm never disappointed!

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Re: Insanity-74s ST205 Rally Hybrid build

Postby Insanity-74 » Sun Aug 26, 2012 6:56 pm

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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Re: Insanity-74s ST205 Rally Hybrid build

Postby Insanity-74 » Mon Aug 27, 2012 5:46 pm

Nearly finished the cage :)

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