In danger of looking professional

I got time to nip over with BRP to Mik's this afternoon so that we could see if my car would fit in his trailer.

That's right - in, not on! A snug fit but all was well and Mik has a "racepod" so the car is completely enclosed and by 'eck it's a great bit of kit. His van's pretty special too so all of that combined with the service crew kit I have got makes us look really professional.

Then we have to see how we perform!

Well, at least it also gave me a chance for a 50 mile drive in BRP and it seems pretty good - a bit reluctant to rev cleanly but certainly more than good enough for first time out.

Meanwhile, I know Sarah has bought some more kit but isn't telling me everything. Apparently, I don't need to know!

Still, she doesn't know about the roof lining yet.

Put the boot in

I don't actually need race boots as they are only "recommended" for national events but I know the way this is all going, recommended now means mandatory FIA spec soon!

When I have all the other stuff anyway it seems a bit daft not to get them - three is a warning note from the MSA not to buy plastic type shoes ie trainers anyway.


The thing is, they seem to be about £140+ for a pair which is a bit of a shock but then I remembered something from one of the forums I frequent.

It had been said a company called Rally Design (who I bought the wheel studs from) aren't into this kind of stuff but had some odds and ends knocking around.

So, I checked out their website and they had only 2 pairs left which were both in my size. I snapped up ones like those in the pics but in red and with the FIA 2000 spec for £54 including VAT & posting.

What a result!

So, I am fully kitted out now and one less thing to worry about.

BTW - note to self, the group 4 disc assemblies are upstairs in the loft and the studs/wheel nuts are in the draw of the tall cabinet in the garage!

Studs & nuts!

If Martin Knapp is reading this - here's proof I take notice!

Having collected the "bells" for the Group 4 discs from Martin last week I checked on something he had said to me previously - scrutineers like to see evidence of alot of thread from the wheel studs through the wheel nuts.

All fair enough as that's what's holding the wheels on!

The solution is longer wheel studs and "open" wheel nuts so that's what I got.

I fitted them to spare hubs I have but in the picture you can see the difference between standard and longer 63mm studs. I have put a wheel nut on each to it's full depth and as you can see from the standard nut there's not alot of room left for the wheel!

Moving on from this I have assembled the "Group 4" discs and hubs as I intend to push on with this after the Roskirk Stages and get the Hictoric Vehicle Document I will need to enter the Jim Clark Historic rally!

Anyway, more of that later but here's a complete assembly.

What's next is decided!

My last post was all about what to do next.

Well there's no time for fannying about so we are now entered in our first rally - the Roskirk Stages on March 8th - you can see the entries on this site http://www.bssmc.com/

I have also now commissioned a reconditioned cylinder head and, as I thought, gone for a standard head but with a helicoil in every possible place. It won't be ready for the Roskirk though so we'll see how the car is on that and then see when I can swap it all over.

In addition a new set of Greenstuff pads have arrived for the front calipers - I am still using the standard ones from when I carried out the conversion to Volvo 4 pot calipers so they'll go in the spares collection.

And Saturday will bring the start of a service for the car.

Meanwhile, Sarah's continuing her education from her naviagtor mentor.

It's all go!

Mad keen

So am I mad, keen or mad keen?

I pondered over this question as I worked on BRP for an hour tonight under my carport.

Just an hour focussed on the navigator's side of the cockpit. Amazing how an hour can be taken up by basically just tidying up - fixing a bracing bar for the dashboard, using good old cable ties to restrain all the new wiring and taking off the navigator's footbrace to re-position it slightly nearer to the seat.

Then there was closing off the grommet where the wiring for the cut out switch had passed through the bulkhead with some "dum dum" putty - all important for the scrutineer.

At the end of it all much tidier and very satisfying really. Next I'll move to the driver's side for some similar work and then finish off the extinguisher pipework as some extra pipe has arrived from Demon Tweeks. Once that's all done and the pipework, wiring all tidied I'll clean the car inside and out (!) before ringing the MSA scrutineer to book it in for it's rally car log book - wish me luck!

Good to have BRP back

Just picked BRP up from the auto-electricans where the cut out switch has been wired up.

Certainly strange to have the car running, turn the cut off switch and everything stops with no lights or electrical power at all - it reminds me of a certain incident in Austria in 2003 but that's another story.

Also ordered some more extinguisher piping so I am now in what I hope to be the final stage - tidying everything up and then ringing the MSA ascrutineer.

But - one more thing, it was so great to just drive the car the short distance home.

What's in the box?

Or then again, what's in the boxes and the bag?

The result of the next steps!

Racesuits, helmets,intercom, 2 AP Racing "Forest" brake discs, a pull cable, 2 door squares and a rally map reading light.

I should get BRP back tomorrow or Saturday and then it can all go back together with the aim of getting the logbook sorted by the end of Jan.

Would you believe it!

Almost finished fitting the extinguisher system today - I say almost because there wasn't quite enough pipework!!

Here's what it looks like under the bonnet though.

You can see two blue nozzles with the rear one next to the coil. The front one is positioned on the expansion tank.

With the engine canted over all the electrics/ignition and fuel systems/connections are on the same side and will be well covered by the nozzles.

BRP goes into my local auotelectrician tomorrow for the electrical cut off switch to be wired up. When this is done it will shut the engine down completely when operated and isolate all the car's electrics.

All in all the car is very nearly ready for the MSA scrutineer to see if it is worthy of a log book,

On plan for our first stage rally in April.

Fettling!

Not easy to see here but I have fastened a cargo net behind the seats to carry the first aid kit, the "OK" board and hold other bits and pirces like maps etc.

I need someone with more of a domestic touch tho I think cos there's a pouch in the net which holds the first aid kit etc but could do with some kind of fastener to hold the top closed whilst still being easy to open.

I'll give it some thought.

This afternoon was a general tidy up with me "fitting" a couple of grommetts in holes in the floor pan and restraining the wiring loom along the nearside inner sill.

That's another thing that needs more thought!

Finally got the column switchgear cover back on though - had to find a spare as one half had broke.

And also - the outer extinguisher switch was a bit vulnerable and could have been activated by anyone or anything brushing against it. Searching around I found something that will sit over it and give it some protection so it was araldited in place (seen in the pic as a black raised circle around the switch).

All in all - a "bitty" 2 1/2 hours but worthwhile.

Next will be finishing the extinguisher system, wiring the cut out switch, having a good walk round the car and check it against the "blue Book" followed by an appointment with an MSA scrutineer so BRP can get it's rally log book.

Extinguisher wiring

3 flipping hours to wire up 2 switches - would you believe it!

Still, here's the result. The extinguisher power pack is above the glove box and the internal switch is on the lower dashboard bottom right of the "E" sticker.

It was quite a relief when we tested the circuit and the correct green light came up.

Now it's "just" a question of the plumbing - the pipework and nozzles. Next week's thrilling installment!

Where's the logic?

After the roll cage the next bit will be the plumbed in fire extinguisher.

I had already bought one to meet the MSA rally specs, electric activation and plumbed in etc etc with all the kit to be fitted so as it "fires" into the engine bay and cockpit.

On reading the instructions it says that the nozzles for the interior should be aimed at the crew's feet - OK, fair enough but -

There's only two nozzles provided, one for the engine bay and one for the cockpit.

Well, if it's ever going to be needed then who do I choose to protect then? That can't be right can it? It's certainly not acceptable to me as I have a strong sense of self preservation but I am certainly not going to leave Sarah at more risk than me.

Having checked this out I found that the spec was right but the FIA system is double the size with four nozzles, not two. So, I contacted Lifeline the manufacturer and Demon Tweeks the retailer and between them they agreed to take my system back and exchange it for a new FIA system.

All credit to them, I had had my system for 5 months and they are time sensitive but they were OK about all this and I got the better system for an extra £120.

At the end of it I have an over spec system as far as national MSA regs are concerned but much better protection should it ever be needed (god knows I hope it never is) and am lighter to the tune of £120, money which could be spent on more performance but that's not my priority.

Fitting it will be interesting but that will have to wait just a little while as the project Manx team are autotesting this weekend.

Mission roll cage accomplished!

Floor painted with white smoothrite - it certainly made a difference and makes the car look so much better. Having taken out all the carpets and trim, along with lots of sound deadening three were lots of different colours on the floor pan - much better now it's all one!









Getting the dashboard in wasn't too bad actually as it's much easier when there's less of it and aesthetics don't matter so much.

Getting the wiring sorted took much longer than expected though and over an hour was wasted trying to work out why the driving lamps now wouldn't work. The reason for this was a dodgy connection which, I am pleased to say, was a BL connection and not a Randle one!





More rally gear being located here - the footrest which has gone back where it was for now but will have to be moved to suit Sarah when time allows.

Then there's the hand-held fire extinguisher which is now actually located further forward than shown as it would otherwise have been tucked under the navigator's seat!





Finally - mission accomplished with the roll cage fully in place although there's a fair bit of tidying and fettling to be done yet.

No fannying about!

Another 4 hours on this - will it never end?

I am really getting excited now though as this rallying lark is getting to feel very real - first event should be in April so that means I have to crack on and get the car log booked etc with the MSA. This is no time for fannying about!

This is where Bryce and I started today - the roll cage pretty much in and tack welded.

Here you can see the door bar in place and I wanted to check how "easy" it was to get in and out with this in place. So, we lifted in one of the seats and I gave it a go - all OK so if I can do it then Sarah, being a slip of a thing will have no problems. (Flattery always helps I find!). Actually. to get the door to shut I had to remove the arm rest/door pull! A bit more weight saved then.

Here's a picture of the front leg mounting. TR7 competiton drivers will know about the dreaded "head banging" syndrome which is usually not helped by the fitting of other makes of cages. In those the front legs "kink in" to mount on the floor whereas ours is on top of the sill.

There should be two benefits to this - with the other makes the leg intrudes into the floor pan right in front of the accelerator pedal and so the driver has to hook their foot around it - this won't happen here.

The other effect is that the top of the bar as it goes along the roof line drops - I may not be explaining it very well but it means that it intrudes into the door opening at the top and comes close to the occupant's head.

This arrangement has helped us get the bar as high as possible - it shouldn't be an issue for Sarah as we have mounted her seat lower than mine anyway and she's about 4" shorter. It's still not great for me but anyone over my height of 5'8" would have more of an issue needing more radical work on the floor and seat mountings.

Next, here's the cross tube which links the front legs above the windscreen.Still tack welded in place in this shot.


We still had to get the offside door bar in place too which took some doing - it just didn't want to know.


Once we had done that tho, like all the other sections the brackets also needed to be tack welded in place so that we are sure (ahemm!) that it all lines up when it goes back in.


Following that it all had to come out again so that all the tubes and brackets could be fully wekded up.


Here's the cross tube, both door bars and one of the front leags all on the floor of the workshop ready for welding.


In addition all the mounting plates on the floor of the car and the sills needed welding fully up.

While Bryce was welding I was removing yet more sound deadening material.

Towards the end of the day all the pipework was primed and painted again.

Next week it's refitting the dashboard and getting the roll cage in.

I'll also be looking at fitting the main extinguisher in a suitable place - on the transmission tunnel between the seats wherre the armrest was comes to mind.

That's all continued

Probably not too apparent here but this is the base of one of the front legs about to be trimmed - gulp!

We took off 25mm and then 3 more lots of 10 mm whilst continuing to offfer it up in the car.

What can't be seen here is the way that there is a dashboard supporting rail that goes just where this leg ideally wants to be.

Rather than cut straight through this rail we then trimmed back the dashboard to look at the rather more substantial rail on the offside.

At this point we decided to call a halt whilst we ponder the next move - as the car needs to be MOTd and ready for August 8th we will come back to the roll cage later in the year.

The roll cage isn't needed for the Little Devils anyway but seats and harnesses need to be in the car for the MOT so that's where we focussed our attention next.

Here's the seats and harnesses in place and they are fine but --

the seats need positioning for the ideal place for both the driver and co-driver.

We'll go for that on the day before the Little Devils if we have time when Sarah will be available for a trial fitting!

Then once the seats are in the right place the harnesses need "fettling" so that buckles are in a comfortable place and everything fits snugly.

All of that could easily take an hour for each side!

Still - next is MOT time in a couple of weeks.

Much has to go right yet, BRP has to pass it's MOT, I need to get my licence, we need to set the car up as described above, we should try a bit of navigational practice, the engine has to hold together after the head gasket change (maybe I should re-torque the head if there's any time) and of course we need it to keep going whilst the crew work together harmoniously on the Little Devils itself.

Not much then really.

That's all for now on the roll cage

Spent another 3 hours on the roll cage today with Bryce but I was amazed at how much work he had already done whilst I was away on holiday.

Here's some of his excellent work

The top mopunting brackets for the harnesses are vsiible here - the outer ones go into the standard production fixing points for the inertial reel seatbelts but the inner ones have been fitted using a patented method Bryce devised.

This involved much ingenuity and patience but means there's a reinforcing plate underneath the shelf here which sits above the fuel tank.

He has also made up brackets for the front harness fixing points just behind the cross rail on the floor - this is where the two front harnneses locate.

They then come up through the front seatbase and between your legs (ahemm) to stop the driver/co-driver "submarining" - ie - sliding forward under the harness.

The rear floor mountings are behind the seat frame and are re-inforced on the floor.

Wakening BRP

Well, it's getting close now when I can return to driving and when the roll cage arrives next week.

So, time to take the cover off BRP and get it ready.

Doesn't it look great!









Under the bonnet shot - all seems to be OK with no overheating and no loss of coolant. Time will see if it stays that way.













I took out all of the spare bits of trim today so it's ready for the fit,ment of the roll cage etc.














I also took everything non essential out of the boot so it is now looking close to how it will when it's ready for the first rally.























I didn't think there was much left in the car but here's everything that came out - amazing!

So, next is to get it over to Bryce's place and start fitting the cage, harnesses and extinguisher system. then it needs an MOT and RFL by August 9th.

Thinking and planning

The extinguisher system has arrived and this is where I will fit it.

The external push button will be next to the electric pull switch.

I will locate the extinguisher bottle where the battery tends to be lcoated in a TR7V8. It is preferred by the mSA that it is iftted in a fore and aft position and here it will be close to the triggering switch so that should help wiring a bit.

In addition it's a fair distance away from the wing should it be pushed in (gulp) but not too close to the spare wheel where it might get damaged lifting the spare in and out.

Fire extinguisher ordered

Next bit of the puzzle - should arrive this week.

So, then it's a question of putting it all together and BRP will be pretty much ready.