Track Project S2000 Safari Buggy

2nd Generation (2004-2009) vehicle added by PhillipM, Tuesday 3rd Feb, 2015

  1. PhillipM Club Member ★ ☆ ☆ ☆ ☆

    United Kingdom Phillip Rotherham
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  2. Ichiban Founder Staff Team

    England CJ Leeds
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    I am sure I have seen that buggy on RDT.tv facebook page , did you get tuned at Wills?
     
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  3. PhillipM Club Member ★ ☆ ☆ ☆ ☆

    United Kingdom Phillip Rotherham
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    No, I don't, might have been an autograss buggy or similar?
     
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  4. Ichiban Founder Staff Team

    England CJ Leeds
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    Must have been bud. Love your buggy thou.
     
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  5. PhillipM Club Member ★ ☆ ☆ ☆ ☆

    United Kingdom Phillip Rotherham
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    Ours is rather heavier built than autograss stuff, the terrain is far rougher.
     
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  6. Ichiban Founder Staff Team

    England CJ Leeds
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    Which event do take part in bud I would like to learn more about this side of racing and come down to see the event meets. I was avid motocrosser and after breaking nearly every bone in my body this could be the next thing to get some air..
     
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  7. PhillipM Club Member ★ ☆ ☆ ☆ ☆

    United Kingdom Phillip Rotherham
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    Comp Safari, we race with the awdc, which is a national club, but the NORC (Northern off road) have events around you, in fact one is in Tong.
     
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  8. Ichiban Founder Staff Team

    England CJ Leeds
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    Cheer Mucca will have a look for sure.
     
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  9. PhillipM Club Member ★ ☆ ☆ ☆ ☆

    United Kingdom Phillip Rotherham
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    Well, Tong is a pretty good event, it's not very open, lots of tight twisty stuff in the forest, but that does mean you can see quite a lot of it with just a short walk into the trees, and there's plenty of rocky paths so you don't need knee high wading boots like some events* , that's on the 23rd of May.




    *(the awdc tend to run courses that are much longer, so can take a few hours just to walk around the course without stopping, up and down muddy welsh hills and valleys half the time)
     
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  10. PhillipM Club Member ★ ☆ ☆ ☆ ☆

    United Kingdom Phillip Rotherham
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    Finished off some last bits of dashboard wiring today (few extra's been added, launch control settings, etc), and tidied all the wiring behind it into neat runs, switched idiot lights out for LED's (which then required ripping them to bits and trying to add diodes and ballast resistors in the case of the alternator charging light....good fun trying to solder them in a space about 8mm x 4mm.....lots of swearing, some burnt fingers.

    DashWiring1.

    Anyway, kettle went on, coffee came out, shiny lights:

    DashWiring2.

    As promised, new front bonnet, ignore the steel box section, it was just there to hold the front square whilst welding as it's fairly thin aluminium, it's on hinges now and will get a gas ram lifter fitted to secure it, much easier to work on if you break down away from the service area then.

    NewFrontBonnet.

    And new floorpan is on, new bulkhead, seat mounts, pedals, etc:

    NewFrontBulkheadFloor.
     
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  11. PhillipM Club Member ★ ☆ ☆ ☆ ☆

    United Kingdom Phillip Rotherham
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    Been a while for progress again, unfortunately once more due to serious family health issues, not having much luck lately, anyway, we've pushed on with a bit more work recently, we found some Mitsubishi wheels similar to the rears which would fit the front - that way we don't have to hand-make our own wheels again, just bolt on, and they're pretty common, cheap, and a kilo lighter than our steel wheels, so we decided to change over.

    Unfortunately, that came with it's own issues - we couldn't use an adaptor/spacer ring because the massive wide-5 front stud pattern and centre spigot made it difficult to get down to the centre bore required for the alloys, never mind getting the stud pattern too, as it mean everything was in the thin tapered section of the upright, unless you ended up with massive amounts of wheel offset, which was no good.
    So, this being us, we took the easy solution, and completely remade our own front hubs, you know, like any normal person would do instead of just using the old wheels....:Wink:

    The process of which was quite a pain in the arse as we don't have a mill or dividing head, just a clonky old lathe we rescued, but the short version goes like this:

    FrontHub.

    RawBilletFrontHub.

    WheelSpigotCap.

    Then halfway through we decided to go with bigger calipers up front as we were worried about the pad/disc interface temperatures - the front pads in the 2 pots are very small, about an inch square, so we rebuilt those and some old calipers and sold them off to fund some bigger Midilites, which required bigger discs. Which meant making bolt on brake bells as otherwise you couldn't get the wheel studs pressed in....anyway:

    FrontHubsBellsfitted.

    Discs drawn up to suit:

    FrontDiscsSmallPic.

    Anodised:

    Frontdiscsfittedhub.

    Fitting checked:

    FrontDiscsandHispecsfitted.

    And then discs plated and uprights rebuilt - not as easy as it sounds as we reamed them out to take a larger metric bearing as they were worn, then hand sanded the hardened spindles down to match the smaller ID, and machined top and bottom flat so that it could take a proper low-friction thrust washer (stock setup is just steel on steel)

    FrontHubsCoatedComplete2.

    Front together:

    FrontAlloysFitted2.

    Machined a boss up to fit a new steering wheel instead of the old Peugeot 106 effort:

    SteeringWheelMounted2.

    SteeringWheelMounted.

    Swapped the TIG welder for a better EWM one, this was the first go with it, beautiful machine - this covers the dry sump belt to stop debris getting in, there's a polycarb window on the front to check the belt through:

    SumpBeltGuard.

    Some aero plans are afoot:

    CarTriplaneRearWing_1.

    WingRibs.

    And courtesy of a very nice man with a 3d printer on another forum:

    SparsPrintedRearWing.

    Will eventually turn into:

    TriRearAoA.

    Skidpans and floor armour going on:

    RearSkidpans.

    Panels getting more louvers than a louvery thing at a louver convention. Where there's a buy one get one free on louvers.

    louvers.

    Got a bit concerned about some of the oil pipes being too near the manifold and silencer as the supplier had made them a bit long - with the hoses being so wide and stiff that means quite an angle to get into the fittings in some places, so we chopped the tube out of the side of the engine cage and moved the exhaust silencer over and made it structural. That mean remaking the panel too:

    NewRearEnd.

    Still needs edges rolling over but welded up:

    NewDriversRearPanel2.

    And as part of that we moved the filter from the rear there to under the sump instead, which keeps the lines away from the manifold and means there's no filter and heatshield blocking airflow from over the manifold:

    FilterUnderEngine.

    Getting closer!
     
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  12. SpeedyGee Administrator Staff Team

    England Speedy Birmingham
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    Wow, you did really well for just having a bog standard lathe. Always love seeing the custom fab work you do.
     
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  13. PhillipM Club Member ★ ☆ ☆ ☆ ☆

    United Kingdom Phillip Rotherham
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    They could have been a bit lighter with some nice profiling/scallops with a mill, but they're still slightly lighter than the old hubs anyway.
     
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  14. PhillipM Club Member ★ ☆ ☆ ☆ ☆

    United Kingdom Phillip Rotherham
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    More louverly things.

    driverslouverslower.
     
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  15. PhillipM Club Member ★ ☆ ☆ ☆ ☆

    United Kingdom Phillip Rotherham
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    Quick snapshot as was just ticking over for 20s at a time to find leaks - haven't even dialled in the timing or fuel yet, just on my base map - found plenty, as you can hear from the whistling noises. Anyway, it's alive!

     
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