FFG 549D Rally car

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FFG 549D Rally car

Post by moose »

i am about to start the restoration of FFG549D i have up loaded a few pics of the before stage is any one interested in the progress of the work?

i plan to compete on bigger events so i am going to add some extra skids and plates etc, the car has done 6 full seasons at an average of 14 events per season approx 100 miles per event. so needs some TLC.


regards mike
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Post by ImpManiac »

I am certainly very interested to follow the progress of your restoration, Mike and I am certain that many of us are. :D Where did you put the photos? I am about to scan the albums to find them.

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Re: FFG 549 D restoration

Post by moose »

updates to follow i have just been too busy, Sam is time consuming :) and the rally car is coming along but once you start the jobs get bigger, step dads cortina twincam is now flying and setting top ten places 9th Berwick classic, 3rd Viking so that is one engine gone and working, Gaz has taken the CVH to put in the Escort, the crossflow has gone and is performing well, no competitive results yet, Dereks Beetle is now handling well and took young Sam (thompson) for a good ride out on a Morecambe car club 12 car after i put him in the nav seat 4 hours before the event and taught him how to navigate in 15 mins, could do no more as i was scrutineering and course closing car. Sam never call in, you never know what you will end up doing!

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Re: FFG 549 D restoration

Post by moose »

Sam your first venture into rally navigation was an excellent effort, Derek was really impressed and the seat is open anytime you want. For a first attempt and a hurried lesson looking at the results you dropped 4 seconds over Haylots and no time anywhere else on route, you collected all passage checks and code boards so if you had continued that for the final 4 controls you would have been second! Never under estimate a Beetle driven by a pensioner. i have been spending long hours on the rally car we are now round to the nearside rear arch and panel, Derek has made another rear corner from a flat sheet of steel! the back panel has been made to fit properly and the exhaust exit cut to allow max ground clearance. the rear arches have been tubbed to increase strength and prevent rot where the inner and outer arches meet. Many thanks for the unserseal and other rubbish you have scraped off i hate that job and because you are doing it to your own car aswell i am even more suprised you came down and helped out. looking forward to being the wrong seat for the Cumbria :roll: just don't hit anything on my side! regards mike
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Re: FFG 549 D restoration

Post by bazzateer »

Sam,

Whatever you do, treat that girl well and never let her go. Take it from one who knows. :wink:

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Re: FFG 549 D restoration

Post by Dave ' Linwood ' Lane »

Great work , like the modded chassis leg , neatly done. :D
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Re: FFG 549 D restoration

Post by ImpManiac »

Very nice work, Mike! :) With practice, I shall be able to produce work like that. :wink:

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Re: FFG 549 D restoration

Post by ImpManiac »

I look forward to seeing the piccies when I get home from... ahem... work. :oops: :wink:

Do polycarbonate side windows not scratch horribly in door drops? I wanted to do this on mine but was advised against it!

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Re: FFG 549 D restoration

Post by moose »

Cheers Basidon i am spot welding one spot a fortnight to keep the panel cool as i put a ripple in the other side even though i was careful, having seam welded and arch in one run on my first car many years ago :lol: i hate rubbing down filler after that experiance.


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Re: FFG 549 D restoration

Post by chris d »

nice work mike
looks like you are making good progress
a true professional at work
like the carpet on the floor
is that for your benefit or the cars :)
cheers chris d
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Re: FFG 549 D restoration

Post by moose »

Chris carpet and covered in a blanket with the air con/de-humidifier running of course it is for the cars benifit!

IM the windows will scratch eventually so i will cut some spares only 21.75" X 17" so not going to break the bank if they need changing every year or so ( i will make my own) it is a pure rally car the only road runs are to shows and the pre-event blast to make sure everything ok, so not a daily driver with the windows up and down all the time. Probably wreck something more expensive during an event anyway! :)


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Re: FFG 549 D restoration

Post by Pobsport »

Be time you ve finished it will be too good to rally. Hopefully that might give me a fighting chance of beating you :lol: . Looking good Mike
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Re: FFG 549 D restoration

Post by moose »

Image
Image

progress this week

car is now on the spit i made this week and the back corner is finished bar a few spot welds cleaning up ready for welding is the next step working towards the front of the car. Back panel is done and engine cover fastening bracket welded in place, really ready to get primed put in bubble wrap and stored for re-spray.


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Re: FFG 549 D restoration

Post by moose »

well we are nearly there and the car is going for a bath, i wasn't quite set up for the whole car chem clean but it is now possible so i am going to dip the whole shell even though i have spent many hours with the nitromors and flab wheels etc but i am confident we will find no more rot but i want the inside to look as good as the outside. The descision has been made to run the car for two seasons and then put into retirement it will be tidied up and only come out for special events when i feel like it, this is due to the poor re-sale value and the fact that i have owned the car for so long i don't want to part with it. So i am hunting round for the next project i have a short list based on different ideas switching between, like an imp to front engine rwd!

the list

1. Skoda 130RS
2. Talbot sunbeam 1600
3. BMW 2002
4. Fiat 127 sport/gt
5. TVR 1600 (cos i know where there is one! NO welding :) )
6. Fiat 131twincam or Lada version of same
7. still thinking

all the excess imp tuning parts will be for sale when i lay the car up and i have scared myself with how much stuff i own! Been to the buildings to list it all how do you collect all that junk?

photo's of the cars progression to follow.

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Re: FFG 549 D restoration

Post by ImpManiac »

What about a Triumph Vitesse? Very tuneable, quite compact, agile... I read an article about a 1.6-litre rally Vitesse in C&SC many, many years ago. It was highly competitive! Even used to catch Lotus Cortinas on stages!

The ramblings of a mad man...? :wink:

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Re: FFG 549 D restoration

Post by Cally »

Hi Mike

Theres a few of us on this Forum that are into Avengers and/or Sunbeams as well - Both cars still being raced and rallied successfully. Russel Brookes recently re-drove his old car and showed he still has 'it'.
Avenger Sunbeam Club [ASOC] which is a sister club within ARCC, covers both these and there are plenty of great guys who could give you answers/information on rally cars > ASOC Magazine Editor Andy Holmes to mention but one > just click on contact Editor on ASOC Website to get in touch with him

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Re: FFG 549 D restoration

Post by ImpManiac »

Nah! The good ol' Vitesse can be made to work! And if the car is to be rallied, it will be getting a full cage anyway, so rigidity is less of an issue. Crank flex may be an issue on 1600s but the one I read about could still spin up to 8k rpm, no probs. :D

But you are right, Tim; the BMW 2002 is a great car straight out of the box. And that engine... A much better proposition! :wink:

But whatever you get, Mike, you'll make it work. :wink:

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Re: FFG 549 D restoration

Post by moose »

thanks for the info and encouragement chaps i have contacts with the ASOC and SLOC in fact i have a pile of spares for such vehicles that maybe on the market soon! to be honest the sunbeam looks favourite as i have always said with the historic rallying front engine rwd is the only way for speed and reliability and the differance between Avenger/sunbeam and Escort is only the driver if preparation is equal on period parts not cost. I am just built to like the underdog hence starting classic rallying with an imp when the obvious choice was a mini based on performance and prices, time marches on and things change like the rules to allow the Escorts to do what they did in their day, i have been put off going for the big events due to the red tape that is unfairly against the clubman (in my view, because they might turn up and do a giant killing) we will leave that there as it is my opinion and i don't want to do politics! so the imp will come out and be abused flat out no matter what and then to prove to myself that the car makes the differance i will spend a load of money/time and effort producing the next period rally car to probably battle against 6R4's which will be eligible by the time i get it done :lol:
pictures taken tonight of the progress so watch this space! (your not really that sad are you?)

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Re: FFG 549 D restoration

Post by moose »

quick update car progress slow but need to make my mind up on the colour scheme, for years now the car has been oxford blue (or near enough) with the works type stripes in bright white, i am considering oxford blue with old english white stripes or going to the light blue of the works cars as per the JDU colour scheme what should i do?



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Re: FFG 549 D restoration

Post by moose »

they are from machine mart and i made the box section to suit check the ends of the chassis where the bumpers bolt on are in really good condition before attempting this, on the front due to the curve of the panel i had to space the box section away from the car by approx 1 inch using some more box section.

http://i56.photobucket.com/albums/g184/ ... 010012.jpg

http://i56.photobucket.com/albums/g184/ ... 010013.jpg

if you are chopping out metal check door gaps and brace the shell as you will be hanging the weight on either end so will havea fair amount of leverage to bend the shell with. Also worth pointing out that you cannot rotate to 90 deg with these stands but nearly and certainly enough to carry out any work required.

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Re: FFG 549 D restoration

Post by ImpManiac »

There is a guy on ebay that sells 'chassis twirlers' for whichever car you want to twirl. They are £90each, plus £20 P&P. I have been speaking with him about getting one for my Imp but I want to use it for my Stag too, which he says is no problem. They are easy to adapt. It might be cheaper than buying two engine stands, although engine stands are useful in their own right too.

Search for the ebay shop of 'Mk2mania.' :wink:

I have no interest in this ebay seller at all, apart from as a possible customer. :D I just thought it might be of interest to some on here.

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Re: FFG 549 D restoration

Post by moose »

update at long last car is striped to bare shell and is going to chemical cleaners ofr a full bath! then works really gets going to build back to working car pictures of before and after to follow then probably silence from me on here as i have to build the car and extend the workshop and start work on two MK1 escorts one for me and one for my evil stepfather as we have both purchased cars to build, i will still compete chosen events in the imp and will probably do one big event or the odd british champ round.


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Re: FFG 549 D restoration

Post by moose »

Not a sulk or strop just need to concentrate for every waking hour to sort the build i will lokk in when at work but time on the internet is limited thanks foe the comments i may make one off picture updates with FFG54D but quick comments on faults may not be there,

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Re: FFG 549 D restoration

Post by niksimms »

Nooooooooo!!. You can't go quiet Mike you are my mentor, you pointed me in the right direction.

Enjoy the Escorts, can't wait to see the Imp when finished.

I wish I could dip my Imp, then again I don't think much would come out.

I read a good article in the practical classics mag september 2009 about surface processing and phoretic coating.
Always interested

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Re: FFG 549 D restoration

Post by moose »

sorry IM too busy wrapping presents will be posted Tuesday :) i will get on when i can but only to post photo's as i down load them of the build, anybody i have helped and passed my number to or who can access it is free to call if stuck.


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Re: FFG 549 D restoration

Post by moose »

well the imps bath is booked and time off work sorted should be 3 weeks flat out starting 5th OCT lots of bits being made at the moment for some shell strengthening ideas i have, 14 point the cage will be another job all the suspension bits and brakes are overhauled and bagged up waiting to go on, the original bespoke wiring harness is going to be modified as i am running less gauges now i know that transaxle oil temp is always ok and same with oil temp, no fuel gauge due to the big tank etc etc actually looking forward to it :) when done it will be a few selected rounds that i can afford to do whilst building the mexico, with guest navigators!


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Re: FFG 549 D restoration

Post by johnh875 »

Good luck with the rebuild Mike, hope all goes smoothly. Can understand you will be not "wasting" time online but as with the others it would be great to hear about your progress etc.

To streamline the process perhaps just throw up a link to the album when you have updated it?

Re the Mk1 Escort - I have one of those in the shed also, also in need of full resto & some smash repair. 2 door Mk1's are rapidly becoming hard to find so I grabbed one.
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Re: FFG 549 D restoration

Post by GURNSIMPS »

Looks very good Mike,
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Re: FFG 549 D restoration

Post by moose »

Absolutley terrible pace on the re-build to much else on but due to start work again soon, just waiting for a couple of more machines for the workshop extension and the imp will move into it's new bay in the other side of the workshop. will post some pics when things change but included is the new building attatched to the workshop as i am moving in and it is too untidy to show it in all it's glory.

regards mike



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Re: FFG 549 D restoration

Post by moose »

New alarm system in training for the workshop
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Re: FFG 549 D restoration

Post by moose »

well one year on and not much done apart from working on everyone elses cars and working on the PWRC and building Subaru's today is a big step i am now employing someone to sort the imp with me, hopefully i can concentrate on the engines i have to do for people and the historic cars that need some prep get them done and out of the way and help with the imp projects so i might start with weekly progress reports from here on in.
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Re: FFG 549 D restoration

Post by moose »

mocking up of various parts in progress lots of discussion around what where, how to mount them, is it safe, is it legal for rally regs etc etc slow progress but it it has got to be right.

Image

Image

Image

Image
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Re: FFG 549 D restoration

Post by moose »

no it is a safety devices one that i have added the extra bars to in accordance with the MSA blue book and advice from PAul loveridges website for historic rally cars, so there are more bars to go in i have ordered the steel today, so progress o nthe dash bar harness bar extra cross brace on main hoop behind seats and the door bars should take place next week. seat positions set this afternoon, boot area layout completed s oeverythign has a place and cosideration taken for fire proofing the bulkhead, mounting thew fuel pumps so they are not effected by heat fro mthe rad, rad ducting to achieve max airflow and ducted to reduce the amount of radiated heat reaching the tank, this will be supplemented by heat sheilding and isulation, spare wheel position agreed and routing of radiator pipes agreed so not much real work but lots of thought that should lead to a speedy build of those components.
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Re: FFG 549 D restoration

Post by ImpManiac »

Excellent stuff, Mike. :D It will be educational to observe how a true expert pieces together a competition car from a bare shell like yours. :wink: Most interesting!

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Re: FFG 549 D restoration

Post by moose »

true expert is taking a it a bit far, Sam has made good progress today engine bay should be complete by now with a few revisions to chassis leg clearance and routing of pipes and wires, he will have welded all the old holes up so now we have to plan and mock route everything and drill the correct size new holes so that the edges get coated in primer and paint when the shell is sprayed rather than drilling through when building the car after the body shop. Made some progress wit hthe design of the dashboard, instruments will be minimum required less in the car less to go wrong. Parts re-furb is the big hit now ready to trial fit 30% of this has been done so not too bad but everything has a knock on effect so sometimes the pace slows down, but good ideas are flowing and constant checking of the rules and regs to make sure we are within them yet keeping weight to an minimum and strength high. few tricks learnt from the building of the Symtech PWRC car will be incorporated but will remain my secret touches nothing controversial just my personal additions you will be able to see them so if you can spot something good copy it by all means but i am not going to tell you what they are! :)
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Re: FFG 549 D restoration

Post by moose »

Sam started at the back of the car and so far we are now in the passenger area so seat mounts to go in so plenty of time making sure i am sat in the right place handbrake system is mounted temp gear lever, steering column and pedal box all in place ready to asses positions so should get the seat right first time but will be fully adjustable in case in the real world of driving we need to move slightly. interior trim soloutions sorted just need to order some material. seem t obe spending plenty ordering al lthe kit to put a car that was on the road back together.
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Re: FFG 549 D restoration

Post by ImpManiac »

It may have been together but that is how you know exactly what it needs to make it better. :mrgreen: All part of the process! Have you any photos?

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Re: FFG 549 D restoration

Post by moose »

a few but too hectic to put on photobucket and then upload here, only able to type this as i am at work! and i cannot access photobucket at work, pics will follow when some visible progress is made at the moment it is old stuf or new unpainted and unprepared parts resting in place. will be taking pictures of every part as it changes from unprepared new and second hand needing re-furb to done and ready to fit, look i nthe gallery at the new Koni's for now.
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Re: FFG 549 D restoration

Post by moose »

cill outer skin and 2 skid plates plus seat mounts and the welding is done (seat trial fitting Friday the 17th When Ian my co-driver turns up) need to crack on with the other parts as time will be lost soon when i go to Finland working on the PWRC. ordering parts still so watching the money disappear at a rate of knotts.
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Re: FFG 549 D restoration

Post by moose »

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Re: FFG 549 D restoration

Post by moose »

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Re: FFG 549 D restoration

Post by ImpManiac »

moose wrote:Image
Seat mounts in the lower half of the picture? :?:

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Re: FFG 549 D restoration

Post by ImpManiac »

Would 1" by 1" be up to the job of seat mounting beam, suitably welded both at the inner edges of the sills and where it crosses over the central tunnel? I ask because I am considering this for my car some time in the future as an alternative to the seat pans.

Your car is coming together at a fair old rate, Mike. :wink:

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Re: FFG 549 D restoration

Post by moose »

check your height if welding on top of the tunnel you may find with the seat bases you are too high, inch would be ok but you need to use good quality tuning try metals for you http://www.metals4u.co.uk/ and then you need some top hat shaped spacer with threads in them to bolt the seat base to.
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Re: FFG 549 D restoration

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Re: FFG 549 D restoration

Post by bks974c »

Hi Mike

Good to see you getting on with the imp again.

The Pro2000 Plus is that the plus the wide bodied version :lol:

Going to be a well sorted car when finished.

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Re: FFG 549 D restoration

Post by leadfoot »

Hi Mike is there any reason you didnt remove the waterpipe channels to the inner sills :?: as in impsters car,
and are you also allowed to have brace across the main hoop of the cage behind the seats :?: i new about the one under the dash, and a seat belt mounting one, but not that , although it has always seemed a good idea,
also whats the cut out on the bonnet slam for :?: :?:
great work keep going :) one last thing what colour
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Re: FFG 549 D restoration

Post by moose »

not sure if modding the cills would be allowed so left it well alone, the cut out i nthe bonnet slam is for the front rad hot air outlet through bonnet and the car will be white inside, white engine and boot area, underside floor and wheel arches then the outside will be as it has always been oxford blue with matt black bonnet, and the white stripes. the roll cage is as per the new blue book regs and the info on the HRCR website regarding rollcages.
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Re: FFG 549 D restoration

Post by moose »

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bonnet pins mocked up and ready to install should be hardly able to see them on the matt black bonnet
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Re: FFG 549 D restoration

Post by ImpManiac »

Excellent. I need to make ducting for mine, so am looking for inspiration. Mine will definitely be exiting under the floor, though but I am interested in how I could construct it. My cooling system works very well but the petrol tank gets too hot! :lol: I think this is affecting the running! It is not helping, anyway.

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