Going to be road-rallying initially, but there'll be some offroad stages when I do endurance rallying, I'm also planning on doing a few stage rallies (like above, but without so much livery!)

Didn't get any further with the sump guard (forgot to take photos) I was busy working out how to get the weld torch in for some of the (pain in the bloody arse) welds! Managed to get the door bars in, the top of the rear stays all welded in (back end completed now) and the main diagonal for the main hoop tacked in before the welder ran out of gas. No more work until the weekend, with a bit of luck, should get the cage completed and move on to fabricating the sump guard proper!

So photos....

oh so you're going to do enduros with it. Some choice mods to get into enduro under their regs, they're quite specific about making it a level playing field. Couple of my friends do enduros, we built a 106 S1 Rallye enduro car a few years ago.

My dad and mates do a lot of rallying mainly navigational events, enduro road rally's, 12 cars 20 20s etc...

be careful with enduro, they require full interior including boot carpets etc, limited engine mods (if any) non adjustable suspension (can lock wire coilovers so they cant be adjuested) not alowed a lsd, or gear sets.

Read the blue book carefully as your car will be pretty sweet and it will be gutting to find out you cant use it!

I'm navigating next year so i may well see you about!!!

wow that is one hefty assed cage!!

how much does that weigh? at least 40kg?

looks badass though;)

Thanks guys, I've been keeping a close eye on the regs and making sure I comply with everything! I've got the carpet, dashboard and door-cards waiting to go back into the car, they're going to require a bit of trimming! Not going for coilovers unless I find problems with retaining the stock struts (and even then I might only go for an uprated, non-lowering spring)

Cage is listed as 45Kg's - serious stuff

Edited 27 August, 200917 yr by majic79

nice! 45kg of correctly placed steel can save your life:-D

question for you, actually..

are you going to place the original stock dashboard back in?

If so, how will you get around the problem of the cage being in the way?

Ill be facing the same situation soon, and am totally dreading that part:(

Trim the dashboard

I'm just finished making it all fit - it's not a pretty job, but then most of what I'm doing doesn't need to be pretty! I'll get some photo's at the weekend

Some cages (bolt in jobs) are dash dodgers, so it depends what cage you're having fitted. This is a custom cages cage, I've got to trim the door cards to fit around the door bars as well

Been a while (I've been a busy bee!) but things are coming along in leaps and bounds!!! Deadline is to get the car MOT'd and road legal for this saturday (12'th September)

Roll cage has been completely installed now (some pics to fill in the gaps):

Got a coat of primer

I got some fast drying gloss, but it gives a crap finish, so I'm going over it again with some decent gloss that leaves a nice smooth finish - enough of that. Someone was asking about the sump guard, so here's how it went....

First we decided where it needs to come to - coming all the way up isn't really any good (it obstructs airflow through the rad, doesn't protect the rad) so we made some stays up to come down from the chassis rails.

Lugs were added to the subframe for the rear mounts and it will be a very shallow ramped plate with a step up at the front to protect the radiator. Start by creating the frame, and get your plasma cutter out and cut 3mm plate steel to size

The tow eye was also welded into the guard on the drivers side

Discs and pads weren't too good looking, so EBC Ultimax discs and Greenstuff pads were ordered

Inside I've trimmed the dash to fit, got that all mounted up with the wiring loom routed around the car to where it needs to go. I've also run fuel and brake lines inside the car (in some proper conduit) and back to the tank. Installed the regulation FIA master switch (T-pull outside the car needs installing)

Discovered the problems with the mysterious non-starting - the switch in the steering column is knackered (it doesn't make the connection when the key is turned to "crank") so I put in a temporary push start button, this will be mounted next to the kill switch

Checked the lines for leaks when we primed the fuel system, no smoke escaped from the wires (always a good sign!!!) so we put fluids in the engine, etc, cranked it and she lives again!

A bit of interior fettling remains, electrics for the spotlights need routing and protecting in the engine bay, but she's almost good to go

Looks absolutely awesome! Top job fella, I'll be intently watching this one

She lives, she drives, she failed her MOT :(

On the good side, it's only lights and horn (slight problem with the horn button, needs some fettling to fit properly)

It's a right hoot to drive though :mrgreen:

Well, a mad rush this morning, and I got the lights and horn sorted, to the MOT station for 11:30 and it passed!

She's now taxed, tested, MOT'd and insured - all set for the first rally in a weeks time. Some tarting up and little detail jobs to do, but not required for rallying, so they'll be done at my leisure

safe!

looks likie a proper job!

i like it man:)

think (when you get the chance) you could take a photo of where you had to cut out the dash?

looks sturdy man:p

enjoy it, make sure to get some VIDEO of you rallying (no one seems to do that on this forum haha)

:)

Don't know about the video, but should be plenty of photo's from the rallying (I'll see if anyone's taking videos - I don't have the equipment for incar recording, but I might be able to borrow some)

I'll get some photo's of the trimming tonight

just strap something to one of those bars;) worked for me! :)

thanks alot man, really appreciate your help!

where are the rally stages held? how many are there?

details

Tidy mate, where abouts will you be road rallying? if it's anywhere near South Wales I do quite a bit of marshalling and I'll keep an eye out for you on the stages!

Was hoping to get in on the Sarn Helen, but I was a bit late for the entry (wasn't sure if I was going to be ready for it) - will be mainly lincolnshire, yorkshire and nottinghamshire to begin with, likely to move further afield later (once I've got my rally boots properly muddied!)

First rally tonight - finished 4th out of 12 starters (11 finished, 1 retired early with exhaust problems)

First rally tonight - finished 4th out of 12 starters (11 finished, 1 retired early with exhaust problems)

UPDATES!!!!

Fucking awesome!! Just read this whole thread - what a car, youve done an awesome job on this

Just goes to show that white wheels and sparco mudflaps dont make a rally car

what are you talking about? if he added those he would have probably got at least 2nd.

what are you talking about? if he added those he would have probably got at least 2nd.

Exactly, and of course if you want to go on the top spot you've got to have viper stripes or Fake sponsers!

awesome man, glad to hear the results! :)

any more plans for thecar?

and strap a damn video recorder in there!!! :p

want to see the action!

There are some little bits to sort out (trying to get my other car sold - Honda CRX del-sol if anyone's interested, good condition, no rust, low mileage jap import with 1.5Vtec, makes 128bhp stock)

Need some FIA approved (in date) Bucket seats (stock seats sit too high)

Rear seats have to go back in (requirement for enduro, but I won't be starting that until next year)

Front and rear shocks/springs (coilovers perhaps) to organise

Had a water pump problem (brand new pump from GSF failed after around 1k miles) so engine out, discovered I'd got the timing belt a tooth out on the crank pulley (lucky escape - no damage!) sorted that, fitted a new pump from VW, checked for leaks, tidied up some of the wiring in the engine bay (stuff that I'd put in) broke the sender for the oil temp (whoops!)

Yesterday I discovered a VW motorsport website with loads of info about the Group N rally spec Polo's (1.4 16V and 1.6 GTi based) and a complete VW parts catalogue. I'm busy drooling over the prospect of a 6spd sequential box with LSD (£5k) and proflex suspension and appropriate springs (£3k)

nice man! sounds like you got a handful coming your way :p

whats that website?

Sequential gearbox would be great!