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Project RX924 begins!
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Andrew NZ  



Joined: 22 Jun 2004
Posts: 744
Location: New Zealand

PostPosted: Thu Nov 18, 2010 2:49 pm    Post subject: Reply with quote

I've struck a snag with the pinion shaft. Details are here: http://www.924board.org/viewtopic.php?p=307614#307614
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Andrew
1977 RX924 rally car
12a bridgeport
www.race4-dcup.co.nz
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Andrew NZ  



Joined: 22 Jun 2004
Posts: 744
Location: New Zealand

PostPosted: Sun Nov 21, 2010 7:00 pm    Post subject: Reply with quote

Busy weekend - I've stripped down my early 5 speed to get 3rd and 4th gears so I can hopefully still use the Audi pinion. I'll know if it's going to work later in the week.

Also spent some time on the body work




Still a lot of work to do, but at least I can get an idea of what it'll look like when it's finished.
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Andrew
1977 RX924 rally car
12a bridgeport
www.race4-dcup.co.nz
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Andrew NZ  



Joined: 22 Jun 2004
Posts: 744
Location: New Zealand

PostPosted: Thu Dec 02, 2010 5:13 pm    Post subject: Reply with quote

Picked up the gearbox bits today, so will hopefully reassemble this weekend.

I had to use the 3rd and 4th gear from an early 924 Audi, which will actually give a more even spread anyway.

The ratios are:
1st 3.60
2nd 2.125
3rd 1.36
4th 0.967
5th 0.829
Final Drive 4.78

With my tire size and an 8000rpm limit, these are the maximum speeds (mph) in each gear:

1st-32, 2nd-54, 3rd-85, 4th-119, 5th-139
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Andrew
1977 RX924 rally car
12a bridgeport
www.race4-dcup.co.nz
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Andrew NZ  



Joined: 22 Jun 2004
Posts: 744
Location: New Zealand

PostPosted: Tue Dec 14, 2010 8:19 pm    Post subject: Reply with quote

Transaxle is all back together now, ready to go back into the car this weekend

Also got the front shocks rebuilt and solid polyurethane gearbox mounts made up.
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Andrew
1977 RX924 rally car
12a bridgeport
www.race4-dcup.co.nz
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Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11332
Location: PacNW

PostPosted: Wed Dec 15, 2010 3:21 am    Post subject: Reply with quote

Good luck!
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Joes924Racer  



Joined: 03 Nov 2002
Posts: 11965
Location: Oregon, Denver Colorado native!

PostPosted: Wed Dec 15, 2010 5:02 am    Post subject: Reply with quote

Awesome pictures. Nice race car you have there.
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Andrew NZ  



Joined: 22 Jun 2004
Posts: 744
Location: New Zealand

PostPosted: Fri Jan 14, 2011 7:05 pm    Post subject: Reply with quote

Most of it is back together now. Hopefully I'll get to drive it around the block tomorrow to make sure it all works!
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Andrew
1977 RX924 rally car
12a bridgeport
www.race4-dcup.co.nz
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Andrew NZ  



Joined: 22 Jun 2004
Posts: 744
Location: New Zealand

PostPosted: Wed Jan 19, 2011 9:24 pm    Post subject: Reply with quote

Had a quick drive around the block tonight

Seems to go a lot better now, and will need a rev limiter fitted soon It revs out to 8k+ very quickly in first and second gear. I can't wait to get it to a track again.
It's nerve racking driving with all the rattles and noises after doing major work like this - trying to remember if that sound was there before the rebuild!
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Andrew
1977 RX924 rally car
12a bridgeport
www.race4-dcup.co.nz
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Andrew NZ  



Joined: 22 Jun 2004
Posts: 744
Location: New Zealand

PostPosted: Mon Mar 14, 2011 3:22 pm    Post subject: Reply with quote

The gearbox and torque tube have just survived 250km's of full on tarmac rally stages! Looks like we might finally have it sorted. I thrashed it all weekend and had no issues with the drivetrain at all. The rest of the car was a different story - more detail;s to follow shortly.

8000rpm and a 4.78 diff are fun
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Andrew
1977 RX924 rally car
12a bridgeport
www.race4-dcup.co.nz
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Andrew NZ  



Joined: 22 Jun 2004
Posts: 744
Location: New Zealand

PostPosted: Tue Mar 15, 2011 9:36 pm    Post subject: Reply with quote


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Andrew
1977 RX924 rally car
12a bridgeport
www.race4-dcup.co.nz
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Grenadiers  



Joined: 20 Feb 2007
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Location: Nelson, WI & Prescott, AZ

PostPosted: Fri Mar 25, 2011 2:16 am    Post subject: Reply with quote

Not sure if you posted this, but what company makes those fender flares? thanks, dave
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Andrew NZ  



Joined: 22 Jun 2004
Posts: 744
Location: New Zealand

PostPosted: Fri Mar 25, 2011 5:20 am    Post subject: Reply with quote

Grenadiers wrote:
Not sure if you posted this, but what company makes those fender flares? thanks, dave


They are reproduction Holden Torana hatch flares (available from lots of glassers in NZ and OZ), and went on with virtually no modifications.
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Andrew
1977 RX924 rally car
12a bridgeport
www.race4-dcup.co.nz
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Andrew NZ  



Joined: 22 Jun 2004
Posts: 744
Location: New Zealand

PostPosted: Tue May 17, 2011 8:20 pm    Post subject: Reply with quote

I had to weld up some cracks around the top rear shock mount tonight. I've also made some brackets up for the other end of the bolt to reinforce the shock mount (because of the coil overs).

I've been working hard on the exhaust too, and now have a twin system all the way up to the rear axle. I've managed to feed it above the rear torsion bar carrier, so nothing really hangs down below the floor level (the advantage of having a raised tunnel and torque tube ).

I hope to have it all running again by the end of the weekend, but have a lot to do still. I've found a leak in the waterpump gasket amongst everything else too!
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Andrew
1977 RX924 rally car
12a bridgeport
www.race4-dcup.co.nz
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Andrew NZ  



Joined: 22 Jun 2004
Posts: 744
Location: New Zealand

PostPosted: Sun May 29, 2011 8:22 pm    Post subject: Reply with quote

Had the first drive with the new exhaust this afternoon. When I pulled up there was smoke billowing out from underneath Turns out that the flash "heavy duty" exhaust hangers melt when they get hot I'll have to redo them all with something different before the rally on Friday.

On the plus side it looks like the new exhaust is worth a few hp

Lots and lots to do before the rally now, but hopefully should get it all done in time.
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Andrew
1977 RX924 rally car
12a bridgeport
www.race4-dcup.co.nz
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Andrew NZ  



Joined: 22 Jun 2004
Posts: 744
Location: New Zealand

PostPosted: Wed Aug 10, 2011 4:23 pm    Post subject: Reply with quote

We've finished three rallies in the car this year now, and the bugs are slowly getting ironed out. The worse thing at the moment is the ignition cutting out for no apparent reason in the middle of stages. All I do is wait for a couple of minutes for something to cool down and it'll start again. I've tried just about everything - ignition switches and relays, fuel pump relays etc etc.

We swapped the two coils around at the rally on Sunday, which seemed to stop the problem for a while. When it did cut out again it didn't completely die this time, so it looks like we might be heading in the right direction (I think the trailing coil might have been still working). I'm going to replace the two coils and see if it makes a difference.

My crew also retarded the ignition a fraction and improved torque and drivability in one simple step
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Andrew
1977 RX924 rally car
12a bridgeport
www.race4-dcup.co.nz
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