Got the shell upright again today. Luckily got a hand or this weighty piece would have rolled all the way round
A dude from my local garage has taken a unit next door to Hardwired HQ to work on his kids' banger racers, so it's awesome when you need an extra pair of eyes, or hands on a Sunday afternoon as in this case, or the voice of some extra experience... as always the people you have around make all the difference
I've propped it up with a stack of wheels and a bare tyre on top just to take some weight and keep it steady.
It looks like the welds underneath burnt in alright, so that's cool. Even some of the snottier looking ones are still well
On the shell welding, and me claiming they're often ugly and it's not just me being a bodger... this is a legit £200k+ Alfa touring car pictured below. If I'd done that on new clean metal with a factory motorsport pay cheque I'd be disappointed with myself haha, so I'll count the guff bits on the dirty old rust and sealant laden Rallye as "all good"
I've got more pics of rough 'uns on cars ranging from Frazero's Golfs (top-notch, ultra-competitive, excellent machines), Prodrive's Mini WRC, McLaren's E36 BMW STW to VWM's own Rallye to make me feel better about it too, so we'll chalk it up to it's just a sh*t job to do and 'function over form'. Not here to call out anyone who's proven their worth a hundred times over, just saying, it's all relative and prettiness isn't a priority
Anyway, negatives and bodge-dodging aside... I decided that although it's FAR from the time, I'd start to have a look at the loom. The ignition coil section is actually not for this, it's for converting the Mrs' Corrado AGU 1.8T to NGK R8 coils over winter, but just using for measurements. The injectors, throttle position, intake temp, crank position, oil pressure and coolant temp bits are all laid up.
I've started making a kind of 'mock' loom first just soldering bits of 24 gauge solid core wire together and labelling what each offshoot is for as I go, and it seems to be a nice easy way of doing it if you're ever making one from scratch. Although there's a little more hands on labour I prefer it to just measuring up and making the loom off of numbers on paper.
I pikey'd out a little and re-used some old rubber boots which I cleaned up, which aren't strictly needed anyway as I use adhesive filled heat shrink at ends and junctions and of course the connectors all have weather seals in the back of the terminals, but I like to add them to tidy it up and as an extra measure.
Got my dash and fuse boxes and whatnot, a handful of switches and buttons for the dash, blah blah
Then got to a loose end, waiting for a Mk2 to be collected, so looked through a box of BTCC electronics from the mid 90's super touring days that a mate dropped off recently.
Almost overwhelmingly tempting to use a load on the Rallye, but I already have a new DTA SX Dash seen above and will be using a DTA S60 ECU.
I have always been a big fan of DTA kit, as the first car I ever wired up had an R32 with a DTA S80 ECU, and I've had an E48 EXP and an S40 myself previously. Personal bias, along with DTA's support and my local mapping options, oh and Alex who owns DTA being a good guy with a history of VW's, makes the switch to tired old Bosch stuff purely for motorsport-kit cool-points pretty much plain stupid
Plus it'd be nice to reunite some of it with the original cars.
Anyway, ECU, Dash and Shift Light, oil pressure sensors, data loggers, lap timing equipment and some other bits etc
Simple things please simple minds I guess, not that Bosch Motorsport stuff is simple, but simply being near any bits that have helped a Super Tourer go out and be awesome makes my day