rallybrick
Member
- Joined
- Jan 12, 2007
- Location
- People's Republik of Socal
(Photo by Me; Backyard following Rim of the World Rally 2007)
Some tongue-in-cheek BS to start things off with...
(I will be updating as we go along).
Consider this an evangelizing thread about rally and RWD's proper place in it (sideways, full opposite lock, that is).
I was a little apprehensive about posting the history of such a car in the “Showroom” thread as this car isn't beautiful – it was never meant to be. It's not the fastest thing on the road, but it's tough and reliable. It won't turn a ? mile in 12's, but it'll do 100 mph in a drift on a fire road with a sheer wall on one side and a 1000 ft dropoff on the other without flinching (the driver, maybe not so much). It's not the most expensive build, either, but it's more important to last a season of hell than a single event of bliss – and the logistics of running races costs money outside of car prep. It's not nicely painted because you're just going to sandblast it with gravel anyway. There's no money in rally, so the less you spend on pretty parts, the more you can spend on go fast bits, unbreakable **** made out of unobtanium, and beer for your volunteer crew. What it is – is a mean bitch with hell-on-wheels determination to do one thing – haul ass on gravel. This ain't a garage queen here – this is the SOB that came in and roughed up your garage queen, made some snide comments to that AWD poofter in the corner, slapped your FWD econobox in the forehead on the way out, and then took off to go have fun with its buddies, tear-assing out in the forest.
It's kept together by souls who will go to the ends of the earth (literally) to spend hours shivering in the dark and the rain or the heat and the dust waiting for the opportunity to wildly thrash on the car for a few mins when you come in for a service break, even going so far as to use a BFH or a truck and a chain to get something more-or-less “realigned” so that it will drive and you can finish a race. Precision? Not always. Blood and Guts (ala Patton)? Yes. This invective applies to body panels as much as axles. It's broken more stuff in a season than most daily drivers will their entire lives.
It's been nosed in, spun out, high-centered, pushed, pulled, towed, yanked, jumped, broken, bounced off of rocks, caught fire, overheated; had its metal torn, suspension ripped off, glass shattered; and eaten alternators like they were jerky. Remarkably, it's probably been less abused than John Lane's 260 rally car.
Unthinkable things have been done to this car in the name of Victory at all costs (or at least “finish” at all costs). Innovative and shameful things. And it has the scars to prove it. It has worn many shades of duct tape like bandages, zip ties like sutures, and ratchet straps like transplanted ligaments after bare knuckle brawls against nature it has both won and lost. And yet it survives another day to taunt those made of a lesser fabric. Each time it drifts past a group of spectators waiting in the forest, they are titillated by the spectacle of the “way of the side”. As it lurches past them in a cacophony of growls, snorts, gravel spray, and dust – it makes mothers shiver, old men cry with joy, fair maidens blush, and young men shout with wild bloodlust.
It is the RallyBrick.
You've been forewarned.
<hr>
(Photo by Ben Simpson; North Nevada Rally 2008)
“RallyBrick” is a purpose-built gravel rally race car that is currently intermittently campaigned in the southwest through the California Rally Series. RallyBrick has also been known as the Valencia R Sport 240 (the original). Calling it a brick is an understatement given its staunch build and considering that the car has endured 87 documented rallies over approximately 15 rally seasons (and counting). Most other rally cars generally have a lifespan of 30-40 rallies before they literally fall apart.
RallyBrick's current configuration includes the following:
Technical Specs:
Chassis:
Originally a blue (non-metallic) 1980 242 DL
Full roll cage (currently NASA Rallysport spec/logbook)
Chassis seam welded and lightened
Integrated receptacles for custom pin-stands (in the rocker panels of all 4 corners) for quick up/down in service
Side and rear windows replaced with Lexan panels
Custom roof vents (the damn things are worthless in the rain)
Aluminum hood vents and intake port
Spare tire wells (“butt cheeks”) removed for clearance
Custom 6061 aluminum skidplate (it's HUGE – about 4' long and responsible for much of the nose-heavy attitude in jumps)
Lots o' HDPE underbody production and LDPE mudflaps
Custom, overbuilt rear tow hook from hell
Engine:
Ported 531 head
Grp A cam (from SAM)
Double valve springs
93 B230FT bottom end (nothin' special – to be replaced eventually with a B21FT block bored to 2400 w/SAM Group A baffled oil pan)
90+ ported/matched exhaust manifold with EGT sensor port
Homologated Group A AiResearch turbo (50mm inlet) (had ETCC track time before it was returned to SAM)
SAM Group A oil feed line
Avalanche Performance Tuning underdrive crank pulley
91+ PS pump directly driven from crank pulley
100 amp alternator
Hallman Boost Controller (manual)
Boring old OEM turbo external oil cooler
Bell custom aluminum intercooler
Ron Davis Racing custom aluminum radiator
Spal electric puller fan; Auxiliary electric pusher fan
SAM heavy duty competition rally engine mounts
Custom chipped LH 2.4 EFI from B204FT (minus the TCG) with custom factory-built harness
960 3” AMM
Blow off valve recirculating to turbo inlet
Custom 3” mild steel exhaust (with high-flow racing cat) – mild steel because it will be pelted with rocks and bits of it torn off anyway – why go stainless?
Driveline:
Flat Bosch 60-2 flywheel
ClutchNet custom 6-puck clutch & red pressure plate
Vintage Performance modified bellhousing and T-5 adapter kit
Ford Racing T-5Z WC transmission w/short-throw shifter
Hurst Shifter with cueball (awesomez)
Custom trans mount (directly to floorpan – for function, not comfort)
Wenco custom driveshaft with custom supports
Dana 1031 rear end with Eaton Detroit TrueTrac LSD
4.10 rear end gearset
Brakes:
Dual Girling brake master cylinders
Tilton brake bias balance bar system (modified OEM brake pedal)
Custom hydraulic handbrake
Standard ABS-model 240 Girling front calipers
Standard 240 ATE rear calipers
Zimmerman cross-drilled front rotors (dumb idea due to rocks having a tendency of getting stuck in there)
Pagid racing pads
Goodridge steel braided lines
Cabin/Electrics:
R-Sport gauges
Terratrip 303 rally computer
Peltor FMT-110 rally intercom (separate FMT-100 backup)
Custom dash w/700 series center-mounted fusebox (yes, we've held aluminized gum wrappers in there to finish rallies before)
122 blower motor/fan box
2 x 10 ABC Amerex fire extinguishers
SFI/BSCI approved roll cage padding
Optima Red Top battery (relocated to center of cabin)
ATL 12-gallon fuel cell (relocated over the rear axle)
Holley red body pre-pump
140 washer bottle
Custom trunk spares accessory box (space for med kit, spare bottles of brake fluid and motor oil, triangles)
Freaking air horn!
Icom dual-band HAM radio (occasionally)
Safety/Comfort:
Momo Corsa steering wheel
Cobra racing seats
Schroth 6-point 3” racing harneses
Sparco co-driver's footrest
Customized $14 Pep Boys cargo net for helmet storage during transits (Sparco helmet box pwnd!)
Suspension:
Boxed A-arms and trailing arms
Poly bushings and some remaining SAM nylon bushings
Front: JVAB 40mm front coilovers w/custom valved Bilsteins
Custom aluminum upper strut mounts w/GT reinforcing plates
Custom strut tower brace
Custom uniball tie-rod ends
Rear: SAM progressive rally springs
Sellholm Tuning custom rally-valved Bilstein shocks
Small swaybars or none at all (we're on gravel)
Exterior/Tires:
Custom removable rally light pod
Hella Rallye 2000 driving lights
Hella Rallye 4000 cornering lights
Silverstone or Michelin rally tires (usually 16/65-15's)
740 Diesel rims with spacers and customized lugs
Tons of character
Jetzt, mit Streifen - nicht Crayola erbrechen!
Fluids:
Cooling: Distilled water with Water Wetter (USFS regulations)
Oil: Mobil 1 synthetic 15/50
Gearbox: Mobil 1 ATF
Diff: Motul or Redline
Driver: 15 year single-malt Highland or Speyside (Glencadam preferred) or IPA
Co-Driver: Anything in a silver can
To be added:
Federal Signal Corp/Whelen 100w PA system (for the “Romeo Foxtrot, shall we dance?”)
Adjustable torque arms with Heim joints
B21 bottom end (bored to 2400) with SAM Group A baffled oil pan
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