K car build

[jull]

I started this build a couple of weeks ago since I don't have a shop or a garage to work in. Didn't have much time to work on it yet. I'm building it for a full weld show, although rules are probably pretty different than in US shows. I'll try to document the build as much as possible for those who might want to use it as a reference. I've managed to grab some pointers off the old wecrash but tips are welcome.

At the beginning, 87 Reliant fuel injected:



Where I'm up to, almost fully stripped, glass will come out when I'll start welding, and I still need to remove the heater core and some bits of carpet:







I plan to get rid of the bumpers and put stiffer ones on it. I can't put a full size bumper on it, so my best bet would be a Taurus bumper or a Caravan bumper along with bumper shocks. I also had good luck with a Volkswagen bumper. I'll see what's available at the junkyard at the moment.

I know these tend to be picky about the wiring, so I'll have to be careful when I'll remove some of it from under the hood. I'll probably run another fuel pump from the original because I had bad comments on them. The ECU will be moved, probably mounted on the firewall or somewhere else safe. I'll also move the coil, and some other ignition bits, passenger front wheel well isn't a good spot.

I'm not allowed to prebend, tuck or notch the rear, so I'll have to find a way to make it go up. I can't put allthread in the trunk either. So I'll probably mount the rear bumper higher than stock, and solid suspension are allowed so the rear will sit higher. It's not mentioned in the rules if I can reinforce the tierods so I'll assume I can.

I'll also modify the cv joints so they don't break at the first hit on the wheel. I'll run doubled tires in front and donuts in the rear. I plan to fully seam weld the car. Doors welded from the inside and the outside. I will also build a steel radiator, which will protect the front.... maybe... I'm still wondering if I build a custom shifter. Up to now I had bad luck with shifter cables.

Any other suggestions?

[jull]

I finished the wiring yesterday. It gave me quite a headache, to figure how to bring important stuff in the car. But all is well and the car still runs great. The wiring harness has been substancially reduced. The bare minimum remains. Some adjustments still need to be done, still a little messy.









I also got all the glass out and bypassed the heater core. I'll probably start welding this week.

[-KNAPPY-]

you get any more work done??

[jull]

Yes. I had to, the derby was Saturday. I was quite in a hurry, I barely had 2 weeks to get it done, so very few pictures.

Doors were completely welded, outside and the inside was welded with the outside. But if you get one of those definitely weld the inside too if you can.


I also got the diff welded. Chrysler transmissions are very easy to do



I also bolted all the inside panel from the hood and the trunk to the outside panel. I welded bumper shocks and welded a YJ bumper on (which hasn't been strong enough and was far below what was accepted)

4 pins were allowed to hold the hood in place. I also had a custom steel radiator built which will be shown in the aftermath pictures.

I used the stock shifter. I didn't put angled iron on the tie-rods and regretted it because it was allowed. One broke during the first heat.

I also had doubled tires, and solid rear suspension ( rapidly done, shock shafts were welded ) and both broke during the ride back home

The trunk barely moved during both runs. I dimpled the rear "frame" from inside the trunk, approximately 12 inches from the rear. And I cut the spare wheel well where I dimpled the frame and hammered it inside the best I could.



Once painted:

[jull]

Here are some aftermath pictures:











Steering column broke loose during 2nd run



Field repair:



Under hood shot with the steel rad



Bent frame rail



What broke:

tie-rod : really important, double them with rod or weld angle iron on them

CV joint : when the tie-rod broke the CV popped out and I lost some pieces of it, I had to put it back in because the subframe started to bend a little and I didn't have a replacement

Steering column : mounting points broke after a frontal hit. Ignition switch broke and the whole column was loose. Important to wire the car without using the ignition switch. And attach the steering column other than with stock points.

Besides that I think the car held up pretty well considering the car was underbuilt for that derby. If I knew rule were to be ignored like that I'd probably would have stayed home and kept it for another derby.

[jull]

I'll be working on the car for the next weeks, it will run on September 2nd.

What needs to be done:

Repair wiring, ignition switch went flying when the steering column fell on my knees
Build mount for the steering column, any ideas?
Replace broken CV with a beefed up one
Straighten the car
Double tie-rods
All-thread in the trunk
Weld the subframe on the car
Put a good bumper on it
Repair rear suspension (if I have the time, both shocks collapsed)
Is there anything to do with motor mounts?