E28 Rally Car Build

[IndyJim]

This probably isn't a common build, but I have a cherry 1985 E28 335i that we'll be turning into a full on rally car.

We need to have this complete with cage by Nov. 1st for our first event.

[328ischef]

Where is the rally?

I am a co-driver for a Saab rally team.

www.saabrally.com

[Skeen]

Rally is a stretch. Democross is the official term.

BTW, Jim, nice avatar-sized picture.

I'm going shitty car shopping tomorrow.

[danny325is]

Mike, i am guessing that Democross is a stretch.

It has been coined a High school beer party

[328ischef]

Dan, High school beer party is a stretch.

technically, its the most fun you can have with your pants on

[TheRedBaron]

There will be quite a few modifications as well, beyond just the "Jaffster" style cage IndyJim originally eluded to. Better lighting, aero improvements, seem welds in critical locations, exhaust work, etc.

[IndyJim]

This is serious build, we have a 3/4 model built for tunnel testing. We'll use that data along with some CFD work to determine the aeropackage.

There is talk of a new technology 'passive' turbocharging system along with some other unique innovations so stay tuned.

We'll also have a guess the weight contest and some other interesting things.

The picture had to be small our engineers didn't want the competition to see too many of the early enhancements.

[Matt]

High school beer party? Can I come?

I've always wanted to build a rally car. Not really to rally, just to jump off stuff.

[AirDoc]

Jim...u da man!!....can't wait to see that beast and more of the "unique" mods you cobble up (thinking of the "bxtch clip" access on the E30).

U got Geiger as slave labor??

[bdigel]

Dan, High school beer party is a stretch.

technically, its the most fun you can have with your pants on

who said they were going to keep thier pants on?? it is at Al's place

[328ischef]

This is serious build, we have a 3/4 model built for tunnel testing. We'll use that data along with some CFD work to determine the aeropackage.

I dont even think BMW had a 3 quarter scale model of an E28

[328ischef]

good Luck on your first rally.

REmember, things can go from this


To this


all too quickly.

dont skimp on the cage.

We rolled our car and the cage didnt flinch thank god

[IndyJim]

We'll be using a new impact absorbing foam to add protection to the state of the art cage.

The course will also feature a jump so we'll be spending a lot of time on the skid plate, various reinforcements, and exhaust placement.

[TheRedBaron]

U got Geiger as slave labor??

I prefer the term race car engineer and chief fabricator.

[IndyJim]

Our first build goal was to get the car to run. We accomplished this early in the day and moved onto prepping the chassis for the cage. Also took the time to mount some extra 'rally' lights to the roof. We ran the numbers and the additional lumens will be worth the aero drag for the night stages.

[IndyJim]

Well it appears that the master cylinder is shot - hence the 'no brakes'. We'll probably have to invent something since a new one (or even a used one) is money that can't be spent on a sneaky pete NOS system.

Special thanks to the FI forum for not helping me figure that out. Thankfully I've learned not to rely on forums for creative problem solving.

In case someone is curious - Summit Racing (who has its HQ like 30 min. to the south of ATL) has two or three NOS options that should do the trick. Search on 'universal' fit and dry. Engine damage is on you. Hopefully we have the budget instead of buying lame stuff like 'brakes'.

Vitamin "S" is good for your engine.



Secret Race Shop Location 2 - note the cherry xmas tree is for show only, the car smells like a moldy carpet, B.O., and really old gas.



More details on my blog - http://www.dtomracing.com

Really the same details but written differently (more or less).

[IndyJim]

I think this pic will tell you all you need to know. Also a charity MC is in the mail so we may have brakes too!

[IndyJim]

Master Cylinder arrived today so brakes are looking like they may work for this event. Also took some time out for decoration, and completed phase 1 of the rear bumper.

Enjoy - as always somewhat different details on the blog.

[328ischef]

making good progress! what rally are you participating in? We were going to run Rally New york on Halloween but we've been delayed so we are heading north to one in Nh or Canada in Novemeber. Keep up the good work!

[vmwerks]

We'll be using a new impact absorbing foam to add protection to the state of the art cage.

The course will also feature a jump so we'll be spending a lot of time on the skid plate, various reinforcements, and exhaust placement.

Use an airbag steering wheel and replace the airbag with a can of expanding foam...

[IndyJim]

I guess 'rally' is a bit disingenuous it is more like a rally mixed with a demolition derby mixed with guns, fire, and alcohol. But there will also be a jump. It isn't really a 'sanctioned' event. More like an underground movement. Democross is the best term we can find to describe it.

[vmwerks]

I guess 'rally' is a bit disingenuous it is more like a rally mixed with a demolition derby mixed with guns, fire, and alcohol. But there will also be a jump. It isn't really a 'sanctioned' event. More like an underground movement. Democross is the best term we can find to describe it.

Alot like Saudi drifting?

[IndyJim]

Well mundane things like 'having working brakes' keep cutting into fun things like 'build an exhaust that shoots flames'.

Good news is that after two junkyards and a charity master cylinder (wrong one), we finally found the parts we needed for the grand total of $15 in parts and admission, probably $40 in gas running around, and 4 hours of driving / walking through junkyards.

The whole team is feeling the pressure since its seems a remote possibility that Jaffe may finish his car before we complete ours.

An important build note - not one measuring tool has been used to date. Democross is more art than science.

#$@%@$ hydraulically assisted brakes! More details and pics on the blog.

Notice "Tag Applied For", I'm sure the cops would appreciate that 'nod' to being legal. It went on another test drive this morning to confirm the function brakes.

[IndyJim]

It is disappointing but I think we've completed the democross car. There may be some quick 'style' updates but the heavy lifting is done. The master cylinder search took too much time away from the 'goodies' section. But we have a long list of things for next year and more time to find them cheaply like: NOS system, musical horn, smoke screen, flame shooting exhaust, air bags, exhaust through the hood, etc.

Still have a few more minor things to come that we'll document, as well as its first event.

And since I know how everyone on this forum is an expert welder and LOVES!!! to critique welds, a close up shot just for all of you. Looks like bird poop to me, but maybe that is by design? You'll never know.

[Skeen]

Is that the new SE28 exhaust? That will definitely fall off when you put it on the trailer.