R5 Turbo Replica build

[GeoffBob]

I couldn't resist doing this for a bit of fun. Anyone who want's the dimensioned CAD file, let me know and I'll post it. The colours are black on white on yellow. I began by marking out the white area on the yellow with a water soluble pen and then masking off the yellow with sign-writers tape (don't use masking tape, the paint seeps under) and paper. I then marked out the black area in a similar fashion after the white was dry. Of course there was the usual colour-sanding between coats, etc. The roof is finished off with clear-coat.

I just spoke with Wil Falkener of FastCarSpares and I am pleased to report that my body panels have at last arrived in the UK!From there it's the long trip south to SA.

 

[GeoffBob]

My panels in the UK, picture courtesy of Will Falkener.

I chose the Maxi front bumper since it is the one which I can most easily modify to accommodate my front mounted intercooler. I shan't be using the two spot-lights and will most likely close these off in order to present a smooth front facia. I will also have to cut the bumper into two halves and widen by about 100mm in order to accommodate my wider front track width. This will also provide the wider mouth required for the intercooler. I'll then use this as the prototype bumper from which I will take a mould in order to produce further bumpers. The finished product should look something like the R5 IMSA GTU bumper, but with a gaping hole for the intercooler.

Due to the uniqueness of the front of this car I will have to manufacture my own glass-fibre bonnet and front fenders. I'll build prototype fenders from mild-steel sheet and plenty of bondo (to get the shape), and then take moulds in order to produce my own glass-fibre fenders. Quite a process for a pair of fenders that will be of no use to anyone else, but worth it since I figure these and the front bumper will be the first pieces to get banged around on the track and I want a ready supply available locally. I could do the same for the other glass-fibre parts, but it is not my intention to do anyone out of business. Obviously I have to do it for those parts that are unique to this car.

I have yet to figure out how to do the bonnet, but I will probably just replace the mild-steel skin of a standard bonnet with glass-fibre.

 

[GeoffBob]

I spent the weekend welding the body to the frame. I hope I got it on straight as it won't be coming off again in a hurry.

After discussions with Jan Morgan I have decided not to fix the position of my engine and gearbox until I have the full weight of the car (including doors, windows, etc.) over the frame. I'll then place the four wheels on scales and adjust the position of the engine, gearbox and other ancillaries until I achieve the best weight distribution possible without rendering the car mechanically impossible (it would still be nice to change the spark-plugs without having to remove the dashboard, if you see what I mean). This decision thus puts an end to my initial plan of having the engine dyno tuned on the rolling frame, and then puting the body over the frame. For the mean time the engine will remain in the garage wrapped in plastic, but its call to action will arrive eventually.

My next job is to start building the rear wheel-arches in anticipation of the arrival of the rear fenders.

 

[Nate]

Superb Geoff. looks fantastic.

If i didnt have a 5, i'd be putting an orde in

 

[GeoffBob]

Thanks Nate, I'm glad you like it.

I won't be posting anything more on this project for a while. There's not much more that I can do until my panels arrive. Latest news is that my panels are at sea and scheduled to arrive in the Port of Durban around about the end of July (if the ship doesn't sink). I should get to pick them up in Jo'burg around the beginning of August if all goes according to plan (which it rarely does). My front suspension parts are now two weeks overdue and, quite frankly, I've been pushing it too hard on this project, working both weekends and evenings. I think, therefore, that it is time to take a break before the panels and suspension parts arrive and I get busy again.

 

[GeoffBob]

Added a new tool to my collection. I'd been wanting an AC/DC inverter for a while now so as to be able to TIG weld Aluminium. My last machine was DC only and thus only good for mild and stainless steel. I'll be doing the floor and firewall from 3mm Aluminium tread-plate when I eventually get that far. I might also consider doing the door and bonnet skins in aluminium plate if all works out well with the floor. For the mean time I continue to take a break from the project.

 

[GeoffBob]

Wouldn't be right to badge my project as an R5turbo, so I've had to come up with something different.



The version with the "o" (for example, as used in "Oberleutnant") is grammatically more correct than with the "ü", although the word "über" has been somewhat accepted into the English language and is synonymous (although incorrectly) with the word "super".

What comments?

 

[Michael]

Of the two I prefer the second one. Or why not get some side stickers made up in the TURBO2 font but worded something like?

ÜBER5
SUPER5
TURBO5

 

[GeoffBob]

Thanks Michael, I like that idea. I'm also leaning towards the second one, although I think I'll put the "R" and the "5" in line with each other, somthing like this maybe ?? I think this would look good on the side and possibly across the top of the back window. What sayeth the jury?

 

[ejk]

---

 

[GeoffBob]

The front suspension components finally arrived. I am now using Koni adjustable dampers from the Toyota Corolla (I have no idea what model) with 50kg/cm stiffness, 200mm long, 60mm ID coil springs. It is a fairly simple procedure to cut off the old spring-seat from the E30 strut and weld in place a threaded tube over which screws the new spring seat. I have also installed adjustable camber plates with spherical bearings rather than the usual non-adjustable rubber mounts as used on the E30. Thus, the front suspension is now more or less (with the exception of castor which is fixed at 8 degrees) fully adjustable. I still haven't decided what to do on the rear of the car.

 

[ejk]

Sorry, no offence intended. Check pm.

 

[GeoffBob]

Well, as I said in one of my previous posts, nothing ever goes according to plan. My cargo of glass-fibre body panels was late leaving the UK and is thus only scheduled to arrive in Durban in about 10 days time. You can track the progress of the container ship MSC Olga by following this link:

http://www.vesseltracker.com/en/Ships/M ... 02580.html

Last time I checked it was just off the coast of Mauritania.

Other news is that in terms of SA law I'm not actually allowed to import these parts. Given the value of the cargo customs and excise "assumes" that I am importing for the purposes of resale, which I am not allowed to do since I am not a registered importer. I am therefore required to pay a visit to our local receiver of revenue and register myself as an importer of car parts. I am told that so long as I explain my position and that the goods are not for resale it will not be difficult for me to obtain a "once-off" permit thus enabling me to get my cargo through customs. Seems reasonable under the circumstances.

 

[GeoffBob]

I have received confirmation that the MSC Olga will dock in the Port of Durban on the 15th of August 2008. My shipment of R5 turbo panels should arrive in Jo'burg around the 18th to 21st.

 

[GeoffBob]

The container ship MSC Olga (carrying my R5turbo panels) docked in the Port of Durban on the 16th August, one day later than expected. After the container has been offloaded it will be railed to Jo'burg, where I hope to receive my panels by the 22nd. All of the red tape with regards to the importation of these parts has now been cut through and cleared with customs. Turns out I am allowed to import these parts after all. The value is well below that which would classify me as importing for business purposes, and I would have to import parts at least 3 times a year before I showed up on the customs radar. With that said I still wasn't impressed with the customs duty, VAT, postage and petties, stamp duties, warfage, cleaning, blah blah blah and you-name-it-we-got-it fees that I had to pay. Cost me an arm, leg and a buttock to get these things here!

 

[GeoffBob]

I have manufactured the rear wheel arches from aluminiun tread-plate. It's great to be working with aluminium as it is light weight, easily formed into shapes (malleable and ductile) and easy to weld when you know how. A 1.5m by 2.5m sheet of this tread-plate weighs 17kg, and there's a lot you can do with one sheet. It should take about three sheets to do the firewall, floorpan and wheel arches.

The outside edge of the arches will be trimmed to follow the contour of the inside surface of the glass fibre panels. The tyre facing surface of each wheel arch will be primed with an aluminium etch primer and then rubberised to protect against impact damage from stones.

 

[GeoffBob]

Feeling rather pleased with myself as I collected my glass fibre panels today. It's been a long wait, but worth it. I'll start trimming the rear wheel arches and fitting the rear fenders this coming weekend. In the mean time I couldn't resist resting a few bits and pieces in place for a photo opportunity.

 

[Nate]

drool drool drool....

keep it up!

 

[ejk]

awesome.

 

[GeoffBob]

Thanks guys for your comments, I'm glad you like.

Maximan, I've PM'd you with regard to the front track-width on the Maxi5, I need your help.

I was under the impression that I would have to split my Maxi5 front bumper down the middle and widen it by about 100mm to accommodate my wider front track-width (1450mm). Turns out it fits a treat, but I can't understand why? Anyone know whether the Maxi5 had a wider front track-width than the other R5turbo's, or maybe it had deep-dish front wheels that accounted for an extra wide toe to toe measurement and thus an extra wide front bumper. This would explain why the Maxi5 bumper fits my car? If this is the case then it means I may be able to order the Maxi5 front fenders to fit my car as well, instead of having to make my own to fit my obscure measurments. I measure about 1.64m from outside edge to outside edge of my front wheels (steering forward).

Anyone who knows the answer to this one, I'd appreciate your input.