Stage car build- It's really happening this time

Documenting your big project with photos/videos? Have photos/videos to share of anything Merkur related? Place your links to photos and videos here. Please - Merkurs and Merkur-related pictures only. Cosworths welcome!!
Carlisle and event related pictures are to be placed in the relevant section under 'Events'.
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Goumba
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Stage car build- It's really happening this time

Post by Goumba » Fri Jun 03, 2016 11:03 am

I've got a team with sponsors, co driver, some parts, the car, all the metal fab stuff and a shop to do it in, DOM tubing, and most of all the ability to complete the car. I work on a few stage cars a year making cages, setting up suspension and also building it from scratch, and I'm also a rally driving instructor at the FIRM. It's time I build my own car and go rally! Finishing touches will be made to the ramp truck this weekend and I'll be able to pick the car up from storage. The build will begin immediately.

Plans for the car are pretty simple to start. The goal is to keep it relatively cheap without cutting any corners so that it can get it's log book and first stage rally done this year. Chassis work and the stage cage will hopefully be done by the end of the month. I picked up some brake brackets for bigger front and rear disc conversion. Suspension is one of my specialties and I'm still unsure of the front. I think 87-93 mustang spindles will give me the shock fitment I need for longer travel and easier fabrication for 46mm dampers. That will be the second to last thing that I complete.

The last mystery is engine choice. I have a SVT 2.5 laying around, but I'm leaning towards not using that. It is nice and light and sits a little further back than a 4 cylinder. It would probably be around 180hp and torque to the ground, but I wonder about it's ability to grow with me as far as power, reliability, and potential replacement after I explode it.
Second is a version of the motor that's already in the car. The roundy round guys get 200+ whp out of the lima motors without a turbo. That would keep the car in G2 and open 2wd light to start me out.
Third choice is a miata motor. I have one that is great, already has a megasquirt tuned for it, makes about 160whp, and is reliable enough to compete in several 24 hour races without any problems at all. Replacement parts are cheap and everywhere and it would look right at home with a escort GT valve cover that had Ford casted into it.
A duratec 4 cylinder would be my preferred choice, but I'm not sure I want to sink that amount of money that it would take to get a competitive one in the car at this moment.

More power, better brakes, and other unnecessary stuff like lightweight hood will come at a later date. After Snow Drift but before SandBalst probably. As soon as I get back to the car next week, I'll post some photos of me loading onto the truck and keep updating this thread. If all goes well the cage will start going in as soon as I get back from Magnum Opus.
1991 Miata-2015 SCCA rallycross champion Mod Rear
2005 RX8
1986 XR4TI
1996 F350
1997 Impreza coupe

John Lambert

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merkurdriver
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Re: Stage car build- It's really happening this time

Post by merkurdriver » Fri Jun 03, 2016 2:57 pm

looking forward to the build

cmouta
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Re: Stage car build- It's really happening this time

Post by cmouta » Wed Jun 08, 2016 11:53 am

hey get back to your AWD contour build!!
Chris
1988 Mono Rosso Red Merkur XR4Ti - Sold!

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Re: Stage car build- It's really happening this time

Post by dunhamr1 » Tue Jun 14, 2016 5:15 pm

Looking forward to the build as well! Saw the Merkur that Dave Clark has at Idaho last weekend, took the 2wd win and 4th overall with a new fiesta ST motor (250 hp, 350 ft-lbs). He ended up taking the hood and the lower bumper off because it was overheating. Great to see it out there though!
-Ryan Dunham
1989 Merkur XR4Ti - nickname: "SheaXR4"
Daily: 2016 VW Golf R "Matti"
E-Street Autocross car: 2001 Mazda Miata
Old daily: 2003 VW Golf MkIV TDI, 200k+ mi

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Re: Stage car build- It's really happening this time

Post by catapultkid » Tue Jun 14, 2016 6:08 pm

Sounds like a fun build, 200hp NA 2.3's are screamers and lots of money in rotating parts to build from my understanding, but so are 160whp miata motors.

"I think 87-93 mustang spindles will give me the shock fitment I need for longer travel and easier fabrication for 46mm dampers."

This is my idea as well for a autox/track/street car. Will be nice to bounce ideas off of someone to problem solve along the way.

-Paul
-Paul
'85 Merkur XR4Ti
K20, VW mk2
'89 K2500, 6.0 swap
'00 Honda Insight

Goumba
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Re: Stage car build- It's really happening this time

Post by Goumba » Tue Jun 21, 2016 12:00 pm

After going to Magnum Opus rally last weekend I'm even more pumped to get this build started. There was even a XR4Ti competing there. The only problem and first delay is getting my old truck started. After sitting for about a year and a half it doesn't want to cooperate. Very soon I'll be picking up the car and getting it built. Pictures and video will be soon to come.
cmouta wrote:hey get back to your AWD contour build!!
No way! I was done with all the custom fabricating on that thing and was definitely more than 90% done with it when I couldn't justify putting any more money into it. That was a great learning experience and I left it at that.
1991 Miata-2015 SCCA rallycross champion Mod Rear
2005 RX8
1986 XR4TI
1996 F350
1997 Impreza coupe

John Lambert

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Re: Stage car build- It's really happening this time

Post by John V » Mon Jun 27, 2016 3:16 pm

You might want to charge up the phone, get a pad and pencil and call the guy that has supplied all the active Xratty rally cars for the last 20 years..Or--for fawks sake go up to NC and buy Matt Smiths car aka Mothra

http://www.rallyanarchy.com/phorum/read.php?7,110540

1985 Merkur XR4TI Rally car - $8,000

Full specifications below but for full disclosure the car will need to have door gussets installed in the cage to be rally ready. There is a small oil leak at the turbo drain line that needs to be sorted. The usual body and paint issues associated with a rally car that has been raced. I can add a car hauler with tie downs for an extra fee to make this a turnkey rally package. Car and trailer titles in hand.

Body/Interior
Bumper mounted light bar with 2-hella 500 and 2-hella 4000
Full roll cage tied to front and rear suspension points (SCCA log book)
Front skid plate
Bumpers from 1989 model
Side cladding removed and all holes filled
Lexan rear side and back windows (door windows glass with electric windows retained)
Custom roof vent
Sparco pedal covers
Momo seats
5 point harnesses (expired dates)
Grant steering wheel and hub
Custom dash with VDO gauges
All AC components removed (stock heat/defrost retained)
Battery (optima red top) relocated to center of car
Spare tire mount
Jack mount
Terra trip intercom
Alpa pro rally computer

Suspension
JVAB Coilovers
Nylon steering rack bushings (MC2)
Powerflex TCA bushings
Powerflex front sway bar bushings (stock sway bar)
Nylon semi trailing arm bushings
Solid mounted rear beam (MC2)
Solid mounted rear diff (MC2)

Driveline
custom 3 inch exhaust (turbo back) - dented, etc
Stock internals 2.3 turbo engine
Recently rebuilt stock xr4ti turbo
Stinger Performance turbo drain line and flange
Stock T-9 (shifts smoothly)
SPEC Stage 2 clutch
Ford Ranger starter upgrade
Walbro 255lph fuel pump upgrade
Stock open rear diff (installed)
40Bob ported and polished upper and lower intake
2wd cosworth front mount intercooler
Saab 900 radiator with dual fans
Volvo coolant overflow tank
Turbochuck polyurethane motor and transmission mounts
BAT short throw T-9 shifter
LA3 engine computer with Large VAM

Brakes
Stock brakes
Master cylinder/booster upgraded to 1989 style
braided stainless steel brakelines

Wheels and Tires
4 - Speedline 15x6 with Hankook Ventus RS-2
11 – Saab 9000 15x6 with assorted well used Michelin gravel tires installed (4 good tires)

Extras (not installed)
Assorted spares
Near new 1985 style brake master cylinder and booster
Stock diff welded
Supra LSD
Supra open diff
New stock turbo with wastegate and cosworth exhaust housing

Stock dash
Stock rear sway bar with stock bushings


Matt Smith

Racing in glorious black and red

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Remember: "a good plan today, violently executed, is better than a perfect plan tomorrow" George S. Patton

"It is the stingy man who pays the most" Old Italian proverb--100% verified true. especially in racing.
John Vanlandingham
Sleezattle WA USA
CALL =-> (206) 431-9696 <-= CALL

http://www.rallyrace.net/jvab/

Goumba
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Re: Stage car build- It's really happening this time

Post by Goumba » Thu Jun 30, 2016 4:53 pm

Wow! At $6500 I should really just put my car off to the side in the event of a bad off and get that thing. It seems that he hasn't been responding to emails in the past few days. I'll still give it a try. hanks for the lead John V! I don't know why I haven't checked the SS or RA classifieds for one first.
1991 Miata-2015 SCCA rallycross champion Mod Rear
2005 RX8
1986 XR4TI
1996 F350
1997 Impreza coupe

John Lambert

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