It's Baaack..... return of the Rally Golf Pt1

**Bluerex** · 07-01-2007, 11:48 AM

After a truely painful 6 months, I finally have my MK1 shell back from Melbourne. I hereby formally retract and appologise for any and all un-charitable thoughts I may have ever had about the time it has taken. The work done by John Rawson and the other Tayel crew (hi Darcy!) is nothing short of breathtaking.
The most obvious is the roll-cage..

Then there is the 6mm alli plate used to reinforce the foot-wells. Remembering that I had some major rust in this area when we started, the plating (and the 30+ bolts each side) makes for a super solid floor.

More in Pt2...

**Bluerex** · 07-01-2007, 11:49 AM

And then there are the hours spent stich welding the engine bay and suspension points

The extra steel that has been added to the fragile bits

And on to Pt3

**Bluerex** · 07-01-2007, 11:49 AM

So I have lots of work ahead of me.. but what a boost to have the shell back with such a brilliant base to build on.

Charles.

**gumbootracing** · 07-01-2007, 12:04 PM

Looking good how far off is the expected completion date?
Ready for the Alpine in November Cheers T

**Oneofthegreats** · 07-01-2007, 12:07 PM

Awesome work!!!

Your not wrong about how much time would have been spent on the engine bay. Did they also stitch weld the steering rack mount's? I had a problem with mine cracking with uprated suspension & bigger wheels.

I'm suprised they didn't incorparate the cage to the front strut housing's & chassis legs & also bar across the dash support too.

**gumbootracing** · 07-01-2007, 12:10 PM

Post 2000 regs dont allow cages to be attatched to the forward suspension I believe its about progressive crumple zones T

**alex g** · 07-01-2007, 04:24 PM

looks great

i know all to well about seeming the bay but the results should be excellent

blackgti1.8 · 07-01-2007, 07:32 PM

Hey - great to see someone who obviously intends to use their Golf in anger (and on dirt)

Look forward to seeing it all come together...
Looks like the basic (time consuming) strengening is there now.

Have you (or do you intend) to seam weld any of the rest of the car? Gives the car tremendous rigidity when you do (lots of time though).

Some nice touches on the roll cage. Looks like a good strong cage.
You didn't consider adding a cross bar between the front legs, and/or bracing the front legs to the firewall? Shouldn't affect the crumple zones, but would give some extra strength.

I like the rear design - bracing the rear legs to the rear struct towers is good - that's where you need the rigidity. The double triangulation should stiffen things up nicely

Not sure if anyone else out does this, but foam-filling all the box sections is worthwhile too - keeps the water out, and adds more strength.
Make sure that you run everything that that you're going to through them first though

What are your plans for the car when it's finished?
It'll be good to get a core of members who are into motorsport...

**Bluerex** · 08-01-2007, 07:23 AM

Originally Posted by blackgti1.8

Not sure if anyone else out does this, but foam-filling all the box sections is worthwhile too - keeps the water out, and adds more strength.

The foam debate has been raging for years

. The final decider for me was that it tends to trap water and so rust out. Damn shame because the Golf side sills are just begging to be filled

but I just cant bring my self to do anything that will re-introduce rust after all the efforts to remove it.

As for asperations and goals, check out my photo gallery.
After all John's hard work, I am not planning on any further welding (did anyone notice that the windscreen, door, hatch and side window frames were all stitched as well?). So it is on to the painting stage now

c