Virginia Motor Sport Club Discussion Forums

General => Open Forum => Topic started by: catapultkid on March 27, 2013, 09:58:57 AM



Title: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on March 27, 2013, 09:58:57 AM
Since I hope to have this thing out in a few events from now I figured I'd share the experiences we have had with this car.

Last October Mindy and I had the discussion about not using her car any longer for autox. About that time she was also interested in learning other aspects of motorsport so we started to hunt. She had 3 or 4 cars in mind, and when it came down too it this, being one of the rarer choices also became one of the cheaper. Not enough people know about these cars to appreciate them so we picked this guy up for "cents on a dollar".

It wasn't without faults but the PO was an original owner to the vehicle and after a short test drive we closed on it and drove it 150 miles home.

(https://lh5.googleusercontent.com/-BPdgPhqGrWc/UIxPrn3kBKI/AAAAAAAADHc/9Eb4rjBFPEk/s1663/2012-10-27_16-58-02_946.jpg)

(https://lh6.googleusercontent.com/-gEkGdioN4xA/UIxPrrl5QVI/AAAAAAAADHc/LmM3aOEz3No/s1663/2012-10-27_16-56-47_651.jpg)

The car came with a basement full of spares and enough upgrades to make it an ok autox/track car.

The interior was also not in bad nick for a 27 year old car.

(https://lh4.googleusercontent.com/-ERDpF9h8oaI/UIQ_HXQ8ycI/AAAAAAAADBc/p8h-l4WoXP8/s1663/2012-10-21_14-23-06_380.jpg)

From here I have to mention that this thing is meant to be a budget car for us to share in the coming year or so and pull double duty between drift, autox and the occasional track day/time attack. At least until the other mk2 VW is finished.

The first autox I think I placed somewhere at the bottom. The tires are old hard snow tires, the suspension is way too soft even with the struts at full dampening, the power comes on way too slow with the stock 1985 turbo, there was some jumping around on left handed turns, the brakes to nothing what so ever and it feels like the car weighs 5000lbs. I know, racers excuses.

First up was the easy stuff. Steering rack had seen better days.

(https://lh5.googleusercontent.com/-N84yGyOgn0U/UIXVGtPXa4I/AAAAAAAADGA/V4ZLrdRDlN0/s903/2012-10-22_17-39-11_772.jpg)

Made a 2 dollar catchcan for the rear diff so it would stop leaking oil all over everything.

(https://lh4.googleusercontent.com/-wHbJytpNmLw/UJe3U9WVAFI/AAAAAAAADM8/LGx9YVAkhH0/s1014/2012-11-04_15-02-33_776.jpg)

Relocated the wideband gauge

(https://lh3.googleusercontent.com/-b1lMzcKJsUs/UJe3U86a8QI/AAAAAAAADM8/wU46UQtHfwg/s572/2012-11-04_15-03-39_163.jpg)

Found out that the passenger side bushing was wore plum out

(https://lh3.googleusercontent.com/-JReqm49NSL8/UKDoZtdwE-I/AAAAAAAADUg/aVM94kbj1jo/s903/2012-11-09_16-25-50_454.jpg)

Made some with some stuff I had lying around

(https://lh3.googleusercontent.com/-a_hY6QxnEgY/UKDoZrlqvzI/AAAAAAAADUg/jFYHNiPKx4g/s903/2012-11-09_16-07-23_558.jpg)

(https://lh6.googleusercontent.com/-oXE5LQXZANY/UKDoZmM5QyI/AAAAAAAADUg/s99scWlKPkc/s903/2012-11-09_16-09-49_875.jpg)

Then offset the LCAs up and out for a little added camber and better geometry.

(https://lh6.googleusercontent.com/-c-dF-mHlVpA/UKDoZq4LEDI/AAAAAAAADUg/Lj8gCGg-tmU/s903/2012-11-09_19-44-56_812.jpg)

The slow spool time was sorta due to this restrictive cat, so I cut all of it out and replaced it with a cut out.

(https://lh5.googleusercontent.com/-1-s9KNGosjY/UKDoZtTQ5BI/AAAAAAAADUg/Kg8WrmlMmnE/s903/2012-11-10_09-59-39_680.jpg)

(https://lh6.googleusercontent.com/-W2x-xGxti0o/UKDoZhpw8MI/AAAAAAAADUg/J4cQLsw4YAg/s575/2012-11-10_12-02-47_846.jpg)

(https://lh6.googleusercontent.com/-MRqqycp0U6o/UKDoZvsapOI/AAAAAAAADUg/cFkp3ktJ4Vs/s575/2012-11-10_19-46-29_241.jpg)

All of this helped, which brings us up too the second autox and last event of 2012 at VMP. Mindy drove her VW and I drove the xr.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on March 27, 2013, 09:59:21 AM
The first autox with these changes was.... exciting... I'll say. (images stolen from Gunny)

(http://farm9.staticflickr.com/8201/8177574523_9983d8234f_b.jpg)

(http://farm9.staticflickr.com/8477/8177575385_bfeed0128f_b.jpg)

(http://farm9.staticflickr.com/8489/8177628199_f43f666af7_z.jpg)

(http://farm9.staticflickr.com/8344/8177629819_81cd1c99e3.jpg)

(http://farm9.staticflickr.com/8343/8177628859_a8da3bc763_b.jpg)

During the day the lifters started getting really loud, and I should have stopped. In the end I will have had the motor starved of oil, with a blown head gasket due to lean conditions and a tow 2.5 hours back home to the shop. Not what I would have called a success.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on March 27, 2013, 09:59:59 AM
And the damage that I caused. Found out later that the low oil pressure was due to the cracked pick-up tube on the oil pump. So it was sucking air and not oil.

(https://lh6.googleusercontent.com/-a9AB4y9_HqI/UKT0RPD9DSI/AAAAAAAADaA/Ldo-JS9ibLA/s1012/2012-11-14_08-36-58_373.jpg)

(https://lh6.googleusercontent.com/-cXoHhNbozqU/UKj4JlDpw8I/AAAAAAAADe0/kjqNbIV2hso/s903/2012-11-17_13-51-33_568.jpg)

(https://lh3.googleusercontent.com/-2CS0kzBUjcA/UKj4JiIN09I/AAAAAAAADe0/4isbqPIcbHM/s575/2012-11-17_13-51-53_961.jpg)

(https://lh6.googleusercontent.com/-LFuBXY0H7t4/UKj4JgPx3iI/AAAAAAAADe0/8H7beNq9Yxg/s903/2012-11-17_13-52-48_962.jpg)

Cylinders 1 and 2 melted the head gasket. This caused the head and block to get nicked. I believe the block will be ok with a resurface, the head is toast, as it is very deep.

So time to strip it apart. I had all winter to do so and one would think that is plenty of time to do this simple fix, but as always, I've been able to extend it with limited time on a car that is 2 hours from my apartment.

(https://lh4.googleusercontent.com/-viJzGGfZL28/UKj4Jn-n6JI/AAAAAAAADe0/mHLqNgFoKys/s903/2012-11-17_15-53-23_848.jpg)

Good new was that the head seemed fine on the cam side. This was a modified head, with oversized valves, high lift cam, upgraded everything else. So I definitely "lost" out on this deal.

(https://lh5.googleusercontent.com/--Rs2AHNMsj0/UKj4Jvwi-CI/AAAAAAAADe0/dSeuNfeBpGk/s903/2012-11-17_10-38-42_354.jpg)

(https://lh5.googleusercontent.com/-GMcBl4-5jyo/UKj4Jp2kpRI/AAAAAAAADe0/w__BCByRPbM/s903/2012-11-17_10-39-06_797.jpg)

(https://lh5.googleusercontent.com/-PW5kZrtJaWk/ULAeAcB_JaI/AAAAAAAADio/EmUJ6ygb8PY/w551-h310-n-k/2012-11-23_17-44-02_879.jpg)

Once I got the head out I started stripping everything apart.

(https://lh5.googleusercontent.com/-8sNXb3oGUDU/UM1FJ00EN_I/AAAAAAAAEEk/dgUMaFyi_KY/s903/2012-12-15_09-44-04_377.jpg)

(https://lh3.googleusercontent.com/-ENa_Cu5IIa0/UM1FJ_x-UPI/AAAAAAAAEEk/V-XlJdXHGbQ/s903/2012-12-15_09-43-32_292.jpg)

Valves where pretty nasty in the head we bought.

(https://lh5.googleusercontent.com/-wcysz32taLc/ULyngyIP_2I/AAAAAAAADpw/8PDec3-qw9M/s903/2012-12-01_17-43-52_829.jpg)

But cleaned up ok

(https://lh5.googleusercontent.com/-EAVrSuXSg8s/ULyng_7li-I/AAAAAAAADpw/emiK0o4vsj8/s903/2012-12-01_17-47-46_183.jpg)

Got in touch with David and we picked up a head from his buddy. Started cleaning that up.

(https://lh4.googleusercontent.com/-quxYp-aQ1o0/UM1FJw3FMLI/AAAAAAAAEEk/-6twENHCJv0/s532/2012-12-15_11-31-34_664.jpg)

On 2.3 ford heads there is some obvious porting. So I went ahead and did some cleaning.

Original Bowl

(https://lh6.googleusercontent.com/-x8Cda0vaCd8/ULAeAQggaKI/AAAAAAAADio/Si6IW1Nob_Y/s1663/2012-11-23_11-38-31_918.jpg)

After porting

(https://lh3.googleusercontent.com/-cofUcBsmivQ/ULAeAWVhGKI/AAAAAAAADio/yVW3zmcDkXg/s1663/2012-11-23_11-38-26_104.jpg)

About 80% done

(https://lh3.googleusercontent.com/-bZX4nFXC838/UM1FJ-MSmtI/AAAAAAAAEEk/5TNMqZKDYCA/s903/2012-12-15_11-31-13_727.jpg)

Lapped the old valves in. These are not the big valves that came out of the original head. They are OE from the head we bought obviously.

(https://lh6.googleusercontent.com/-TK8kWfnAulY/UNitTVUJYFI/AAAAAAAAELU/ymNqaie4uS8/s902/2012-12-22_14-32-58_826.jpg)

(https://lh3.googleusercontent.com/-VUm2B4XIXTk/UNitTXSY1TI/AAAAAAAAELU/4cCTAdJm7ic/s902/2012-12-22_15-24-40_749.jpg)

(https://lh5.googleusercontent.com/-TtIFr68-jRg/UNitTV6Y9XI/AAAAAAAAELU/NMxXQWNAwFo/s902/2012-12-22_14-32-32_722.jpg)

Then the head was put back together. We decided to go with the Ford Gray paint. I like the color.

(https://lh4.googleusercontent.com/-CFlIZKtVbJY/UM1FJ36z-KI/AAAAAAAAEEk/XLacYIk2Hns/s903/2012-12-15_18-10-17_802.jpg)

(https://lh4.googleusercontent.com/-nSHAdf-gnIQ/UM1FJ1-JufI/AAAAAAAAEEk/wIy5rprxYnQ/s903/2012-12-15_18-24-31_523.jpg)

Now ready for the rest of the motor

(https://lh5.googleusercontent.com/-6IOj8354u3U/UM1FJ2PYtsI/AAAAAAAAEEk/7M9oqO9gkNw/s903/2012-12-15_18-56-17_39.jpg)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on March 27, 2013, 10:00:21 AM
I got side tracked a little on this project. In the end it didn't work out but I figured I'd share.

Basically I wanted more flow, and these ford upper and lower intakes have super long runners but are restrictive. So I took one and started cutting. Along with that it would give me the ability to clock the intake and not run it over the valve cover of the motor. Meaning shorter boost pipes and much cleaner set up.

(https://lh6.googleusercontent.com/-y78nzKicUck/UNitTa7LSLI/AAAAAAAAELU/AWMtXKERstQ/s575/2012-12-22_18-28-15_418.jpg)

(https://lh3.googleusercontent.com/-0aiEKVTmIN4/UNitTR5GP8I/AAAAAAAAELU/Id1FstrIF2Y/s902/2012-12-22_20-08-28_408.jpg)

(https://lh5.googleusercontent.com/-KeiblgmNUEA/UNitTVkA_nI/AAAAAAAAELU/2JN9cTznxTo/s902/2012-12-24_10-03-27_154.jpg)

(https://lh5.googleusercontent.com/-ewdqQ0CviyQ/UNitTVJOgGI/AAAAAAAAELU/IJw8tidf-3M/s575/2012-12-24_10-38-35_568.jpg)

(https://lh5.googleusercontent.com/-IvQebjVX7Z4/UNitTb2qaKI/AAAAAAAAELU/EWR0fkBLvrw/s902/2012-12-24_11-27-38_566.jpg)

Back to the motor. David again came in super handy as we picked up a use block from his friend as well. It showed some wear, but was complete. Started stripping that apart and doing the necessary cleaning/painting. Ordered a full rebuild gasket kit and had it together pretty quick.

(https://lh3.googleusercontent.com/-fO2a0cPw-sA/UN5qY7FsGfI/AAAAAAAAEQ4/WS6No_lSV2U/s902/2012-12-28_10-42-05_372.jpg)

(https://lh5.googleusercontent.com/-PKO6jL1-we8/UN5qY5AWJhI/AAAAAAAAEQ4/cTjOuJ4FNrM/s902/2012-12-28_10-42-22_637.jpg)

(https://lh3.googleusercontent.com/-Gas5GEE3ItA/UN5qY-J-pBI/AAAAAAAAEQ4/QBhLi1jEezw/s902/2012-12-28_11-14-02_633.jpg)

(https://lh6.googleusercontent.com/-v5esmXGbmY8/UN5qY4vVr4I/AAAAAAAAEQ4/kReYGWKRb48/s902/2012-12-28_16-20-49_868.jpg)

(https://lh6.googleusercontent.com/-7kENF5viuSk/UN5qY9_PONI/AAAAAAAAEQ4/iaR6bw_sXpg/s902/2012-12-28_19-09-43_333.jpg)

Ordered new water pump, timing parts, and other stuff.

(https://lh3.googleusercontent.com/-0c-tKP_b4DM/UOD7_SzwqyI/AAAAAAAAEUw/pZ9bkMnsNl8/s902/2012-12-30_19-39-51_23.jpg)

(https://lh5.googleusercontent.com/-fZEkphvZZbU/UOD7_fUs2MI/AAAAAAAAEU0/5byvaSiyqDQ/s575/2012-12-30_19-40-26_310.jpg)

(https://lh4.googleusercontent.com/-EtwYdSCyZNw/UQ_ebyos-bI/AAAAAAAAGeE/o0QqFd-CE7I/s771/20130202_122526.jpg)

Reused old stock turbo. Hopefully it will last awhile.

(https://lh4.googleusercontent.com/-cYFhC9q0CIE/UQ_eb476FhI/AAAAAAAAGeE/vf36T__8zNs/s1028/20130202_174847.jpg)


Then pulled the old motor, reused the old clutch and bolted everything back together and placed it in the car. At this point, wiring is a mess, boost pipes are leaky, exhaust is a mess, and the vacuum lines are all cracked from age.

(https://lh5.googleusercontent.com/-0sgF_BxX6z4/UOD7_WgGekI/AAAAAAAAEU8/vB0NUa838PE/s575/2012-12-30_14-04-33_118.jpg)

(https://lh6.googleusercontent.com/-m99J6R4-pbg/UQ_eb9hoIgI/AAAAAAAAGeo/pXnt0IkkXTw/s1028/20130202_200338.jpg)

(https://lh3.googleusercontent.com/-uTJn13DoYks/UQ_eb9rNJfI/AAAAAAAAGeE/WBY1J_0gD98/s1028/20130202_203816.jpg)

(https://lh4.googleusercontent.com/-S7k9EkvoheY/UQ_eb4AO3qI/AAAAAAAAGeg/rKx65zMjpvo/s1028/20130202_203920.jpg)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on March 27, 2013, 10:06:30 AM
First I immediately tore into the old wiring. Removing what I could. Some back ground on the old motor. It had been converted to a MAF when originally a small VAM set up. So it had a piggy back which converts the signal to the appropriate one, then that ran into a old standalone that looks like the original game boy. Whole thing never really work well, it would stall on deceleration due to the air stopping or reversing around the MAF. They where nicknamed "mess air" for a reason. This car needs its reliability so I decided to scrap the old MAF and converter box and go with a large VAM setup similar to stock and hope for the best.

(https://lh3.googleusercontent.com/-SyKCEmc17K4/URlrlNtdgLI/AAAAAAAAGkg/SZOSk2lruOw/s992/20130210_180720.jpg)

(https://lh3.googleusercontent.com/-W7XfY_3lfPM/URlrlKrusII/AAAAAAAAGko/-G3WjVhF4uo/s744/20130210_180727.jpg)

Getting a little better

(https://lh3.googleusercontent.com/-glQXsPOxREk/USFsxxjoZuI/AAAAAAAAGrI/4SXj4nrD1BM/s767/20130216_210805.jpg)

Dropped lower dash out and wires just came from everywhere.

(https://lh6.googleusercontent.com/-Sd_O5XmBYx4/USFsxyn74eI/AAAAAAAAGrI/sYVDjFiKnb8/s767/20130216_111812.jpg)

The standalone piggyback says "AudioBuster" on it? I assumed he was using the case

(https://lh6.googleusercontent.com/-E8LP22e18Lg/USFsx_mRgcI/AAAAAAAAGrI/CqU_-dBIa1Y/s767/20130216_114335.jpg)

(https://lh3.googleusercontent.com/-Qrp8yDrEaig/USFsxy5onxI/AAAAAAAAGrI/rDl7gEHqSkE/s992/20130216_210742.jpg)

Another little story to this stanealone, it uses a standard MAP sensor. Well after pulling stuff out of the car I finally found that the vacuum line had come off of the MAP sensor. May be the reason I was running lean at the end. To fix this I'm replacing everything with silicon hoses and stainless clamps. Now it will take a lot of pressure to it to fail.

(https://lh6.googleusercontent.com/-Y9zYtXFBVQ4/USFsx__JwhI/AAAAAAAAGrI/M1m0fR9p0lc/s743/20130216_123601.jpg)

(https://lh3.googleusercontent.com/-g17znLmPaEA/USrYV-qGeYI/AAAAAAAAG5c/nWeomSG6t64/s575/20130222_152152.jpg)

Coolant hoses are much the same way. Something that needs to be reliable so I went with silicon everywhere. High temperature ratings, don't get hard, and high burst pressures. They dont make kits for this car, like a lot of automobiles, so I had to use stock off the shelf stuff.

(https://lh6.googleusercontent.com/-EXMITtm2-90/USrYV2uij1I/AAAAAAAAG5U/ED9ubl2ne74/s767/20130222_151235.jpg)

Ran the coolant lines (which I end up changing I think) and started mocking up and installing the new boost pipes.

(https://lh3.googleusercontent.com/-jttboWi5Hlc/USrYPObIhTI/AAAAAAAAG5I/oL6YYJvUUbA/s767/20130223_102700.jpg)

Tacked together

(https://lh4.googleusercontent.com/-fL_Nhzzq30c/USrYPFMU8QI/AAAAAAAAG5I/-MeTNTdF7Ng/s575/20130223_115414.jpg)

Welded

(https://lh3.googleusercontent.com/-rH2JF1grdvs/USrYPBSOsKI/AAAAAAAAG5I/XTnxWxJGqLc/s767/20130223_143012.jpg)

Installed

(https://lh6.googleusercontent.com/-Koh4way6O5g/USrYPDT2cpI/AAAAAAAAG5I/eDRkdNtOGm4/s649/20130223_181630_0.jpg)



Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on March 29, 2013, 04:55:23 AM
At this point I wasn't real real happy with anything but it was coming along pretty cheap. I wanted to do the exhaust on a budget. After looking around and knowing what I wanted and what was out there I settled on this. Not completely new system, but gets rid of the worst of it, and still has the 80s mustang look.

3" downpipe to help the long spool time

(https://lh4.googleusercontent.com/-6ih-jshgCwY/USFsx1ZwJoI/AAAAAAAAGrI/MDIIOnMd7Q0/s575/20130216_211250.jpg)

Then got some cheap stainless tubing in various sizes, along with some V-bands

(https://lh6.googleusercontent.com/-phpJ37xOZjQ/UTQcPnIAhFI/AAAAAAAAHFQ/hYU7us9qQf4/s1251/20130302_114416.jpg)

(https://lh4.googleusercontent.com/-8u42oNyGDxM/UTQcPg-QK-I/AAAAAAAAHFQ/K2DFoga9WNU/s1251/20130302_133410.jpg)

(https://lh3.googleusercontent.com/-za6c0prWVME/UTQcPpZn2kI/AAAAAAAAHFQ/hxz_Kp8hj5M/s1251/20130302_143515.jpg)

(https://lh3.googleusercontent.com/-VdYMUTvcKNw/UTQcPvGARHI/AAAAAAAAHFQ/Z05_NUIhrm4/s938/20130302_143506.jpg)

(https://lh5.googleusercontent.com/-gefWO5gqWnE/UTQcPnxDfAI/AAAAAAAAHFQ/3J-6N6CObHo/s1251/20130302_181626.jpg)


Also got rid of the OE plastic vacuum stuff in exchange for a aluminum block with ports. And lots of silicon hose.

(https://lh4.googleusercontent.com/-QEh5G4RCtrQ/UTQcPqkEoBI/AAAAAAAAHFQ/3Piu-T5KCj4/s1251/20130303_192532.jpg)

Installed the Big Vam

(https://lh6.googleusercontent.com/-NZBEZOvzfY8/UTQcPj8F0eI/AAAAAAAAHFQ/J7720ITtWbk/s938/20130303_192724.jpg)

(https://lh5.googleusercontent.com/-iVJSeN31kEs/UTQcPgWZNfI/AAAAAAAAHFQ/dGrOzbCYFAM/s1251/20130303_192738.jpg)

Made a quick ground block

(https://lh5.googleusercontent.com/-TaZ3WMvg8r8/UTQcPlplcwI/AAAAAAAAHFQ/DTMNN_Ludog/s1251/20130303_192807.jpg)

And added a power steering cooler for those drift events

(https://lh6.googleusercontent.com/-Ez44awk5rsU/UTQcPl7CWUI/AAAAAAAAHFQ/0fGieje9oYQ/s1251/20130303_192639.jpg)



Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on March 29, 2013, 05:29:04 AM
Started getting the rest of it together. Lower radiator hose was next. Of course they dont make anything that works with the car any longer so I made my own from silicone and some aluminum pipe I had lying around. I was going to weld everything together but did this in the interest of time.

(https://lh5.googleusercontent.com/-qDWVgcPiSQw/UVCy7_aSaiI/AAAAAAAAHc4/QDxcA-YBGvc/s1251/20130322_155728.jpg)

(https://lh4.googleusercontent.com/-Zz2SyQ-_Fks/UVCy793iKZI/AAAAAAAAHc4/cXJyr_yUFMo/s938/20130322_152820.jpg)

Then put new transmission fluid in it. Love this $7 tool from autozone.

(https://lh5.googleusercontent.com/--KXcX3YwsyE/UVCy73z-01I/AAAAAAAAHc4/079xvgS6Glk/s1251/20130322_180008.jpg)

Lots of small things that take some time. Block off plate

(https://lh3.googleusercontent.com/--__rUWIV2YI/UVCy70KB8ZI/AAAAAAAAHc4/f3iOUP2Uoro/s938/20130322_184551.jpg)

Mindy made a gauge panel for the kill switch and two important gauges.

(https://lh5.googleusercontent.com/-eSzsNqEYSIY/UVCy7wygr6I/AAAAAAAAHc4/1TZSdTfE0wk/s1251/20130323_183114.jpg)

The old school piggyback standalone

(https://lh5.googleusercontent.com/-ZIcKANI4LhY/UVCy743fytI/AAAAAAAAHc4/oYiWNTTXk7Q/s938/20130323_183123.jpg)

Got it running this weekend. Have had a few problems with an over boost and spark. Seems to have dropped a little weight. It was over 3k lbs it is now 2840 with 1/3 tank of fuel.

(https://lh3.googleusercontent.com/-EAUQeK01QIA/UVjYSgisyzI/AAAAAAAAHn4/cAtJMlomrtE/s767/20130330_105506.jpg)

And 1480 up front which puts it very close to 50/50 without a driver.

(https://lh5.googleusercontent.com/-fH0AfFsOQVQ/UVjYSrNmy9I/AAAAAAAAHn8/ZAQhMoG4Icg/s767/20130330_105609.jpg)

1 more weekend..... then test and tune. Got it driving around. Seems to be boosting to about 18-20 psi which is a little high so I will be lowering it before autox.

Drivability is up with the VAM set up over the old MAF. No more senseless stalls coming to a stop light. It is running about 10.5:1 at WOT full load. I may take a little more fuel out of the tune.

(https://lh5.googleusercontent.com/-P1RXuQBSzrs/UVjYSqgbv9I/AAAAAAAAHn0/jvn0YnFC_M0/s1251/20130330_153319.jpg)

Mindy also added her new seat in!

(https://lh5.googleusercontent.com/-eEGXaznW35w/UVrRm2Q8ppI/AAAAAAAAIL8/pXG41FaUXLo/s1251/20130401_175235.jpg)
 


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on March 29, 2013, 06:05:08 AM
Last weekend for the first autox on the new motor. I was really busy so I didn't get to take pictures of everything I did but here goes.

Also would like to thank Pat for all the fender work and dad for assistance in the brakes and alignment.

Got some stuff in, Hoosier's in 225/50/16, springs and collars from Justin. Thanks again.

(https://lh6.googleusercontent.com/-UbMNuPwwXCA/UWK16eUbGEI/AAAAAAAAISA/hMbB0WJ0XqI/s1295/20130405_143404.jpg)

Started having to make them fit so the first thing was to remove the giant front perches and springs.

(https://lh3.googleusercontent.com/-87VWL-77WZY/UWK16dr6nEI/AAAAAAAAISA/2qFYgtK1QBw/s1295/20130406_094309.jpg)

Apart

(https://lh5.googleusercontent.com/-gQsgibHyBVk/UWK16WlUsqI/AAAAAAAAISA/yzApD00qs3U/s1295/20130406_094246.jpg)

(https://lh3.googleusercontent.com/-jB0VjDV0_Vs/UWK16bwecRI/AAAAAAAAISA/LWoxf-0yIJk/s1295/20130406_102106.jpg)

Cut down the size

(https://lh4.googleusercontent.com/-SY_EBsl-_J4/UWK16b_TgtI/AAAAAAAAISA/zGkAtlGxXYk/s971/20130406_091946.jpg)

Added a plate to the collar to sit flat on and tacked it on

(https://lh3.googleusercontent.com/-XLxd8kzc6K0/UWK16Wmg87I/AAAAAAAAISA/879Y5YN00tI/s971/20130406_102803.jpg)

350lbs springs on the front

(https://lh6.googleusercontent.com/-3tkhy8_qwkY/UWK16XqVY4I/AAAAAAAAISA/3CqeIOMwIqk/s971/20130406_120226.jpg)

Inner fenders crumbled away

(https://lh6.googleusercontent.com/-_2Ppsy_tXcI/UWK16eKxLjI/AAAAAAAAISA/YiEWgmfN_e0/s1295/20130406_095727.jpg)

Installed

(https://lh6.googleusercontent.com/-B0xD-uaVOJ0/UWK16ZtrrrI/AAAAAAAAISA/7GUYtCRW1qo/s971/20130406_144849.jpg)

Made new shields for the wiring under there

(https://lh4.googleusercontent.com/-YGaj6--F3pY/UWK16YlregI/AAAAAAAAISA/MIKIZt9sym4/s1295/20130406_212835.jpg)

(https://lh3.googleusercontent.com/-1GUIBE-IeMs/UWK16fvGGEI/AAAAAAAAISA/_4Ao448OUno/s1295/20130406_213407.jpg)

Started having to remove exterior trim

(https://lh4.googleusercontent.com/-q0oH6ffuh70/UWK16dz7MtI/AAAAAAAAISA/GVY_CpwfNJc/s1295/20130406_154314.jpg)

Here is why

(https://lh6.googleusercontent.com/-J34GrlCixHo/UWK16aKT0aI/AAAAAAAAISA/2aMLfs0Ev4c/s971/20130406_154402.jpg)

(https://lh5.googleusercontent.com/-HL87J-5SI2o/UWK16cF6snI/AAAAAAAAISA/llizMzsfBiY/s971/20130406_173751.jpg)

Made some more room

(https://lh3.googleusercontent.com/-zrHy3SH87Ow/UWK16TIWYnI/AAAAAAAAISA/oGGWzsL2ZjQ/s1295/20130406_174810.jpg)

We will see

(https://lh4.googleusercontent.com/-4ZsfGOVxF6s/UWK16fVrVOI/AAAAAAAAISA/YZiN8z56jAw/s1295/20130406_174754.jpg)

Bled the brakes and this came out. I think I pulled about 16-20oz of this stuff out.

(https://lh5.googleusercontent.com/-ybygJEPfmmo/UWK16ZwA0RI/AAAAAAAAISA/Jq9GutMh6DY/s971/20130407_100520.jpg)

Added a copper heat shield/heat sink to the wideband along with the protectant to the wiring.

(https://lh3.googleusercontent.com/-j_MYrcjebhs/UWK16X2O39I/AAAAAAAAISA/MB1cLIjJhwk/s1295/20130407_082058.jpg)

And after a alignment, 0 toe in rear, 1/8" out up front, I packed... "just the essentials" to get me home and run at the event next weekend.

(https://lh3.googleusercontent.com/-NlriDoEMr80/UWK16RG2KPI/AAAAAAAAISA/qScvh8kFN0M/s1295/20130407_133904.jpg)

Issues so far.

1. Believe the turbo is burning the oil, still not convinced but it may be the return line has more bends than it likes. Looking at rebuilding the turbo after I look at shaft play today.
2. The tune is still pretty bad at WOT and heavy load but good and drivable everywhere else if the motor is warmed up.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: gunny on March 29, 2013, 02:04:21 PM
The first autox with these changes was.... exciting... I'll say. (images stolen from David)

I remember taking those pictures!

I cant wait to see it go again! I'll take some more pictures.

Gunny


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: ccann26 on March 29, 2013, 03:27:50 PM
It looks great ! All the work you put into it looks awesome. You put a cage in it too ?


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on March 31, 2013, 05:56:29 PM
Gunny, I'll have to change the credit. Thanks again, currently the only proof that I have it ever ran in the first place.

Chris. No cage in this one yet but will get a 4 point before too long I think. You can see my brother's 240 in the background of one photo next too the covered up mk2. As I was building this car we traded some work and I put the cage in his car. Hopefully he will make a FarmBoy Fab post someday about it as it is a lot nicer than this.



Title: Re: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: RedZero on April 02, 2013, 01:26:17 PM
Simply love it and I'm glad I could help in sourcing out some parts for you guys.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on April 03, 2013, 04:55:20 AM
Yeah we owe you a beer David. Thanks again


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: 90efcivic on April 17, 2013, 07:06:04 AM
I always liked those Merkur's. Finding a good one now is rare. Body looks in really good condition.
Like the condition of the brake fluid.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on April 17, 2013, 10:20:18 AM
Thanks. I hope this car last a little bit of time for us, at least until the VW is finished.

As to why it wasn't out at the last autox.... Here we go, but first I have to name a few that made this really happen, even though in the end it didn't happen... First Justin for driving out and picking the heap of junk up and letting me use the garage since ours is far away, second Dad for driving all night to deliver some parts and help work on this thing and David for sourcing stuff here local and offering up advice. Thanks guys!

In the beginning...

Started smoking a lot after a drive home from work (this was the daily for the week) and I noticed this when doing a compression test, to be sure it wasn't the same thing happening again (head gasket failure).

(https://lh5.googleusercontent.com/-yFzYPz5tc6U/UWNd3af3IxI/AAAAAAAAITs/Ck6PpwEgWeU/s575/20130408_195421.jpg)

It turned out to compression test at 150 across all 4 so I made a check valve thinking it was the issue, burning crankcase oil.

(https://lh6.googleusercontent.com/-I4Cvqg0bl9E/UWNd3ZgbvSI/AAAAAAAAITs/yvOkCIC8olk/s778/20130408_190406.jpg)

Put it inline with PCV

(https://lh3.googleusercontent.com/-QAyU21TRnGg/UWPo_sypWyI/AAAAAAAAIUE/9WaJSBM8lSQ/s938/20130408_191805.jpg)

Didn't help. Played with the oil return line thinking there was a low spot. Also didn't help. Now what?

(https://lh4.googleusercontent.com/-2zfVM62q7CQ/UWSgoGq7c1I/AAAAAAAAIUc/bR0o4I2b25o/s408/13+-+1)

See the oil built up around the hot side which happened almost instantly.

(https://lh4.googleusercontent.com/-QLXx0AjnQpI/UWSpLiUHw5I/AAAAAAAAIVc/tIbxuH2X1Vk/s767/20130409_184842.jpg)

So Justin was kind enough to help me and delivered it to his house where we pulled the turbo and saw this instantly. This means it wasn't the turbo after all which meant more serious issues where at hand

(https://lh3.googleusercontent.com/-QyYdidpV0u4/UWYs5LDoj3I/AAAAAAAAIa0/Hd8ODWFfyRs/w515-h386-p-o/20130410_213747.jpg)

Leak down tested it and once again it passed. Only one thing left, valve stem seals

(https://lh6.googleusercontent.com/-Pm2edEqEY8U/UWYs5LFFsTI/AAAAAAAAIa0/BGjmDXdbX48/s767/20130410_215043.jpg)

Cylinder #1
(https://lh4.googleusercontent.com/-bJzzbsHKAMY/UWYs5MO84SI/AAAAAAAAIa0/VMmdVr-vcJI/s575/20130410_221649.jpg)

Cylinder #2
(https://lh4.googleusercontent.com/-1QEHIGi1D7M/UWYs5MZmFEI/AAAAAAAAIa0/CSf_6WNzs8g/s575/20130410_221654.jpg)
Cylinder #3
(https://lh5.googleusercontent.com/-ttfSKEIwggg/UWYs5MT7zNI/AAAAAAAAIa0/-KNnFXhMxi4/s575/20130410_221700.jpg)

Cylinder #4
(https://lh4.googleusercontent.com/-u4ROMUiIZBE/UWYs5Fo2OfI/AAAAAAAAIa0/GLquJNnzNJ8/s575/20130410_221704.jpg)

After talking with Shannon at Stinger Performance in Kansas City he mentioned that High lift cams can damage the valve stem seals by running the keepers into them. So Dad drove several hours to bring me a old cam I found in a box that we had gotten from the PO.

(https://lh3.googleusercontent.com/-shHWUM4vdIg/UWb5MszylpI/AAAAAAAAIbI/4IJM5zOBgAY/w497-h373/13%2B-%2B1)

(https://lh6.googleusercontent.com/-P7h-NyjA_4A/UWb5SNx7USI/AAAAAAAAIb4/K-NE9IzdZR8/w497-h373/photo.jpg)

That night (the night before the pratice autox at MEP) we pulled seals and replaced them with some Felpro ones I gathered from AutoZone. One was damaged.

(https://lh4.googleusercontent.com/-1srTXY74bmg/UWfw7erPvPI/AAAAAAAAIeg/MdrMho53SNU/s778/20130411_203710.jpg)

But the others seemed ok. I replaced them all however.

(https://lh4.googleusercontent.com/-i3XF7pzWv74/UWfw7ZbpDrI/AAAAAAAAIeg/l_9jqDaeEyo/s778/20130411_211247.jpg)

(https://lh3.googleusercontent.com/-XiuZAALblQc/UWfw7eqLmcI/AAAAAAAAIeg/r8Sridp057o/s1037/20130411_211252.jpg)

(https://lh5.googleusercontent.com/-gAYC9sjeAhI/UWfw7SWRUVI/AAAAAAAAIeg/Tm2RSHKaESk/s1037/20130411_223908.jpg)

In the end we got it all back together and started the car. It didn't smoke much at all but oil was spraying out everywhere under the car. We removed the oil filler cap and it reduced, but did not stop. Why? These lines can handle 100s of psi?

Now with oil everywhere under the car. I kind said screw it, there must be something blocking the crankcase vent. Here we go. First the PCV line went, that didn't help so intake mainifold went to check the mesh box. Maybe I left tape over something?

(https://lh4.googleusercontent.com/-qlalR5wO0Es/UWjiGaz4smI/AAAAAAAAIgo/fSnztZEaOOM/s767/20130412_232631.jpg)

Nope it was clean and easy. So it must be the turbo right? So I took the turbo off again and realized what I had done. Aluminum fitting with steel fitting, who is going to win?

(https://lh3.googleusercontent.com/-LoKr5VxGcWA/UWjiGZmbR7I/AAAAAAAAIgo/WFuriYGIr34/s767/20130412_232646.jpg)

DAM IT! ok now there is no way to make the practice. It is way too late in the morning, maybe I can make the event on Sunday.... I should have stopped there but didn't, while I had the turbo off I decided to look into it a little further. Some shaft play, but nothing too crazy, so I got to talk to David about sourcing another 60/63, he said he had one and picked it up from him at the autox practice Saturday.

(https://lh3.googleusercontent.com/-QpoC7PKPqkg/UWjiGY-GoQI/AAAAAAAAIgo/G3iN9os3se0/s575/20130412_232641.jpg)

That night, after we set the course up for the next day, I went to Justins and tried swapping parts around to make it work. Which I hadn't noticed before but was not the same wheel sizes, even though they were both 60/63s.

(https://lh3.googleusercontent.com/-TRouGzEHlwI/UWwEjOyJurI/AAAAAAAAIjM/IrTWVgcgYmA/s1037/20130413_214336.jpg)

I could have stuck everything back together at this point to make the event but wanted to see inside the seals of the turbo, still thinking they were bad... So I took it apart. It had been burning lots of oil, but the seals were in OK condition. DAM

(https://lh6.googleusercontent.com/-50TnGe4PMnU/UWwEjG97zII/AAAAAAAAIjM/iLGeati7Mrk/s778/20130413_214520.jpg)

So I finished the night off we a mockup of the new turbo and we are waiting on parts now to put the new turbo on, with new return line fittings and new valve stem seals and a nice big open crankcase catch can.

(https://lh4.googleusercontent.com/-rchgDWMv2e8/UWwEjLylIzI/AAAAAAAAIjM/5WvcEBRiR3Y/s778/20130413_231306.jpg)

Wish us luck, hopefully it will be out by the next event. As long as the cylinder walls are not the "real" underlying issue.

Anyone have a small bore camera that I can see inside the bores with through the spark plug holes?


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: whiteryder on April 17, 2013, 04:55:57 PM
Wish us luck, hopefully it will be out by the next event. As long as the cylinder walls are not the "real" underlying issue.

Anyone have a small bore camera that I can see inside the bores with through the spark plug holes?


I have one of these, is that what you're thinking of?
http://www.harborfreight.com/digital-inspection-camera-67979.html

(Impulse purchase - was deeply discounted in their Thanksgiving sale last year.)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on April 18, 2013, 05:05:06 AM
Beth, that is exactly what I need. How big is the diameter of the camera? Will it fit through a spark plug hole?

Amazon has these USB camera but they are all too big


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: whiteryder on April 18, 2013, 10:01:33 AM
Beth, that is exactly what I need. How big is the diameter of the camera? Will it fit through a spark plug hole?

Amazon has these USB camera but they are all too big

The manual says "16mm / 8.5mm" but I checked and in fact all it has is the 16mm head.
That might not fit through the hole, you'd just have to see what you could see from the opening.

BTW this looks like the 8.5mm head, available separately: 
http://www.amazon.com/Autel-MVIHC85-AxiVideo-Replacement-Imager/dp/B005R3SRBY/


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on April 18, 2013, 01:34:57 PM
Yeah too expensive. I'll see if the car runs as is, it isn't hard to remove a spark plug and find out later. I'll look on fleabay and see if there is anything worth while.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: rothaus on April 18, 2013, 05:28:58 PM
I got a Ridgid boroscope, but it's also to large for the plug hole.

When I looked at the pictures when you took the engine apart, I commented that the inline 4 is simple, however, with all the stuff around, it becomes quite complecated. At least I have not to deal with turbos and anti freeze.

Hope this turns out OK.

 


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on April 19, 2013, 04:12:57 AM
These are still about as simple of a motor as you can get IMO.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on April 20, 2013, 06:12:26 PM
This weekend made a catch can out of a old box I had made a few years ago for a friend. Hopefully this will keep the crankcase pressure at bay.

Started by drilling some holes in a plate to make a top, and one on the side of the box.

(https://lh4.googleusercontent.com/-yUM_bDo8nLE/UXM6nAvgF-I/AAAAAAAAIoo/996GzhhFdgo/s767/20130419_142914.jpg)

Tacked on the lid.

(https://lh3.googleusercontent.com/-mvBFIBWILYE/UXM6nCsXE2I/AAAAAAAAIoo/_gesUzAEiDQ/s767/20130419_143214.jpg)

Welded everything up with some large NPT fittings over the holes.

(https://lh5.googleusercontent.com/-dBcJyvuH4MY/UXM8lWlT2uI/AAAAAAAAIpI/2DrW2imtf4c/s575/20130419_153424_0.jpg)

Finished it by adding the barbs and a breather

(https://lh6.googleusercontent.com/-A7WQM5qyg3w/UXM6nH41dUI/AAAAAAAAIoo/2MXOFbPDf20/s575/20130419_153546_0.jpg)

Most likely will add some stainless wool inside to slow the vapors down some. Fun little project, we will see how it goes.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: Autox on April 22, 2013, 11:19:57 AM
I had to have one of those Flex sections added my exhaust on the Subaru.  8" long by 3 1/2 diameter.  The exhaust was cracked up near the turbo due to the motor mounts which I had to have replaced last week.  One was bent and all 3 were worn with the rubber cracking. 


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on April 22, 2013, 12:33:40 PM
I had to have one of those Flex sections added my exhaust on the Subaru.  8" long by 3 1/2 diameter.  The exhaust was cracked up near the turbo due to the motor mounts which I had to have replaced last week.  One was bent and all 3 were worn with the rubber cracking. 

Yeah you have to have a flex coupling in there somewhere. The motor mounts were most likely not meant for the number of standing launches you do in a short 10 month period.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on April 30, 2013, 09:42:20 AM
Ok so it seems the roots cause of smoking was the combination of valve stem seals and high crankcase pressure. After adding the new seals, a smaller cam lift, and lastly the catch can it has seemed to clear up quite a bit.

Here was the improvised oil feed return.

(https://lh3.googleusercontent.com/-kFtO3XafewM/UXdA9ITIFwI/AAAAAAAAIrc/yMX29U7dnEE/s575/20130423_194151.jpg)

Initial startup after the changes. Still burning oil off

(https://lh4.googleusercontent.com/-auPPnh2TsZY/UX5tf1w5_JI/AAAAAAAAIt0/19ye822Ca20/w1108-h831/20130425_190344.jpg)

New turbo sitting in engine bay plumbed together and catch can in far right.

(https://lh4.googleusercontent.com/-5sZvlWvpF_Y/UX5tf1Qh2QI/AAAAAAAAIt0/Tt8GhO2Cys0/w1108-h831/20130425_190350.jpg)

Started clearing up some

(https://lh4.googleusercontent.com/-TYK6GFWT5Z0/UX5tf0bDF5I/AAAAAAAAIt0/eN_skZhVmzE/w1108-h831/20130425_192608.jpg)

The last two cold starts have been completely smoke free, which is a first for this new motor. Hopefully that means we can move on from this subject to the next.

More updates soon.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: rinkdink72 on May 06, 2013, 11:37:06 AM
Thanks for paying rent!!!


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on May 07, 2013, 07:13:59 AM
Yep, no prob.

Going to the next stage of the car. Megasquirt (standalone) which started by doing a few little changes to the wiring and using the stock system wiring.

First was removing the old standalone system stuff.

(https://lh6.googleusercontent.com/-SuujFPXtlFg/UYOpCfSbu8I/AAAAAAAAIzo/bJSfj6VbfZE/w1037-h778/20130502_201433.jpg)

Then I had to setup the configurations in the PNP standalone. Megasquirt based.

(https://lh3.googleusercontent.com/-NM6O-Cc-NsM/UYOpCS24dRI/AAAAAAAAIzo/UeElu3fFnII/w584-h778/20130502_201707.jpg)

From there a few wiring changes

(https://lh3.googleusercontent.com/-bL429Os9BYM/UYOpCYgEtQI/AAAAAAAAIzo/iuJpD4wGX3Y/w1037-h778/20130502_200841.jpg)

Double checked the wiring with some 80s documentation

(https://lh5.googleusercontent.com/-SdoxKbTxQZ8/UYOpCTyOhpI/AAAAAAAAIzo/xqzwGL-His8/w1037-h778/20130502_201228.jpg)

Then I had to add a intake temperature sensor

(https://lh5.googleusercontent.com/-B9M5cTnClIY/UYOpCbQ0ysI/AAAAAAAAIzo/KxC7dy2wevY/w584-h778/20130502_201240.jpg)

Welded the bung into the boost pipe, post intercooler and before the TB

(https://lh6.googleusercontent.com/-SeybWAcOERo/UYW-mewln5I/AAAAAAAAJMc/-gQs4vDGmQU/w767-h575/20130503_163435_0.jpg)

Installed new boost pipes

(https://lh4.googleusercontent.com/-AU2Lbj1y7o8/UYW-mbyBjqI/AAAAAAAAJMc/yoxi_AW7mZU/w767-h575/20130503_165318.jpg)

(https://lh6.googleusercontent.com/-kSQ1jVLJ1P8/UYW-mRvvuKI/AAAAAAAAJMc/aQORT6Mnsw8/w767-h575/20130504_083818.jpg)

Then went to the computer to start initial start up. More to come soon.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on May 13, 2013, 03:56:15 PM
Well once we got the hardware settled on the car there where a few days of playing with the software to make it run. The unit was suppose to come "pre setup" however that wasn't really the case at all. Once everything was figured out and driving ok Justin, Mindy and I went to VMP for the drag strip.

(https://lh5.googleusercontent.com/-fWOwEr6zSQU/UZFrpHmtRVI/AAAAAAAAJRs/m1sT4_ZOdbk/w767-h575-no/P1017138.JPG)

I learned a lot and not only about tuning.

Much of the night was spent on the laptop.

(https://lh3.googleusercontent.com/-Y7qCTQaV0v8/UZFrrlvl2bI/AAAAAAAAJR8/CrPUzf77PLQ/w767-h575-no/P1017140.JPG)

(https://lh3.googleusercontent.com/-EQetpikywW0/UZFrt2g46bI/AAAAAAAAJSM/8CZHkLAErT8/w767-h575-no/P1017142.JPG)

I started upping the boost to about 14psi with a dremel I had, slowly adding the psi This is a waste-gate bleed off I made. This is still less than even a stock car has so it is pretty slow no less.

(https://lh5.googleusercontent.com/-eJPlJz_2OoE/UZFuX7-uHTI/AAAAAAAAJSo/HZot03Nfzqg/w767-h575-no/20130510_145323.jpg)

I even thought I had made it without any trouble until the drive home. Which the car started getting pretty loud on the inside. I figured it was the downpipe coming loose and that is all I could think about on the way home.

However when I landed back at the apartment it was something a little worse.

(https://lh3.googleusercontent.com/-EQetpikywW0/UZFrt2g46bI/AAAAAAAAJSM/8CZHkLAErT8/w767-h575-no/P1017142.JPG)

The hydraulic motor mount had popped with all the launches at the strip. No good.

(https://lh6.googleusercontent.com/-aoKmbif5zVg/UZFpyCRaXzI/AAAAAAAAJRo/Pie4p8ssKwE/w431-h575-no/20130511_091335.jpg)

This meant the oil pan was sitting flat on the steering rack and causing all kinds of engine vibrations.

So, once again, Justin was nice enough to take it back to his place where we made something that couldn't break...

Old mount

(https://lh5.googleusercontent.com/-sBMRrhPeHs0/UZFpyEwH_6I/AAAAAAAAJRo/zPowmFRlLuI/w767-h575-no/20130511_194139.jpg)

New mounts, steel tubing with plates top and bottom. This is where I sub in "Because racecar..."

(https://lh6.googleusercontent.com/-tSo9Vk9SpJQ/UZFpyHs2R2I/AAAAAAAAJRo/NtW78lRRULQ/w767-h575-no/20130511_222709.jpg)

(https://lh5.googleusercontent.com/-KslSUJuq08A/UZFpyK3fl2I/AAAAAAAAJRo/bBUvRUlt9hY/w431-h575-no/20130511_231212.jpg)

(https://lh4.googleusercontent.com/-tShL2YZVTEY/UZFpyBKIedI/AAAAAAAAJRo/ibmoH_r-gPo/w431-h575-no/20130511_231221.jpg)


Up next the first autox


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on May 13, 2013, 04:20:05 PM
First autox with the new setup complete. This time it made it back in one piece.

First the few pictures I have below. Lots of time worrying about the tune, no effort spent on tire pressures, alignment, the "line", or struts? It was about getting it there and back in one piece.

(https://lh5.googleusercontent.com/-egsScvSjN4s/UZFv-DjBEWI/AAAAAAAAJTc/nC198YlHrp8/w767-h575-no/13+-+1)

(https://lh4.googleusercontent.com/-ujtDF_TiIPo/UZFv-BfoY1I/AAAAAAAAJTs/yQID9DetJK0/w767-h575-no/13+-+2)

This setup came in super handy for keeping the laptop supplied with power.

(https://lh5.googleusercontent.com/-_YO7P3ew3PQ/UZFv-KIH4LI/AAAAAAAAJT8/9JJEQ6TmJLw/w431-h575-no/13+-+3)

Every run a little fuel was added or subtracted here and there in the table. Then played with some of the other features of MegaSquirt.

(https://lh6.googleusercontent.com/-8L7jWD1oRPQ/UZFv-LjWS4I/AAAAAAAAJUk/H-3iO5JQjFA/w767-h575-no/13+-+4)

(https://lh4.googleusercontent.com/-dOrbb5CSf9E/UZFv-D4Q7kI/AAAAAAAAJU4/7CcHPkHrlI4/w767-h575-no/13+-+5)

(http://i1215.photobucket.com/albums/cc503/ktaffner/VMSC%20AutoX%205_12_13/DSC03593.jpg?574)

Things we liked:
1. Car stayed together
2. Initial turn in was tight and very predicable
3. Seating position and wheel where a nice addition.
4. Awesome exhaust/BOV note of a turbo 4 cylinder... when your outside of the car.


Things we didn't like
1. Car pushed too much, partially due to the lifting of the inside front wheel in mid corner and also because of the lack of camber/caster.
2. The brakes where horrible, but that was completely expected and known upgrade we need to make.
3. Lack of power, not so much overall but having to wait until 4k-4.5k to get it was really annoying. This wasn't the case with the old turbo and tune so we are looking into this pretty hard.
4. Didn't build boost on launch without 2 step. This needs to be added soon. Yay more noises.


Lastly it was really nice to see another xr4ti running at the club, Greg Larson drove 3 hours to show up am I'm glad he did. A lot of fun watching him drive in another xr and getting to meet him. Hopefully it won't be the last time. Here is a shot of him driving.

(http://i1215.photobucket.com/albums/cc503/ktaffner/VMSC%20AutoX%205_12_13/DSC03614.jpg?95)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on May 14, 2013, 04:58:41 AM
David/Gunny/Donna thank you for getting this shot. I needed to be able to see this front tire lift.

(http://farm8.staticflickr.com/7287/8736496277_03449e6d35_z.jpg)

Other shots

(http://farm8.staticflickr.com/7287/8736430039_8ae2015291_z.jpg)

(http://farm8.staticflickr.com/7283/8737575906_48af8d4121_z.jpg)

(http://farm8.staticflickr.com/7286/8737617310_bfacf62697_z.jpg)

(http://farm8.staticflickr.com/7281/8736497551_8d9fed2251_z.jpg)

(http://farm8.staticflickr.com/7284/8736497879_7aee2d5b34_z.jpg)

(http://farm8.staticflickr.com/7283/8736595125_70d370183d_z.jpg)

(http://farm8.staticflickr.com/7282/8741888995_8c8ac07f81_z.jpg)

(http://farm8.staticflickr.com/7287/8743004562_21538a411e_z.jpg)

(http://farm8.staticflickr.com/7287/8736496277_03449e6d35_z.jpg)

The other xr

(http://farm8.staticflickr.com/7287/8736461457_944be89956_z.jpg)

(http://farm8.staticflickr.com/7288/8737583080_b4c795f9e6_z.jpg)

(http://farm8.staticflickr.com/7283/8736462077_035417c395_z.jpg)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: ccann26 on May 30, 2013, 04:37:38 AM
Maybe take some grip out of that drivers side front or put a bigger sway or stiffer springs in the rear..... Good to see it complete the Autox faultless.




Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on June 01, 2013, 07:36:02 PM
Yeah, I think you are right, stiffer rear springs are in order to put the front back on the ground some. Also the rear struts are single adjustable (rebound only) and where set to max stiff, so during a corner the rear loads/compresses and until a straight or a switch in direction the rear strut holds the trailing arm in position. Therefore never letting the front come back down. So first step is adjust the struts to full soft and go from there.

So since brakes where an issue last time I've been on the hunt for a bigger set. I scored these used mustang calipers w/slider fully dressed for 90 shipped and seem to be in good condition. I already had a conversion bracket here from the previous owner so it was a easy choice as far as an upgrade is concerned. Went to autozone and found some $25 white box rotors that are 11" in diameter vs the old 9.5" or whatever it was. They are also a little thicker. I think the master cylinder will have to get bigger before it is all said and done to get the prefect feel but this should be a quick fix until then.

Mocked up on one of the spare spindles

(https://lh5.googleusercontent.com/--PR6Q7mkAYU/UaqquD8ShqI/AAAAAAAAJxE/UYSXDGEEcKY/w825-h619-no/20130601_074958.jpg)

(https://lh4.googleusercontent.com/-EKn_eKFn5qU/UaqquE2v-aI/AAAAAAAAJxE/VCYqVqXH4ys/w825-h619-no/20130601_075336.jpg)

(https://lh4.googleusercontent.com/-BgDiylHYpWA/UaqquPlneKI/AAAAAAAAJxE/QNIblQBClMk/w825-h619-no/20130601_075319.jpg)

Caliper size comparison, much bigger than what is on there now.

(https://lh4.googleusercontent.com/-3gSZBZUzfN0/UaqquEbgboI/AAAAAAAAJxE/ovA5T4Z1M3U/w464-h619-no/20130531_151202.jpg)

Also spend some time adding a electronic boost controller to the mix. Can't use it yet but it is wired in at least. Getting in a 15 psi wastegate in as well soon. We noticed that the 7psi wastegate we have is cracking under moderate to light load and leaking a bunch of the exhaust pasted the turbo meaning more LAG. I did the quick fix of adding a wire to keep the wastegate closed and boost came on about 400-500 rpm sooner with a bunch more torque down low.

(https://lh5.googleusercontent.com/-S59OkEetP4I/UaqquJrQlMI/AAAAAAAAJxE/ze65fAHhapQ/w825-h619-no/20130531_155409.jpg)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on June 14, 2013, 07:20:07 PM
Well I had set Saturday aside to get something done before sunday's event. However nothing worked out.

I had scorpio LCAs and inner tie rods ready to go on but the ball joints/outer tie rod end had completely different threading, so that was a bust.

I had all the mustang brake swap parts here but the banjo I got wasn't the correct size and the line wasn't as long as I had hoped.

However I did get the 15psi wastegate in, which is boosting it to 20psi from some reason. And I got launch control wired in and working for the hell of it. Then just before leaving (10pm saturday night) to make the 100 mile drive home I noticed the clutch pedal wasn't feeling right... Took the pedal cluster out and wow I was lucky to catch that before all hell broke loose.

(https://lh4.googleusercontent.com/-1EA_o9x7c2M/UbZFSQw1MtI/AAAAAAAAJ3g/ANdq1jKmW-s/w616-h821-no/20130608_190235.jpg)

(https://lh5.googleusercontent.com/-7TI7xVZDw8g/UbZFSSZ4RBI/AAAAAAAAJ3g/6krKl5A7MaA/w616-h821-no/20130608_190206.jpg)

Spent a few minutes getting it back together.

(https://lh6.googleusercontent.com/-Cr9tO4Np-NI/UbZFSeYNroI/AAAAAAAAJ3g/Yqvq5f3ELPg/w1095-h821-no/20130608_191535.jpg)

Then took a look at the gas pedal and noticed it wasn't even opening the throttle all the way... The cable spring mechanism had broke so I patched it real quick. Once in Tunerstudio my throttle sent from 0-70% open to 0-145% open! What a difference that made the car feel in response...

(https://lh5.googleusercontent.com/-Ee5iqSQdsBA/UbZFSTkuSdI/AAAAAAAAJ3g/YDbYJ-bIKCA/w1095-h821-no/20130608_194125.jpg)

Added a heat sink and the copper plate back to a new sensor. I know this isn't a great fix but it helped calm the AFRs down a bunch. I want to read the temp on the sensor at some point. Needs to be below 900 degrees on the outside.

(https://lh6.googleusercontent.com/-uWNf3_CWFdY/UbZFSd7bUkI/AAAAAAAAJ3g/DmwsIUltohY/w616-h821-no/20130608_190215.jpg)

I hid the activate switch in the seat heater however I never got the limits set right (lack of time saturday night/sunday morning) to get it for autox.. It was set around 3500 rpm launch and needs to be 4000 or 4500. The next event has a test and tune so I hope to take advantage of it then.

(https://lh5.googleusercontent.com/-BRMU91YashU/UbZFSZD-n8I/AAAAAAAAJ3g/4VCcwS_sn9w/w1095-h821-no/20130608_190224.jpg)

Sunday the autox went well. I didn't have my ducks in a row to datalog and whatnot this time. However I took some advice and set the tires to 40psi all around. That helped, a long with the boost coming on around the 3500-3800 mark with the new wastegate was a help. Then set the rear shocks to full soft which didn't really help the tire lift, new springs it will be.

We ran 3 drivers and 2 in a single heat. The car, with two drivers, got a little too hot. Sitting around 210-215. I was a little uncomfortable with that and will be adding a oil cooler very soon to help combat the heat. We tried taking the hood off, but it really didn't help I don't believe.

The car did better than I though it would, even with those small changes. It was a tight course and I even used 1st in one hair pin before the finish, which have never had to do before. Here are some photos.

(https://lh5.googleusercontent.com/-rERnFLtz8Os/UbZFSdZkouI/AAAAAAAAJ3g/P3XyZJbe2hQ/w1095-h821-no/20130609_133217.jpg)

(https://lh3.googleusercontent.com/TYLqOR0XK4zUpnAklhCPR3rLCJUCRFE1sHsQRxOwdMc=w1095-h821-no)

(https://lh6.googleusercontent.com/-NWuXbs8iD7I/UbZFSeNpvfI/AAAAAAAAJ3k/4rPdgEvPnSg/w1095-h821-no/20130609_150248.jpg)


(http://farm6.staticflickr.com/5321/9012893390_b7f62ec53c_c.jpg)

(http://farm8.staticflickr.com/7392/9011707411_8bb3a5d1da_c.jpg)

(http://farm4.staticflickr.com/3745/9012895402_524710a4af_c.jpg)

Pete driving, Mindy showing him the ropes!

(http://farm6.staticflickr.com/5337/9011760183_47c78e409d_c.jpg)

I like these two as well

(http://www.roddyhoggphotography.com/img/s9/v90/p1850635935-2.jpg) (http://www.roddyhoggphotography.com/p672493124/e6e4e769f)

(http://www.roddyhoggphotography.com/img/s8/v75/p1670166404-2.jpg) (http://www.roddyhoggphotography.com/p672493124/e638cb784)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: ccann26 on June 15, 2013, 05:42:15 AM

 I have a couple left over parts from my old 07 mazdaspeed3. A voltage clamp and a manual boost controller I fugured I could donate to you guys for the merkur or maybe you can sell them off to a mazdaspeed guy who doesn't hink his engine will blow up for the lemons car budget.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on June 18, 2013, 06:53:08 AM
Sure man, I'm not sure if I'll be able to use everything or not, but I'll happily take a to Justin's help.

Here are so quick images of the PBR brake swap. I ended up using the ebay brakes as cores while I kept the sliders and what not. I found one brake had two cracked pistons and AutoZone didn't have rebuild kits. So it was a easy decision.

Painted the DG brackets

(https://lh6.googleusercontent.com/-BB-CGKN21W0/Ub-RAn-V0aI/AAAAAAAAJ8o/Qsr4fKCtLtc/w1207-h905-no/20130614_144456.jpg)

Added the flex line and slider, also bought some $28 pads.

(https://lh6.googleusercontent.com/-Xuqgb5ZNW-w/Ub-RAk4bH5I/AAAAAAAAJ8o/ir6FSC9xZ0w/w1207-h905-no/20130614_150053.jpg)

Comparison of rotors and calipers

(https://lh5.googleusercontent.com/-UFmV-ECIlnM/Ub-RAqhitJI/AAAAAAAAJ8o/J1EB6B8CY5c/w1207-h905-no/20130614_144432.jpg)

(https://lh5.googleusercontent.com/-gZgqyscVcNQ/Ub-RAoUAT9I/AAAAAAAAJ8o/48HllEIbZiU/w1207-h905-no/20130614_144448.jpg)

Just does clear the wheel weights on 15s.

(https://lh5.googleusercontent.com/-xqnWdJlVcdE/Ub-RAsZgm4I/AAAAAAAAJ8o/iW2N1NgqLtQ/w679-h905-no/20130614_151308.jpg)

Bled them and took it out, long long pedal stroke but it will lock them up pretty easily once you get down there vs before where I couldn't ever get it to lock up. Upgrading to the later year master cylinder soon I hope. It's autoxable but I'd like it to feel a little better. Also better pads would help. Semi metallics are not the best.

Shot of what was accomplished on the VW for those who know about the project. Excited to see this come to life in 6-8 short months... Thanks Justin for the help. He made the dash w/defrost vents and all the panels as well as pedal stuff. Nice fit up too.

(https://lh3.googleusercontent.com/-4kE8vzv03Gw/Ub-RFhmtfiI/AAAAAAAAJ8w/XD2uOQDCADY/w656-h875-no/20130616_125624.jpg)

(https://lh3.googleusercontent.com/-9ofopuxoPlg/Ub-RFstLHUI/AAAAAAAAJ8w/PHAQ87tYccs/w1167-h875-no/20130616_125650.jpg)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on June 24, 2013, 10:28:38 AM
So, another weekend and more surprises. This weekends intent was to head home and finish up some welding for my father. However that soon went by the wayside as I discovered some stuff not quite right in the rear.

It started with me taking a rear wheel off to see what it would take to install some stiffer springs. I happen to glance over the CV on the passenger side and noticed this.

(https://lh4.googleusercontent.com/-UsCO3zApQoI/Ucc0uezMhVI/AAAAAAAAKC8/0epzhWeeHIM/w464-h619-no/20130622_091431.jpg)

And after poking around a bit I found a few other issues. All but 2 on the passenger side CV where hand tight, and all on the driver needed a little more snugging up, oh well easy fix and tightened them up. Then I took a look at the Diff and it was missing 90% of its hardware! I can't believe I hadn't noticed it. The car hadn't made any more noise than when I first got it, so my guess it had been missing for some time. All was holding the front of the diff up was a single, hand tight, 1/2" bolt with a broken nut.

I made a bunch of new bushings and heavy washers in the lathe. Then got new grade 8 bolts and lots of locktite to finish putting everything back together and torqued the crap out of it. I felt very luck to have caught this before something serious had happened. Especially considering the number of autox's this thing is going to see over the next few months.

Here is the heavy washer painted with locktite and ready to go on.

(https://lh6.googleusercontent.com/-h5ww2AsqTeI/Ucc0ufzn-lI/AAAAAAAAKC8/uFkNsPkV6EY/w825-h619-no/20130622_134834.jpg)

Bushings I had made.

(https://lh3.googleusercontent.com/-BVGpQakmB0A/Ucc0ufX6oKI/AAAAAAAAKC8/yvCQ9FIbRI8/w825-h619-no/20130622_135251.jpg)

While I was there I put in the new 650lb springs.

(https://lh4.googleusercontent.com/-_KSzye52m7c/Ucc0uQVj7DI/AAAAAAAAKC8/LFNTR_ekRXo/w825-h619-no/20130622_162917.jpg)

Then cleaned everything up on the underside. The driverside rear pumpkin seal is leaking some, so that is something higher up on the list.

(https://lh5.googleusercontent.com/-uDPnovJ5bYo/Ucc0ubA6Q7I/AAAAAAAAKC8/t39KWH6zMMk/w825-h619-no/20130622_180325.jpg)

I did decide to so some lightening of the car.. Got roughly 95 lbs out with the following. 15-20 more to go with the tar. It sadden me a little but I'm keeping everything nice so it can go back in late next year when we "retire" the car... we will see.

(https://lh5.googleusercontent.com/-eXVCbQOTREo/Ucc0uXSi3OI/AAAAAAAAKC8/XLvSvV5ks1U/w825-h619-no/20130622_211347.jpg)

(https://lh5.googleusercontent.com/--YghZ_fwbuM/Ucc0uTalbFI/AAAAAAAAKC8/UtK1Pw6RjXY/w464-h619-no/20130622_211350.jpg)

(https://lh4.googleusercontent.com/-cIHPY8PK5sg/Ucc0uQNX70I/AAAAAAAAKC8/Re6UL99arco/w825-h619-no/20130621_180230.jpg)

Here is current race weight. I think we can get into the 2600's with a few more "easy" things. More on this later. For comparison my mk5 GTi weighs in at 3200lbs and Mindy's rabbit is 2900lbs. 

(https://lh3.googleusercontent.com/-ATjvBfhczkM/Ucc0uVvAzOI/AAAAAAAAKC8/3xLPZJiqq5I/w825-h619-no/20130621_191716.jpg)

Then swapped out the pads and bled the brakes again in the front. The new master cylinder is here from merkurdepot and I am looking forward too the upgrade. The pedal is still too long for my tastes but these new pads are so much better. AutoZone let me take the old ones back and pay the difference to these ceramic pads. I'd daily/autox these, as they bite harder once a little warm and have a decent cold bite.

(https://lh5.googleusercontent.com/-66-4d7xAuSc/Ucc0ufByj-I/AAAAAAAAKC8/j4VIHBnFjtc/w825-h619-no/20130621_184105.jpg)

(https://lh5.googleusercontent.com/-7mLmwZzl3Yk/Ucc0uY285xI/AAAAAAAAKC8/4pNEGkzT22E/w825-h619-no/20130621_184116.jpg)

Till next weekend.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: jloehlein on June 26, 2013, 05:49:15 PM
I think we can get into the 2600's with a few more "easy" things.

Remove the rest of the bolts on the car?  :)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on July 01, 2013, 11:21:24 AM
Yeah no kidding. The car tried undressing itself.

OK so this weekends work...

I finished swapping out the LCAs with the longer scorpio units. Along with new ball joints and also new bushings.

Started making new bushings as I didn't realize the bushings where bigger in the scorpio units vs the old xr ones. Luckily I found a block of nylon I had lying around that was thick enough.

(https://lh5.googleusercontent.com/-nF1UKLOs6Ks/UdCIiyvFjUI/AAAAAAAAKJA/9GuMA7LXpjA/w825-h619-no/20130629_084754.jpg)

The block it came from

(https://lh3.googleusercontent.com/-u7qP6SpQrMI/UdCIi78LVoI/AAAAAAAAKJA/H_MhQiRZOL4/w825-h619-no/20130629_085300.jpg)

While I was making stuff I also made some caster bushings. Everything helps.

(https://lh6.googleusercontent.com/-QhNCTGBHzUk/UdCIi8Qfr8I/AAAAAAAAKJA/k-fp2nhnGVE/w464-h619-no/20130629_094951.jpg)

(https://lh6.googleusercontent.com/--hMzmAoawC0/UdCIi-8BIDI/AAAAAAAAKJA/T5He5LIyk8U/w464-h619-no/20130629_095004.jpg)

New inner tie rods where needed. Here are the comparisons. I'm not sure where Mike at merkurdepot got the middle one but it was perfect. The longer of the 3 was a tad too long and I had to move the steering wheel a hair to the right and realign.

(https://lh4.googleusercontent.com/-lezQeBAmAvg/UdCIi1HJmWI/AAAAAAAAKJA/IhpByDmPfBI/w464-h619-no/20130629_102715.jpg)

Everything buttoned up.

(https://lh3.googleusercontent.com/-yHtVa9bUkZ8/UdCIi-3EnaI/AAAAAAAAKJA/di38snk6cB4/w464-h619-no/20130629_122719.jpg)

Better view of the caster adders

(https://lh6.googleusercontent.com/-0Tx9F4kmGFg/UdCIi-cxPxI/AAAAAAAAKJA/QlL7Z3Oyz9A/w464-h619-no/20130629_122734.jpg)

Took some "persuasion" to get the sway bar back in place with all the changes (longer arms/caster adders)

(https://lh5.googleusercontent.com/-QCdpDOlgcGM/UdCIiyml5ZI/AAAAAAAAKJA/Zbrqyyavjo0/w825-h619-no/20130629_120642.jpg)

Finial camber, can't find our camber gauge so I'm not sure where it is lying right now. But it is better than before and the front track is noticeably wider. I feel I will have to clearance our wheels now again.

(https://lh3.googleusercontent.com/-CJPgdyo-H0U/UdCIi-vMw9I/AAAAAAAAKJA/tLfcPJwN490/w464-h619-no/20130629_161414.jpg)

On the way home there is definitely a change in feel. My rear toe is off right now and the front alignment was done by myself and is around 0-1/8"  out? Next weekend I'll have extra hands and I can do a proper alignment all the way around in preparation for the upcoming events.

Issues to attend too next weekend.

1. Rear main seal is leaking and I can't find a level plug on the diff. Which is really confusing as I looked all over the place for it. Does anyone know something I don't about this and these covers?

Right side

(https://lh4.googleusercontent.com/-04A4MD2iKM8/Ucc0udypMSI/AAAAAAAAKC8/2qp6mp2dJBw/w825-h619-no/20130622_180358.jpg)

Left side

(https://lh6.googleusercontent.com/-D23pyO4_GjI/Ucc0uYMjZbI/AAAAAAAAKC8/1fC-d8ITXos/w825-h619-no/20130622_180333.jpg)

Cover pic. See the fill? That can't be level right?

(http://www.jegs.com/images/photos/600/619/619-101-10.jpg)

2. Hits boost cut (20psi) at 4k-4.5k (wastegate isn't opening all the way/too much preload or there is some other issue at hand)

3. Removing the rear tar should drop a little more weight out, plus clean it up back there some.

4. Oil cooler, car is still getting hot in traffic.



Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: jloehlein on July 01, 2013, 06:17:39 PM
Fill level is usually about axle height.  I believe the aftermarket covers put them up so high so that you just add a specific amount of fluid, not filling it until it comes out the hole.  Maybe take an axle out and fill it until it comes out the axle hole.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on July 02, 2013, 11:36:25 AM
I was worried about that. So the amount of fluid needed: Thunderbird spec'd + the amount that the LPW cover gains you... = ?

I think you are right though. Clips hold each half shaft in the axle, let fluid start to drain out the side. Stop adding fluid and pop axles back in.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on July 08, 2013, 08:21:33 AM
Another weekend and more work done. I didn't document everything as I usually do but I will hit the highlights.

Things fixed:

1. Rear toe by adding back the rubber spacers above the rear springs. Toe at 0 maybe a 1/32 in.
2. Aligned the front, was at 1/4" in (super spongy) now at 1/16" out. Nice and tight feeling.
3. Fixed the over boost issue with less preload on the wastegate. Now boosts to 15psi and no further, time to get the EBC working
4. Rear driver side seal in the differential and new fluid.

(https://lh4.googleusercontent.com/-fFkwv-Ce0WU/UdqvXSbd2BI/AAAAAAAAKPg/EFVhyDarccc/w1096-h822-no/20130706_220644.jpg)

(https://lh4.googleusercontent.com/-pg3mY1D5XXc/UdqvXXl3j2I/AAAAAAAAKPg/qf4-yM_-cEE/w1096-h822-no/20130706_204805.jpg)

Started making a aluminum water tank.

(https://lh6.googleusercontent.com/-Pgmz-11qkMw/UdqvXcpvGsI/AAAAAAAAKPg/XPa4Apw_M6E/w1096-h822-no/20130707_184350.jpg)

This little guy ran into the arc when I was welding. Never had that happen before.

(https://lh4.googleusercontent.com/-nTakDKLSuWo/UdqvXRaj06I/AAAAAAAAKPg/GSlDZ9pZngI/w1096-h822-no/20130707_180159.jpg)

Just need to finish up a few little things.

(https://lh6.googleusercontent.com/-CEMoW3Tj9gQ/UdqvXSgNH0I/AAAAAAAAKPg/W89aWpsyDmk/w1096-h822-no/20130707_184509.jpg)

Autox next weekend and I'm excited to see how the car fairs now.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on July 15, 2013, 01:43:54 PM
Ok another weekend and another event in the XR. This thing is starting to come together now.

This weekend was a autox on day 1 and a test and tune day 2. First day was a tight course, two places I used 1st gear. Second day was more open, stayed in 2nd. Justin and Jeff both confirmed this by taking some driving excursions Sunday in it. Needs more low down, some how we have got to get it. Smaller turbo, more timing downlow, V8.... something...

With the scorpio arms our setup up front. Looks to have increased the camber and track width quite a bit.

(https://lh6.googleusercontent.com/-LQmq2UpxrUc/UeGrsyYknAI/AAAAAAAAKRE/XpItGVkl0T8/w584-h779-no/20130713_092940.jpg)

Before grid

(https://lh6.googleusercontent.com/-eajeIIJ7qo0/UeGrs3WKHhI/AAAAAAAAKRE/vmcCYFGB09Q/w1039-h779-no/20130713_092948.jpg)

Issues we had to deal with.

Over heating as always. Here is the XR with it favor flavor of cooling. It was mid 90s outside.

(https://lh3.googleusercontent.com/-7OVGBf1KMwE/UeQqS6dE-EI/AAAAAAAAKSQ/uInjQKfo3IE/w1039-h779-no/20130714_132725.jpg)

Fender clearance was also a issue. Hammer won't fix this so we will have to raise the front of the car a bit.

(http://farm8.staticflickr.com/7345/9279163979_dbf8ccec73_b.jpg)

At the end of the second day the steering rack went to shit. 3/16" toe in and out and a bad wobble on the passenger side. It was a new autozone rack. I'll have updates on this hopefully soon. Next weekend is also a two day event so I got to get it fixed before then.

Other additions before Saturday.

There is a new firmware for Megasquirt I'm going to try in order to stop this start kick back issue we have.
Pressure test the MAP sensor line. Getting boost shutter around 16psi
Raise car in the front
Re-align after rack replacement
Fan relay sticks on so we will need to get a new relay
Make some clearance for the brake pads in the sliders as they are sticking and getting the pads hot = not the best hot braking.

Going to be a busy week...


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on July 19, 2013, 09:07:44 AM
The inner tie rod loosened up and gave me a ton of wobble. This was a scorpio inner and I didn't have a replacement so I had to make one. First thing I did was beat the hell out of the joint to tighten the socket around the ball up some. That helped but I was a little sketched out as I will be putting the sticky tires back on it again this weekend for another event.

(https://lh3.googleusercontent.com/-wtQJREGV83M/UelMvmVtvGI/AAAAAAAAKUI/siiTV4d-9ZU/w1167-h875-no/20130717_201941.jpg)

Then I drove to the shop yesterday and made this replacement by adding .875" to the overall length of a new xr4ti unit. All I had to do was machine a little bushing and weld it in place.

(https://lh3.googleusercontent.com/-T6th3WqgYMY/UelMvq-B3PI/AAAAAAAAKUI/aBy7RMVpT-o/w1167-h875-no/20130718_202432.jpg)

(https://lh6.googleusercontent.com/-aSyW8XFLSTQ/UelMvkX62zI/AAAAAAAAKUI/Qe2S5PFnKJ4/w1167-h875-no/20130718_202441.jpg)

Everything is nice and tight now. Happy with the results so far.

I also got the brakes working a TON better by removing some small rivets on the top of the pads that were causing the caliper to twist and keep some pressure on the rotors. It releases well now and I can actually spin the wheel freely. Braking improved a bunch as did pedal feel. I'm still on the stock early MC so I think once I have the bigger MC on it will be perfect.

Lastly I jacked the front of the car up around 3/4" to see if that will keep the tire rubbing at bay. Will lower it as necessary.

-Paul


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on July 22, 2013, 03:30:29 PM
Ok update. Here we go, one step forward, two steps back.

Packed the car up to go to the Virginia Commonwealth games autox. Wheels and tires fit nicely with no back seat.

(https://lh6.googleusercontent.com/-4ks7aqRGFjE/Ue2lR4fN_cI/AAAAAAAAKaM/k3mHuRXgH2E/w1167-h875-no/20130720_062029.jpg)

Got there, unpacked, walked the course and noticed the differences in make up of concrete and asphalt. I decided to get Mindy to run in the second heat due to the fact that the heats were small and having a car that overheats doesn't make it friendly with two drivers. I would run the third heat.

(http://farm8.staticflickr.com/7404/9328830757_cd08ba8e82_b.jpg)
(http://farm6.staticflickr.com/5450/9331625116_b19e516214_b.jpg)
(http://farm6.staticflickr.com/5546/9329775979_c4d139e413_b.jpg)


On her 2nd run she was saying how hard it was to control the rear end as this course had bumps and kinda like a washboard effect in areas. I adjusted the rebound and she went out for her 3rd run, she came back saying it got better but still a little too loose, we decided to leave the settings alone. On her 4th run she hit that washboard area which was also a fast 3 cone slalom. From there it got loose and it bit back taking her straight off into a ditch/hill combo. That was the end of our weekend.

(https://lh4.googleusercontent.com/-dGyfzWG8QT4/Ue2lR2o9K0I/AAAAAAAAKaQ/Rn8_H6uQeuM/w1167-h875-no/20130720_170651.jpg)

(https://lh5.googleusercontent.com/-gal1AEnDXaI/Ue2lRwgSHtI/AAAAAAAAKaU/pfb-ZkRdNXc/w1167-h875-no/20130720_170500.jpg)

(https://lh4.googleusercontent.com/-M99v9ZsaTKA/Ue2lR2aJENI/AAAAAAAAKaQ/IGDmHgawIvQ/w1167-h875-no/20130721_105714.jpg)

(https://lh4.googleusercontent.com/-NK9oRJLwX28/Ue2lR5eXdOI/AAAAAAAAKaQ/t6It_ZlduRM/w1167-h875-no/20130720_131751.jpg)

(https://lh6.googleusercontent.com/-s1Lex9UzUEI/Ue2lR9f5WPI/AAAAAAAAKaQ/QXMf8CemJPc/w1167-h875-no/20130720_220432.jpg)

Damage is as follows.

Radiator fans
Kinked both frame rails
Moved both quarter panels in
Exhaust is bent up
Fuel tank bent up
subframe bent up
LCA on passenger side may have issues
Intercooler
Bumper and supports
core support
piping for intercooler and radiator
1 hooser has a cut, other flat spotted
Possibly the sway bar
Possibly the steering rack

So, now comes a few more things to do. A NPR intercooler popped up on ebay saturday night and I snagged that for 150 bucks. Radiator will be replaced with a dual core unit that will fit and perform much better than what I had. I already had a larger fan and oil cooler at the shop, so those didn't get damaged and will be added. Going with a volkswagen jetta bumper most likely. Next weekend I hope to cut out everything that got bent up and start fresh with tubing and new straight material vs trying to straighten this crap.

So glad she is ok. She wants to get back in the seat again at the next event which is in the middle of august. Hopefully I can have it at least driving by then even if not street legal with lights and what not.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: jamescarriv on July 22, 2013, 05:07:47 PM
Bummer, I look forward to seeing your fabrication work. I know how hard fabrication can be. It takes me 4 hours to make a block of aluminum into a smaller block of aluminum with a hole in it.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: rothaus on July 23, 2013, 06:43:54 PM

(http://farm8.staticflickr.com/7404/9328830757_cd08ba8e82_b.jpg)

Wow, this looks like Verona, just recognize that trailer in the background, it's where you go to that turn-around. Than place is very bumpy and full of gravel, it always feels like the car is getting sand, or gravel blasted. I actually go up there on August 4th for the PCA AX.

I may missed something, but what was the reason ? Suspension something ? I hate to see this, and I hope you get that car back soon.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on July 24, 2013, 04:45:53 AM
It was Verona like you mentioned. The car was way over damped and even the spring rates where a little too high for that environment. Most people were on a stock or close to stock spring rate, it was a noticeable difference between watching them and watching Mindy. Not only that but she was on cold tires which made grip even harder to come by. We learned a lesson or two from the weekend, hopefully it will be the last time for this car.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: KasbeKZ on July 24, 2013, 05:00:40 PM
it's tough seeing that happen after all that work we've seen you put into it before! i hope it gets back up and going without too much fuss.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: gunny on July 26, 2013, 04:06:20 PM
I've see them do magic on the car in 30 minutes!
It went from a smoking mosquito killer to a drivable car in just a hour or so!
I'm sure the car will be better than ever when Dr.Frankenstein and his accomplice get there hands on it.

:)

Gunny


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on July 28, 2013, 07:37:06 PM
Thanks Gunny, I'm not sure if this is considered better than ever but its something. Here is this weekends work.

I got some alone time in the shop this weekend. After many people offered up straight shells and things like that I decided to go against the gain a bit and just hack out everything and make it my own construction. You be the judge. Upgrades include a bigger aluminum radiator, big fan and much much larger NPR intercooler.

Roughly cutting it out

(https://lh5.googleusercontent.com/-bQaEiAxtM3o/UfXMoxa6HoI/AAAAAAAAKqc/YWxK9dX6lK0/w825-h619-no/20130726_115449.jpg)

(https://lh4.googleusercontent.com/-o3m3Y18Wibg/UfXMo7_LsCI/AAAAAAAAKqc/oS2Nl4hSgH0/w825-h619-no/20130726_115501.jpg)

The material

(https://lh4.googleusercontent.com/-p5diCa9cPFk/UfXMo9xJX3I/AAAAAAAAKqk/YpAWF0D3SGY/w825-h619-no/20130726_145838.jpg)

Added some tubes back in its place. Mocked in radiator and intercooler. I had to lean everything a lot of get it to clear everything. I really like it so far as it leaves tons for room for the fan assembly.

(https://lh6.googleusercontent.com/-8_Pnvwt1OY0/UfXMo_glpcI/AAAAAAAAKqo/BUxpead4Soo/w825-h619-no/20130727_133307.jpg)

Upper support that I will be changing and adding the OE latch back I hope. You can see everything there. It all fits pretty tightly.

(https://lh3.googleusercontent.com/-sQh29BhfRto/UfXMo2wht6I/AAAAAAAAKqo/5aUuyAquEbc/w464-h619-no/20130727_185115.jpg)

Added some splash shields and called it a day.

(https://lh4.googleusercontent.com/-a_9PqfXE_tc/UfXMo3aR1KI/AAAAAAAAKqo/7N-cz0oR2Y4/w825-h619-no/20130728_140251.jpg)

Tubes will be blue, everything else will be a semi matching silver we found. Mindy did the painting and specifying of the colors.

(https://lh5.googleusercontent.com/-Ly_peAkDKT0/UfXPG8CqwOI/AAAAAAAAKq4/vktWl4OjiY4/w825-h619-no/20130728_142225.jpg)

(https://lh3.googleusercontent.com/-vpZmws8O5A0/UfXMo3fAogI/AAAAAAAAKqk/YSJ6zAnq40o/w825-h619-no/20130728_145059.jpg)

(https://lh6.googleusercontent.com/-VTs1cIkc098/UfXMo-Bd6II/AAAAAAAAKqk/SMXSTCIW1vM/w825-h619-no/20130728_145115.jpg)

(https://lh6.googleusercontent.com/-Wu75nEP2LSo/UfXMoz61jKI/AAAAAAAAKqk/CklVVNKvbMg/w825-h619-no/20130728_151715.jpg)

Long weekend of shop work but so far so good. I'll have part of a day next weekend to make a coolant take and possibly start figuring out the new intake structure and direction. Got a couple ideas there as well. We will see.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: jloehlein on July 29, 2013, 09:55:48 AM
Good stuff.  It looks happy, especially in the last picture.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: rothaus on July 29, 2013, 05:21:12 PM
I agree it looks happy

(https://lh6.googleusercontent.com/-Wu75nEP2LSo/UfXMoz61jKI/AAAAAAAAKqk/CklVVNKvbMg/w825-h619-no/20130728_151715.jpg)


Great job on getting it back together, especially if you have a mechanic like this

(https://lh5.googleusercontent.com/-Ly_peAkDKT0/UfXPG8CqwOI/AAAAAAAAKq4/vktWl4OjiY4/w825-h619-no/20130728_142225.jpg)
.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on August 04, 2013, 03:24:16 PM
Ok. Mindy and I got a hot moment, between family events, on the car this weekend. I'll let the photos do most of the talking.

Started mounting the bumper. Picked this up for 89 shipped brand new on ebay. Gotta love ebay crap...

(https://lh4.googleusercontent.com/-y31zPnjDhzw/Uf7MxXJIlfI/AAAAAAAAK14/Vn1Yyk8PBgI/w825-h619-no/20130802_105513.jpg)

Used a simple hood pin setup that I did with the VW. Works really easy and when I need to go on a trailer... which seems to happen a bit... It pulls off super easy with 2 clips.

(https://lh6.googleusercontent.com/-ivA966SxLAw/Uf7MxVSyOYI/AAAAAAAAK14/eV8x35ZTyMw/w825-h619-no/20130802_200626.jpg)

If the readers remember back I started making an intake. This weekend I figured I finish that up and get it on the car.

(https://lh4.googleusercontent.com/-nFqz5TVP2KQ/Uf7MxVSSohI/AAAAAAAAK14/9PvxgD-5mXU/w825-h619-no/20130802_190710.jpg)

Started pulling the wiring apart for the head lights, fan and LC1. Then rolled it outside to sweep up the shop.

(https://lh5.googleusercontent.com/-YzvGXpxobic/Uf7MxXbbheI/AAAAAAAAK14/4_nSCVjCB_0/w825-h619-no/20130802_200657.jpg)

New jack point works well too.

(https://lh4.googleusercontent.com/-vUwwGRtKgZM/Uf7MxRn6HAI/AAAAAAAAK14/rxcmuuxF1_U/w825-h619-no/20130802_135421.jpg)

Then Mindy finished painting the front silver.

(https://lh4.googleusercontent.com/-sLmhSwLoS3c/Uf7MxZTEiPI/AAAAAAAAK14/l82m7PeuL4Y/w825-h619-no/20130803_115038.jpg)

(https://lh5.googleusercontent.com/-Fl9wexaypFA/Uf7MxZb_ojI/AAAAAAAAK14/uo4y6HoYIJw/w825-h619-no/20130803_120028.jpg)

Look how much room I have now to pull a motor!

(https://lh6.googleusercontent.com/-oo_QPLMNp6c/Uf7MxR3AdII/AAAAAAAAK14/gb-vCqEIG0s/w825-h619-no/20130803_120015.jpg)

(https://lh4.googleusercontent.com/-7EkfHkiBMyI/Uf7MxdQuxGI/AAAAAAAAK14/Lk5bhFGmZ6U/w825-h619-no/20130803_120021.jpg)

Then I cut the front for some intercooler flow.

(https://lh5.googleusercontent.com/-lcQ1wkNsAaA/Uf7Mxfk3LxI/AAAAAAAAK18/8YwsYm9l9Mg/w825-h619-no/20130803_133142.jpg)

(https://lh5.googleusercontent.com/-wFoBx8VRqfM/Uf7MxWpj5OI/AAAAAAAAK14/dgb-m_hWTak/w825-h619-no/20130803_133203.jpg)

(https://lh6.googleusercontent.com/-suCefRL8bFg/Uf7MxZ2K48I/AAAAAAAAK14/4qZ_fiVDzeo/w825-h619-no/20130803_133119.jpg)

More next weekend I hope. Boost pipes, radiator tubing, a little wiring clean up, fan mounted, and make a coolant tank. Then we will see what happens.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: rothaus on August 04, 2013, 05:37:59 PM
Great work, looks good. I like the hood pin idea !

These new bumpers give you a great start to put some flares on the front fenders, if I look at this picture on the right fender.

(https://lh6.googleusercontent.com/-ivA966SxLAw/Uf7MxVSyOYI/AAAAAAAAK14/eV8x35ZTyMw/w825-h619-no/20130802_200626.jpg)



Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on August 05, 2013, 06:18:38 AM
Keen eye there! I've already got some flares from the VW here that I matched up and they fit very well. However Mindy isnt a fan of plastic flares so we will have to work it out.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: ccann26 on August 05, 2013, 08:17:37 AM
After seeing Jeff's csp miata and Martin Kriz's sti I'm a fan of flares :-)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on August 05, 2013, 04:42:53 PM
If it is done right. It looks pretty sweet as those cars do.

I wish I could afford/cared enough to get a real cosworth flares.

(http://fc09.deviantart.net/fs44/f/2009/146/9/a/Ford_Sierra_Cosworth_RS500_2_by_Kverna.jpg)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: rothaus on August 05, 2013, 06:58:26 PM
It looks like it came from the factory like it. Wait a minute.... this is not your car.. LOL


How about this version, some fiberglass and some patient, and replace the Labatt's with Legends or Extra Billie's

(http://airboxer.com/images/beer.gif)


(http://listmymotor.com/images/uploads/admin/sierra4.jpg)

Looks like you got the center cooling opening correct.

Cheers
Engelbert


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on August 08, 2013, 09:42:59 AM
I'd love too. Even have rolls of carbon fiber sitting right here. However this thing is suppose to be a "budget build" as the VW is getting all the goodies. We are hoping to do a CF hood for this thing this winter if time allows to lose another 25lbs on the nose.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on August 19, 2013, 06:39:06 AM
Didn't get much done this weekend. Lots of chores that weren't car related but here is what I have done.

Started another attempt at getting a hood latch and other fixture in the car. I want to retain the OE hood latch and not drill holes in the hood. Hopefully it was worth the extra amount of time. The best part is I made a quick hood prop, no more tubing. You can see the top has weld on tabs for a plastic panel that gets laid in. That way air can't escape up and over the intercooler. Side skirts are next around the intercooler possibly.

(https://lh4.googleusercontent.com/-V_W81M3vW30/UhAuEDvjWWI/AAAAAAAALMA/nsOBgdUs8sc/w825-h619-no/20130817_194935.jpg)

Started making another water tank. This one is smaller and should fit better. The other wasn't working due to the various tubes I had put in. Just need to get some fittings so I can finish welding on the bungs and what not.

(https://lh3.googleusercontent.com/-f77b1kWzQ_c/UhAuELGl9XI/AAAAAAAALMA/rsZDLc67_6o/w464-h619-no/20130817_180648.jpg)

(https://lh5.googleusercontent.com/-9W6D7yUbkpk/UhAuEINqrBI/AAAAAAAALMA/J875dIw-tyQ/w825-h619-no/20130817_195027.jpg)

I'm in the area where it doesn't look like much is getting accomplished with the time invested. Next planned event is Sept 21st and 22nd. Wish us luck


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on September 02, 2013, 06:43:54 PM
I got some time on the car this weekend. I hadn't in the last couple so it was nice seeing a little progress.

Started by finishing the coolant tank. This was also pressure tested for the first time and seemed to be fine at 10psi.

(https://lh4.googleusercontent.com/-b0EzsTcFRDQ/UiUD2kZOOAI/AAAAAAAALWk/_bCKDp4Xd-A/w825-h619-no/20130831_124711.jpg)

(https://lh4.googleusercontent.com/-bXtcQbhMlpc/UiUD2h7ir3I/AAAAAAAALWk/3ITKsvA0Res/w825-h619-no/20130901_174438.jpg)

Then I moved onto the boost pipes. This didn't go so well as I made the mistake of buying cheap aluminum piping. I know I remade the driver side 3 times. Such a waste of time but now it's done.

(https://lh5.googleusercontent.com/-zB2rsYx34V4/UiUD2o_FmpI/AAAAAAAALWk/StDcSt8b484/w825-h619-no/20130831_124750.jpg)

(https://lh6.googleusercontent.com/-p9zz3XntGxU/UiUD2iQZWwI/AAAAAAAALWk/UKggNgYR7OA/w464-h619-no/20130831_124728.jpg)

(https://lh6.googleusercontent.com/-ve_TIbqKU_c/UiUD2oCyNiI/AAAAAAAALWk/-VF7_JiI2YA/w825-h619-no/20130901_204122.jpg)

(https://lh3.googleusercontent.com/--YVi34qG-Ag/UiUD2n6k8AI/AAAAAAAALWk/PxmveVLS6U0/w464-h619-no/20130901_204230.jpg)

From there I started a bunch of details. This included porting my intake some.

(https://lh6.googleusercontent.com/-6DZfWgI2_1I/UiUD2rc-gbI/AAAAAAAALWk/0LWhV5Ru5Fs/w825-h619-no/20130901_152554.jpg)

Adding features to the bumper support and started playing with wires.

(https://lh3.googleusercontent.com/-18Qupkr44RE/UiUD2ohN-II/AAAAAAAALWk/EoxTjUZ6etw/w825-h619-no/20130902_151806.jpg)

Running boost lines and water lines

(https://lh6.googleusercontent.com/-oq_3CZ2G4yY/UiUD2pXi2MI/AAAAAAAALWk/DdzBZhdgjkA/w825-h619-no/20130901_204340.jpg)

(https://lh3.googleusercontent.com/-FEheQS8NayY/UiUD2jQ1DzI/AAAAAAAALWk/UZyhVWTtjsg/w825-h619-no/20130901_204212.jpg)

(https://lh5.googleusercontent.com/-Z3sR9tRatns/UiUD2ucVqZI/AAAAAAAALWk/-w1Kg29XZ08/w825-h619-no/20130901_204152.jpg)

Just before I left I removed the sway bar. It is bent slightly so I'll have to figure something out very soon. Is a 28+mm bar, do it must be a rapido.

(https://lh5.googleusercontent.com/-bYW7pxg_-sk/UiUD2vIrg4I/AAAAAAAALWk/mNOTtq5970o/w825-h619-no/20130902_144745.jpg)

Still a huge amount but getting closer.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on September 09, 2013, 08:00:30 AM
Got the car running this weekend.

Swapped out the bent/tweaked sway bar with another I bought local. Turns out is was bigger than the Rapido bar.

(https://lh5.googleusercontent.com/-0u_POKzdLxs/Ui3C4ICpycI/AAAAAAAALcs/5yq1dzekuu4/w656-h875-no/20130908_102920.jpg)

Scorpio wagon bar.

(https://lh6.googleusercontent.com/-yrxrwRmdLWE/Ui0lrFIi9kI/AAAAAAAALZs/nbS5Ff1BIZU/w656-h875-no/20130908_102939.jpg)

That straightened out the front pretty good. Still need an alignment since a few little things are different.

Got everything else buttoned up somewhat. Coolant tank isn't leaking which is a plus and I like my little gauge.

(https://lh6.googleusercontent.com/-UgKyzVvHq4I/Ui3C4I8K09I/AAAAAAAALcs/AgBQOhYfc_0/w656-h875-no/20130908_190832.jpg)

(https://lh4.googleusercontent.com/-Pa1v_ITBGnk/Ui3C4CCURjI/AAAAAAAALcs/uDcC_OeX4r0/w1167-h875-no/20130908_175611.jpg)

(https://lh6.googleusercontent.com/-6JrM95zsi2c/Ui3C4DyIsvI/AAAAAAAALcs/_tOKpr9nkeo/w1167-h875-no/20130908_175624.jpg)

(http://[img]https://lh3.googleusercontent.com/-iR6IDvhAdJI/Ui3C4EoFcBI/AAAAAAAALcs/MZGRC9O4fNg/w656-h875-no/20130908_175631.jpg)

(https://lh3.googleusercontent.com/-iR6IDvhAdJI/Ui3C4EoFcBI/AAAAAAAALcs/MZGRC9O4fNg/w656-h875-no/20130908_175631.jpg)

Issues:

Car is getting hot sitting at idle outside with the fan on? 205-210
Coolant leak from around the front main? May be water pump gasket or the like.
Different hoses will be used for upper and lower.
Wiring is still loose.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: jloehlein on September 09, 2013, 01:55:05 PM
Nice!  What temp thermostat do you have in there and have you replaced it recently?  Could be causing it to run hot.  Also make sure you purge all the air from the coolant system, can be a pain in the ass.  Since your expansion tank is pressurized - do you have a bleed valve at the high point on the cooling system or something?  May need to add one.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on September 09, 2013, 02:10:36 PM
Coolant tank is actually the high point in the system. I'm going to put in a new t-stat or gut the current one for the following weekends event. Also running new upper hose as it has a kink in it as it, not bad, but not how I like to see it.

I asked a few other 2.3 turbo owners and they said 205-210 is normal.... IDK. I'm metering the water temp from the coolant returning to the tank (hottest possible) vs post t-stat like last time. So I expect the temperature to read a little higher. Once I get it back on the computer I should also be able to compare the temperature from the ECU sensor as well. I've got old data logs showing running temperatures.





Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on September 26, 2013, 03:43:37 PM
Ok update.

Got the car pieced together very quickly for a two day event. Car did ok. Still the same complaints.

Day one:

Had a water leak so I replaced the water pump and t-stat gaskets.

(https://lh4.googleusercontent.com/-QjnpLTj2fYY/Ujzk4vj_qUI/AAAAAAAALxE/SOGDkmNw6cU/w656-h875-no/20130920_144333.jpg)

Car was overheating quickly when I had last ran it with the new radiator and hoses. So I found a small pinching issue with the "universal" hose I used. So I went to ebay and got a few Samco hoses with the correct bends. I also threw in another t-stat. This seems to keep the temperatures down most of the way at idle while in the garage at least.

(https://lh3.googleusercontent.com/-VH9BmC4j5xg/UjzlBbkvBKI/AAAAAAAALxQ/2LXM_qhBi9M/w656-h875-no/20130920_194455.jpg)

(https://lh6.googleusercontent.com/-tAF1-zOntSo/UjzlaFoNNGI/AAAAAAAALx0/Xv89YKr8ogU/w1167-h875-no/20130920_194521.jpg)

Then pulled the car on the trailer, wrenched on the launch control switch and headed to the event. Up until this point the car had run maybe 5 minutes since the accident. So I wasn't going to risk driving it to the event. Father and Uncle assisted with the loading early that morning.

(https://lh4.googleusercontent.com/-vHcSpi0DUSM/Uj4FKmDPUhI/AAAAAAAALyk/03uyXRRRK88/w1167-h875-no/20130921_083750.jpg)

The event was 2 hours away at RIR and I showed up late. Got in the car and ran some times with the street tires. Those tires are incredibly hard and old. From there I moved to the hoosiers. It was a short course at about 35 seconds. Spun the car big time (360*) for the first time staying in it after a straight trying not to lose boost over the little crest in the middle of the lot. Complaints where the same as they always are. TURBO LAG!

The car ran really really bad at idle and I found out that the Alternator was messing with the TPS sensor. Fixed it on day 2 by twisting the wires and moving it above the TB. Thanks for the advice Bernard!

(https://lh6.googleusercontent.com/-yRabBqMEzJ0/Uj-W1-mpz1I/AAAAAAAAL2M/m2qno_tQllc/w656-h875-no/20130922_090801.jpg)

Day Two:

Points autox. Long course at about 60 seconds. I thought I was doing better than I really was. FTD was around a 52 seconds. I landed a 57.2. I knew I could do a 56 but it never materialized. I wish I had GPS this event as I thought I made some improvements to the line in several areas but never could prove it. Playing with how early I could get on power as there were 4 big sweepers.

I think David took pictures at this event. I'll post them when they post them.

(https://lh6.googleusercontent.com/-czN7KfGwi-8/Uj-XQoVeZnI/AAAAAAAALzk/KHyyWwp43QY/w1167-h875-no/20130922_150955.jpg)

Complaints:
    1. Turbo lag still, looking for deals on ebay and the like. Once I get it on, I'm going to the dyno for tuning.
    2. Measured rear toe. Toe'd in 1/4" after the accident! something has moved. It was 0. Rear seems to "jump" around now.
    3. Car was overheating after a run. I've decided that I need more fans, the oil cooler installed and water wetter. It would climb to 220F+ if I let it.
    4. The front of the car seemed to bite better with lower strut settings, however everything up front feels numb by comparison.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on October 08, 2013, 01:36:46 PM
ITS BEEN A YEAR!

Wow car has really really changed over the last year. Hopefully next year will go a bit more smoothly with more tuning and less big changes.

Not much to add this weekend. Things are going to slow down a bit until early next season I think. Still have two events however they are farther away and towing a car for 6+ hours round trip for 5 minutes of driving seems silly.

But...

I did pick 4 of these things up for 100 bucks. They need a little work but should work nice as a HPDE/street wheel wrapped in 225/45/16 starspecs. Sorry for the blurry pictures.

(https://lh3.googleusercontent.com/-OzCKYxcq97k/UlHWL9_gqpI/AAAAAAAAL7U/BNiEAfa9SzQ/w825-h619-no/20131005_164607.jpg)

(https://lh6.googleusercontent.com/-j8YhxmW26Tk/UlHWLw5nygI/AAAAAAAAL7U/AyG8Y2DUyyE/w825-h619-no/20131005_164638.jpg)

Then I played with the VW tires on the xr. I dont think these will fit easlily :) I'm pricing rubber and wheel combinations for next season. Got all kinds of ideas in my head. I refuse to pay more than $100 a tire, so that puts a damper on what I can afford to do and how fast the car will be.

(https://lh4.googleusercontent.com/-T9jpk5kut9U/UlHWLyP1DRI/AAAAAAAAL7U/Z7b1OuCmKDw/w825-h619-no/20131005_170009.jpg)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: rothaus on October 08, 2013, 07:32:56 PM
Are these road race slicks ?

They looks bad A$$


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: wahoo5 on October 08, 2013, 09:25:49 PM
Paul,

Here is a list of used tires this guy named JP publishes. I got this form an autocross friend from DC. I have not used him, but Danny recommends him.

 October 7, 2013 Tire Inventory

20- 225/45/17 Continental Dry $400 for 4 shipped
12- 225/45/17 Continental Wet $500 for 4 shipped

20- 275/35/18 Continental Drys $500 for 4 shipped
4- 275/35/18 Continental Wets $600 for 4 shipped

4- 275/35/18 Continentals Dry NEW $200 each plus shipping

4 305/645/18 Pirelli slicks with 3/4 tread $150 each shipped

8 285/645/18 Pirelli Slicks NEW $200 each shipped

3- 205/50/15 Hoosier SM6
12- 205/45/16 Hoosier A6
4- 205/45/16 Hoosier HWET
6- 205/45/16 Hoosier R6

8- 245/40/17 Hoosier A6
2- 225/45/17 Hoosier HWET
2- 225/45/17 Hoosier H2.0
1- 280/680/18 Hoosier R100 Cup
1- 280/680/18 Hooser R100
3- 245/40/18 Hoosier R6
1- 275/35/18 Hoosier R6
10- 205/50/15 Toyo Proxes RA1
2- 200/600/16 Pirelli Slick
2- 245/620/17 Pirelli Slick
6- 225/45/17 BFG R1 (NEW): $180 each plus shipping
4-255/40/18  Yokohama Advan Neova ADO8



2 Bridgestone Potenza 225/40/18 RE050A RFT Run Flat Tire
2012 Build Date
9/32nds tread
Retail for $275 each

Asking $350 plus shipping ($175 each)


205/50/15 Toyo RA1
225/50/15 Toyo RA1

205/50/15 Hoosier R6
225/50/15 Hoosier R6

23/9.5/15 Hoosier R80

245/580/15 Hoosier R80

245/45/16 Toyo RA1

225/45/17 Hoosier A6
245/40/17 Hoosier A6

240/640/18 Yoko Slicks
280/680/18 Yoko Slicks

255/30/18 Hoosier R6
255/30/18 Hoosier A6

275/35/18 Hoosier A6
315/30/18 Hoosier A6

285/30/18 Hoosier R6
295/30/18 Hoosier R6

30/68/18 Michelin Slicks
30/65/18 Michelin Slicks
27/65/18 Michelin Slicks

2- 275/645/18 Pirelli Slicks
2- 305/645/18 Pirelli Slicks


Everything is $125 each plus shipping and 3/4 tread unless noted otherwise.

JP

You can get on his email list by sending him an email. His email is jphglobal1 (at) gmail (dot) com


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on October 09, 2013, 02:17:17 PM
Tires are from the VW. Originally from Bobby. I hope to run them on the EMod car.

Here is a blurry picture from way back.

(https://lh4.googleusercontent.com/-U00j8IS7xpQ/UB-vAtz2XFI/AAAAAAAACcE/YifjdoMS_CU/w1552-h875-no/2012-08-05_09-46-04_59.jpg)

An obligatory better one.

(https://lh6.googleusercontent.com/-L6klvczbL9Q/UXM6dqP6aRI/AAAAAAAAIog/tg7M8009l3A/w656-h875-no/20130420_094942_0.jpg)

David: Thanks for that list. I have a much better idea of what I will/should be getting by looking at that. Hmmm


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on October 17, 2013, 09:58:03 AM
Thanks David, as always, for the photos. I think Gunny took some of these as well. Thanks!

Here is a little bit of the wheel lock up we are experiencing. As soon as a wheel gets light, it locks. Even in small trail brake maneuvers.

(http://farm3.staticflickr.com/2850/10200668774_0ea484bf4c_b.jpg)

When I tightened down the front grill it bent it slightly. I'm now using zip ties so it doesn't look like this. Stupid mistake

(http://farm8.staticflickr.com/7435/10200863853_be4fc2bf79_b.jpg)

Couple of Mindy driving.

(http://farm4.staticflickr.com/3782/10200723374_1e3519f127_b.jpg)

(http://farm6.staticflickr.com/5526/10200666425_b9631d7cec_b.jpg)

(http://farm8.staticflickr.com/7441/10200686956_bdd25d10e9_b.jpg)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on October 28, 2013, 05:00:00 PM
So the off season has started on the car. Currently we are trying to get prepared to buy our first home in the coming months so money and time are a little tight.

Fast, cheap and reliable... Pick 2 so we are going to cheap and reliable this next season.

First order of business is the unreliable wiring. I started cleaning up unused items by stripping the loom and labeling the important items. Next I'll try running the wiring around in clever places to keep it looking decent.

(https://lh6.googleusercontent.com/-h-skkz-RM4I/Um1mvfJ-YwI/AAAAAAAAMC8/x4HcXjKLnVA/w464-h619-no/20131026_201258.jpg)

(https://lh3.googleusercontent.com/-tJzEOqdiOtM/Um1mvewnV9I/AAAAAAAAMC8/uDo4S15r080/w464-h619-no/20131026_201204.jpg)

(https://lh5.googleusercontent.com/-OyJRaIiJnAk/Um1mvfhx-NI/AAAAAAAAMC8/StzHTq_5cJE/w464-h619-no/20131026_201244.jpg)


Other reliability issues.

1. Brakes: Need to get bigger so I've got a plan using some more off the shelf items. I'll provide more details when I get some items in.

2. Cooling: Oil cooler installed and bigger fans that are ECU controlled

3. Tires: Street tires, drive to event and participate. I think there is a lot of "tuning" to do before jumping back to slicks again.

4. Turbo: The item on there now is a 60 dollar ebay unit. Moving to something like a used OE "modern" turbo.

5. Camber/Caster plates: If I can get them on in time. Not a expensive upgrade.

We will see how much time I have over this winter to complete the list.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: whiteryder on November 04, 2013, 08:39:03 PM

Did you catch the XR4Ti article in the latest issue of Grassroots Motorsports?


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on November 05, 2013, 11:12:02 AM
I'm still waiting to see it. That is Ben Martinez, really nice guy with loads of experience. I've been talking to him for a year or so now and actually had to turn down an invite for Mindy and I drive that exact car at nationals this year. He since has retired the car from nationals, shoulda coulda woulda. Hopefully his retirement won't last long and we can finally meet.

Glad someone recognized it. They are hard to find in the autox world.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: whiteryder on November 05, 2013, 12:37:40 PM
Glad someone recognized it. They are hard to find in the autox world.

Oh it's easy to recognize.  Just hard to spell.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on December 02, 2013, 02:47:50 PM
Long weekend but not any real work on the car. Hope everyone had a good turkey day.

Here is the electrical box I'm using and how I'm running my new wiring stuff.

Found these ammo boxes for 12.15 on ebay. Reason: its water tight, dust tight, keeps the heat off and organizes stuff pretty well.

Put a couple terminal blocks inside for common ground and common +12V supply (there will be more later).

(https://lh5.googleusercontent.com/-N0app3eqpAU/UpocUHx9FjI/AAAAAAAAMRs/pwxL5cQXXhM/w792-h594-no/20131130_105144.jpg)

Added these NEMA 6 cord grip fittings for all of the various wiring.

(https://lh4.googleusercontent.com/-WDxFea65re0/UpocbQOdAMI/AAAAAAAAMR4/lrbAcVdMQw0/w792-h594-no/20131130_105200.jpg)

Here is one installed

(https://lh3.googleusercontent.com/-H8r1ZgdBwqc/UppxIifdHNI/AAAAAAAAMSM/T8BJbE11Hm0/w792-h594-no/20131130_143028.jpg)

Started running ground and starter as well as some other circuits like LC-1, and sensors that need power from a common source. So far so good.

(https://lh4.googleusercontent.com/-ofS8bza57vM/UppxWfvjT_I/AAAAAAAAMTs/wWdYDdwJZ4I/w792-h594-no/20131130_165759.jpg)

Also ordered my custom "big brake kit calipers". Details coming soon!


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: 500KEG8 on December 03, 2013, 10:57:29 AM
Using a ammo box for the electrical box is bloody brilliant!!! It also seems like the ammo box could also be used as a battery box for a relocation if needed.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on December 30, 2013, 07:22:12 AM
Didn't get too much done over the holidays, as time became an issue. Here is a small update.

I took a pause on the wiring for a bit to get the master cylinder replaced/updated to the larger bore of an '89 and add in a brake bias valve.

(https://lh5.googleusercontent.com/-hc7xY-omf2I/Ur45VdfA9gI/AAAAAAAAMc8/2zB9ZKQ4hWA/w1165-h874-no/20131227_094631.jpg)

(https://lh6.googleusercontent.com/-cS-hzmgpBzA/Ur45cajd54I/AAAAAAAAMdg/trh5dcCbao8/w1165-h874-no/20131227_101546.jpg)

(https://lh4.googleusercontent.com/-ZeBtNrRwzN8/Ur45Xxt516I/AAAAAAAAMdI/x71UqzwfFfI/w1165-h874-no/20131227_101537.jpg)

(https://lh4.googleusercontent.com/-I3m5JR3_zNM/Ur91yJk3ztI/AAAAAAAAMek/rbpqMvlrXfw/w656-h874-no/20131228_123423.jpg)

However I believe the fitting on the bias valve is ruined because there is a leak on the fitting that is facing the fire wall.

The wheels came back from a friend of my brothers who traded acid dipping these for a welding service.

(https://lh6.googleusercontent.com/yUPcwjnlPvTw1RfNxjZxd80Oq4AhvKmu_HiEoweeMqI=w1165-h874-no)

I played with them for a second polishing them up.

(https://lh4.googleusercontent.com/-XtMysbXnZq4/Ur915KdDOBI/AAAAAAAAMfI/WhHIbz9fIGQ/w1165-h874-no/20131228_123452.jpg)

Hopefully Mindy can paint them soon.

Later


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on January 12, 2014, 07:43:01 PM
Car hasn't got much attention since I've been working on another project over the last few months. This weekend I turned these pretty pieces of steel into a little system.

(https://lh3.googleusercontent.com/-024k88ksf3g/UtCL9x82QnI/AAAAAAAAN0c/aepjiUi8qPM/w792-h594-no/20140110_155856.jpg)

(https://lh3.googleusercontent.com/-Q3jm018YtuE/UtIApxZkHfI/AAAAAAAAN4o/jyjyV9Vwovo/w792-h594-no/20140111_154448.jpg)

(https://lh3.googleusercontent.com/-0MruOqxmwzk/UtIAwcs2BsI/AAAAAAAAN5M/vZgrW9gY1JE/w792-h594-no/20140111_161249.jpg)

Here are all the other bits. The thick stuff is 1" plate, the smaller is 3/4" plate to give you a perspective.

(https://lh5.googleusercontent.com/-vBCFg9fnrCk/UtIAy7C0ntI/AAAAAAAAN5Y/Xtm-sW989qA/w446-h594-no/20140111_192201.jpg)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: whiteryder on January 15, 2014, 11:54:00 AM

Look what I found.    :)

(http://i.ebayimg.com/t/Ford-Merkur-XR4Ti-Sierra-No-1-ICS-british-salon-Car-Championship-1-43-/00/s/MzAwWDUwMA==/z/v~kAAOxy7rdRFUU9/$(KGrHqNHJEwFERuY949CBRFUU9YN4g~~60_1.JPG)
http://www.ebay.com/itm/Ford-Merkur-XR4Ti-Sierra-No-1-ICS-british-salon-Car-Championship-1-43-/271153171881


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on January 16, 2014, 06:38:30 AM
That is sweet. What were you looking for on ebay to get that to pop up?


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: whiteryder on January 16, 2014, 10:58:29 AM
That is sweet. What were you looking for on ebay to get that to pop up?

You know how it goes.  You do a general internet search for X, which results in (among other things)
some hits on ebay for stuff related to X - that piques your curiosity so you check out the ebay links,
which then show you stuff related to stuff related to X - so you check a couple of those out and before
you know it you're looking at XR4Ti scale models.  (And just lost 1/2 hour of your workday.  ;) )


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on January 19, 2014, 07:16:02 PM
Successful weekend on the merkur. I've been meaning to trying this new brake idea I've had. Here goes.

MkV Gti calipers and pads
SVT focus rotors (almost 12")
'89 merkur master cylinder (larger bore than the '85)

On paper it should be a great setup, but I won't know until I drive it.

This weekend I got a moment to try to fit everything up. Here is the pad and rotor.

(https://lh4.googleusercontent.com/-wJRQMlnIbSM/Usmj8sdJhaI/AAAAAAAANjI/qnNPJE_lc9c/w792-h594-no/20140104_183012.jpg)

Size comparison between the previous 11" rotor from a SVT Contour

(https://lh4.googleusercontent.com/-Q7qTT6XG_iA/UtnPnSPg-KI/AAAAAAAAN8g/h6XfhjDXXIs/w446-h594-no/20140117_140517.jpg)

Made some adapters out of 3/8" bar stock

(https://lh5.googleusercontent.com/-traEaiMpkHo/UttFbSuZKiI/AAAAAAAAOE8/X-9xcBdmaaA/w792-h594-no/20140118_183111.jpg)

Bolted up. Same banjo bolts and crush washers where used as the mustang calipers needed. (Lucked out completely)

(https://lh4.googleusercontent.com/-86g6S5GwwvM/UttFgImnyVI/AAAAAAAAOFk/icbyw4qbjoM/w446-h594-no/20140118_185319.jpg)

Outside

(https://lh6.googleusercontent.com/-_0_iotUUXzs/UttFhq_JMwI/AAAAAAAAOFw/_UP_dAqfgVQ/w792-h594-no/20140118_185331.jpg)

Wheel clears! I've Only got about .020" or so between the slider and the wheel's inside pattern so a small spacer may be required. However these pads are only going to wear down, so that gap is getting larger all the time.

(https://lh4.googleusercontent.com/-4n-YfpCNL6k/UttDv6WENuI/AAAAAAAAN_U/yGZ43b_Dne0/w446-h594-no/20140118_101427.jpg)

Thanks and enjoy


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on January 27, 2014, 05:39:55 AM
This weekends work included mounting the two of the four tires and fixating the oil cooler. Not much else.

(https://lh4.googleusercontent.com/-wtx4Gha_-Lo/UuRvuWrhEfI/AAAAAAAAOJA/AG--xrjKXMA/w1207-h905-no/20140124_141343.jpg)

(https://lh3.googleusercontent.com/-JwGgYXInweM/UuRxQz64jhI/AAAAAAAAOL4/xU8-7-bWmiQ/w1207-h905-no/20140124_194357.jpg)

The club has a dyno day March 8th and I would really like to attend that. So I have got to get going.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on January 30, 2014, 11:02:20 AM
Here are a few other photos Pat took with an actual camera.

(https://lh6.googleusercontent.com/-UEFAOYt7OxQ/Uub_6GZUzwI/AAAAAAAAOv4/FjoghXMsm5Q/w1183-h784-no/DSC_0123.jpeg)

(https://lh3.googleusercontent.com/-UhGw-FywBA0/Uub_7X_kZbI/AAAAAAAAOxs/PMKmzlNAvEw/w1183-h784-no/DSC_0091.jpeg)

(https://lh5.googleusercontent.com/-B8MAKhAXgbE/Uub_0qBxeEI/AAAAAAAAOxk/K-H1cwdDyVw/w1183-h784-no/DSC_0127.jpeg)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on February 02, 2014, 04:31:12 PM
Another weekend and some more work completed. Coming down to the wire even though the first event is still 2 months out.

Items completed:

Wiring is at 90% now. Just a few little things left over. The box still has some stragglers in there but it is getting cleaned up.

(https://lh6.googleusercontent.com/-HjeVujtRXNA/Uu0tPpL5kTI/AAAAAAAAOyg/HAHHT24-bDA/w793-h595-no/20140201_120343.jpg)

Head light wiring is found at another fuse block up front. Note relays and fuses. This time I was smart and not only left extra wire length with a coil, but also added more wires in the harness than I needed for future growth.

(https://lh6.googleusercontent.com/-HsE5s5P2ISQ/Uu0tue1rBiI/AAAAAAAAOzQ/BhYDluG0Ipk/w446-h595-no/20140201_120429.jpg)

Dad finished up all the wheels for me. See before and after below. We are just going to leave them like this for now.

(https://lh3.googleusercontent.com/-Is32uY1svyE/Uu3BOvDddSI/AAAAAAAAOzw/G0_Ezn7CuRE/w446-h595-no/20140201_152959.jpg)

(https://lh4.googleusercontent.com/-dVoO4AlDHuE/Uu3BQ-6YoYI/AAAAAAAAOz8/uRZqMAkCrGA/w793-h595-no/20140201_153006.jpg)

Got a heat shield made for the turbo.

(https://lh6.googleusercontent.com/-nxoA1aY56HE/Uu3BSocDC3I/AAAAAAAAO0I/hgt6MHfBZw0/w793-h595-no/20140201_165317.jpg)

Almost got it complete until the welder cord crapped out. Made of stainless, I'll get better photos of it when I have it off next to finish it.

(https://lh4.googleusercontent.com/-HR18HQqZIwU/Uu3BulGra8I/AAAAAAAAO10/qB345LrkFV4/w793-h595-no/20140201_203818.jpg)

Passenger side of the engine bay is looking better than it ever has before. Wiring is run inside of fiberglass heat proof stuff.

(https://lh4.googleusercontent.com/-tGytyEjIlJg/Uu3B2dGz73I/AAAAAAAAO5g/-FKX6iD7M_I/w446-h595-no/20140201_203832.jpg)

How I left it.

(https://lh4.googleusercontent.com/-ldACb7ln8zc/Uu3B82DArVI/AAAAAAAAO2Y/WKdz_mnk0_0/w793-h595-no/20140201_203853.jpg)

Till next weekend.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: whiteryder on February 02, 2014, 07:15:11 PM
First time I've ever seen a heat shield made of cardboard.....


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on February 14, 2014, 06:51:44 PM
Ok. Some like these updates so I'll post. I haven't been lazy I promise.

Last weekend I spent all of Friday and Saturday burning some wire on Dad's project. Here are some photos.

First thing first. Finish one half of the machine so we can mimic it on the other side and be sure it works as designed. Here is one of the two Tangs I had to weld up for the cylinder. My uncle did some of the internal machining to this part. The ball joint presses in. No welding required.

(https://lh4.googleusercontent.com/-wx3y_vdRlIA/UvbZI1CfY9I/AAAAAAAAO6Q/ihDZrZ83T7g/w793-h595-no/20140207_135648.jpg)

This allowed us to place the cylinder...

(https://lh3.googleusercontent.com/-dOCgSF-S8dw/Uve8m5nxi9I/AAAAAAAAO6w/O7tDEUUICwM/w793-h595-no/20140207_135725.jpg)

...and that let us test the machine. Worked well but still a lot to go and much to be proven yet.

(https://lh6.googleusercontent.com/-EwhB1I4DIhk/Uve-DEPBnJI/AAAAAAAAO80/eO8q-v4mztA/w793-h595-no/20140207_174735.jpg)

Swung around nicely so its time to wash, rinse and repeat for the other side. Here is the large hinge before placing the cover over it.

(https://lh4.googleusercontent.com/-3MVyxEPdNyI/Uve_4LKgcSI/AAAAAAAAO_I/3q29S1vQkb8/w446-h595-no/20140208_110508.jpg)

Here it is almost fully welded up. Knowing when to put heat into the work piece and when to keep your hands off of it is an art in itself. It is so easy to screw this portion of the process up by letting it get a hair to hot in the wrong place. I actually had to move a portion of that 1" plate by heating and quenching because I didn't leave it alone long enough.

(https://lh6.googleusercontent.com/-K1Nl35BOhpA/UvfALQbZugI/AAAAAAAAO_g/WitWSI1baps/w446-h595-no/20140208_115328.jpg)

Tacked in place

(https://lh3.googleusercontent.com/-pEdabu4NX6E/UvfDSrLy2wI/AAAAAAAAPCE/THBbLqpVWJg/w793-h595-no/20140208_192216.jpg)

Next is to build the linkages for this side. Another long weekend and my portion should be about complete. Then just maybe I'll be able to return to car work.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: wahoo5 on February 14, 2014, 08:19:34 PM
Very nice work. It looks really heavy-duty. Is this to make the planter easier to transport on the road? Do you use a pin to lock it into place for planting or does the hydraulic cylinder hold it well enough?

David


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on February 15, 2014, 03:21:46 PM
Thanks David. Yes you are correct. One position for transport the other for field work. 15' is about max that we can have going down the road. This unit in total will be roughly 26'-27' long once complete.

Field position is below. I didn't take a photo of it fully closed. I've got a small movie of it folding but can't post it for some reason.

(https://lh6.googleusercontent.com/-RnJv6c_V4Ao/Uve9ZNFTvjI/AAAAAAAAO74/fTDLplOiCl8/w736-h552-no/20140207_135826.jpg)

No real need for a pin to lock it into field position as the loading under operation is keeping it pulled into place. However, it does have enough cylinder pressure to boot. It is 4 inches in diameter, equating to roughly 19 tons of pressure. Its has been a fun little engineering project to say the least, not to mention the fabrication, one of the few times I get to do both not just one or the other. All of the components where modeled and simulated in 3D CAD, as best possible, for real life situations and stresses. We will soon see how close "real life" is to the virtual world.




Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: wahoo5 on February 17, 2014, 12:50:10 PM
Thanks. Very impressive. Let us know how the field test goes.

David


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on March 02, 2014, 06:31:53 PM
Ok. Got a few hours in this weekend and glad I did. Car is still not running but hopefully not too much longer.

Couple things tackled. First the cam shaft. The A237 doesn't build much vacuum and is all top end... (hence why my power brakes have not been up too par) Therefore I moved to a Ranger Roller cam and retarded it 4*. Need more low end anyways. Also used the recommended/expensive valve cover gasket because the Felpro kept sweating.

Pulled the timing belt cover off and saw this! So glad I decided to looked into changing the cam now. Distributor bolt had backed out and caught against the cover. Then it started boring its way through the plastic but I caught it before any real damage was done.

(https://lh3.googleusercontent.com/-irtf6LQ_5fQ/UxLMmNJvgMI/AAAAAAAAPfw/QZ2KrpgHjs8/w793-h595-no/20140301_180328.jpg)

Cam in, new timing set all around, loctited distributor pulley bolt and the mentioned valve cover gasket.

(https://lh5.googleusercontent.com/-B8zTavUSLFc/UxLM06G9UFI/AAAAAAAAPgU/9ZlV_-Ogjjk/w446-h595-no/20140301_200820.jpg)

Next up was a Mocal oil cooler. Made up some -10an lines and put everything together. Lines still need tightening but short oil filter from Bosch and thermostat cooler are in place.

(https://lh5.googleusercontent.com/-dWaHxXR67m8/UxLOWccvpTI/AAAAAAAAPjk/yApf42IDLwI/w446-h595-no/20140301_223131.jpg)

To oil cooler

(https://lh6.googleusercontent.com/-zpVlbtL5DK0/UxLOxobGHAI/AAAAAAAAPkg/mHlT9aB0Eco/w793-h595-no/20140301_223219.jpg)

Then I put the intake side back together.

(https://lh5.googleusercontent.com/-HT8EmYyYT1Q/UxLOOUJ9vtI/AAAAAAAAPjM/zOACoxlAy9U/w446-h595-no/20140301_223042.jpg)

How I left it

(https://lh4.googleusercontent.com/-Gu9H45LxnoU/UxLN1hi2-1I/AAAAAAAAPic/2nkAgw78eCo/w793-h595-no/20140301_223029.jpg)

Then I saw the turbo is leaking a bit of oil... Maybe time for something new/rebuilt.

(https://lh5.googleusercontent.com/-hHm0CoYkT3I/UxLNT0Y-U8I/AAAAAAAAPhg/aHm8jo-A0Nw/w793-h595-no/20140301_222959.jpg)

On another note, since people have been asking. The drill also received a bunch of attention this weekend.

More linkages made up.

(https://lh4.googleusercontent.com/-FAX1fKz9Ufo/UxLKC-TlkqI/AAAAAAAAPZE/84pg_7ZdLec/w793-h595-no/20140301_093944.jpg)

(https://lh3.googleusercontent.com/-g9BRuu6s0cY/UxLKWr115EI/AAAAAAAAPZ0/K_XldbUB4AQ/w793-h595-no/20140301_094023.jpg)

Attached.

(https://lh3.googleusercontent.com/-Vjka6da_Sug/UxLLGDOpStI/AAAAAAAAPb0/VjfGBZhidgA/w793-h595-no/20140301_124039.jpg)

And lastly the wing installed and swinging freely. Hydraulic power still needing to be complete.

(https://lh4.googleusercontent.com/-l0c8BA-th2Y/UxLLcYjfLQI/AAAAAAAAPcw/WDeaWOQwKWM/w793-h595-no/20140301_140411.jpg)

Next time it will have the seed boxes on it and the power system for each side should be well underway.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: wahoo5 on March 03, 2014, 06:45:41 AM
Very impressive on the drill. How many rows total?

David


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on March 03, 2014, 07:13:59 PM
Let's see. It started with 24 rows from the factory and now it sits with 40. Typical 7.5" row spacing. The tongue weight of this machine, with only one wing on, is over 7600 lbs empty. I think our tractors are going to know its back there :) can't convince dad he needs to upgrade a couple more models up yet. "Its only money"


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: wahoo5 on March 03, 2014, 08:42:33 PM
Wow!

David


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: ccann26 on March 05, 2014, 02:49:59 PM
Let's see. It started with 24 rows from the factory and now it sits with 40. Typical 7.5" row spacing. The tongue weight of this machine, with only one wing on, is over 7600 lbs empty. I think our tractors are going to know its back there :) can't convince dad he needs to upgrade a couple more models up yet. "Its only money"

This one !

http://www.youtube.com/watch?v=zFBik861VpY&feature=youtu.be

But not much work would get done I suppose.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: wahoo5 on March 05, 2014, 07:11:15 PM
Holy shit. What kind of motor is in that tractor? He can plow the field without a plow. He must have changed the gearing too to get it to run that fast.

David


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: ccann26 on March 06, 2014, 07:30:20 PM

  I read somewhere that its a old volvo 240 series engine turbo'ed. I want one !!


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on March 10, 2014, 10:00:14 AM
love that video, don't know how he hasn't flipped it on himself yet...

Got some time in. I'll let the pictures do the talking.

(https://lh6.googleusercontent.com/-H4GCCSbWMgU/UxprTA6Dx5I/AAAAAAAAPpc/ctQkdLTUx_w/w656-h875-no/20140307_164120.jpg)

(https://lh3.googleusercontent.com/-B2ZgJrJ4OiI/UxvcjrnxPhI/AAAAAAAAPrE/f8hVZwwPmS0/w1167-h875-no/20140308_090415.jpg)

(https://lh3.googleusercontent.com/-PjpnvGvA2Ns/UxvdEyDiusI/AAAAAAAAPsM/fYkpfLNF_qg/w656-h875-no/20140308_100720.jpg)

(https://lh4.googleusercontent.com/-2E1itYuIyuc/UxvdRJu-L1I/AAAAAAAAPtI/vPhM5wgL_hk/w656-h875-no/20140308_105352.jpg)

(https://lh4.googleusercontent.com/-fVEmU_fBaSY/UxprbVBywiI/AAAAAAAAPpo/W5qBGgvP7U4/w656-h875-no/20140307_193326.jpg)

(https://lh3.googleusercontent.com/-M10XPo00vrA/Uxvef4Ik6iI/AAAAAAAAP0w/WknMMiihB8s/w1167-h875-no/20140308_201211.jpg)

(https://lh3.googleusercontent.com/-VNjZERHn-V8/UxproKocMLI/AAAAAAAAPqA/KEb-_N7W5gM/w656-h875-no/20140307_193350.jpg)

YAY!!!!

Then made a little mount for the throttle cable

(https://lh4.googleusercontent.com/-rZuIyXSMG-E/UxvdetwcH1I/AAAAAAAAPuQ/Sbi3gGlZuIk/w656-h875-no/20140308_140804.jpg)

After that I did a bunch of small stuff and fixed this guys shovel that had cracked

(https://lh3.googleusercontent.com/-CgNDrUvhBEI/UxveAAVhv1I/AAAAAAAAPw4/H6UQU-tIhHY/w656-h875-no/20140308_184811.jpg)

Then did a bit more work on this silly thing.

(https://lh5.googleusercontent.com/-dwxUsz7zKb8/UxveOVim91I/AAAAAAAAPx0/VSMoOoe2hMo/w1167-h875-no/20140308_194311.jpg)

(https://lh5.googleusercontent.com/-ohCQ5WldPF0/UxveMfb8-QI/AAAAAAAAP08/2BVrLpPFJnQ/w1167-h875-no/20140308_194238.jpg)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: ccann26 on March 12, 2014, 05:13:17 AM
Looks like you can now get camber and castor that should be a huge improvement .


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on March 13, 2014, 05:55:45 AM
Yeah. It is set to "max camber max caster". Justin's formula for a fast street car.

For those interested in our farm projects. We got some publicity on another project, that wasn't listed here, we completed a year ago or so.

It is a short read, but interesting.

Here is the link:
http://www.progressiveforage.com/index.php?option=com_content&view=article&id=5341:the-mt-pony-special-double-barrel-baler&catid=90:equipment&Itemid=124


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: whiteryder on March 13, 2014, 06:18:27 AM

Great article!  Love how the family teams up to get stuff done.

Really want to learn some metalworking skills someday.   :)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on March 16, 2014, 06:11:48 PM

Great article!  Love how the family teams up to get stuff done.

Really want to learn some metalworking skills someday.   :)


Thanks Beth. It is pretty cool growing up on a farm I must say. All kinds of opportunities.

As far as welding goes. I'm self taught and if I can do it, anyone can. Just pick up a wire feed little MIG and go to town. Learn as you go. Nothing like hands on experience.

Decent weekend on the car. Here is the latest.

First thing first. Here is my idea of a bleeder/coolant swirl pot. Basically the coolant swirls downward as the bubbles in the system rise. I have reason to believe that is why I was having over heating issues, I just couldn't get the air out as the radiator line had ups and downs. Now this way I can purge everything. Basically it just a tube that is capped top and bottom. Then a NTP bleeder added it to the top to provide the exit for the air. It is made of stainless and it has some really pretty welds. However they are all on the bottom... you can kinda see one on the lower stainless line... hate it when I do that.

(https://lh4.googleusercontent.com/-y_0A58rIgXY/UyUISRXZR7I/AAAAAAAAQBU/kKUd37YIiTk/w446-h595-no/20140314_171827.jpg)

Ran out of engine bay room on the intake side so here is where I mounted the catch can and power steering cooler.

(https://lh6.googleusercontent.com/-O3DHS8yDUdY/UyT7oElemBI/AAAAAAAAP5k/YG5RgohiZTs/w793-h595-no/20140315_132702.jpg)

Work being done image.

(https://lh6.googleusercontent.com/-3IExgLtwSjk/UyT8Bn9WJtI/AAAAAAAAP6M/2MKsfgz3aVA/w793-h595-no/20140315_132739.jpg)

Note the changes. Lots of heat protection on the electrical stuff as well as the oil feed line to the turbo. Ran the vacuum block and all the lines. IAC wired in and ready to go. New Motocraft OE plugs and wires, plus my cool little zip tie wire spacer.

(https://lh5.googleusercontent.com/-k4Y5XlbsuaA/UyT-hXIomjI/AAAAAAAAP9M/_GDGmAg0q6M/w793-h595-no/20140315_185943.jpg)

(https://lh5.googleusercontent.com/-8_EE5s3eyNI/UyUAcGqMjII/AAAAAAAAP_Q/ESS0dmuhDfA/w793-h595-no/20140315_190052.jpg)

Then I played with the stupid Chinese bumper and stupid Chinese blinkers. Nothing fit and I was so mad, but what should I expect?

(https://lh3.googleusercontent.com/-lIy-D7NgPTY/UyUBT9bpDUI/AAAAAAAAQAk/elYrNfK-81I/w793-h595-no/20140315_190853.jpg)

The car started and ran for 25 seconds or so. I need a timing light to set timing. Then it is just a matter of finishing a few little things, swapping the turbo back out and making the exhaust. Hopefully it can be done and driving this time next week, but I'm not holding my breath.

Next weekends activities already planned out... Side exhaust or rear? Anyone?

(https://lh4.googleusercontent.com/-85M1lI9Q66E/UyUBETAN_tI/AAAAAAAAQAM/_MeNf0JlTNs/w446-h595-no/20140315_190122.jpg)

And here is something for those of you who may be interested. I picked this up way way tooo cheap to pass on. Just don't expect updates and time soon as my plate is pretty full.

(https://lh5.googleusercontent.com/-Z-AGOPH5p_A/UyT9RtJJ-eI/AAAAAAAAP74/aC4rTLKlWfk/w793-h595-no/20140315_153533.jpg)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on March 24, 2014, 10:26:09 AM
Ok soooo the weekend from hell in nut shell. Here goes (still super sleepy)

Got the turbo back from evergreen. (all stock + thrust seals and various other upgraded internals)

(https://lh6.googleusercontent.com/-HUnrhln_Fic/UyzPzionhKI/AAAAAAAAQDY/AWoiFJoz36A/w1167-h875-no/20140321_144828.jpg)

(https://lh4.googleusercontent.com/-KCdtOSrg1IE/UyzS52mwzNI/AAAAAAAAQG8/8dZXNO_ePjw/w1167-h875-no/20140321_160428.jpg)

Finial assembly.

(https://lh3.googleusercontent.com/-_G0ge8lYK5U/UyzQn8aTQeI/AAAAAAAAQEI/nys9K7YzbmE/w656-h875-no/20140321_164213.jpg)

(https://lh5.googleusercontent.com/-f7kw2lweEfY/UyzRcoIMobI/AAAAAAAAQFQ/w-nPATcjgRI/w1167-h875-no/20140321_175758.jpg)

Built an exhaust.

(https://lh3.googleusercontent.com/-jQfveNf-AAQ/UzBk_1x_SpI/AAAAAAAAQJU/lrDVtx1uAYQ/w1167-h875-no/20140322_113209.jpg)

Painted and heat wrapped next to the exhaust. Here are a couple shots.

(https://lh3.googleusercontent.com/-gwN3GYDzixM/UzBh-Ql7m_I/AAAAAAAAQJU/qF0tT6ozIQ8/w656-h875-no/14+-+5)

(https://lh4.googleusercontent.com/-sJverlzWdJI/UzBjoTBaYZI/AAAAAAAAQIk/yLYTLoHa0FM/w656-h875-no/20140322_144608.jpg)

(https://lh3.googleusercontent.com/-qPlX8nGpRr8/UzBk-vtmXOI/AAAAAAAAQJs/SsozRdTL08g/w1167-h875-no/14+-+2)

(https://lh6.googleusercontent.com/-4lmNRbiRajY/UzBk_2JMRjI/AAAAAAAAQJg/Vo9YNcyxZKk/w1167-h875-no/14+-+7)

Things that worked well.

1. Bled the brakes and everything looks good/stops well.
2. Doesn't get hot at idle. Sits a 190-195F. Very happy about this as the little swirl pot seems to be doing the trick.
3. Sounds good with the new exhaust
4. It drives!

After that the problems started creeping in and you know how it goes. When you are tired everything is more difficult.

1. 2 big oil leaks one cam and the other the front main and pan (if you ever have done one of these you'll understand the frustration) (Dad saved my ass on this one late at night/morning)
2. The new megasquirt program (PiMP BETA version) I'm running had some hiccups in my (http://my) settings. Took in the neighborhood of hours to get some of those found, set up correctly and working.
3. Had a bad surge that would start coming into play after some time idling. It was running too lean and first spent way too long looking for a vaccuum leak.
4. One of the tires I mounted by hand didn't seat correctly which creates a bad wobble going down the road.
5. When loading the car on a trailer it stalled. Then wouldn't start. Thinking it was out of gas Dad and I went to town and filled two 5 gallon jugs. It only took maybe 4.5 gallons to fill the tank completely. Then it started right up. I think it is a bad TFI and it had cooled down enough that it started when I got back... I'm not sure though. I really hope if it is, it will rear its head again before too long so I can swap it with certainty.

Still needing to do before the weekend.

1. Balance tires get that one to seat.
2. A real alignment
3. Need hubcentric rings on all the wheels
4. Complete tune for boost
5. Fan control with MS if applicable.
6. idle settings need to be smoothed out
7. Battery is flat so I'll have to figure something out there.
8. Wire the front blinkers

Anyways it is sitting in it's new home in Goochland, VA.

(https://lh4.googleusercontent.com/-VepXO5zlbgQ/UzBh-bgIOXI/AAAAAAAAQJU/z8TFOpvNAmU/w1167-h875-no/14+-+1)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on March 25, 2014, 10:00:02 AM
On a whim, I checked the runout last night on the front hubs with a tool I borrowed from Justin.

.015" out on the passenger side since Mindy had the accident, .005" or so on the driver. I think I need to put in new hubs.

(https://lh3.googleusercontent.com/--d6lCaYmMis/UzG0tsXX_rI/AAAAAAAAQNg/0j4kwHtAsMk/w320-h240-no/14+-+1)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: sonomadrifter on March 25, 2014, 11:30:05 AM
(http://i818.photobucket.com/albums/zz109/mnkymits1/DSC_0765_zps4abca559.jpg) (http://s818.photobucket.com/user/mnkymits1/media/DSC_0765_zps4abca559.jpg.html)

(http://i818.photobucket.com/albums/zz109/mnkymits1/DSC_0773_zps12b91b26.jpg) (http://s818.photobucket.com/user/mnkymits1/media/DSC_0773_zps12b91b26.jpg.html)

(http://i818.photobucket.com/albums/zz109/mnkymits1/DSC_0774_zps1a842ade.jpg) (http://s818.photobucket.com/user/mnkymits1/media/DSC_0774_zps1a842ade.jpg.html)

(http://i818.photobucket.com/albums/zz109/mnkymits1/DSC_0776_zpsc354cd4b.jpg) (http://s818.photobucket.com/user/mnkymits1/media/DSC_0776_zpsc354cd4b.jpg.html)

(http://i818.photobucket.com/albums/zz109/mnkymits1/DSC_0779_zps8ed220c8.jpg) (http://s818.photobucket.com/user/mnkymits1/media/DSC_0779_zps8ed220c8.jpg.html)

(http://i818.photobucket.com/albums/zz109/mnkymits1/DSC_0781_zps3d5b8783.jpg) (http://s818.photobucket.com/user/mnkymits1/media/DSC_0781_zps3d5b8783.jpg.html)

(http://i818.photobucket.com/albums/zz109/mnkymits1/DSC_0788_zps932bf2d4.jpg) (http://s818.photobucket.com/user/mnkymits1/media/DSC_0788_zps932bf2d4.jpg.html)



Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on March 25, 2014, 01:32:18 PM
Thanks Pat.

When are you going to add your Farmboy Fab build? I'm sure everyone would like to see it.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on April 15, 2014, 10:14:56 AM
Ok. Two autox's down and we learned a lot.

The March event (for those who didn't attend or tried to forget) was a high of 45 and wintery mix of sleet and rain. Miserable conditions for a autox in my opinion but mainly because of the "events" that led up to that point. Here is the story of the few days before the first 2014 autox in listed form.

Thursday before Justin and I decided to meet up and tune the car's air fuel table at afternoon. That ended up being a very late night as the car stranded us at a gas station after only 30 minutes of tuning. For some reason the fuel would cut out after a few minutes. 10:30 that night it was towed home on the back of a tow truck. Justin really saved our ass there.

Friday I was off at 11am and ran home to see if I could find the electrical bug. The fuel pump would kick in sometimes and not others. Found out quickly there was a electrical leak into the ECU power circuit of 3-7 volts depending on where you took the sample. Spent until 10:30pm that night pulling every fuse, every relay and every sensor. Nothing...

Saturday morning I was up early and around 7:30am I had found out that the fan circuit was indeed bleeding back into the ECU and causing running issues. Justin was over around 10:30am and we re-did much of the "general" wires powering injectors and what have you. This time, cutting out many of the relays and fuses I had put in the car.

Saturday around 5:30 we fired the car back up for the first time since it had stranded us. Not feeling confident just yet we let it idle for 20+ minutes in the driveway. Up until this point we had been jumping the car at every start because the starter solenoid would just click otherwise. This had been an issue as someone always had to accompany the car in another vehicle.

At 6pm Saturday or so we came to the conclusion that the alternator had died and wasn't producing voltage at idle and only a hair at higher rpms. Thinking this wasn't a big deal I called and drove out to a parts store to pick up a ford ranger of similar year alternator since they too ran 2.3 8v motors. However upon further inspection the ranger alternator didn't have a rectifying circuit inboard of the alternator. They used a completely different system externally. Therefore, in a nut shell, I was out of luck.

At 8:30pm, and after many phone calls, I located a stock merkur alternator in Suffolk, VA that was proven good. So I began the 5 hour drive there and back in the rain. Got home around 12:30am that morning and start putting on the new, to me, alternator. Of course it wasn't going to be that easy as I snapped the output stud of the alternator. Another 2 hours were spent fiddling with the alternator to get it mounted. I tired out around 3:30am that morning.

Sunday morning (day of the event) around 7am I was back out in the garage again putting some last minute touches on the car. Justin showed up around 8am and we drove the untuned (running rich as hell), unproven car, 40 minutes to the autox in the rain. Him in the caprice just in case because we still needed to jump the car at every start.

Show up the event, Justin runs first. All I really remember is all the cones we hit all day. I think it fared OK but honestly I don't remember much of the event. Passed out at 7:30 that evening after getting home and woke up late for work at 7am the next morning wondering why I did all that for 5 minutes of driving?

I didn't take any photos so I kinda left this post linger for a bit.

Last weekend was autox #2 for the season and things went a bit smoother. However we are still not out of the woods yet. All week I had been making fiberglass molds and of the bumper to use in mounting the blinkers.

Final product looked like this. It takes days to even make something this simple because of the curing time in cool weather. Not just for the resin but also for my mold making materials.

(https://lh5.googleusercontent.com/-fvEmx9ioGFs/U0nDPOyM97I/AAAAAAAAQY0/IvKXopjP22U/w1597-h538-no/20140410_210645.jpg)

I made some covers since I didn't want to paint the bumper. All went well until I realized that the voltage out of the signal wire was not enough to power the LEDs, therefore I've got to add relays now. Ah well.

(https://lh4.googleusercontent.com/-_xpV4yLgWRI/U0nDTmxehQI/AAAAAAAAQUI/0e8guYUi4vU/w1167-h875-no/20140411_144441.jpg)

Also got a new wideband installed for tuning.

(https://lh3.googleusercontent.com/-8LbwkquDVdI/U0nDKL5J_5I/AAAAAAAAQTM/7R5yDU554LU/w1167-h875-no/20140406_174346.jpg)

And installed a new starter solenoid to prevent the jump starting at every start.

(https://lh6.googleusercontent.com/-k_9f7M-HvUk/U0nDqYanbzI/AAAAAAAAQVU/_YRfuiZaD18/w1167-h875-no/20140411_164420.jpg)

Then did a bit of tuning. Not to get into the specifics here but basically we have some oscillations in the AFR happening at cruise. As soon as load the throttle the car it clears up. Also between the school on that Saturday and the autox Mindy and I lowered the camber to +3.75* and 3/16" toe out up front.

Drove the autox Sunday and had a blast. In the dry the car did much much better than expected. Still has a lot of room for improvement as there are clear "holes" in the current set up, but it isn't without some reward of the possibilities.

(https://lh4.googleusercontent.com/-jhdKDzPlb6E/U0xOq5EUJBI/AAAAAAAAQXU/IfkE6Xaq0nM/w1167-h875-no/20140413_135855.jpg)

(https://lh3.googleusercontent.com/-rREyhwxNvvs/U0xO5Ku8buI/AAAAAAAAQYc/qvfeedRvmK0/w1167-h875-no/20140413_140731.jpg)

Justin's run on youtube.

https://www.youtube.com/watch?v=2c2m1Q_XjKc

enjoy.

Next up:

Adding the caster back without adding camber.
Fresh and smoother tune with more POWER! We are only running a hair under 11psi now, stock was 15psi and I'd like to shoot for 16-17psi. Hopefully at VMP we can have this ready.



Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: jamescarriv on April 15, 2014, 05:27:26 PM
Nice work. Looking good.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: rothaus on April 15, 2014, 05:53:18 PM
I really like that car, it reminds me on the good old time back in Germany, when I had one of these. Back in Germany they were called Ford Sierra.

However, at that time the Sierra was a 4-door family car, after I stopped doing these things:

(http://airboxer.com/images/fiesta1berg1.jpg)

(http://airboxer.com/images/comodore1Hockenheim1.jpg)



Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on April 16, 2014, 09:22:54 AM
Thanks for the compliments everyone.

I didn't know you had a sierra. Did it have the 2.0 16v turbo?

The first of the photos are popping up and I'm excited to see them. David and Gunny are doing such an awesome job!

Justin and Mindy. Still have a bit of lift coming out of a few turns. Car looks like it is trying to claw out of the turn. Also may be why it has some mid corner push.

(https://farm8.staticflickr.com/7008/13887596804_170e724b50_b.jpg)

Mindy turning in. We need more caster.

(https://farm8.staticflickr.com/7051/13887366163_bba1627417_b.jpg)

Mindy again

(https://farm8.staticflickr.com/7043/13887638194_833375678b_b.jpg)

(https://farm6.staticflickr.com/5303/13887090565_002542cf8a_b.jpg)

Justin landed the fastest time in the car at a 44.8 but a small cone somewhere, I landed a 45.5 with a cone carried over from a re-run and Mindy was a constant 46.3 all heat long. Those were the fastest times without penalty, Justin and I were both a hair slower on our clean runs. Those clean runs were enough for two of us to be in top 15 or so in RAW time and in PAX. Very impressed with Mindy as she is still coming off of the thought of wrecking the car mid last year, she is definitely "manning up to it".

 


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: ccann26 on April 16, 2014, 02:01:41 PM
 Wow looking at those tires rolling over makes me cringe !


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on April 17, 2014, 09:19:02 AM
Haha yeah those little 225 are working hard.

(https://farm8.staticflickr.com/7120/13883320986_3aa7d589e2_b.jpg)

Nom nom nom

(https://farm4.staticflickr.com/3765/13906495963_61bd755f4e_b.jpg)

Gunny did an AWESOME job! Thanks man!

(https://farm8.staticflickr.com/7377/13883320541_df03c6d24f_b.jpg)

(https://farm4.staticflickr.com/3722/13883316001_ec29b9a5f0_b.jpg)

Couple more of Justin

(https://farm6.staticflickr.com/5501/13887258403_8953752385_b.jpg)

(https://farm6.staticflickr.com/5252/13887192805_3c186c2262_b.jpg)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on May 14, 2014, 10:09:29 AM
Not a big update.

New:
Wheel bearings
Spindles
Lower control arms
Inner tie rods
Bushings
Lower the seat some

The idea here is to have the shorter XR control arms with the top plates maxed at caster and camber. Now sits around 3.75* camber and tons of caster. On top of that XP10 carbotechs up front did a amazing job of eating the front rotors.

(https://lh4.googleusercontent.com/-h4Iu8FRbO-0/U3AWtbLpKoI/AAAAAAAAQgU/57yUeklcyl0/w1010-h758-no/20140510_134523.jpg)

Rear got treatment as well.

(https://lh6.googleusercontent.com/-ox6sI-txxR8/U3AWxVI_hsI/AAAAAAAAQgs/rvMCadb7SbM/w1207-h905-no/20140510_153145.jpg)

Had an autox and the results from the worked great! Car ran a 52.7 with Justin last weekend. Knowing that Chris and Keith are in the high 49 low 50.0 second range that is truly impressive for a car on these little 225s.

Thanks Gunny and David for the photos once again!

(https://farm3.staticflickr.com/2900/14174866264_801f628464_z.jpg)

(https://farm3.staticflickr.com/2923/14174933304_ed2389ffb7_b.jpg)

(https://farm8.staticflickr.com/7420/13988243619_a4b71f237f_b.jpg)

(https://farm8.staticflickr.com/7398/14195043183_95d5eb53a3_b.jpg)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on May 24, 2014, 01:22:31 PM
Ok. So the last three weekends have looked like this. 14 hour Lemons Race at CMP, VMP autocross and lastly VIR with the PCA group. A first for the Merkur handling itself on the track and I am pleased to announce the it did very well. Running in the solid 2:30 mark with a sub-par driver and a top speed of only 113mph on the back and front straight due to less the stock boost levels (13-14psi). Hopefully this means the motor has lasted through it all despite running 10:1 afr at high rpm.

I didn't take too many photos or videos so there isn't much to show for any of it but here is what I have.

(https://lh5.googleusercontent.com/-fTrpSvG41f0/U4D6wfE0MOI/AAAAAAAAQx0/WqaaaNoSx1A/w793-h595-no/20140517_175707.jpg)

(https://lh6.googleusercontent.com/-hjie0BFWM2U/U3-_-pgX6fI/AAAAAAAAQxY/Vd-81CDYlWo/w793-h595-no/20140517_100806.jpg)

Down pipe issue at VMP the weekend before.

(https://lh5.googleusercontent.com/-GnuChI3GwS0/U4D63WZckcI/AAAAAAAAQyA/OFoR7UXPZPw/w793-h595-no/20140510_191506.jpg)

What I found in the catch can after VMP that had me a little worried for VIR.

(https://lh4.googleusercontent.com/-WmcT6X4Zsjg/U4D63QR5yEI/AAAAAAAAQyA/Cmz2WyyISBI/w793-h595-no/20140511_194822.jpg)

Couple of notes:

Apparently it was throwing some big flames when trying to catch Beth in her Porsche up the Esses.

Carbotech's worked really well. No fade and still have a ton of life left in them. Hopefully Mindy can finish them off at the next track day.

Turbo's downpipe didn't come loose like it had been doing before. I added studs and lock nuts (not the nylon type).

Motor has a bit more back pressure than when it showed up. I guess I'll just have to up the boost a little more to compensate... :) Hopefully the rear main seal is ok as there was some oil spraying from somewhere.

Hopefully I can relax a bit more on this car now. I'm looking to start up the next project in a month or so. Therefore this one really really needs to take a back seat.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: jamescarriv on May 24, 2014, 06:57:38 PM
Looking good. How did your tires hold up? Any over heating?


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on May 26, 2014, 07:29:13 AM
Looking good. How did your tires hold up? Any over heating?

Tires held up well. Always can use more tire but it really stuck very well. Set the pressures on them one tire and never looked back.

It did over heat some, I'd pedal it on the back straight to let it cool down a little most laps then attack the corners again. It would get to about 220-230 and I'd get worried. Never boiled over however. Temperatures during the day where roughly mid 70s so a bigger radiator is a must if we ever did an event in the summer like this. Or some more baffling at the minimum. I think the next autox we are only going to run a single driver per heat.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on June 13, 2014, 07:09:11 PM
Super exciting weekend. This was the first event that we didn't change a thing. Nothing. Put it away after the event at VIR, replaced some air in the tires and ran with it. Car felt good, nice and balanced with a touch of under steer at mid corner and a some over steer when getting into boost at corner exit. The highlight of the weekend however was the merkur landed FTD on street tires. Very exciting and all this work seems to have paid off a bit. It really is a small mile stone for the car and the work Justin, Mindy, Dad and I have laid into it, but we gotta keep it up. There is still major room for improvement, it has a name, and that name is BOOST, we need more sooner.

Here are some shots of Justin and Mindy along with a video or two. The tire squeal is 95% the rear tires, it is hard to tell in the videos with a helmet mounted camera. However the big thing we are learning is that sliding the car in a small drift and not dropping boost makes a faster overall run. As soon as the car loses boost we have to wait to receive it again, killing the runs time.

(https://farm3.staticflickr.com/2922/14365081796_d9ec06b00c_b.jpg)

(https://farm4.staticflickr.com/3926/14201736347_5f7e5652c7_b.jpg)

(https://farm4.staticflickr.com/3875/14208843579_4f36b37f9a_b.jpg)

(https://farm6.staticflickr.com/5573/14209041737_d59fa06d44_b.jpg)

(https://farm6.staticflickr.com/5548/14208847269_5c8caa35a3_b.jpg)


50.7 run --> https://www.youtube.com/watch?v=pmkUSHbQdII&t=0m20s
51.2 run --> https://www.youtube.com/watch?v=PGHLtrVkyoo

Thanks
-Paul


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on July 08, 2014, 03:43:22 PM
Not much going on. Just a quick little task that I had been putting off. Rewrapping the downpipe. The old wrap split in one place and it unraveled at VIR.

This time I added wire bands to keep it together. I didn't want to wrap a single wire because I was worried about it breaking of something odd and it would do the same thing. So I decided to spend the time with several bands.

(https://lh4.googleusercontent.com/-aUqOeO_WBe8/U7xxoPauYhI/AAAAAAAARts/kSvTk5QbYoo/w793-h595-no/20140706_134710.jpg)

Red tips are high temp silicone to prevent me from cut the crap out of myself over and over again.

(https://lh6.googleusercontent.com/-i1rXMHbcpx0/U7xxoHCCo9I/AAAAAAAARts/I7tsVMX16ck/w793-h595-no/20140706_173834.jpg)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on July 21, 2014, 09:59:21 AM
Had a fun two back to back weekends. First was a test and tune, then autocross that Sunday and lastly a small track day the following weekend. Break down below.

Test and tune. Don Haulsee came out and joined us which was a nice surprise. He brought this folvo (volvo head, ford block) euro capri. I really see the benefits of this head and block combo and am toying with starting that project one day. However Don was impressed to see the response of the stock head and .63 A/R turbo on an autocross course. Had a little too much fun and the car boiled over at the end of the day, luckily I think everything is ok.

(https://lh4.googleusercontent.com/-xJpCGnLnMRU/U6LPBIwI2xI/AAAAAAAARKg/0Q_IgrRiqYA/w1109-h832-no/20140607_130759.jpg)

Autocross. Justin kicked our asses again, no surprise there but am happy to see the car performing so well with a good driver. Justin placed 3rd overall in PAX, to me, that is respectable.

NCCAR. A small "dynamic testing facility" located at the boarder of NC and VA. We got invited with the Mercedes club. This small 2.2 track comprised of several very constant radius turns. Not the most exciting of tracks but really put your car into perspective in comparison to the other vehicles of the track. Mindy and I were able to run opposite run groups so two people in one car. This meant the car really didn't sit idle very long and there was only 15 minutes between the end of her session and the beginning of mine. The Merkur had a slew of small things happening, fender flare falling off, power steering leak, and the EGR plug I had in the E6 manifold popped out at 100+mph down the front straight. (Thought I had put a whole in the block with all the noise it made) Therefore my day was cut pretty short.

Hasty repair of the power steering pump, before we found out that it was the high pressure line.

(https://lh6.googleusercontent.com/-KQHqYQuOdwU/U8vGw0cc54I/AAAAAAAASA4/rhLLv3gdmg8/w1109-h832-no/20140719_134524.jpg)

(https://lh6.googleusercontent.com/-9YBrWJAo1IQ/U8vHTzgql2I/AAAAAAAASBo/6Z_eobAhk1g/w1109-h832-no/20140719_135311.jpg)

Melted Ebay turbo blanket.

(https://lh6.googleusercontent.com/-rsU6JBm0eek/U8vHmNZb0EI/AAAAAAAASCA/36hWC6tF_pU/w1109-h832-no/20140719_153748.jpg)

She will live to fight another day, just some small stuff. On another note Jeff, Audie and I have been spending some time on her time attack Prelude and that worked great! Here are a few shots of some items we had made/fixed.

Carbon fiber gauge panel

(https://lh6.googleusercontent.com/-7WQoDZMEs_c/U51cRtkXNdI/AAAAAAAAREA/SPYbm8kXKAk/w1109-h832-no/20140613_130320.jpg)

Some interior re-work, gauges and hole filling

(https://lh4.googleusercontent.com/-CZuUFck_BB8/U69PyQmS0BI/AAAAAAAARNo/_sPstH_8sOM/w1109-h832-no/20140628_112412.jpg)

(https://lh6.googleusercontent.com/-iMCoCOFA7es/U51ckeFExII/AAAAAAAAREY/OFLxc8tuxGk/w1109-h832-no/20140613_130343.jpg)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on July 26, 2014, 01:55:14 PM
Well got something small taken care of on the car.

Found the culprit to the power steering leak that stopped our track day short. 30 minutes and $50 bucks later it is all set to go.

(https://lh3.googleusercontent.com/-9Non-q34w3E/U9QMpKhcDMI/AAAAAAAASUo/0yWoSTZ3Ot0/w446-h595-no/20140725_211517.jpg)

(https://lh5.googleusercontent.com/-62GIGHMToF0/U9QMEdl3TII/AAAAAAAASUc/UwCcfklFF1g/w446-h595-no/20140725_211444.jpg)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on August 20, 2014, 09:56:52 AM
Couple weekends ago we had an autocross. I'm getting the car to the point where I don't actually have to do anything between events any longer. Best feeling ever BTW.

On the docket this week was flushing the coolant a few times, then using the bleeder to get all the air out.

(https://lh3.googleusercontent.com/-4rQS5I1DhjI/U-ZiZYMZ7_I/AAAAAAAASlc/2WDtUrxdscA/w1167-h875-no/20140809_140251.jpg)

Then i fixed the panel that fell off at the track day.

(https://lh3.googleusercontent.com/-BVjmO-PVixQ/U-ZjYtB62hI/AAAAAAAASlo/P-tuPf-6cbg/w1167-h875-no/20140809_140702.jpg)

(https://lh3.googleusercontent.com/-iM6dLThD2Oo/U-ZpcxsfMzI/AAAAAAAASl8/psufNc4vzJg/w656-h875-no/20140809_143251.jpg)

Then washed it!?

(https://lh6.googleusercontent.com/-HS9S01E1BYU/U-ZpzqU_5AI/AAAAAAAASmI/NlGnW7XvFsI/w1167-h875-no/20140809_143410.jpg)

The following day was the autocross event. My brother Pat drove with Mindy and I. Really looked forward to his feedback on the car because he has a lot of experiences in many other cars over the years. His suggestion of removing the bumper for more airflow was a good one. The car barely got hot at all. Maxing out at around 210*, so between the flushing system and increased flow it ran much better than normal. Typically we start seeing the temperatures in the 220-230 range just after a few short runs.

(https://farm4.staticflickr.com/3848/14877077214_cc816f171a_b.jpg)

(https://farm6.staticflickr.com/5591/14879613395_25b1f94df0_b.jpg)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on September 24, 2014, 04:29:19 AM
Another autocross and the competition is getting stiff. Between Ricardo who just got his new suspension and brakes, Gunny in the Corvette, Joe in the miata and Stuart who is also gearing up with new suspension the merkur has got it work cut out for it between now and the end of the season.  Here are some shots from the last event. Tires are feeling older now, I'm not sure if they are down to base rubber yet but there can't be much left, they just don't stick like they did in the beginning of the season but it does make it more entertaining to drive. After the beating the said people put on me last event I'm starting to formulate a plan to boost the merkur's performance for the beginning of next season. We will see if time and budget allows.

Thank you for the pictures David and Gunny!

(https://farm6.staticflickr.com/5576/15130238869_1ccd1e46d7_b.jpg)

(https://farm4.staticflickr.com/3838/15130418700_f2a53917e3_b.jpg)

(https://farm4.staticflickr.com/3846/15314117671_8b78e85be4_b.jpg)



Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on October 19, 2014, 03:32:44 PM
Another autox.

Got the TPS replaced and new motor mounts in. More updates on those later. Car felt really good and throttle response was better than it ever has been. The TPS may have been an issue for a long time. Even though the car did well, I didn't, but was please to see the car run within a few tenths to Richardo even though I coned it away.

(https://farm4.staticflickr.com/3953/15519871832_21e2f73d44_b.jpg)

(https://farm4.staticflickr.com/3940/15520265035_487d5a4d72_b.jpg)

(https://farm6.staticflickr.com/5597/15333608168_b1c5965c3e_b.jpg)

(https://farm4.staticflickr.com/3928/15333654808_03a2fb83e7_b.jpg)

-Paul


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: gunny on October 22, 2014, 03:39:38 PM
Car is awesome!
Can I drive it for a run or two maybe three if my times are close to yours next year at a practice?

Gunny


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on November 04, 2014, 04:32:44 PM
Thanks Gunny. Mindy's car = Mindy's rules but I have no problem with it. I'd love to know what you think about the car and how it compares.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on November 21, 2014, 10:42:07 AM
11-2-14 ends the season. Car did very well and I had a ton of fun.

(https://farm4.staticflickr.com/3949/15697960076_1754cb09e6_b.jpg)

(https://farm8.staticflickr.com/7472/15697938106_428e6ef01c_b.jpg)

(https://farm4.staticflickr.com/3948/15697953346_49108cb255_b.jpg)

So the big question. What is going on next year... well stay tuned. Looks like the Merkur won't be dropped as quickly as I had originally intended.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on December 14, 2014, 06:54:55 AM
Because it relates, here is another water tank I made for another Merkur owner. I hadn't welded aluminum in over 9 months so I was a little nervous about how rusty I may be. Didn't turn out too bad.

This tank has a thick front too so you can tap NPT holes for fittings/barbs or level indicators as necessary. This cut down on the overall cost of the tank and amount of time I spend welding. I was going to produce these, maybe a run of 50 or so, to sell because Merkur tanks are getting hard to find in good shape and the ones you do are expensive. This would be a OE replacement and last forever. I'm not sure if I will still do this however. I have 60 or so dollars in this tank and my time is worth something so unless I sell them for 130-150 I'll just break even. Not sure if anyone, that owns a merkur, would pay that. This one I finished off because someone approached me directly and asked, I had a free morning so why not?

It started by making a jig of the OE tank, since our car doesn't have that location any longer (read wreak). The welding rods are there to map out the general area.

(https://lh3.googleusercontent.com/-xHSPbcpOeBk/VIzUgRvR-1I/AAAAAAAATtA/aHvlYnvgW90/w958-h539-no/20141213_105652.jpg)

Here is the new bottle and its general location.

(https://lh5.googleusercontent.com/-vB_VcI7KZ30/VIzWRISLJ5I/AAAAAAAATtc/yNpXEfnOnjM/w335-h595-no/20141213_105747.jpg)

Then made a few aluminum tabs

(https://lh4.googleusercontent.com/-NuHrMtezILQ/VIzZ6Hw156I/AAAAAAAATuU/FzOGewUNsJc/w958-h539-no/20141213_105932.jpg)

Welded up one on the top and one on the bottom.

(https://lh4.googleusercontent.com/-3vl1yrb0gK0/VIzbLqS_LrI/AAAAAAAATus/zY7ftGp9VuE/w958-h539-no/20141213_115527.jpg)

(https://lh3.googleusercontent.com/-92iAC78oi9w/VIzb2fbLBbI/AAAAAAAATu4/G-h8aVoBuWE/w958-h539-no/20141213_115533.jpg)

Lastly punched a hole in the top and welded a Canton aluminum neck on.

(https://lh6.googleusercontent.com/-GWvOoaE9CHo/VIzce0T2_lI/AAAAAAAATvE/yllbWPvyfYs/w958-h539-no/20141213_121022.jpg)

(https://lh4.googleusercontent.com/-1NYGuAULch8/VIzjcaMCg6I/AAAAAAAATw0/L0__CL8Fdes/w958-h539-no/20141213_123844.jpg)

(https://lh4.googleusercontent.com/-uwHZJuv-pek/VIzjS84EPPI/AAAAAAAATwo/AGEPJApGffA/w958-h539-no/20141213_123824.jpg)

-Paul


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: rothaus on December 14, 2014, 11:05:56 AM
Nice work Paul, looks like I need to get with you when I need some Aluminum welded.

Cheers
Engelbert


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on December 21, 2014, 07:30:25 PM
Not a problem Engelbert, just LMK what you need. I'm local now.

So this weekend I made a little progress on the merkur's face lift that is happening this winter.

(https://lh5.googleusercontent.com/-SayGJj399jg/VJd-GEuzj9I/AAAAAAAAT6I/TFJbDG5KEJo/w958-h539-no/20141220_084838.jpg)

40 minutes later...

(https://lh5.googleusercontent.com/-LEBWFmF12Ys/VJd-GL4Vp4I/AAAAAAAAT6I/oJ8vKDP2ivw/w958-h539-no/20141220_093208.jpg)

Then I cut out all the brackets that mounted the old radiator and intercooler setup. Then started test fitting the new setup.

(https://lh6.googleusercontent.com/-POmmdtQXteQ/VJd-GJJyzOI/AAAAAAAAT6I/N8-4TqQO3xw/w958-h539-no/20141221_112133.jpg)

Trying to figure out how the hell I'm going to get the intercooler fed air past this massive radiator... maybe upside down.

(https://lh4.googleusercontent.com/-3dgqfg3qnxM/VJd-GOf0QLI/AAAAAAAAT6I/y4-7sOo3cJ8/w958-h539-no/20141221_144207.jpg)

-Paul


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on December 28, 2014, 09:01:36 AM
Hope everyone had a good christmas. I got some help this weekend from Pat and we were able to get the nose of the car sorted.

The face lift continues by cutting the end tanks off of the intercooler.

(https://lh6.googleusercontent.com/-YWO-2rQjQx8/VKAmCjDfuPI/AAAAAAAAUBU/3oKshyD22kU/w958-h539-no/20141227_101907.jpg)

(https://lh4.googleusercontent.com/-lmRTh_CAAAA/VKAmCgdkocI/AAAAAAAAUBU/mNAjTGZURkQ/w335-h595-no/20141227_101921.jpg)

Bars underneath were added for supporting the intercooler and radiator.

(https://lh3.googleusercontent.com/-Chckb_F8kaw/VKAmCiW6baI/AAAAAAAAUBU/DyrpHtUVQDA/w958-h539-no/20141227_174207.jpg)

(https://lh6.googleusercontent.com/-EVYFOPoHoIU/VKAmCk9f8XI/AAAAAAAAUBU/m7HGjHIAByc/w958-h539-no/20141227_174217.jpg)

Pat then traced out the splitter design on a piece of cardboard.

(https://lh3.googleusercontent.com/-vrhFAM85hVs/VKAmChH9Y4I/AAAAAAAAUBU/giDCzwkdM5A/w335-h595-no/20141227_114318.jpg)

Here is the potential design. I'm thinking fiber laminated plywood for cheapness.

(https://lh4.googleusercontent.com/-IlyU6y363Cc/VKAmCoOfnRI/AAAAAAAAUBU/Iu5YhA0Brao/w958-h539-no/20141227_163945.jpg)

The idea is to control the air coming into the nose and use more of it for cooling and some downforce. I can't go too low with the splitter like a true race car because it is still street driven, and it overhangs a bit. This is with 5 inches of clearance.

(https://lh4.googleusercontent.com/-WHMv0cAc_tI/VKAmChiXnkI/AAAAAAAAUBU/IFoZRuu3KBM/w958-h539-no/20141227_175327.jpg)

I believe I will be loosing the steel hood with this setup as well and going with a carbon/fiberglass setup because there is no room for a latch. Of course it will need to be home made so we will see how my fiber skills are.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: GeneCooley on December 28, 2014, 12:51:24 PM
I'm not sure where you are going class-wise (Do I see slicks?) but make sure to read the splitter rules before you get too far into construction.  There are several classes where splitters are allowed, but if your splitter functions as a "wing"--air can pass over top and bottom of the splitter--then you have to put body work behind that portion to stop the over/under flow.
Looks good though, we are looking to add a splitter and spoiler to the Fiat.
Gene Cooley


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on December 29, 2014, 06:05:32 AM
Hey Gene,

The current plans are to run nitto nt-01's (100 treadwear) for street and autox. Along side that I should be in C-Prepared. I know many cars that run with rear wings but I don't see many with large splitters. I took a look at the rules and XP allows aero of all kinds and the CP paragraphs doesn't speak on the manner.

I've been reading into Mark Bardbury's Tbird, Nationals CP car. He has some aero but is notably smaller than what I plan to do.

(http://oversteergarage.files.wordpress.com/2014/09/dsc_0099.jpg?w=774&h=514)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: GeneCooley on December 29, 2014, 08:30:48 AM
The 2015 Rules are available in draft form.  I used the current 2014 rules for section numbers because it's easier to read.  See Section 17 and the CP area in Appendix A.
The T-Bird is most likely maxed out on aero.  The front spoiler/splitter does not protrude beyond the bodywork (bumper cover in this case) and does not extend beyond the front wheel opening.  I missed the maximum width, but I think it's related to body width.  The rear spoiler is approx. 10" blade width measured from the trunk.  There are no endplates or intermediate support plates.  If there was one, the original wing has been removed as required before you can run the spoiler.
See Section 17.2--O & P.
Section 17.10.C has intake restrictor sizes--52mm and a required location.  (This might be for "limited prep" cars but I think it's for all turbo cars.)
There is also more CP info in Appendix A.
All of this is annoying when you are building a car, but it's been developed over the years by CP participants and if you run any SCCA events you want to be legal.  Also, everything we do affects PAX and year end points for everyone in VMSC.
I'm looking forward to seeing it run in its' new configuration.
Gene Cooley


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on December 29, 2014, 11:49:38 AM
So it may get a bit interesting. The other aero portion of the car that I haven't revealed yet (pending on a deal that hasn't been settled) is the addition of a cosworth wing. Below is a image. This really doesn't have much if any bearing on downforce just a nice conversation piece. Until it is in my hands I can't give specifics on dimensions however it does extend more than 10" from the metal but not more than 10" from the orginal OE wing placement as well as it doesn't have more than 10" of a vertical like face. Would this be legal in a prepared category?

(http://bringatrailer.com/wp-content/uploads/2007/06/1985_Ford_Cosworth_RS_Sierra_Merkur_Rebody_Rear.jpg)

VS.

(http://bringatrailer.com/wp-content/plugins/PostviaEmail/images/1987_Merkur_XR4Ti_For_Sale_Rear_resize.jpg)

I can see where the splitter needs to be tucked under the car a bit more than I have shown in the cardboard cutout. I can make it flush with the bumper no biggie. It actually doesn't protrude much past the bumper already if at all. The sides just need to be brought in.

(https://lh6.googleusercontent.com/-3ALZqxwEk0o/VKAmClIVgcI/AAAAAAAAUBU/-PyRtht2acQ/w1556-h875-no/20141227_163952.jpg)

Last night I was able to formulate the endtanks to the intercooler. Here is how much room I have to play with.

(https://lh5.googleusercontent.com/-0WH0AFD_4Hw/VKDSsm08rhI/AAAAAAAAUB0/-5Wwk4P5vHQ/w492-h875-no/20141228_150012.jpg)

First attempt

(https://lh6.googleusercontent.com/-QQBCkfGs_os/VKDTSescd1I/AAAAAAAAUGc/1WnlI4opYxc/w492-h875-no/20141228_153755.jpg)

Second attempt

(https://lh6.googleusercontent.com/-i6soMEtlZX0/VKDUQ1iG8aI/AAAAAAAAUDU/Q5MJS2gPKug/w1556-h875-no/20141228_160000.jpg)

Final result

(https://lh5.googleusercontent.com/-HYlaI4cUthk/VKDVgYWbDCI/AAAAAAAAUEo/B5YRO1aUC9Q/w1556-h875-no/20141228_164215.jpg)

(https://lh5.googleusercontent.com/-h96dCTBnmZM/VKDV_ykb1JI/AAAAAAAAUFM/AuMg1VfvaXE/w492-h875-no/20141228_164318.jpg)

(https://lh4.googleusercontent.com/-_R10j0UfLS0/VKDWvH-xziI/AAAAAAAAUF8/CtKQr8TUXYI/w1556-h875-no/20141228_164731.jpg)

Now I just need to convert this to aluminum but both my welding helmets have died...


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: GeneCooley on December 29, 2014, 05:59:56 PM
My first guess is that if the wing isn't original to the car or an option then it's not legal.  If you use the 10" spoiler then you can't keep the wing anyway. 
You need to read through the rules to check bodywork restrictions and get an idea of mechanical restrictions.  It's a pretty open class but it's not "everything's free".  Prepared classes (except XP) are loosely based on Road Race Production class rules rewritten to suit Solo conditions.  They are very specific in some areas and free in others.  It's good to know what they say.
Gene Cooley
PS: It's still a serious looking wing; I'd buy it even if you don't use it.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on January 01, 2015, 06:28:17 PM
Happy new year. Reviewed the rules. Seems like everything will be doable, I'll post something that puts the rules and what is done to the car in a summary sometime.

Here is the tacked together supports for the radiator and intercooler. I cut off all the old tabs that mounted the various coolers in order to clean everything up. I seriously rushed through the car last year getting it ready so this year I intend to do the things I never got around to doing last year.

(https://lh4.googleusercontent.com/-uOH7X41XYb8/VKXWbIMhGnI/AAAAAAAAUNk/tTbQA2ryRB4/w335-h595-no/20141230_154925.jpg)

Here is where I decided to mount the oil cooler. I had to tuck it slightly in order to get it behind the bumper. I stuck the catch can behind that vertically. All of this will be shielded from the tire before it is all said a done. Still need to find a place for the power steering cooler, I believe it will be on the passenger side as I nicked one of the lines with the sander anyways.

(https://lh6.googleusercontent.com/-5JPXtap8bOI/VKXYO-WZfTI/AAAAAAAAUIw/o9ZXJ0TqrEA/w958-h539-no/20141231_155236.jpg)

Then moved to a some bumper modifications.

(https://lh5.googleusercontent.com/-gz2EHl6mito/VKXZ7z1m2XI/AAAAAAAAUKs/0aarZrViJys/w958-h539-no/20150101_150818.jpg)

Cut some garden trimming in order to fill the gap between the coming splitter and the bumper.

(https://lh6.googleusercontent.com/-GOs_jpdVvHI/VKXaG1-8k_I/AAAAAAAAUK4/3A9-PVaFqDo/w335-h595-no/20150101_153123.jpg)

Here it is mounted.

(https://lh3.googleusercontent.com/-MtljBheGSZs/VKXa05vWc6I/AAAAAAAAULs/KP-JXu7_JRU/w958-h539-no/20150101_180022.jpg)

(https://lh6.googleusercontent.com/-V1wFFqOW1YA/VKXbJWxTTHI/AAAAAAAAUME/pkI95RjkApc/w958-h539-no/20150101_180048.jpg)

(https://lh5.googleusercontent.com/-nTZSRIX1w_w/VKXbi_KxNPI/AAAAAAAAUMc/DPGr4T2p_ZE/w335-h595-no/20150101_180123.jpg)

Now here is the cardboard splitter again. It won't be this low when done. This is at around 3.5"-4" the finial result will be closer to 5" due to being a street car. I wish I could keep it around 3" for track use but it just isn't realistic.

(https://lh5.googleusercontent.com/-YpFHI8wct7Y/VKXcBEDD6wI/AAAAAAAAUNA/McR6mRNWgA8/w958-h539-no/20150101_180349.jpg)

Till next time.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: jloehlein on January 02, 2015, 01:11:37 PM
While you're there, you should grind the pointy stubs off those damn rivets in the bumper!  I don't know how many times I've caught my leg on them.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on January 05, 2015, 07:24:49 PM
While you're there, you should grind the pointy stubs off those damn rivets in the bumper!  I don't know how many times I've caught my leg on them.

Haha yeah I need to take care of those little buggers. I scratched the hell outta myself not that long ago.

Got a little done on the car this weekend.

Passenger side of the intercooler done:

(https://lh4.googleusercontent.com/-4WdAsPEQ8UI/VKtEAprChcI/AAAAAAAAUSE/nEhgIOIMLpI/w958-h539-no/20150103_113419.jpg)

Driver side done. It is very tight trying to get this over the radiator and between the light and supports.

(https://lh3.googleusercontent.com/-mBKdnQZBG80/VKtEAi_BZeI/AAAAAAAAUSA/s0DUZuzN7ZI/w958-h539-no/20150103_163023.jpg)

So I bought this "ON SALE!... DIRT CHEAP!..." intercooler piping. That stuff is absolutely miserable to weld, I don't even think it is real aluminum. Not my best work for sure...

Here it is mocked up.

(https://lh5.googleusercontent.com/-bFRbYnzBynU/VKtEAhBfavI/AAAAAAAAUSA/qKyrdgDswfY/w958-h539-no/20150103_145143.jpg)

Here it is welded without the blow off valve and IAT sensor added.

(https://lh4.googleusercontent.com/-ilXh0RS1nVs/VKtEAhyypDI/AAAAAAAAUSA/3r7MF6r_JSs/w958-h539-no/20150103_162909.jpg)

I'm surprised but the stock hood closes. It doesn't work with the stock latch and rubs stuff. I've got a idea for it though. Or I'll make one, I've been wanting to do that for some time.

(https://lh6.googleusercontent.com/-W24zPPV9alo/VKtEArnCIqI/AAAAAAAAUSA/MYEUaFUqMks/w958-h539-no/20150103_162936.jpg)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on January 13, 2015, 03:01:57 PM
Didn't have much time this weekend but I'll add some stuff just to keep up with it.

I started by mounting the new wastegate setup. Ben, SCCA DSP champ, believed in this thing, so for 180 bucks I decided to try it out. You can see the difference in sizing compared to stock.

(https://lh4.googleusercontent.com/sJocMlxyVfJhdQ9S7agwXvcxCWa5FcpWRF1dePGKXp3v=w335-h595-no)

(https://lh6.googleusercontent.com/-7B1haasbfRc/VLL060q1JBI/AAAAAAAAUW0/SOebmUJc56o/w335-h595-no/20150110_105953.jpg)

Mounting and building the downpipe is going to be tighter than I thought.

(https://lh6.googleusercontent.com/-VYjoDpQnUE8/VLL1oUz9yYI/AAAAAAAAUUc/Fn6X_CyUsb8/w335-h595-no/20150110_113149.jpg)

Next is just some photos of the fab work on the pipes, a tank for Anthony and the intercooler.

(https://lh6.googleusercontent.com/-pruRC9UqJhs/VLL1xk6JfJI/AAAAAAAAUUo/SH5GjvACAcs/w958-h539-no/20150111_155835.jpg)

(https://lh6.googleusercontent.com/-urn7LaRin24/VLL15NmBtVI/AAAAAAAAUU0/4vEzSTmyfnE/w958-h539-no/20150111_155842.jpg)

(https://lh4.googleusercontent.com/-X4szwuOx9Ko/VLL2CujxvjI/AAAAAAAAUVA/L45h2IdeZrU/w958-h539-no/20150111_155847.jpg)

(https://lh3.googleusercontent.com/-JkbukIo4EF8/VLL2f-VD6AI/AAAAAAAAUVk/Wac-CyH-8DA/w958-h539-no/20150111_155910.jpg)

Going to get bead blasted next weekend. I like the matte finish.

(https://lh3.googleusercontent.com/-Es_2JAf5BFw/VLL3Qhp3qNI/AAAAAAAAUWk/rEkxUbQ6WWs/w335-h595-no/20150111_160250.jpg)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on January 19, 2015, 06:36:50 PM
No real updates with weekend, doing other things, spend a few minutes on this. Here is the down pipe. I started it and it wasn't really that bad just need to add a bit more heat wrap/shielding to keep the brake line from baking.

(https://lh4.googleusercontent.com/-hjHtEHsjNiI/VLx4juqWwrI/AAAAAAAAUck/N5s1po-aeH4/w335-h595-no/20150118_174126.jpg)

(https://lh6.googleusercontent.com/-qpi6-EmtefM/VLx446Y4fNI/AAAAAAAAUdA/17aZeCdDwsI/w958-h539-no/20150118_174149.jpg)

I was able to head to Englebert's garage this weekend and bead blast the boost pipes. Didn't quite match the bead blast I has done on the tank and other pipes but it is better than half of it being shiny. Thanks again Englebert!

(https://lh4.googleusercontent.com/-kgndahZYWXU/VLx5Mz-oQLI/AAAAAAAAUdY/4RArHsmJNm4/w958-h539-no/20150118_174208.jpg)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: rothaus on January 19, 2015, 07:47:57 PM

I was able to head to Englebert's garage this weekend and bead blast the boost pipes. Didn't quite match the bead blast I has done on the tank and other pipes but it is better than half of it being shiny. Thanks again Englebert!

(https://lh4.googleusercontent.com/-kgndahZYWXU/VLx5Mz-oQLI/AAAAAAAAUdY/4RArHsmJNm4/w958-h539-no/20150118_174208.jpg)

You could try some scotch bright.

The next time we powder coat them, that would look nice.

Cheers
Engelbert


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on February 28, 2015, 12:06:52 PM
Few images of the changes over the last few weeks. It has been cold and the motivation to go to a unheated garage is low.

Some paint, fans and mounting of items.

(https://lh6.googleusercontent.com/-PNMK_jMl1ds/VO_kz_2Rg9I/AAAAAAAAUt8/blnLv8pVilI/w1556-h875-no/20150226_192921.jpg)

(https://lh4.googleusercontent.com/-voaCiSuzR7M/VO_maGhGKrI/AAAAAAAAUvg/mMVhypHeFYQ/w1556-h875-no/20150226_195041.jpg)

Turbo feed

(https://lh5.googleusercontent.com/-K4XKY0K2YDM/VO_lXx6CyyI/AAAAAAAAUuk/SDQX1p6AfXo/w492-h875-no/20150226_194407.jpg)

Baffles on the inside to force air through the radiator and intercooler.

(https://lh6.googleusercontent.com/-hNQMi4HX6hs/VO_jH3jPSgI/AAAAAAAAUsQ/18qpNz_bhS0/w1556-h875-no/20150222_195540.jpg)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: whiteryder on March 03, 2015, 06:37:31 PM

Have you see this vintage MotorWeek segment?
https://www.youtube.com/watch?v=Xw6zjoJUop4



Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on March 03, 2015, 08:29:06 PM
That pretty cool Beth, haven't seen it. He even says it right!

Few more additions to the car. Nothing major.

Lower radiator tube made form some tubing I ordered. It runs under the crank pulley nice and tight.

(https://lh3.googleusercontent.com/-w-DUJSDsygQ/VPUijZ2EfmI/AAAAAAAAU5Q/tFIeSJxzHKE/w983-h553-no/20150301_155213.jpg)

Mocked up some of the exterior stuff it is all in the details now.

(https://lh3.googleusercontent.com/-ElApZpo1b40/VPUi8SSwT0I/AAAAAAAAU5c/JeIDe2KEVbY/w983-h553-no/20150301_155507.jpg)

Order most of the remaining parts this weekend. So I should be able to get it running in a week or two. Just before the first season autox.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on March 16, 2015, 04:05:13 PM
Got a little work in late one night/early morning this weekend. Successfully got the car running again with coolant. No leaks and started right up. Just have a downpipe leak issue that needs to be resolved with some sort of gasket.

Car looks better without the body work, shows off all the hard work.

(https://lh3.googleusercontent.com/-aAZLa5VJfnc/VQdfTtUucII/AAAAAAAAVA4/eNZQ-0itskY/w1026-h577-no/20150315_014756.jpg)

(https://lh4.googleusercontent.com/-OZ536_77p30/VQdfTg199LI/AAAAAAAAVA4/uV9iMCN5oOU/w1026-h577-no/20150315_014747.jpg)

Other than that, downpipe is wrapped and rear extended ARP studs where installed.

(https://lh5.googleusercontent.com/-uXR73niNS9I/VQdfTgTmLwI/AAAAAAAAVA4/ZfM4qSKBVnA/w1026-h577-no/20150314_203121.jpg)

(https://lh4.googleusercontent.com/-kXGnMERibL4/VQY_5WsTloI/AAAAAAAAU_g/bSX9niMH1Gs/w1026-h577-no/20150315_203319.jpg)

Two more weekends.... but the list is still a little long.

New pads
Hood latch of some kind
New tires mounted and balanced
Panels in front of tires to keep splashing at bay
New wastegate install
Fix turbo oil return gasket as it is leaking a little oil
Change oil
Roll fenders
Paint cross bar
Rear differential flush
Put it all back together.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: ricardodemoraes on March 18, 2015, 07:15:32 AM
What tires and what size are you running this year?


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on March 18, 2015, 11:46:26 AM
Ricardo: 145/65/14s

:)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: ricardodemoraes on March 19, 2015, 01:24:30 PM
Interesting, don't forget I know your neighbor, I'll ask him to take some pictures of the car. No hiding setups in this club!


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: 90efcivic on March 20, 2015, 03:45:08 AM
I've been looking at these hood latches for the hatch seeing that my hood does not close all the way.

http://www.amazon.com/AeroCatch-Plus-Flush-Locking-Latch/dp/B006F441SW (http://www.amazon.com/AeroCatch-Plus-Flush-Locking-Latch/dp/B006F441SW)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on March 23, 2015, 06:36:18 AM
Richardo: I guess I'll spill the beans...

Scott: Aero catches are nice, they are by far the cleanest was to do hood pins.

Here are the tires and as you can see they got pretty big...

(https://lh5.googleusercontent.com/-eaDR0R9TxxA/VQ96bbxLP-I/AAAAAAAAVXc/CJ1xqXPjf48/w335-h595-no/20150319_191357.jpg)

The challenge was getting them to fit obviously. Thanks to Chris and Amanda being neighbors I get them mounted up in short notice. Thanks again!

They are ballons. 245/50/16 nt-01s

(https://lh3.googleusercontent.com/-nPfhrJe2gTE/VQ97Gqd332I/AAAAAAAAVYc/cee0GvsYKGY/w958-h539-no/20150319_221049.jpg)

A little beating later with a cheap hammer and dolly set I flared the fenders...

(https://lh4.googleusercontent.com/-QyuVPMwXmKk/VQ99xFtrPxI/AAAAAAAAVcA/32zX479K09g/w335-h595-no/20150321_143423.jpg)

Got a bunch of little things done as well, exhaust leak fixed, hood pin system made etc. Then took it out on its 2015 maiden voyage. Rear still rub pretty bad so I will need to do the same back there.

(https://lh5.googleusercontent.com/-t2WenmqaqLI/VRATmTzTg-I/AAAAAAAAVfg/EvCVGL5SZLo/w958-h539-no/20150322_200905.jpg)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: ricardodemoraes on March 23, 2015, 11:24:34 AM
Nt01s????? Cheater!!!


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on March 23, 2015, 02:15:18 PM
I know right! Had to do something since im in c prepared now...


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on March 24, 2015, 09:19:43 AM
Put a hundred or so miles on the car last night. Everything seems good. I call it "big foot" now. The tires are much less precise than before and the gearing is completely different. I can hit fuel cut at 21psi pretty quick with the new downpipe so I've got to turn it down a bit. It comes on strong but not as strong as I thought it would be due to the extra large tires. I can be mid corner and plant the gas and it hunkers down and grips coming out. Remember I'm still on stock turbo making maybe 170whp at most with a bunch of low end torque. From 2.5k to 4.5k it is pretty torquey. Other than that it is dead, I may have made the car worse this winter but we will see how it does next weekend on its first autox of the season and I'll adjust from there.

(https://lh3.googleusercontent.com/-v6g4WGIT-ys/VRDKTROxYZI/AAAAAAAAVf8/DSQOwMGTCr4/w1556-h875-no/20150323_174613.jpg)

(https://lh6.googleusercontent.com/-8qeHWI0lkNw/VRDL23IyM1I/AAAAAAAAVgY/HUUqS_sxZVk/w1556-h875-no/20150323_174652.jpg)

-Paul


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: GeneCooley on April 03, 2015, 02:47:29 PM
Paul, I was thinking about what you said about your problem stopping the car on Sunday.  Is there any chance that boost is getting into the vacuum side of your brake booster?  This was fairly common on turbo cars of the 80s (my Pontiac Sunbird Turbo for instance).  After a long pull the boost would fill the "vacuum" side of the brake booster.  At that point you didn't have brakes until the pressure was gone.  It usually didn't have much noticeable effect on short pulls.
Gene Cooley


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on April 06, 2015, 06:50:34 PM
Paul, I was thinking about what you said about your problem stopping the car on Sunday.  Is there any chance that boost is getting into the vacuum side of your brake booster?  This was fairly common on turbo cars of the 80s (my Pontiac Sunbird Turbo for instance).  After a long pull the boost would fill the "vacuum" side of the brake booster.  At that point you didn't have brakes until the pressure was gone.  It usually didn't have much noticeable effect on short pulls.
Gene Cooley

Not a bad thought Gene, and something I should check. I know the biggest issue was the finish was fast and I had the throttle pinned going in a left hand arc and I couldn't lift until I got the car straight and settled. Then I'd hit the brakes and they would lock up quick and we'd slide. It was pretty bad.


First Autocross with the setup two weekends ago. Car did ok, more grip than before. The steering inputs where not as precise however due to the sponginess of the tires. Stopping however was still a big concern as I just had put EBC yellow pads in. Tires pressures are still something we need to play with as they fluctuate a lot being as large as they are.

So here are my rotors after a year of autocrossing (12 events and 3 pratices) with 3 drivers... I can still see the factory cross hatching. It basically polished them. I replaced the pads and in a single event have worn off all the cross hatching with 3 drivers. These old pads are worthless.

(https://lh5.googleusercontent.com/-KD5cKVQDrMY/VSL_xMGaeSI/AAAAAAAAVmQ/k_GXm8KKfH8/w1556-h875-no/20150328_113739.jpg)

Swapping pads.

(https://lh5.googleusercontent.com/-0H7PegYNAyo/VSL_xDaDtnI/AAAAAAAAVmQ/A8V19LzMlo4/w492-h875-no/20150328_113756.jpg)

At the event

(https://lh3.googleusercontent.com/-vrYmYN7LEmA/VSL_xNkrvZI/AAAAAAAAVmQ/W7pawTaJMZU/w1556-h875-no/20150329_133927.jpg)

(https://farm9.staticflickr.com/8720/16404749183_3167aa4d33_b.jpg)

More photos and bigger update coming soon when David releases his photos.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: gunny on April 07, 2015, 03:40:01 PM
I use a BFH on things I dont like too!
awesome.

Gunny


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on April 09, 2015, 09:32:55 AM
Gunny, that was my fender clearancing device... works too :)

Couple of photos and notes.

So Gunny, Stuart, my own brother Pat and Richardo are the Raw time contenders for the Merkur this year. Out of the 5 of us the Merkur was bettered by the M3 and Corvette. Total separation was less than 8 tenths of a second between all of us! I hope to do more driver comparing as this season progresses as it adds a personal element to it.

Here is a few of us on the same corner. Note the different lines. Richardo is fast for a reason and it ain't just that car. He visually is better prepared than Mindy and I in that turn alone.

Mindy
(https://farm9.staticflickr.com/8768/17058086546_aa2edf6c13_b.jpg)

Richardo
(https://farm8.staticflickr.com/7665/17084031045_3a0f19e3b3_b.jpg)

Paul
(https://farm9.staticflickr.com/8745/16876619547_82808fc27d_b.jpg)

The merkur lacked brakes big time, I'd mash the stop pedal wayyy to late and that became an issue very quickly at the end of the longish straight and through the finish by locking up tires. I will take some camber out of the front before next event to see if I can gain some braking. I doesn't do much for confidence when I can't trust the brakes.

The new balanced tires still kept the car neutral in the slow corners but it is still very oversteery in the fast corners. I'm not sure what to do here but next event I will try keeping the rear tires at a lower tire pressure. I think a big wing would help in the fast stuff. Mindy isn't convinced.

The new intercooler/radiator placement kept the car nice and cool (even though it was only 40* out). No leaks so far.

The new downpipe did help with boost pressures early on. The day before Richardo and Gunny drove the car and it was noticeably harsher when boost came on. We de tuned it some before Sunday but it came out a little soft for my liking at the event. It was only at 15 psi vs the 18-19 that I'm trying to run. Down 10-15 hp I'd say. Torque curve felt linearish... as much as a 80s turbo car can be...

Till next time. Thanks David for the photos as always!

(https://farm9.staticflickr.com/8737/16896330920_dab278c64e_b.jpg)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: ricardodemoraes on April 09, 2015, 10:48:18 AM
Was that a compliment? Weird, usually I only get trash talk. hahaha
It's a shame that I wont be able to make the next event.
By the way the whole "So Gunny, Stuart, my own brother Pat and Richardo are the Raw time contenders for the Merkur this year." thing... CHALLENGE ACCEPTED!


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on April 23, 2015, 08:09:12 PM
Don't let that head swell too much there buddy. I'ma coming of you!

Another weekend and another autocross. This time my brother and Richardo couldn't come play so it was the boxster and corvette who remained. The course was 63-65 seconds and the merkur was once again bettered by Gunny in the vette but only by 2 tenths. Stuart in the boxster lagged behind the merkur a tad, however I know next event will see him on new tires which are by far his biggest handicap right now.

The event was at VMP which had the obligatory lane change with slalom down one side, a cross over or two and a few off set gates coming back. Typically I've found it a very rewarding setup if you get it right from the start, as soon as you get a little behind your time usually reflects it because of how easily it compounds. Also grip is down at VMP and at the top of 2nd gear with the throttle pinned most modified cars are skipping, gentle inputs are required.

The night before the event Mindy and I pulled most of the camber out of the car, raised the nose a inch or so and realigned it with 1/8" toe out. This resulted in a much more confident setup with a touch of under steer in the slow corners and a lot more stability in the fast turns. The biggest change however was the braking effects. It was like we where driving a new car. It stopped very well with only a little lock up once braking way too late for a cross over turn. 44 psi in the fronts and 40 in the rear also helped keep the car feeling precise but stable.

Thank you Laura for the photos! The look fantastic.

(https://farm9.staticflickr.com/8727/17030689698_c11cc7a777_c.jpg)

(https://farm8.staticflickr.com/7677/16630447473_4ba41f72e4_c.jpg)

Now the bad news. The car still overheats! very strange so I'm working that out. So far I've tested 3 different thermostats in boiling water and the one that was in it (generic parts store) didn't start cracking open until 198-200 degrees, it is a 192* thermostat?! The OEM unit from Ford (motorcraft & also 192*) didn't open much faster however a 180* thermostat from STANT was wide open at 190ish. Looks like I need to gain more flow at 190* so I hope that is part of the issue. I also added a bleed nipple to the upper rad hose so I can make sure there is no air in the system.

Next event is VIR... more on that later.



Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: sonomadrifter on April 28, 2015, 04:21:13 AM
Sounds well sorted - Photos from the last RIR event:

(http://i477.photobucket.com/albums/rr133/mnkymits/88700004.jpg)
(http://i477.photobucket.com/albums/rr133/mnkymits/88700007.jpg)
(http://i477.photobucket.com/albums/rr133/mnkymits/88700005.jpg)
(http://i477.photobucket.com/albums/rr133/mnkymits/88700008.jpg)
(http://i477.photobucket.com/albums/rr133/mnkymits/88700020.jpg)


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on April 29, 2015, 03:27:51 PM
Thanks Pat!

Look awesome.


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on May 10, 2015, 06:29:16 PM
VIR update.

So this last weekend was pretty sweet. Great track, tons to do/see, awesome time hanging out with friends and family. This was Hyperfest's first time at VIR and all in all in it went really well. For those who don't know, Hyperfest is a NASA mid-alantic event holding HPDE levels, various races (Spec miata, Honda Challenge, E30/E36) as well as various time trials mixed with USDrift and there Hooliganism on the Patriot course all in one weekend. On top of that there was a 2 hour kart enduro, helicopter rides, rally rides, pro drifter ride alongs, burnout contest, beer garden and a car show, just to name a few things. There really isn't any other grassroots auto event that I know of state side that has the same amount of shear stuff going on.

Before getting to the even coverage I had a couple of loose ends to finish up on the car. First a bleed nipple for the upper rad hose to purge out any air. Worked very well, no leaks.

(https://lh6.googleusercontent.com/-P-2KrsK8ff0/VU66bRVCAyI/AAAAAAAAVx0/T3f22GQdBao/w1026-h577-no/20150423_213826.jpg)

Also moved to a 180* thermostat. Notice the difference at 195*. The 180* is wide open and the OE and part store brand just started to crack open.

(https://lh4.googleusercontent.com/-78luBggFC48/VU66bbGt9CI/AAAAAAAAVx0/qyDs7o9gsvk/w1026-h577-no/20150423_184114.jpg)

Then Thursday evening Justin came over and we loaded his trailer with the car and tons of tools for the trek to VIR the next day.

(https://lh6.googleusercontent.com/-46Qf5GJYD7Y/VU66bd2-c9I/AAAAAAAAVyE/ZzjhPIJDNqQ/w1026-h577-no/20150430_195618.jpg)

I didn't take any photos through the weekend so I'll keep it short and sweet. Friday Mindy and I made it to the track pretty early, around noonish. A couple of old friends of ours, Renzo, Jorge and Chris where on the way as was Justin with the merkur as well as Jeff and Audie with the integra and Stu with his boxster. We scoped out an area for us all to park. At 7 or so everyone had arrived, had a beer, I got tech'd and relaxed. Open track was on full course and we watched a few of the racers start to prep for the weekend races.

Saturday morning was like a typical HPDE, some driver's meeting along with a classroom session and such. Then by 10am it was track time. Each day we got 4 sessions of 25 minutes or so on full course.

(http://www.catesracing.com/flp/nasa/2015events/2015_05_vir/hpde2_4/VIR50543.JPG)

Here is Jeff in his k20 integra following me around VIR for a bit. Every now and then you'll see a flame at a shift.
https://www.youtube.com/watch?v=EYciZbY0Pzc

Saturday evening I caught a ride with Pat, who was participating in the USDrift sector of Hyperfest, and it was epic! Before we headed to the 2 hour Karting Enduro with Mindy, Justin, Pat and I. We placed 9th of 12 teams.

(https://farm8.staticflickr.com/7770/16746364653_1d593d4273_b.jpg)

(https://farm9.staticflickr.com/8890/16746314463_468abebca7_b.jpg)

Sunday was more of the same just a little less hecktic. USDrift was winding down and the crowd started to thin as the afternoon progressed. Jeff and Audie headed out a bit early due to some power steering issues with the integra. Justin, Mindy and I got out a bit after the last session.

(http://www.catesracing.com/flp/nasa/2015events/2015_05_vir/hpde2_4/VIR50371.JPG)

Sunday's last run, at the end I got to play with a Cayman, other than that, clear track as you will see. I did better the cars personal best at a 2:25.9 on Saturday's 2nd session out. However with the mechanical issues I couldn't improve on that late Saturday or Sunday.
https://www.youtube.com/watch?v=MuHuolpmuBg

Currently car is under going the knife again, It felt noticable weaker through the weekend and I quickly found out that the gasket between the turbo and manifold had blown out, letting all some exhaust gas escape past the turbo. More on that later as a new turbo is being built along with what I hope a fresh bottom end. Car needs more than 160whp around VIR...


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on June 15, 2015, 06:47:36 AM
Well it has been a month or so. Here is the latest series of events to bring this up to date.

Cliff notes: Made a CF hood.

(https://lh3.googleusercontent.com/86efKIYj-rAdVKCaj6AjJKhiSE69WUhw5R9Xj5L9hY8_=w1218-h685-no)

(https://lh3.googleusercontent.com/GhkEJhcCuO4vFQOcVH1cxLcZY5UIBdkyeRGrNkYM_zC4=w1218-h685-no)

(https://lh3.googleusercontent.com/ISkuQGXX5MqGu2bxFjDffivjqNSndvlGKm_I6dyWA8EI=w1218-h685-no)

Added studs and copper nuts everywhere:

(https://lh3.googleusercontent.com/reVM7fbd9WcyvhDV6CHXc8_9Hv0QWtkYy6-Qd8YqXRl3=w1218-h685-no)

(https://lh3.googleusercontent.com/7vqdnfZZQcg1aGu5JRoueUePGZGX8xiKkO-bd1G7tt9y=w386-h685-no)

Had an issue at VIR with the intake on number 3 cylinder. The cam lobe had a gouge in it. It also cracked the upper portion of the lifter like something had gotten between the rocker and cam. Then in compressed the lifter and smacked the valve down all the way.

(https://lh3.googleusercontent.com/32_egqoZw6tDjybBDhRBxNZK0zBCL9LkREDEqaPfEtwD=w386-h685-no)

(https://lh3.googleusercontent.com/wKL6xaAwnXNYxSinLQA9NbWRMbpnMpZ8tHfDOX8WAwZN=w1218-h685-no)

So I shimmed the lifters up a bit and it ran fine, just made a lot of noise.

(https://lh3.googleusercontent.com/9TrkQCmg-j4F6x-74hC6-t2NSgpcQYoGRSrtd-QREmLd=w1218-h685-no)

(https://lh3.googleusercontent.com/3-hIIH9dI-GHVLNpxtu19_wXRa62MZd6fM20jy0kVH6c=w1218-h685-no)

Had an autocross

(https://lh3.googleusercontent.com/gulXXpD40qKwg36-5MVKxYBlW75rqyO2pUqNEi_wgsK5=w1218-h685-no)

Then took it to CMP for a track day where it didn't stop giving me motor issues. Overheating by getting air in the cooling system, turbo studs backing out all the time. Eventually the wastegate failed, it over boosted and pop! no more merkur motor. Coasted into the pits and loaded it on the trailer.

(https://lh3.googleusercontent.com/0S-WecU3kQ7bSJ9lgeNXtO2-MiJPR0D-wiw2x0y7WZdY=w1218-h685-no)

(https://lh3.googleusercontent.com/iYAzdn1GMnn1dgPm9cnyXjbQ8Aq9a817NFhfg6CbDF_h=w1218-h685-no)

(https://lh3.googleusercontent.com/PI76CpBoGr-bPCFbYrJaStYNDzHTSC2ga9OJ4eRb9qsI=w1218-h685-no)


Now I'm a cross roads on what to do. I'm not sure if I'm going to finally put that 50 trim on it that I've horded with a rebuilt 2.3, I have a volvo head sitting here as well. Or say screw the turbo stuff and go V8.

For now the project will be on hold until I can get myself in a position where I can do some work in a direction that I'm certain on.

-Paul


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: MikeDe on June 15, 2015, 06:14:26 PM
As long as it will live again, I can sleep at night. FMC tried to kill it in 1989 and yall loved her and gave her another life as a race car....I loved these quirky cars when I was a kid..... The XR4tI and the Mercury Capri....But then again there aren't many cars I don't love.....


Title: Re: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"
Post by: catapultkid on March 06, 2016, 10:35:35 AM
Update:

Its been awhile and the car has gone through some small changes over the winter.

Where we left off last July was a blown motor. After that I threw together the 6.0 truck swap, did some house work and drove a combination of Jeff's civic, Gunny's vette and James si. It was really nice to have folks in the club that trusted me enough to drive there cars. THANKS AGAIN GUYS!!!

Some time in december I finally had a bit of time to turn back to the merkur. I drove to PA with Mindy and picked up a "0 mile freshly rebuilt motor" from some guy that needed money. Got it back to Goochland and a few months later with Jeff's help one night made the swap. Long story short the motor made NO OIL PRESSURE. I was a little pissed and took the next 2 months trying to figure out why. Finally I just pulled the again in February and this is what I found. I don't know how to resize the photos.

Installed the first time

(https://lh3.googleusercontent.com/HYxBvBkEHIdT6T-wXXoa54jt6lu40m4nOcjxjh5ySEvxJOpf9xiY_9Gd6efXLWFbmeqrhW_gbGqmqmQ1r4RmBm9Yfci85CxpQBEnhjCxn1a30ypXXEPmpbhkJMWhmDJfnTW0efvkS3xgSACHlkCm32tgBafpXsA4yKhgPsrN1Cf6U_UNoItktafYwlHY20tA2qqsa2xbrd9FPqQyxJV8VTcizu5TeA4I1Dd0-EzTzfwP8LLAaKzDVCLD6THnzO4dSAEVjg4UjKx0CDY_Wu1oCXxZvER7zv9Jg6gIJ2J-cJzn2FS8mlub5iT7kSSzB3_uQnYAySN4q0L7N-nHq-eJyCBBS4RyWwsJB8nhf5QiUO-JNWR1uqt9srtOlX6Phi6mnwU_0pj-IdJuG3CBhhTieDrUTPTtuCAuggclGHIt3PsF2Uix1ILZGuk2COv7lQF9lEKAaOpsWcxzYjD_21ziksQFpl1ECzNq_6BxXLMCx5bj_aVQu-BiaW_8021w4SOA_ilNP6QdYn-PoxnXGrFgZJMVXctNNOuiV6A3CRDO56JdoGnkCHLISFEWxeBuRy7OHruPCg=w1709-h961-no)

Intercooler set-up. Made new piping and end tanks to the intercooler. It was a tight fit.

(https://lh3.googleusercontent.com/IydOL3nb3TSTXL4hHOK3CD9vBPztpNBMVzRldSO3CjEEwkyPnYmqLTtWkX5MNj4Rx-oUZTObzvasobXHilys5DbDX-5GUEgd6eG09z2AU8znrdunlMyeazmhbuIDjaVOMl8vARFBy_whypzlqvmk5evFiTMVDZGTWeiZvd5_fwsLC6RPDbgNI5azz8dYZK6t89aZ_nhtcZtTGEdTOBiyS5YRRNDcTsIhPKySLxI4ACZpuDGkQ4_63Ce2PlBuD8GoZDv5ivvwBECfnk15gZsw1v-_fwAZgQsRExpQjF-rY7junAyTGl0zYOBwO5DLA1AIs4EuoPhKVvZ0TnXXJ5enDYvv4shqN54l_abAAMsVdhyQsWKyGTyUFpczCW0TTynNINcGR-E6bqJctHgUf8GT-BC6dvmVODmSYzq2XpYEpf-vlTRv0VstV-ip-rLUuXOi6gDJ4OfbYIt534fSb_KjRFNbhwMNwVywAbu33CDoabuf8Und0E_tksIsp2OI-ngtBNdFHvJdqB4AZ_BgWqkSy4hNYNbT3zw0kTJDpf-xEpbIothLfBySjRUN04Yzd7YIn177Rw=w1709-h961-no)

Removing the 2nd time

(https://lh3.googleusercontent.com/BRL7-rJVSR3j5lwvVrXMkiz78-ruxd5ZHa1BYmqdDsjSErziCJLFXiEdY4H_s-iUhGCjSs51g6RQ1k5_AzHcBs6cPXQMNrFxVc4JT3IK8I_4_36oPzxNaodGSWtMjjMyL_IbHbwdqhmXvLsDcVRVUGspN6DzollswxVLedVi2iIO3Eopa9DHcBBTy-DwsSnv9exyf22TQZGDIcXyyRw5CBZ8CWuhwNxyqP31kN7gxPCBECtYgoB9lmPnDHaMjKvbXgcw-Icll4QbxUtdtnosYWWTEHa6uKXYUnPMvHGkTPuLgmKarM2xDd2iaSYdLlYhMju5T6enR8zddcVBnUAhu5WKFohEDXGwc1jsoj4qKlD7Xl9KoFxEHAp0zm9ZV8Cz1lQzLmbUsmFTprbPTHTmrX0SmiQrJHMYaKsYZDUEW4MAamOGyU1lsOUsIsgzlkLQW_I1A-JNLL_xdv9y1TXeHYC-Q65T7h97OTALYtk77V_2HOTQeWMdvn7F87ot-2dwD3mO3v0dWERXMQ6NAbIOxbJQRjY2IF9mjof9ZO0jVrfVE7gD_gzQ9c5omdb1YibAsDkgCA=w1709-h961-no)

Brand new bearings already worn
(https://lh3.googleusercontent.com/hrrx8ytqeBwvQxD-2-qWTXjbXa-R86OzH2Z-1Gn-TK5nENGhU_xKC4Y_hGd9bASaIC_XJuQv9F7qY70CQZoyOWeyCoviAfgSZca7lyWsJfoi1Tdu4_kc2hZnXBFMNWouVh_aNCb6VMFCfBpRPYCgmvKwnU6cyswJKxdCsYXU3XtqIiwBmaPmUr860xbdFFTfLIlOVyof-S0CPWP_YZ0iBtkvPtzbjq0-PcS3eHTiU5sFuDaqhqhfM_bhVqkmyuqqh_BHnly81QKKflFofLq05FkmmhvQQAta8ivzuuokvl-nbpL7-ommztLDGiEvG30jXWPDDwOnP4PnC-9WXT9hFrDKUNfinxk4qkUuqy1VeQZxAenU237TdYqq6fZceQWE_2DTw5lT5MpYIn3sNcaASKPPFtz5KhLiaXtiFqJB2mqoXCC2h1CSAKb0-GRGbiod2WCEdGAQeghgB94SNNmHt2B_GPwRkWXrAe9zdeveP31VFDsy0Ts0WgakwfAKZttHRB1uRvhR3TXKgAAVnUfvqLuPi4-dYGWCJ78SljTn56AMhVQgtHfyqWXxTQJvJm__LFpQTA=w1709-h961-no)

Bearing clearances.... ~3/32"... support to be .0008" - .0026". No wonder it didn't have oil pressure.

(https://lh3.googleusercontent.com/6lXzt4J-F0CzRKk-V4ovD8P5_pH9mwOa_uK1pTE6RJTB0UUvUWQr-sl9qBxFYkt4zmeZL_loxJ1ilik9_NTYhOOlWiY02Rv9jn69tOuXQxtmC35iAyUxwfRM_w4dsfrzgvYiqRgohGZYQEQcidOHvlO_TVrQ1dLX5fEgddPWutjIOhEIDOrND1JCW0iSe6SX5zyMHu0ivqo46HM8gudxu9CWDBRBykLXTv7w3vNQCHWK8az_BqMbhnXghDHi0383pBFICVFU5iGoJWNSIApOWxgzh4UVUd-ledHwj5MyPQT-ZJ-l0tseLmoKypRmaxSoAJAvqvNM0bsrVj8lbSjgP0NVuyT9cv20_67fhL41aUEHmwZm_O6LcLXjpL3smbp7sGawYUWalpx7fBnvFGkVGitp2TYwG-WZ171d_uYpWT32mw3Ih_KJipZyc6qa_VxOirluqEVgSgMpwV7z2ataO7yCBXrhGaKg9cpsKEyvu3-osj9EF_2TnzhxZke_mlKhHlJGUTzIE9iM4_G_KSc-yonnL53LNYNnxihKDehX7dtPbJMo8E16UDnCbdyd-HsApOkQmA=w1709-h961-no)

Then I found out the bearing caps weren't from the same motor. There all of the tolerances where screwed up.

(https://lh3.googleusercontent.com/R6VNl7X2cQbeVnnqB0H9sWuDIIde9POOS6UzFWMYkJjhLFBpm7Hoe-JMym6kFqmjoI8y8Ef9EefX50ouSgg-IYbbyDfKYWOYe82dq-SS2eRPOwVX8GxQUfwOx-mvnbusfbTNLmd80ZmeT1hVQxJmepxUJYVec0Uq8Hn5P6EzqU94Nw-kaAHhJa-3AwN1BTo90wqnaiSDEQ0wEgfI9sm0t-R_ckV6Peulg0_5yFhhXqNcJ28dtGDZnVfhC_D2JvM-T5gC7ULosJkj7hFwg7n93XFvbrfmLLISgUMvEvYLXZ4dAYkWl079CyuqrXKsXNF6MRADwnMJoijNQFlPZ7jbKnVOs0bbj18_SvDA9PRbVK0_PRzwvwTV_oSu8Tt1EobeNQ7S1z5fqwNqm2IKhorCrZx_Vj6DS1MzFyVXZUICNdd4mB1NeaIszto7st1zieGaZlm0-i_iUIjIbeRwOePAPYfA4ogcDXYAfWXKJVKGbCEE32nPmYWajowvFf774hFYiJ2pbygr1fP9hVHf8kyhNzVw4TVsiidr2rwf-eq5BudKVuLxSJYrI2WFV82bTXxFxLYTzA=w934-h526-no)

Here is a list of things I found where wrong.

Crank was cut .030 under
Miss matched bearings sets used (aftermarket and ford of all different sizes)
Crankshaft wasn't from a 2.3 turbo motor
Rear main cap from another motor

Free motor from Don Haulsee. Thanks DON!

(https://lh3.googleusercontent.com/Eo2qCxVPRYqUx0bV5Qk0DAkq7zUw6wy4U-g9T-DPGcNz-DqOYayq2KbgAy9aBO8J3CivCB3EjlGRje-aeS3HR2yeZvl1wXwnAq2gUfsDpEBHRAR6YTL21RWMpH4orYIiqS35cfaB-djluF5xtPlV6UxuqoG_LeiSKnOqHXVTlz5DQJADhgKp8niLj6DMIhHiBgfKfXNT5CE3nn73_2RCr0GSAFiDNDyfkK8u7w_HDfwdNO5d88HcPrExz6I8oQ-0SK01bv-27CCBP17mk0Y9Oi1Zsqf_pmu3fZ7-iY4_RpOY15UIEkEZPT0TcPa1vBgI-Em2gNMVzafbscV7iV7OqUwSoYBb2TmndS4-NjsklRm4jm3jKEZlJ3v5WmtO1zjyoMU2ORiS4HvPRENSrg9Axz1Ll_S07mSE3GPQ_M2Iq23hioDmC5r_zO8ufNUXrdEGCflJWwOcg_ay-PMzBOjNMe9EZkFh2dKfv_IpuLO8IEp2vZdccIjUxCdHsCnklOmUFBOsDc7aue5TMSWMBPMiSYLrVvzPWQAI_JNvveLQiTvSQ06PaXvJVOdwOq4zNF4IrHmhEg=w1709-h961-no)

Cleaning with engine degreaser and carb cleaner

(https://lh3.googleusercontent.com/j3r27RH7gCJk1nem3-yh2gDXuRMmvjwTz47nnhvtQGRX7etlRml8QRoTSMSoBGK3vcHnSil-4YtYQnzIObwmgS2JRMgdDn9xrkf2jhrXFkwSWTvTqKpUyt7-uMLU64Gw40MQ0nMiObdvuhZUdU-w6lOuIXDkFjHUkuYdiDoPaTDzIEk43CCUGRMVjHPxX5HB_FMlFhmHJgnJGoiZ1qZHDn07THfuMbv-fQ06t2ciYBLOIKK5Hl8vYHswXK1Mtdv0n9tT9SfZFKWkpsSI4lD1Cq5480guCfN9n9B1t-5sYz5pDSd3f7FLpKxfAFjJzY9NxGOhaajrK7OdKIFITrwZZBwMBTyVBYownF9cF3Bl7bJLuy2ILbQ9M9ZPAitxs_mz9czSJ74zrQ3tUeNX0LQPhQlZ2wCg40KN4OT_vhSHf2TP2xx5-6RMEV3B4c1bShUpGmlbBcAXdkRYbap2p9LPKoDJk2RyFmtuqy_7nzY-PJqEtEm4dRt15QC-9UemQZBnKp6NL1VQ8AwNTr-f5rGuQH1Ebt9qQSogpxZvyeic16G-Kc6uwpvG_7dgWEBQls78yXWl6A=w1709-h961-no)

Cleaned up

(https://lh3.googleusercontent.com/tYCd-Tvd_O7En2SosGr-I3X_ba7ZrnUDBG3QWorDBwk2-N8KQ46O2bdq7m5kOzpoXVKdXO02wGVuKlgeEjv380uzh0CY0uqgrUQWr09SHT09FUwIDLgDAf-B0hCP1EYpzi5buTxUTX6R-j3qio3TWhY-l2Mfr53izrjrHoo10t69BPvVvR7u8V3ImWlBeYxzRxoKsupgHtEJe2TdSs4xQw_dHPMBgNKLmE0uul22z9c2scPvC6lhGwXQLgFYjsX7U7bKckiTrOLOwb_A0bfCwGVm2OH67CG-z4CXyofn2kK2wHlpbDKytfLsOP6_SJhaogcAmCL-_2gVMsCLLEVTdOl8-X-8_U4tqeNRfBpObdymAsCsynyRyAWE2RPcvIdx60clvOgS-1BiR7GrgyISk_ex81rxldhPWi-2UJG2m0r7jgZmuz941G6SFAbF_eLUtOACwCHjkwo0TuDorckfC7pqB2Kihxlq8T74thTXsVcN02NkVsWrycLuF3x3MV8qVQeLStXzpJE7SX2dxzqWnizynaFjidE7gc4fF9hldoX1TrA375hHdFA3ZbSfbbDMZ71RYw=w1709-h961-no)

Cleaning pistons

(https://lh3.googleusercontent.com/cvzedqiqZt4f9E851GW0uRFrmwQWpz2EuAk4rFr2knuCVeHQZCA6nRW0Tl-2h5IYpRrzjvPEQyonW0ucgaumQV6fJmr5CpP0ACpBuEpaGGxUr8ud-Zi9xDat4QCFVJdbh9zlGNTtHdYwuuPO9LRsY6chCiyHk1oF-oXeTBrGgVKl2oiv9Ht7bjpBiBV2uY9YeNiM4ccusddKLl5d8ZDhU39CNwfYzuOSusRCFjLYSaWl9gUBnIxs1TeUSeJ5j_sc2eGyNf4PyCVAZ_JrkX4pIMkbrm4CAvWBppxASA6f6kKWMKAgOM4cHTyzcu5v0z2d93CxkSlUfdmKF1_xHrF0z2YyF-ox9ufWt1MplxztrwngHuBfAWBuVq-ZyROUkFn9sWmtM9W_5C1PO8X15mNPvYyDh-JjcUuOKGZvjhsVNx_Qrb8O_T4U_22JEAVnvxITZDEz5DKB1IL7M05pc8x35qEIt7Vv7Z5rw3S9G0cQdvMy2Sf_Yq_PVzqNg-x0tuLPi0DUPHBNXjSrkG_zSwks7q9vawn1egBqLV24RNKHia60uU3aR28lK4J0wWOm7h0zdEGDFA=w1709-h961-no)

Painted with engine paint
(https://lh3.googleusercontent.com/AsyugDH04FlcPoJIJGEME7pE1L5GJ_LeGPgHCTpGkChlxm-A2659uh2LFz4x1_INScFZJq0rNmX5K3N6H0vE9IEEwJ7lzRvQG8cmOrnF8nIFC2U0Ai54Gv3i6sLWuwbar4b21zX5XECIURtURa6soKifg8b_J_FROu0u4VqP2mETPRmxhI8YXZxcSXcgQAAhDPOpX9f1DB35t_sKaX127LUIRHPz2w9mcOKZslSjZg-0V2HR9mMrUczk5hWxPhgZmzo2Hc7-7TGiMhdayHbkh3oHCGNg9p3mZoeWYFayQAZijUJ6dDxqd4hKtuiiwFgKoKUR3KdxLt1v8hR7RFebv4KWphDMTmhpfrfI5fRForFt2Gxxai4sEJ7CgQCaz2sR0J5fEm6eK85JR08LG24ciiiyH3iq-qpFtfWLDFaRq9F5t86oRb6_q7RmEmRSPGRu1Vl_3_8j3xpNzBShOHTI5HvKj6qIxFurWe8Hr2NzjTnooreLtfYCR2z5BLlcD3ayLmHtCw0yZ_oGYAFgY3IDTucyDZphz3jSuP28gOzCGtamJjz1N5fthgzZENIUNB_WJFnOPg=w1709-h961-no)

Till next time.