Insanity Racing

An Amateur Cross Country Racing Team

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 The Project, Insanity Too

Here is the story and some images of the project build of "Insanity Too".

The project.
This car is based on a shortened Discovery 1 chassis with the engine and gear box moved back in the chassis.

I had decided to go down this route as I had a very good chassis from a scrap car I purchased for spares, it meant I could easily recover a lot of parts from the first car and it meant I would be using many standard Land Rover parts that are relatively cheap and easy to source.

The roll cage (ROPS) and body panels where provided by Tornado Motorsports, Derbyshire.


This is where it all starts, with the arrival of the new frame. roll over protection and body panels.

 


The first job was to "clean" all the unnecessary parts of the chassis, removing the outriggers and various brackets.

Its amazing just how much metal we cut off at this point.

Next we located the new ROPS on the chassis to understand where everything was going to sit, We did this many times before we work out where everything needs to go and get an Idea of how things will line up.

 


Then we cut out a large section of the rear chassis to eliminate the overhang that a standard Discovery has.

The rear Chassis legs and rear cross member are cut off as close to the spring hangers as possible.


The old rear legs are cut profiled & welded back on in there new location, to provide the correct support for the rear of the ROPS.


Once the shortened rear chassis legs are welded back on in there new position. We chose to reinforce the joins with the triangular patches.

Next we located the new ROPS on the chassis again and start Welding it in to place. We've used ratchet straps to hold things into place.


The engine and transmission where relocated in there new position and the ROPS welded into place.
 
The more observant will also notice that the axels have been removed and its all sat on axel stands, Hind sight suggests that this should have been done earlier in the project.

All off a sudden it starts to look like a car again but there's a long way to go!


In the meantime I have been rebuilding the axels, replacing the brackets for the radius arms and spring mounts etc. Fitting new bushes throughout.
The hubs and swivels are rebuilt with new bearings, swivel seals and brake disks.

All of this goes onto the chassis with new springs and the shock absorbers from the original Insanity car (some of the many parts that we recovered from the old car).

With the axels and some wheels on things look good. Back on her feet again, you start to get a proper feel for how its going to look.

The next jobs were to fit the additional cross bars in the doors and fabricate the seat mountings.

We went through about five iterations of seat mountings just to get the seats in the best location.

There where also at least three iterations for the footwall construction before I found one I was happy with, it may not be the lightest option but gives a lot of security and mounting opportunities (and will allow me to change the auto pedal box for a manual version in the future). The welding does not look brilliant, this is at least in part because the sheet material is galvanized.

    

The steering column can now finally be located in place, not as simple as you might think. The length of the shaft from the steering box influences the location of the bottom of the shaft, but the driving position determines where you want the top end to be.

                                     

The next job is to start fabricating the floors and transmission tunnel sections. The fabricating of the interior body involved a lot of time staring at large sheets of aluminum wondering how to start. Then an other long session with lot of cardboard making templates etc. to try things out. Cardboard is cheap and a lot simpler to cut. We have also hung the doors to enable the door strikers to be located and fitted.. The end results are very pleasing, and actually "create" a large open interior space.

The rear bulkhead panels can just about be made out and the new inner wing panels fitted to the rear "load space". The fuel tank has also been put in place, With the first MK1 version of the fuel system.

The newly manufactured inner wing panels for the front wings, these proved very difficult and time consuming to get right, again with large amount of cardboard involved.

     
      
But the end result creates a neat engine space.

 

It feels like a long time coming but along with a lot of small jobs like connecting water hoses for the radiator and fitting the PAS reservoir etc. but finally we start putting the major the panels on.


The Windscreen panels fitted and all of a sudden the space inside starts to become "real"

            
Door panels fitted and door hung in place.


I have also made the decision to fit a smaller steering wheel this is a 14" sports wheel with the flat bottom from QT.

Also not clear in this picture I have changed the pedal box from the auto pedals to a manual pedal box (smaller brake peddle).


The wiring inside the vehicle can now be started, Switches, fuses and Relays, it took several iterations to get this correct. (See the Dash layout lower down)


All the Brake pipes and brake balance valve are fitted, All the pipes on this project are Aeroquip braided pipes, made "routing" a lot simpler.

And finally the vehicle is as close to ready as it is likely to get.



At this point we thought there was just some small "fettling" jobs to do but this is very much how the finished car looks. Although check the ride height as the suspension turned out to be one of the first deliberate design changes, it proved to be too high making the steering very reactive to the "road" surfaces. so i change the springs on the front for shorter stiffer versions, again it takes a couple of attempts to get this so I felt comfortable with the way it worked at speed.

And ready to race at Radnor July 2013
Or At least I thought so...........



This is how the dash finally turned out.


As it turned out  did not get to run the car competitively at this event as the expensive new Bosch Pump I am using Failed before I got to the start line!

The story continues:
See  the news pages for how we got on as the seasons progress.