Before I start to describe some of the steps we went through building the car, a couple of words of advise,
if you decide to build a car like this or any other project of this kind;
Planning and budgeting the big items and larger stages is relatively simple, what will catch you out. is all the seemingly infinite number of small items and jobs that will take up a considerable amount of time and money
Insanity Too, The build project.
As has already been stated elsewhere the I have enjoyed racing in the
cross country events so much fun even in the old worn out Discovery
that I had decided to take it more seriously, I could not aford to
buy a serious car so started planning to build my own car. The demise
of Insanity 1 accelerated these plans.
It all starts, with the arrival of the new frame. Roll over
protection and body panels at the location we now call the
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
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 chassis legs are cut profiled & welded back on in
there new location, to provide the correct support for the rear of
the ROPS.. We chose to reinforce the joins with the triangular
Next we located the new ROPS back on the chassis again and finally
start welding it on to the Chassis. We've used ratchet straps to hold
everything into place.
The engine and transmission where relocated in there new position.
The new location of the engine was determined by swapping the front
and rear prop shafts.
Whilst all this was going on the axles have been removed and its all
sat on axle stands, Hind sight suggests that this should have been
done earlier in the project.
In the meantime I have been rebuilding the axles, replacing the
brackets for the radius arms and spring mounts etc. Fitting new
The hubs and swivels are rebuilt with new bearings, swivel seals and
All of this goes back onto the chassis with new springs and the
Milner Varidamp shock absorbers from the original Insanity car (some
of the many parts that we recovered from the old car).
All off a sudden it starts to look like a car again but there's a
long way to go. With the axles 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 footwell
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 aluminium wondering how to start.
Then another long session with lot of cardboard making templates etc.
to try things out. Cardboard is cheap and a lot simpler to cut, This
became referred to as the CAD process “Cardboard Aided Design”.
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
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 CAD involved. But the end result creates a neat
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 also made the decision to fit a smaller steering wheel this is a
14" sports wheel with the flat bottom from QT to replace the
standard land Rover part.
Not clear in pictures I have changed the pedal box from the auto
pedals to a manual pedal box (smaller brake peddle) this is to make
any change to a Manual transmission in the future simpler, Well that
was the idea anyway!
The wiring inside the vehicle is now be started, Switches, fuses and
Relays, and once again it takes several iterations to get this
correct. (See the final 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.
N.B. 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
changed 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. Getting the suspension to work properly
is one of the biggest ongoing challenges with the car and it will be
changed many times over the following years.
The car is ready to race at Radnor July 2013
Or At least I thought so...........
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!