Build: A New mk2 Rally Shell for mid 2009

**DubbersReject** · 12-08-2009 07:40 PM

Quote, originally posted by QuantumRallySport »

OK, it has been a while since we updated this with pictures and everything because we have been busy racing.

The shell is now ready for paint & drivetrain (with the exception of 2 gussetts missing from the X in the main hoop in these pictures)
The floors have both been replaced with fresh sheetmetal
The rockers are doubled
The seat bases are installed
The areas around the front and rear strut towers have been seam welded....

http://quantumrallysport.googlepages.com for more details and the latest news

that is some awesome fab work! how much support did you have to add to the rockers for those jackstands?

**QuantumRallySport** · 01-07-2010 10:17 AM

Quote, originally posted by DubbersReject »

that is some awesome fab work! how much support did you have to add to the rockers for those jackstands?

Sorry I missed this earlier.

The pin sockets go all the way through the rockers and have 1/8" plates on either side roughly 3" x 5" plates...

The front pin sockets actually go through the boxed tower that supports the cage at the base of the a-pillar. If you look at the cage photos closely, you cn see where it comes through and a small disc was welded on the inside to keep out dirt.

**ilovepinups** · 01-11-2010 07:25 PM

really good build. i can't wait to see the finished product!

**QuantumRallySport** · 01-18-2010 05:21 PM

OK, so as some of you know, Eric Langbein has been helping us to develop a tubular subframe that fits mk2 and mk3 VWs in order to make the front of the car stronger, lighter & easier to service. Soon he will be doing tubular control arm set to go along with these.

Pictured below is the first version of the subframe. This one has no motor mounts and will be in our TDI powered mk2. I will add a pendulum mount once the motor is in place. There is already a second generation in the works that will be even lighter and stronger.

Weight: 13.8lbs
Stock weight: 21.8lbs
Savings: 8lbs
Strength: Increased significantly
Coolness: Very high

Contact me for Eric's contact information if you are interested.

**turoc** · 01-19-2010 12:30 AM

That thing looks awesome!

**Convallo** · 01-20-2010 12:00 PM

spectacular! Wish i lived closer so I could check this thing out!

**QuantumProject** · 01-21-2010 03:59 PM

Ozgur, Put in your order! I spoke with Eric about one on Monday.

**turoc** · 01-21-2010 08:11 PM

You gonna be at Sandblast?

**QuantumProject** · 01-28-2010 09:15 PM

You bet. I'll be running a stock subframe until Eric can finish up the second gen tubular subframe with stock motormounts.

**GodSquadMandrake** · 01-28-2010 11:12 PM

This is getting on the level of WRC modifications. Very impressive!

**QuantumRallySport** · 02-01-2010 12:34 PM

Update: Slow and steady progress. We have basically a van full of parts on the way---Diff, intercooler, turbo, exhaust,. And the list of things to do is still s long I don't even bother writing it down.

Worked on getting the mk4 dash to fit. Still have to make brackets etc to hold it in place so in these pics, it is just sitting in there a bit out of position.

TDI head fresh from Justice Racing Engines http://www.justiceracingengines.com

TDI Lump pre head removal:

Sunroof Panel test fit, drilled & ready to install after it is painted:

Misc bits for heat & defrost etc...

**Greasecar** · 02-03-2010 07:57 PM

Looks good Josh! Glad to see you are back at it. I can't wait to see what you are going to put together with that box of fans and rivets.

**MrMook** · 02-11-2010 01:06 AM

This looks amazing! Great work!
To show my appreciation, here's an animation I whipped up from your photos

**BJosePHD** · 02-21-2010 05:08 PM

looks great top notch, someday i wish to walk on my garage floor with just socks on...
any chance we will see you in maine this july? i hope the Rally master has sorted through the issues we had last year.

**woodrowstar** · 02-26-2010 02:36 PM

NEAT! I have to ask....

1) how do you decide what to have "spares" of?

2) and is the decision to "one off" a part, make it that much difficult to decide?

Modified by woodrowstar at 11:45 AM 2-26-2010

**g60vwr** · 02-28-2010 01:03 PM

Have to get in on this... Nice build

**QuantumRallySport** · 03-01-2010 09:12 AM

Quote, originally posted by woodrowstar »

NEAT! I have to ask....

1) how do you decide what to have "spares" of?

2) and is the decision to "one off" a part, make it that much difficult to decide?

We typically only have spares of things that are likely to break while we are at an event---Control arms, stub axles, tie rods & ends, etc. If it can't be fixed in a 20-30 minute service by 2 people with basic hand tools in a gravel parking lot, we generally do not have a spare...

**QuantumRallySport** · 03-01-2010 09:13 AM

Quote, originally posted by BJosePHD »

looks great top notch, someday i wish to walk on my garage floor with just socks on...
any chance we will see you in maine this july? i hope the Rally master has sorted through the issues we had last year.

Good chance we will be in Maine this year with one car or another

**-RalleyTuned-** · 04-06-2010 01:00 AM

I see you guys are registered for the olympus rally this month up here in the NW

**QuantumRallySport** · 04-06-2010 11:55 AM

Quote, originally posted by -RalleyTuned- »

I see you guys are registered for the olympus rally this month up here in the NW

Not in the Golf, Jeremy will be riding with ACP in his EVO

**-RalleyTuned-** · 04-06-2010 02:09 PM

ah sweet

good luck to him then

**late_apexer** · 04-12-2010 12:00 AM

interested in the subframe. IM sent. thanks

**QuantumRallySport** · 04-12-2010 10:26 AM

Quote, originally posted by Greasecar »

Looks good Josh! Glad to see you are back at it. I can't wait to see what you are going to put together with that box of fans and rivets.

**QuantumProject** · 04-12-2010 11:09 PM

Looks good Josh! Can't wait till you get this thing up and running.

**QuantumRallySport** · 04-13-2010 09:54 AM

Quote, originally posted by QuantumProject »

Looks good Josh! Can't wait till you get this thing up and running.

Thanks for all the help last weekend.

**turoc** · 04-13-2010 08:50 PM

Will we expect to see you guys in this car at Maine?

**DemonRally** · 04-14-2010 03:59 PM

you making underbody molds?

**QuantumRallySport** · 04-14-2010 04:36 PM

Quote, originally posted by DemonRally »

you making underbody molds?

Not molds, just laying it straight on and bonding it with the resin.

We will be adding some 1" plastic strips with rivets to make sure it does not get pulled loose anywhere.

**Wagonsport** · 04-20-2010 02:18 PM

Any pics of the second generation subframe?

**QuantumProject** · 04-20-2010 05:23 PM

Eric is working on a new one with stock motor mounts for my car. Hopefully I'll have it in a couple weeks and I'll get photos posted then.

**QuantumRallySport** · 05-11-2010 02:24 PM

Put up some pics of some reprep done to the gasser while preparing for Rally TN this past weekend

http://www.facebook.com/pages/Quantu...9179600?ref=ts

**mhoche** · 05-12-2010 05:19 AM

You've got a bolt missing.

**QuantumRallySport** · 05-12-2010 10:05 AM

Originally Posted by mhoche

You've got a bolt missing.

Is that like having a screw loose?

What bolt is missing?

**mhoche** · 05-16-2010 12:53 AM

Just messin' with ya.

**QuantumRallySport** · 06-01-2010 03:35 PM

Video from Rally Tennessee this weekend... Still in the gasser.

http://www.youtube.com/watch?v=rfsX99XPE2E

More to come

VWVortex

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