To Dakar and Back

[California Jay]

Some of you may recognize the thread title, a title covering a book of Lawrence Hacking through the Dakar Rally.

A Google search will give you plenty of info on what this man has accomplished, but the book expresses it better.

This thread will show a journey for a few people, as I'll be covering the progress of his next entry for the 2010 Dakar - where ever they hold it. This will not be a two or three week build blog, as some of us are used to on here seeing the odd engine swap in a VW. I'm sure the truck will be wrenched on to the last minute before leaving the country. Consider this a test of team work, quality manufacturing, build technique , technical insight, reliability, durability and in the end - perseverance. Lawrence has already competed in the Dakar... on a bike. This private entry of his will fall in the T1 Open class for the rally.

The best thing about it - The truck is equipped with a VW Turbo Diesel.

Here's some pictures on the entry as it sits now. I'll certainly go over all the details of the truck shortly, with more pics of course. It will fill you in on what it is composed of and what regulations the truck follows.

Just a small bit of info of who I am.
I've been doing automotive related fabrication/design/car prep for a decent amount of time, roughly 10yrs... Covering quite a few realms of motorsport recently, and daily driven cars from time to time. People know me mostly for turbo manifold fabrication. If some of you have followed some of my other work you will know I don't leave out details. I like to let people feel involved/informed. If you dip into my sig a little bit, it will give you a taste of the work I do. I hope you all enjoy whats to come.

If anyone sees an opportunity for Lawrence to take on some additional support during this journey, by any means, let me know via IM or contact:

Lawrence Hacking,
offroadrider@aztec-net.com

Jay Thornton,
california_jay@hotmail.com

Please remember the build may not be updated day to day, but will be a great source for info on whats going on surrounding the truck and its progress.

A few more pics.

Modified by California Jay at 1:23 PM 1-12-2009

[California Jay]

Today I thought I'd give a rundown of the details of the truck... Added in some more pictures too.

Chassis Type: Mason Motorsports Pro-runner, number #006 of 11 to date, is CAD designed and built by Neal and Robert Mason of Mason Motorsports, Escondido, California. It meets SCORE International technical and safety standards and is SCORE tagged (inspected). Roll cage is constructed of 1.75” x .120 wall thickness tubing.

Two wheel drive, solid rear axle scaled-down (7/8 scale) Trophy Truck.
Wheelbase: 111 inches or 282 cms.
Wheel track: 76 inches or 193 cms.
Powerplant: 1.9 liter VW / Audi Turbo Diesel engine

Transmission: Toyota R154 5-speed that has been rebuilt and modified with short-throw shift mechanism upgraded thrust washers for strength by Marlin Crawlers, Fresno, California.

Some of you may wonder how the trans mounts up to the engine... there are a couple companies that supply hybrid bell housing kits. This one inparticular was from Acme Adapters.

Rear differential:Trussed Ford 9 inch with 6:33 gear ratio using 35-spline rear axles, Strange modular third member.
this combo is good for 700hp Certainly durable for this application

Brakes: Willwood calipers and 11.5 inch steel rotors that are same for all 4 wheels reducing need to carry unique spares.

CNC Master cylinders (for clutch and brakes) and brake bias proportioning valve.

Cooling system: PWR aluminum multi-core radiator with 2 electric cooling fans mounted above and behind the driver’s cockpit out of harms way.

Oil cooler plus Canton Oil filter cooling lines adapter.

Tires:33-inch x 12.50 BF Goodrich Baja TA radials (truck carries the mandatory 2 spares).

BFGs are best off-road tires available with numerous Baja 1000 wins.
Rear Suspension: 3-link full floating solid rear axle with anti-sway bar supported by FOX 3.0 triple bypass and 2.0 coil-over shocks, 2 per wheel.

Maximum Travel: 23 inches or 54 cms but reduced to 18 inches to comply with FIA rules.

Front suspension:Center-mounted fully boxed A-arms supported by FOX 3.0 triple bypass and 2.0 coil-over shocks, 2 per wheel.
Maximum travel: 21 inches or 53 cms also reduced to 18 inches.
Amount of bump steer throughout full suspension travel stroke:

Gross vehicle weight: 2600 pounds or 1176 kilograms.
Top speed: 85 miles per hour at 4,500 rpm.

Body Type: Fiberglass, 4-piece generic pick-up truck.

Fuel Cell: Fuel Safe FIA Approved 32 US gallon or 121 liters.
Fuel range at 28 miles per US Gallon: 886 miles

Power steering: Howe hydraulic ram with billet reservoir and filter.
Wheels: 15-inch Walker Evans Bead locks to prevent the tires from going flat as a result of lateral impact.

Modified by California Jay at 2:26 PM 1-13-2009


Modified by California Jay at 1:58 PM 1-15-2009

[Wes@motivemag]

Do you have any more pictures of the engine, Jay? That thing looks incredible!

[G0to60]

definently in to keep an eye on this. i've always wanted to see what it takes to build a Dakar vehicle. to you guys and good luck with the build.

[California Jay]

Yes there will be plenty.. I've got lots of work to do on the engine.. you will probably get to see some rapid prototyping to aid in evolving some parts. We have stereolithography on site.

Modified by California Jay at 2:19 PM 1-13-2009

[Isgro]

Wow, that's very cool. I'll definitely keep an eye on this thread.

[Kid Hobo]

No 1.8T?

[California Jay]

A race like this you need to keep it simple and reliable. Fuel needs to last... Mechanical Diesel injection turbo will take care of that.

[Kid Hobo]

Quote, originally posted by California Jay »

A race like this you need to keep it simple and reliable. Fuel needs to last... Mechanical Diesel injection turbo will take care of that.

Yeah, but if it had been, you would have had close to 95% of the TCl community follow you down there to help out with anything from impromptu engine swaps to a cup of refreshing ice cold water. The remaining 5% would have been waiting for VTAAAK to kick in yo.

[California Jay]

LOL I guess you win some and loose some.

Here's a quick shot of the steering rack I forgot..It's nice and compact to the center line of the car.... much needed for something with so much suspension travel.

Also a good aerial for some of you.. gives a decent engine shot.

[hotweiss]

Wow, that truly is a mid-engine car.

[G0to60]

so the engine is halfway into the cockpit or am i seeing it wrong? i guess that would help with weight dist.

[GTIbyJB]

This thing is awesome, I have the pleasure of working with Jay on a daily basis (More fun then it sounds, he goes a little crazy sometimes, well all the time actually) and to see this in person is amazing. The whole thing is one huge piece of engeneering!

[RavinJetta]

Very cool build

[Nourdmrolnmt]

Quote, originally posted by California Jay »

LOL I guess you win some and loose some.

no, with the 1.8T you nevar lose

[California Jay]

Quote, originally posted by G0to60 »

so the engine is halfway into the cockpit or am i seeing it wrong? i guess that would help with weight dist.

Your vision is 20/20

It looks a bit farther back in that pic than it really is, the engine and trans area are designed to accomodate a full LS1 drive line if need be.

[Eg2Driver]

lol at the fram filter......nice truck!!!

[California Jay]

thanks mate,

[Kid Hobo]

1,8ts aside, this is a sweet frakin' ride. Have you put it up on a dyno to see actual output? Did you modify/swap the turbo?

[inarisilver78]

It is amazing but change the freakin filter

[Mcstiff]

Wh are your goals for the engine? I thinking about using one in m CJ6

[California Jay]

Everyone has to understand something... this is work in progress. Some things are installed temporarily to give the representation of something that will be there in the future, it makes it easier to estimate what part has to clear another if there is something new being installed or fabricated... so obviously that filter will not stay. Second to that, when you break in an engine...you don't put the best of filters or oils in first.. its a waste of money.

Generally my first stage of break in on a motor like this will be 50km or a documented amount of hours. Then the oil is drained and filter tossed for the next stage of break in.

Goals for the engine are still being disscussed... I'd like to see if I can get Garrett on board for the TDI upgrade they offer, its a great torque increase. But tuning it for mechanical injection is another hurdle. We'll see.

[tip]

Quote, originally posted by California Jay »

Second to that, when you break in an engine...you don't put the best of filters or oils in first.. its a waste of money.

Isn't it funny how people attempt to point out every little thing "wrong" with what you're doing to come across as "intelligent"?

Don't listen to the keyboard jockeys in this thread telling you to do this or get rid of that. You and your crew know what you're doing...

Props to a guy who's a part of a unique project, I'll be watching this

[Kid Hobo]

THIS:

Quote, originally posted by tip »

Isn't it funny how people attempt to point out every little thing "wrong" with what you're doing to come across as "intelligent"?

Minus this:

Quote, originally posted by tip »

Don't listen to the keyboard jockeys in this thread telling you to do this or get rid of that. You and your crew know what you're doing...

Equals this:

Quote, originally posted by tip »

Props to a guy who's a part of a unique project, I'll be watching this

Modified by Kid Hobo at 9:20 PM 1-13-2009

[California Jay]

Quote, originally posted by tip »

Props to a guy who's a part of a unique project, I'll be watching this

thank you!

[phryxis]

very very cool.

the dakar rally is something i've always been interested in.

[beatenb3]

I can't wait to see more. I want to see that thing run.

[VW Tuna]

Quote, originally posted by beatenb3 »

I can't wait to see more. I want to see that thing run.

x2!

[Preppy]

Out of curiousity, is RWD capable enough for this event? Most of the vehicles (motorbikes aside) are AWD ya?

[SteveMcqueen]

This is why I joined TCL. Detailed build threads are great and this is definatly setting the benchmark. Great, clear pictures. Great information.

Too bad you couldn't give some more detail on the actual frame build. I love browsing pirate4x4 and seeing the actuall bones of the car form.

Either way, thanks, good luck, and keep this thread bumped!

[climbingcue]

Very cool, I will be watching this build

[axe]

Wow

[G0to60]

Quote, originally posted by Preppy »

Out of curiousity, is RWD capable enough for this event? Most of the vehicles (motorbikes aside) are AWD ya?

Robby Gordon has done it the last few years including this year with a RWD truck.

[California Jay]

A shot of the dash and configuration for seating, not much room but you cerainly need to sit in there nice and snug. Although, it gives lots of mounting area for the GPS, guages etc etc.

This also shows the kick up for the wind screen as the fiberglass body is mounted.

Modified by California Jay at 12:53 PM 1-14-2009

[California Jay]

Some mounting and decisions on the location of certain items are still being decided, but the power steering reservoir sit quite nicely here... a small circular clamp holds it to the frame nicely.

Notice the replaceable filter, nice feature. We still have to figure out the fittings for this item as the suspension travel is so vast, fittings to the drivers side would interfere with suspension components if not placed properly. Manual steering on this is not an option with these big tires.

Some other small brake lines got routed today too. Nothing secure...some lengths of line need to be adjusted also.

Modified by California Jay at 1:56 PM 1-15-2009