Chevette HSR C20XE Rally Car

[fearless]

Not content with having one ongoing project (Corsa S1600 Rally Car)

Building a Corsa C C20XE Rally Car

I'm now involved with rebuilding this Chevette HSR Rally car


Although the Corsa S1600 will be be our main focus - my mate wanted a 'cheap' RWD rally car to compete in, have a laugh and do a bit of drifting in the process - Not worrying about beating the £60K+ Mk2 Escorts out there

Having viewed a few Ford Anglia's (My Mates has a soft spot for them), any other RWD car's were considered - then this one came up on Pistonheads

Rally Cars : chevette hsr lwb rally/trackday car


Another roadtrip last Sunday saw this car coming back home on the trailer to gather dust in the workshop next to the Corsa

One day one will be finished

[Melv]

Can't wait to see this one progress.

[fearless]

The plan (although the Corsa started off like this) is just to rebuild it as cheap as possible !!!

The chevette was used as a forest rally car - so the car does have a few battle scars - but was stripped and repainted by the previous owner who then didn't have the time to rebuild (Took up the expensive route of rallying EVO's)

All the basic ingredients are there - Long wheel base shell - caged - LSD Atlas 5 linked rear axle - Bilstein suspension - 4 pot brakes - bias pedal box

Just need engine and gearbox, seats and harness's etc

Came with a van full of spares as well :





1.5 2.3 Engines





1 Getrag dogleg gearbox



A spare atlas axle and all these parts







The engines and gearbox are destined for ebay to be replaced with a C20XE on carbs with a quaife box - all quite retro !!!




Hope to end up looking something like this






Don't expect any regular updates - this is a very very long term project (possibly even longer than the Corsa S1600) - LOL


Dave

[lee303]

looks stunning, nice project

[Rallycorsa]

Look forward to seeing this one over the next 10 year My mates got 4 HSR 1HS and a mint 1256 unfortunatley hes just melted a piston on the rollers this week so pulled his entry for the Pirelli.

Hows the Corsa doing?

[gazturbo]

I like thre chevettes, Looks smart

[Mr_GSi]

Will look super cool that bud

[Astra Dan]

Oh very nice!

[jonlem]

Proper car !

Although I prefer to see cars like this doing what their best at I wish someone would drop a big power LET in one and do some serious drag racing with it. Would make a nice change from the usual fwd entries from the Vauxhall camp

[Spinbitch]

Oh now that I do like lots! Be an awesome bit of kit when its built.

[Gordo]

Any progress?

[Benn]

Looks like another awesome build...

[corsablue]

project looks good mate cant wait to see this unfold are you going to use it for tarmac rallying or forrest rallying

[fearless]

Decided to upgrade the spec of the shell - and seeing that the MSA have changed the requirements to obtain a new competition log book for the car - now seemed a good time to modify the shell and improve safety at the same time

So a Custom Cages multipoint weld in cage was installed














And fitted weld in seat rails (not as straight forward as it looked)




There's not a lot of room in these Retro rally cars - in order to get the competition seats in and have enough head room and side impact room - meant having to remove the exhaust tunnel on the co-drivers side and mount the seat rail almost on the floor pan - we opted for safety rather than looks !!!


Couldnt resist chucking a set of shorter coilover springs on the rear for that ultimate 'Tarmac Spec' stance






Dave

[fearless]

A quick coat of etch primer before the final top coat









Enough room for the hydraulic handbrake on the transmission tunnel

[gazturbo]

Nice progress mate

[corsablue]

looks great buddy

[fearless]

Progress is moving along quite quickly now - sourced a ready built C20XE and quaife straight cut gearbox from a Rally colleague - freshly rebuilt straight from a Mk2 Escort


This engine has undergone a full professional rebuild 4 rallies ago (sub 400 competitive miles) costing £3000 alone with complete strip, re-core-plugged, all bearings, seals, dipped and stripped, new piston rings, carbs overhaul and new service kits & floats etc, ran in on engine dyno.

Engine runs on a dry coil pack and has shortened head/cam to allow close bulkhead fitment

Dellorto DCOE 48's Carburettors and K&N large filters
Omega pistons
Kent mild / Rally Cams, good strong mid-range pull
Twin Vernier cam pulleys
Arrow forged steel rods
Iskie valve springs
Lightened flywheel
Cylinder head ported and new race valves
Alloy Big Wing Manta Sump


MBE ECU and Loom
Tilton 7" paddle clutch, cover and plate (BRAND NEW CLUTCH FITTED MAY 2012)
Tony Law 4:2:1 Exhaust manifold (matched to engine spec)
Dellorto 48 Carbs
2 x K&N large filters (relatively new)

Ford Quaife Pro straight cut 5-speed Type 9 Gearbox; with Quick-Release Alloy Bell Housing for XE/Vauxhall Redtop, comes with Rose jointed gear stick & Alloy Gearknob

This box has just been fully rebuilt two single venue rallies ago (sub 100 competitive miles) with replacement shafts, gears, all bearings and seals (£680+vat in parts !).










So with this lot bolted together - time to introduce it to its new home






After taking many measurements and calculations - its position was finalised and engine mounts fabricated












Ended up looking something like this






Whilst waiting for more parts to arrive - the roll cage and interior was painted and lacquered






Finally bolted on a set of 8 inch minilites to get an idea of looks




Still lots to do but getting there


Dave

[Melv]

Wow. That's a well specced engine. She's going to go like ****!

[Kev_G]

that thing will go like shit off a shovel

[Gordo]

Very nice!

About the only thing I'd suggest is replacing the gearbox top plate with the Quaife (or other supplier) alloy cover to help stiffen up the gearbox casing - I understand that case distortion can be an issue and so gearset/bearing life can be shortened.

[lee303]

looks great dave! really nice work on the mounts and cage, gonna be a pair of cracking motors when they are both done, a trio if you get yours done finally too!!

[vxlgsi]

very very nice indeed, and bob knows his xe's!

this thing is going to shift!

[Rallycorsa]

Nice work Dave hows the Corsa doing ?

[fearless]

Nice work Dave hows the Corsa doing ?

Still waiting for you know what !!