Tarmac Rally Stratos Build begins

[ByrneEngineering]

Thanks guys, We are madly running around trying to get ready for its first rally in 2 weeks, Targa High Country. Not expecting any great results and treating it more as a shake down for Targa Tasmania later this year.

I'll make sure to post some updates

Looks like it shifts pretty well

I am amazed (and very happy) with how well it shifts, super precise good short throw, and gear shifter is in a nice spot.

[Ken Tomblin]

Brilliant Colin. Love all the mods plus the lathe hose cutter “magic” best of luck in the rally.
could you provide more details on you’re gear box stiffening mod and the top mounting bracket that you fabricated for the front damper mount.

Kind regards Ken.

[ByrneEngineering]

Hi Ken
Re the gearbox, we pulled the rear cover off to see what could be causing failures that we had heard about and noticed that there was minimal material between the 2 shaft end bearings. The main forces the end case has to contend with are the 2 shafts pushing apart so decided to try and reinforce the bearing housings. We cut out a thick ali plate, cleaned up the casting and welded it on the outside, to create a sort of "strap" between the 2 bearings. It weld on very well, and no issues with warping. I'll try and dig up a few photo's of the fix, i think my dad has some

the top mounting bracket for the dampers was a basic box section, just spent a long time making sure the damper would clear the top arm. Since i cut out the fiberglass section that goes around the spare wheel and replaced it with a steel section, that section of the front chassis is very strong now
cheers

[Ken Tomblin]

Hi Colin. Any photo,s would be be very helpful on both mods as I am trying to replicate them on my Hawk.

Kind regards Ken.

[Bernard]

Congratulations Colin, its been great to watch your progress this last couple of years....
Cheers
Phil

[ByrneEngineering]

here's a good shot of the gearbox sterngthing plate, we milled it out of a 12mm plate so we could leave a 6mm edge to aid with welding and leave a 12mm rib, but that was overkill and due to a crippling Milling machine addiction, a simple 6mm plate would have been fine



Some more pics of the front strut mount to follow
cheers

[Strat Fan]

here's a good shot of the gearbox sterngthing plate, we milled it out of a 12mm plate so we could leave a 6mm edge to aid with welding and leave a 12mm rib, but that was overkill and due to a crippling Milling machine addiction, a simple 6mm plate would have been fine


cheers

I haven't actually seen an Alfa box fail in the bearing area but I have seen a couple that have worn through from rubbing on the inner wings when the top engine steady in the donor car fails.

The one I have seen that failed in a Stratos replica (former member on here) was much more catastrophic and the weak point was actually around the outer edge of the end casing.
The increased traction of the mid engined layout must have been too much and the thrust put back up the shaft from the crown wheel was too great for the casing.
The old 164 gearboxes were much stronger in this area where they had the additional bolt on end casing.

[Basher]

Colin, Enjoyed a brilliant compilation of videos, the car looks and sounds great , good luck on the rallies , Cheers

[Stableblock]

Thanks Colin, Its been great to follow your rebuild and see everything you have done. I imagine I'm not alone with my workshop (and skills) envy! Good luck with your season.

Best wishes

Peter