BITD 2012 Season DSR1 Build

[cfyca]

My dad and I have been working on this for a little while now. We started with Rupert14's old Rhino, then decided to cut it in half and convert it into a DSR1 car. Hopefully after seeing a couple extended car builds, other members will get excited about the DSR1 class and decide to build one as well. While we are by no means fabricators, or experienced with UTV's and building them, I am pretty pleased with how it has turned out thus far!

Right after we cut the rear of the car off, wondering what the hell we did.
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Where we are now.. We have the engine installed and rear suspension mounts done. With this setup we will have the engine and headers completely behind the firewall, but still be able to run the stock headers.

Now we are ready to build the fuel cell support stand and the rest of back framing, then move into the driver compartment.
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[rupert14]

That looks great!! I cant wait to see the car racing again. I have a bunch of pics of the new rear hubs with 930CV's and 4 piston brakes. The fronts are coming along nicely also. That frame extension section looks really strong. Great Job and keep the pics coming!!

 

[cfyca]

Thanks! It is starting to look like something. We are still interested in those hubs, just keep me posted on them. What tire/wheel combo are you going to be running with them? I was also curious how you extended your wiring harness, and if you had any problems with resistance changing in the wires with the added length running up to the dash? Maybe I am over-thinking it..

Can't wait to check your car out this weekend!


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[cfyca]

Not a ton of progress (going to watch the BITD Henderson 250 this weekend didn't help, although we got some great ideas and pointers from Bobby Raber and his DSR1 build)!

We had the fuel cell mounted, but decided to re-configure what we were doing so that got scrapped. As soon as we get some tubing bent we can finish tying the back together, mount the seats, then get the interior moving forward.

The new pedal assembly and all the shift linkage parts should be getting here Thursday, so hopefully we can get going on that this weekend! Can't wait to get this thing going... Especially after seeing Raber's new car in action!

A few pics..

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[rupert14]

Looks great!! Keep it up. When do you think it will be done? We are planning on Parker and I was hoping to have someone to race against. I like the vertical height in the cage. It will make the car VERY comfortable.

 

[450grl]

Depending on what our schedule and budget looks like, maybe you'll have one or two more Sr1s to battle at Parker.... I aint skeered of those little whoops - lol!

 

[cfyca]

Looks great!! Keep it up. When do you think it will be done? We are planning on Parker and I was hoping to have someone to race against. I like the vertical height in the cage. It will make the car VERY comfortable.

After checking out everyone's rides in LV this weekend, we realized this thing is built like a tank. WOW! Hopefully we can get it geared down enough to compensate.. We have an extra 1/2" clearance between the bearing carrier and the skidplate due to our engine/swingarm mounting to 2.5" rather than 2" tubing, but that really doesn't help all that much. Only time will tell...

Our original goal when we started the build was to have it going for Parker, but at this point that is looking a little ambitious. We will probably have to just shoot for the next race. Which, I guess is the Mint for UTV's?? What a race to shake stuff out on...

We were actually thinking about taking a couple inches out of the height of the cage to make it a little more streamline and sleek. We will have to see how every thing ends up with the seats, etc.. We are all quite short so the head room really isn't an issue!

Any updates on your hubs and spindles?

 

[rupert14]

After checking out everyone's rides in LV this weekend, we realized this thing is built like a tank. WOW! Hopefully we can get it geared down enough to compensate.. We have an extra 1/2" clearance between the bearing carrier and the skidplate due to our engine/swingarm mounting to 2.5" rather than 2" tubing, but that really doesn't help all that much. Only time will tell...

Our original goal when we started the build was to have it going for Parker, but at this point that is looking a little ambitious. We will probably have to just shoot for the next race. Which, I guess is the Mint for UTV's?? What a race to shake stuff out on...

We were actually thinking about taking a couple inches out of the height of the cage to make it a little more streamline and sleek. We will have to see how every thing ends up with the seats, etc.. We are all quite short so the head room really isn't an issue!

Any updates on your hubs and spindles?

Keep on it. I just got my 65 tooth titanium rear sprocket in the mail yesterday. Unfortunately my motor was not mounted higher even though I know we spoke about it somewhere along the build. I will be making some kind of rear skid plate to protect it. With that gearing, the rear chain drive ratio is in the 5.5 range. That should be WAY low. I will give you feedback on the ratio so you know if it is the way to go or not.

We are currently selecting the uniballs/heims to assemble the front spindles. All the plates are ready to cut out. Since we have our own plasma table, we can do it in about 20 min. We still need a set of stock rear amrs and a stock rear hub so we can make sure everything is perfect before we cut everything out. If you have any or know of any let us know. We have a stock frame we are mocking everything up on and checking angles.

As for Cory Weller, come on down to Parker!! We love this new car and look forward to building momentum for the new mini class 1 cars. (DSR1) Last weekend I realized that it takes days to wipe off the smile created by breaking 100mph in a UTV.

 

[cfyca]

Keep on it. I just got my 65 tooth titanium rear sprocket in the mail yesterday. Unfortunately my motor was not mounted higher even though I know we spoke about it somewhere along the build. I will be making some kind of rear skid plate to protect it. With that gearing, the rear chain drive ratio is in the 5.5 range. That should be WAY low. I will give you feedback on the ratio so you know if it is the way to go or not.

We are currently selecting the uniballs/heims to assemble the front spindles. All the plates are ready to cut out. Since we have our own plasma table, we can do it in about 20 min. We still need a set of stock rear amrs and a stock rear hub so we can make sure everything is perfect before we cut everything out. If you have any or know of any let us know. We have a stock frame we are mocking everything up on and checking angles.

As for Cory Weller, come on down to Parker!! We love this new car and look forward to building momentum for the new mini class 1 cars. (DSR1) Last weekend I realized that it takes days to wipe off the smile created by breaking 100mph in a UTV.

I have a stock rear hub, but not the arms.. If you need it let me know and I can send it down your way. We are moving forward, I think it will start coming together a lot faster now that we are past the majority of the fab work. Now it is largely just sheet metal work and electrical to get it going. I will keep updating the post with pics as we progress. I am supposed to get the bent tubing back this afternoon so we can start mounting the seats and the pedals. Can't wait!

 

[MRPAT920]

Keep on it. I just got my 65 tooth titanium rear sprocket in the mail yesterday. Unfortunately my motor was not mounted higher even though I know we spoke about it somewhere along the build. I will be making some kind of rear skid plate to protect it. With that gearing, the rear chain drive ratio is in the 5.5 range. That should be WAY low. I will give you feedback on the ratio so you know if it is the way to go or not.

We are currently selecting the uniballs/heims to assemble the front spindles. All the plates are ready to cut out. Since we have our own plasma table, we can do it in about 20 min. We still need a set of stock rear amrs and a stock rear hub so we can make sure everything is perfect before we cut everything out. If you have any or know of any let us know. We have a stock frame we are mocking everything up on and checking angles.

As for Cory Weller, come on down to Parker!! We love this new car and look forward to building momentum for the new mini class 1 cars. (DSR1) Last weekend I realized that it takes days to wipe off the smile created by breaking 100mph in a UTV.

if its in the name of progress ill sponsor stock rear a arms for driver and pass. side and A stock rear spindle

 

[cfyca]

if its in the name of progress ill sponsor stock rear a arms for driver and pass. side and A stock rear spindle

Look at that.. Let's get these babies done!


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[MRPAT920]

Look at that.. Let's get these babies done!


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lol thats what im saying

rupert14 send me your address thru PM and i will ship them tomorrow...what bolt pattern are the hubs going to be ?? vw 5 x 205mm

 

[rupert14]

lol thats what im saying

rupert14 send me your address thru PM and i will ship them tomorrow...what bolt pattern are the hubs going to be ?? vw 5 x 205mm

Yes they are the wide 5 VW pattern. I willl PM the address and once we have everything we should have the first set done in a couple weeks.

I will have my dad send some pics of the actual hubs as they were cut. Needless to say no one will be breaking these babies!!

 

[cfyca]

Some pretty good progress over the weekend... Got both seats in, pedals mounted, shift tower fabbed up, and a horizontal foot bar for the passenger to brace themselves into the seat.

Now we will start wrapping up the rear-end and getting the wiring straightened out. I am hoping we will be able to fire this bad boy up in 2011!

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[rupert14]

Wow! That looks great!! I like the seat position. I wish I had a little more headroom so my seats could be a little more off the ground. The wiring and engine stuff is easier than you think. My first two motors I just bought the factory handlebar start and ignition switch and then either used them or sorted out the wiring and added my switches. My last build I let Weller do it. They did a great job but it was not cheap. Let me know if I can help in any way. I still think the gel coat in that hood is a really cool color. Tons of progress. Keep it up!

 

[cfyca]

Thanks Bobby! I am pretty pleased with the way everything has gone together considering the tools we have to work with..

I have been playing with the bike harness a little bit just identifying the plugs and getting them rearranged so it is a little cleaner. As soon as we get the rear tubes back from the bender, then the fuel cell mounted, I can get a better idea of where the fuel pumps are going to end up and really start moving forward on the wiring. I have been talking to Ben/WildEarp on here a bit about the wiring and think I have a pretty solid idea of how things go together, if I have any questions I will be sure to let you know though.

I am very, very curious to hear how that sprocket worked out and if it was large enough. Our engine is a little higher, but I don't think it is enough to make a difference.. We are probably going to have to get a dished skid plate made as well. Where did you get your sprocket?


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[cfyca]

It's been a minute since an update. We have been working on it through the holidays, which has been nice. Pretty much got the back of the car together. Now we are on to the little things that take forever! Just need to get a couple hose fittings, etc. and the exhaust finished and we should be able to have it running. Then it is onto the body panels and dash! Can't wait to get the Raber Racing hubs and spindles so we can get it sitting on all fours!

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[cfyca]

The R1 showed a little life today..
It's not too far from running now!

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[the stripping shop]

looking good is your goal the mint 400 for the first race

 

[cfyca]

Sure is!

Quite the race to end up shaking it out in aye? We are hoping to have it finished the end of Feb./first of Mar. so we have some trail time to hopefully work out some of the bugs.


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