XJ List Spring Fling 2016

XJ List Spring Fling 2016
Harlan, KY

This year’s spring fling was one of the more interesting ones for me in a while. I was happy to get away for the stress of work and just be in the woods with no access to my work computer or cell phone for a few days.
The prediction had been for rain so I think we all planned more for leisurely trail riding and hanging out at camp. Neal and Frosty built a huge shelter so we could hang near the fire in the rain.

Harlan-shelter

It also provided nice shade during the sunny times. We also had a couple of EZ ups for shelter as well.

Evan and I arrived Thursday noon. Neal, Frosty and Derek were already there. We made it out onto the trails Thursday afternoon.

Evan is now wheeling the chop top long arm XJ that Josh built. As a training exercise, we headed to lower rock garden. We made our way there via, trail 45 up the mountain from the Harlan County Campground. Trail 45 is becoming quite a challenge itself.

We then took trail15 with is not too bad when dry and dusty. I managed to find the elusive 15 connector that we always seem to miss and dropped us down to trail 20 to get to lower rock garden.

We watched Evan begin to explore the capabilities of his new rig. About five minutes in he found the limit of the tie rod. Both front tires got a good bite while the rear was hung and just toed in making a big arch in the tie rod.
bent-tie-rod

We removed the tie rod from Evan’s Jeep and used a winch and Frosty’s metal working skills to get it straight enough. We made some calls for spare parts to be delivered by the later arrivals and then headed to Killin’ Time.

I had never run this trail before. It is a short run just above the lower rock garden. The change in terrain in such a short distance is amazing and one of the things I like most about Harlan. While the rock garden was flat and dry, Killing time was steep and sloppy wet.

Neal hopped in an powered through the mud and up and over the rocks on his 38” swampers. My 33” Buckshots required finding some more gentle lines and eventually the winch cable to get up some of it. This was a very fun run for all of us. We attracted quite a crowd of spectators in the parts that can be seen from the parallel road. This viewing point is another thing that makes this a fun trail since once you exit you can come back and watch those behind you run.

killin-time1

killin-time2

We then headed back to camp and enjoyed our set up.

The next morning, we used a piece of water pipe donated by Adam to sleeve Evans bent tie rod.

We then made a decision to go explore some trails that we have missed in the many years we have been going to Harlan. According to the map, we saw there was a middle downhill trial leading out of middle fork that I had never run. I lead us onto that one with no promises on not getting lost.

I managed to lead the group to a nice lunch spot close to where I thought we were on the map. After our on trial lunch, we moved on to Your Turn. We dove in knowing that we could likely not make the exit. Your Turn is nice and wide so there are multiple lines. None of them are easy.

We worked Evan and Derek over the big ledge in the last third of the trail when we caught up with another group of Jeeps. They had gotten stopped by a tree across the trail even before the impossible exit. They chose to take a bypass to the right that involved a long narrow winch run.

We chose the left exit. All of use but Derek had to winch past a big rock with an under cut. When my winch stopped working at a critical moment, Red turned his rig around and set up to winch me and the rest up the last few feet. His new synthetic winch line got a lot of use this weekend.

Derek was able to go wide and powered over the rock. We waved him on to the last point where most of us had also winched. He carried more speed than any of us had and ended up on his side.

derek-flop

It took a bit of rigging but we were able to get him back on his wheels pretty quickly. His exo cage saved him from any new damage. But somewhere along the way he developed a brake line leak that slowly consumed his brake fluid.

We then looped back around to the entrance and continued exploring new trails. Next was trail 8. It does not have a name like some of the tougher ones. But it is coded orange (difficult) on the map.
I soon found out why as I headed up. The trail has some very long very steep climbs. They would be much tougher if it had been wetter. Eventually we all made it to the top.

Then we decided to try T_R_O_U_B_L_E. I have wanted to run this one for a while also. But were had never seemed to be able to find it. It was right at the top of 8 so no trouble finding it.

The gate keeper is a steep dusty climb with a undercut rock right at the top. The ruts were deep enough for me to drag my diff. I tried hopping out of the ruts at the last second to hop over the rock but it did not work. I had to call for assistance in pulling my winch cable to make it over the ledge. Frosty got behind the wheel of Evans rig and tried the right side line. He needed up getting scary sideways and we winched him to safety.

Kim then drove Frosty’s Toyota up. Just as the trail got really steep at the top she stalled and then found neutral. She took a scary roll backwards several feet before getting it stopped.

After seeing our struggles the rest of the group decided to bypass and meet us at the end of the trail. I explored an unmarked short cut that took us right were we wanted to go and we made our way back to middle fork and then down the mountain.

End Part 1.

Porsche 944 Rod Bearings

At our last race at Road Atlanta the driver in the final stint mentioned he saw a red light flash on the dash occasionally but did not know what it was. A routine oil level check showed the oil level had gotten very low by the end of the race. Therefore I decided we needed to inspect the rod bearings. And I am glad we did.

I used info from Clark’s Garage to establish a procedure. I began by purchasing an engine support from Harbor Freight. Then with the car on the lift, I removed the rear control arm bolts, the ball joint pinch bolts, the front sway bar and then lowered the cross member out of the car. It turned out to be much easier than it sounded form reading the instructions.

With the engine supported form above and the cross member out of the way, the 22 bolts holding the pan in place were easy to access. The pan separated easily but it would not drop down. The internal plastic baffle hung on the oil pickup. I ended up breaking the baffle before I figured out he right twist to get the pickup to come out the hole.

With the pan down, I had full access to the rod ends. Knowing number two to be a problem I started with that one. The Babbitt was gone as well as much of the copper. There was copper embedded in the crank throw as well. I thought we were looking at a complete rebuild. However the other three bearings looked fine.

So I decided to try polishing number two in place. I watched several you tube videos on crank polishing before I chose a method. I ended up wrapping a strip of 600 grit sandpaper around the journal and used a string to spin it back and forth. I lubricated it all with WD 40 during the process. In no time at all I had a shiny smooth journal that measured in the middle of the range.

I then installed new bearing in all four positions using new rod nuts as recommended. on reassembly, I notice the strap that holds the two sump tubes together was broken so I took time to weld it back together.

I was not able to source a used baffle in time so I decide to just glue together the crack I caused in the existing one. With it out of the oil pan, I made several practice runs to get the twist right on re installation.

Putting the oil pan back in place was the most challenging part of the whole process. The gasket is very thick and needs to be compressed just to get the bolts to start. I used wire ties threaded through the holes to keep it lined up while I made the twists to get the pan in place. Then I used my under lift support to lightly press the pan up while I started the bolts. I then used my inch pound torque wrench to set all the bolts to 36 inch pounds. This took forever to get the m all down as the gasket continued to compress causing the bolts to loosen as the one next to it was tightened. I hope I figure out a better method next time I do this job. Once they we all at 36 I then put them all to 72 inch pounds. This step went much quicker.

Once the pan was back on, I lifted the cross member back up and reattached all the under car stuff. I installed a new oil filter and refilled with fresh oil.

We are now ready to race at NCM. I will do this all over again after that race to see how much wear is on a fresh bearing set. Since these bearings were in place when we bough the car, I have no idea of their age or history.

20R – no oil pressure

Chumpy

We have been rebuilding our first ChumpCar. It is a 1975 Toyota Celica. The car belongs to our team mechanic. He has found he has cancer so we have all pitched in to build it for him to race at Daytona.

When we got the freshly rebuilt engine in the car, we found it would not make any oil pressure. We tried priming the oil pump and every other thing we could think of. It simply would not build oil pressure.

After studying the oil flow diagrams, I noticed there was a galley plug in the bottom of the engine. I had noticed that the front and rear plugs were pulled by the machine shop. Of course the builder had replaced those. I called him and asked about the lower one. No one could remember putting that one back.

celica-oil

I really did not want to pull the engine back out just to check to see if the plug was missing.

My first check was to run a wire down the passage from the oil filter to the bottom of the engine on a spare block. I then did the same on the engine in the car. The one in the car would go an extra inch or so.

My next step was to see if I could get the oil pan off with the engine still in the car. There is very little clearance between the oil pan and the cross member.

I began by seeing if I could access all the bolts. I got most by using a short 12mm socket on a wobble extension.
The two right above the cross member I got using a wobble socket.

I had to remove the two engine to transmission braces to get to the back four bolts.

Next, I disconnected the steering rod from the pitman arm and the idler allowing it to drop. I then removed the four bolts holding the motor mounts in place.

I set a jack under the front pulley and began to slowly lift the engine. I had to raise it a couple of inches to get the pan to clear the oil pick up.

With the pan off I could easily see that the lower galley plug was missing.

oil-galley-plug

I pulled the one from the spare block and transferred it to the engine in the car. Then I had to figure out how to get the pan and gasket back on.

It would have been easier to just glue the gasket to the pan but I used a trick I have learned on the Jeeps. I threaded long wire ties through the pan holes into the gasket. I put one on each of the four sides. I then lifted the pan into place and put on the two nuts for the two studs. I then carefully slid the wire ties out while inserting bolts into the holes that were opened up.

Once the pan bolts were snug, I set the engine back in place and reattached the motor mounts. I then reinstalled the engine to transmission braces and the steering rod.

After refilling with oil, I tentatively turned the engine over. I was very happy to see the oil pressure gauge start to move. We were back on schedule with our Daytona Build.

Racing at Road Atlanta

2016 ChumpCar race at Road Atlanta

We ran our 1986 Porsche 944 at Road Atlanta.

The car ran flawlessly all day. We got a couple of new battle scars but still drove it on the trailer after the checker flag.

Our pits stops went well and even though our laps times were not as fast as we would have liked, we finished 32nd out of 110 cars. We found that there car can go over three hours on fuel so we skipped fuel on two of our driver swap pit stops. That gained us a lap or two. We completed 338 laps this year in the 14 hour race.