Not PT, but progress on my XR4Ti project

[DarkBuddha]

Since the Mach isn't making any progress, I bought an '89 Merkur XR4Ti with 60k original miles to hold me over. For anyone who doesn't know these cars, they've got a 2.3 turbo (same as the SVO Mustang), 5 speed, and IRS, so they're quick, cheap to build, and fun to drive.

Well, I finally had some time to do a few things recently, so it got a manual boost control valve, removed the pinstripes and rear emblems, and installed a set of wheels and tires (ALT 16x7 wheels with 215/45 Falken Azenis RT215). And I've already got an intercooler, an Turbocoupe ECU, large VAM, a rear disc conversion, lowering springs, and a few other things for the car too. Just need to install 'em. So far I'm only into the car for around $2500 including the purchase cost.

Anyway, I just thought I'd share a couple pics:

Before:

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After:

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What I'm shooting for (with 260hp and under $3K)

https://static1.pt-content.com/images/noimg.gif

[4MuscleMachines]

Looking good, I like the new color of the rear spoilers.:twothumbs
Wow, $2500 including car?

[Damn True]

looks like it'll be a fun little auto-x weapon

[DarkBuddha]

Looking good, I like the new color of the rear spoilers.:twothumbs
Wow, $2500 including car?
Thanks... I like the black bi-plane spoiler too. I was thinking I'd paint it, but after mounting it, I think I might just leave it. And yes, $2500 including the car. I only paid $1200 for the car itself, and it was a driver with a recent clutch job, new-ish tires, and a full 3" exhaust and downpipe. These cars don't really cost much at all... I know lots of folks that have gotten theirs for free and they're often for sale for under $750 running and driving. You get a lot of car for your money with these things.


looks like it'll be a fun little auto-x weapon
That is exactly why I bought it... I know it'll be a great car to cut my auto-x teeth with before I do the same with the Mach.

[elcamino80]

Looks good. The only thing I don't like is that "C" pillar that divides the rear side windows into 2... The Ford Sierras don't have that

https://static1.pt-content.com/images/noimg.gif

[DarkBuddha]

Looks good. The only thing I don't like is that "C" pillar that divides the rear side windows into 2... The Ford Sierras don't have that
I kinda agree, but have to admit that I like the unique look of the extra pillar too. I've actually been considering "embracing" the odd pillar arangement by going body color on the B pillar too.

Still, I did consider doing a single window conversion using Lexan for the window itself, but figured it would put me past my $3K budget cap. I'm hoping to hit mid 13s and have very very decent handling (.85g+ and mid 40s mph 420' slalom speed) for under $3k. Ambitious but do-able according to lots of Merkur folks I've become aquainted with. I figure that'd be a lot of car for my money.

[jvike]

All Ford Sierras have the C Pillar, the ones that don't is the ones to watch, they're equipped with the Cosworth engine. 2 Litre Turbo, 220 bhp, in stock form, but easy to tune. The got quite a reputation here in europe.

[DarkBuddha]

All Ford Sierras have the C Pillar, the ones that don't is the ones to watch, they're equipped with the Cosworth engine. 2 Litre Turbo, 220 bhp, in stock form, but easy to tune. The got quite a reputation here in europe.
I'm starting to get familiar with the Euro models... XR4i, Sapphire, Sierra, Cosworth, RS500, 4x4, etc. I'd love to get a Cosworth front bumper, but they're very pricey stateside. One place sells 'em for $1500+. That's just for the bumper cover, no lights, no under structure. That's half my budget! :hammer:

[dhardison]

Those are awesome little cars with tremendous performance potential. I especially like it because you won't see yourself coming/going. Keep the updates & pics coming!

[DarkBuddha]

Thought I'd share some updates... finally installed the intercooler and bov, and turned up the boost to 17 lbs. That made a huge performance difference. In fact, I surprised myself and shut down an early '80s 911SC the other day. I think he'll think twice about throwing revs at funny looking little hatchbacks.

Also, I installed a set of white face electroluminescent gauge faces, which greatly improves night visibility of the gauges. I sometimes think these things can look a bit cheesy, but I'm pleasantly surprised at how much I like them.

Also, I spent the weekend hanging with a local ex-Ford of Europe Rally team guy. He was the guy in charge of building, developing, and maintaining the Ford Sierra Cosworth (which the XR4Ti is based on) rally cars back in the day. He's a huge resource and a certifiable mad scientist genius type, and generous with his knowledge, time, and patience in teaching and guiding "younger guys" like myself. He's actually developed a monster front disc brake kit for these cars that would put some of Baer's big brake kits to shame, and for around $600. It's now on my list.

Anyway, here are a few pics of my IC, bov, and gauge faces:

gauge faces:

https://static1.pt-content.com/images/noimg.gif (http://img206.imageshack.us/my.php?image=img0524resizedjd7.jpg) https://static1.pt-content.com/images/noimg.gif (http://img206.imageshack.us/my.php?image=img0525resizedmi0.jpg)


IC and bov:

https://static1.pt-content.com/images/noimg.gif (http://img82.imageshack.us/my.php?image=img0511resizediq1.jpg) https://static1.pt-content.com/images/noimg.gif (http://img82.imageshack.us/my.php?image=img0503resizedgc8.jpg) https://static1.pt-content.com/images/noimg.gif (http://img161.imageshack.us/my.php?image=img0516resizedrg8.jpg)

[Rick Dorion]

Gotta love it. Thanks for the update :)

[DarkBuddha]

Gotta love it. Thanks for the update :)
Thanks... I've really been enjoying the car, especially since the Mach is still stuck in "resto jail". What I've really loved is that I'm having a good time building the car without having to lose any driving time. I've been driving it everywhere and have been very impressed with the comparitive performance. I've frustrated quite a few drivers in more highly rated "performance" cars... an '80s 911SC, several stock WRXs and Legacy GTs, a number of ricer type cars, Integra Type-R, and even an '80s 5.0 Mustang. Not bad for a $2500 car.

[DarkBuddha]

I thought I'd post another update since it's been a long while. I had a bunch of stuff sorta go wrong (but not really), which resulted in me doing quite a bit of work since last November. I ended up replacing the Ford Motorsport intercooler with a Cosworth intercooler and installing an SVO VAM and ECU, and a Forge 004 style BOV. With the boost set at 20lbs and the 3" exhaust, I should be within spitting distance of my 260/260 hp/tq goals. I've got a ported exhaust manifold (E6) on hand, and I'm going to gut the upper intake and "knife-edge" the lower. I'm also going to be swapping to a Cosworth exhaust housing on my turbo. That should put me where I want to be if not a bit higher.

I also "embraced" the bonus pillar look, which I think looks great. I also got a fully poly suspension bushing kits (front and rear), larger Cosworth front and rear sway bars, a set of AVO Cosworth spec lowering springs, and new KYBs going on all four corners. I've also busted my budget and bought a Cosworth arch/sill kit, upper rear spoiler, and RS500 lower rear spoiler.

What I can say at this point is that the car is getting right quick... quicker than a new WRX or RSX-s for sure. I've got traction problems when I roll into the throttle from a 3000rpm roll in first, second, and sometimes third gear. Now I just need lots more brake and tire!

Well, here are a couple pics for kicks:

https://static1.pt-content.com/images/noimg.gif

https://static1.pt-content.com/images/noimg.gif

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Could this be pro-touring afterall? Hmmm... it is an 18 year old rear wheel drive "american" car that I'm adding performance and functionality to make it better than stock.

[72NovaSS]

COOL! Sorry to hear about the road bumps in your project. The things lookin awesome bud! I see all the hard work you have put into it. Great job!

[ixfn]

My mother's car was a Merkur Scorpio for a while back in the day, and my pops had the XR - chock full of Rapido goodies (custom turbo stuff, enormous intercooler, misc int. goodies etc, etc). I drove the XR for a few months; I liked having a 25+ mpg car that liked 135mph. I used to race my friend in his '95 GSX Eclipse - he won always... Just FYI; the engine is the same as a 2.3 Ranger :( I about sh*t when the gas station monkey called it a glorified Escort :throw:

[DarkBuddha]

My mother's car was a Merkur Scorpio for a while back in the day, and my pops had the XR - chock full of Rapido goodies (custom turbo stuff, enormous intercooler, misc int. goodies etc, etc). I drove the XR for a few months; I liked having a 25+ mpg car that liked 135mph. I used to race my friend in his '95 GSX Eclipse - he won always... Just FYI; the engine is the same as a 2.3 Ranger :( I about sh*t when the gas station monkey called it a glorified Escort :throw:
Funny... I don't get the "what year Escort is that anyway?" questions much anymore. Rapido is still around, but now that there is some history to check the validity, some of the Rapido mods don't appear to be very effective really (like the Rapido intercooler).

Oh, and the 2.3 is the same 2.3 that came in Pintos, Mustang IIs, Futuras, T-birds, Mustangs, Cougars, Capris, Rangers, and the SVO Mustang. Very little difference between the turbo and the NA motors other than the head really. Still, it's amazing what 20lbs of boost will do for a lousy Pinto motor.:seizure:

[vintageracer]

Use some gloss black exterior sign vinyl to cover the "C" pillar. Match the top and bottom of the vinyl to the 2 rear windows. This little trick will make the 2 rear windows look like 1 window as on the Sierra. It will not be perfect however it will fit the theme of a cheap upgrade that looks great! Easy to install with a razor blade and a heat gun for the compound curves.

This looks the best when you have tinted windows that are 35% or darker.

[DarkBuddha]

I've seen a couple cars done like that with the blacked out c-pillar and tinted windows. It's pretty effective, but since removing the blackout on the b-pillar, I actually like it a lot.

BTW, the planets aligned yesterday so that I could get my XR over to a friends shop (with a lift) and we rebuilt the suspension and installed a set of Cosworth spec lowering springs and the KYB struts/shocks. It's made a huge difference but it now sits pretty darn low... the exhaust is scraping on big dips and bumps. I was going to replace and relocate the muffler and cat anyway, but now I've got more incentive. Anyway, here are a couple pics of the new ride height:

https://static1.pt-content.com/images/noimg.gif

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[elcamino80]

Looks good but why do you have a german license plate behind your own plate?

[DarkBuddha]

Looks good but why do you have a german license plate behind your own plate?
Oh... it's just a nod to the fact that these cars were originally built in Europe. In fact, the XR4Tis that came to the US were actually hand modified by Karman before being exported to the US. This is why some of the electrical stuff is a bit sketchy on these cars sometimes... hand soldered circuit boards and the like.

And you know, to be honest, these cars are pretty much shunned by everyone. In general, the import kids don't even recognize them, the european crowd doesn't acknowledge them, and the domestic folks don't know them. The only exception is other turbo 2.3 Ford guys, and even then they think of 'em as donors for turbo 2.3 Ranger swaps. Feels very lonely sometimes. :candle:

[DarkBuddha]

Well my '70 Mach has been in mothballs for so long now it looks like I might have to redo some stuff to fix some problems from it just sitting. It's just plain too hot in Tampa in the summer to work on it.

But my XR4TI is making little bits of progress. Since it's my daily driver I can only do little things and bolt-ons because I really can't be without it a day. Most recently I did some maintenance stuff, replaced the high pressure turbo oil feed line, cut out the leaking gouged muffler, and cut a new grille (until my Cosworth grille finally comes). I've also bought a bunch of parts, including a gutted/ported intake set, the Cosworth turbine housing I mentioned, a billet fuel rail and AFPR, a nicely ported exhaust manifold, a set of ARE 16x7 wheels for auto-x days, and a few other bits and bobs.

Oh, and I got it to the dyno and got some mixed news. I should start by saying that I went to just confirm that the changes I made from last year resulted in the kind of improvement I anticipated, which they sorta did. So that is good. But there was some bad stuff too... First, the first dyno run was botched because my exhuast was rubbing on the rollers, so the subsequent runs were with the engine a bit heat soaked. Second, the clutch is going south. DAMMIT!!! It was obviously slipping on the dyno. And third, the afr went way way rich to 10.3 when boost came on and stayed rich around 11.5, which means I'm actually losing power because it's overly rich. Sure rich is great for preventing knocking, but it also kills power.

So it made a corrected 176hp/220tq with a slipping clutch, slightly heat soaked, and way rich, which is actually not all that bad, but it isn't the 210/240ish I was hoping for. And these numbers were on a Mustang dyno, which is the heartbreaker of dynos really. Still, the potential is there.

Anyway, a couple pics to show the grille and the dyno sheets:

https://static1.pt-content.com/images/noimg.gif (http://img254.imageshack.us/my.php?image=img1394smallgy6.jpg) https://static1.pt-content.com/images/noimg.gif (http://img141.imageshack.us/my.php?image=dynochartresizedqq9.jpg)

[hechtrod]

Slap a T3/T4, run 18-20psi! My bro built an '87 Turbocoupe motor and put it in an 87 LX Mustang 4 cyl car. He ended making 320hp wiht it. He front mounted the stock intercooler, ported the head, TB and intake manifold, fpr, tweaked the vam (not sure exactly what) and put a 3" downpipe and exhaust in it. It was such a cool car. Dummy sold the thing. It was killer! I can email pics. Just PM me or email me
Chris
[email protected]

[twosaturns]

Feels very lonely sometimes. :candle:

try modding a saturn sometime...

[curly]

Cool car! I remember a girl had a red XR4TI when I was in high school and I always thought it was a neat car. She had the only one around and I don't think there was another one after she left / got rid of hers.

[DarkBuddha]

try modding a saturn sometime...
Been there, but that was back in the mid-90s with the '92 SL my parents bought new. After driving it for a few years in the late '90s (it got a K&N filter and some synthetic oil) I gave it back. Good car though... original clutch went 125k miles, and the car has 185k on it now and runs like a top.

[Damn True]

C'mon Wyatt, make with the auto-x action!

[Frank Grimes]

i like those cars personally i would try and get rid of the pillar and make it look much more like the euro cars but your car is a looker for sure.

[paul67]

Over here in the UK they are ford sierra's and in aussy they used to put ford v8s in them.

[DarkBuddha]

Over here in the UK they are ford sierra's and in aussy they used to put ford v8s in them.
They put V8s in 'em in South Africa too... called 'em XR8. I'd love to have a legit Cossie, but they're impossilbe to import and too pricey anyway.

[paul67]

Why are they so hard to import?

[DarkBuddha]

Why are they so hard to import?
There are laws and NHTSA rules that decide what can be imported and what hoops you have to jump through. In Canada it's pretty simple, but getting it into the US is much tougher. It can be done, but it would be cheaper and easier to build a copy using an XR4Ti. In fact, there is a guy local to me that has the stuff to do a complete 4x4 Cossie 2.0 coversion if I wanna spend $8K-$10K, which I might do one day, but for now I'm happy tail-sliding with the boosted Pinto motor.

[DarkBuddha]

I thought I'd share my most recent upgrade on my XR. The stock front brakes were getting a bit sketchy and shuddering because of warped rotors. So I took it as the perfect opportunity to upgrade. There's a local guy who does rally car builds and used to be a Ford rally team mechanic when they raced Sierras and Escorts, so he spec'd me a new set of brakes based on the Ford rally gravel setup. It uses a custom two piece rotor setup using an aluminum hat and machined heavy duty 283mmx1.25" Coleman rotors. The calipers are Wilwood FBSL 1.62"x4 piston calipers. We also built new braided stainless brake lines. Having done it now, I'll never buy prebuilt brake lines again.

Anyway, here are a few pics:

Side by side comparison with stock rotor:

https://static1.pt-content.com/images/noimg.gif (http://img176.imageshack.us/my.php?image=IMG_1671_small.jpg) https://static1.pt-content.com/images/noimg.gif (http://img176.imageshack.us/my.php?image=IMG_1672_small.jpg)

Mounted up:

https://static1.pt-content.com/images/noimg.gif (http://img176.imageshack.us/my.php?image=IMG_1687_small.jpg) https://static1.pt-content.com/images/noimg.gif (http://img176.imageshack.us/my.php?image=IMG_1684_small.jpg) https://static1.pt-content.com/images/noimg.gif (http://img176.imageshack.us/my.php?image=IMG_1685_small.jpg)


It sure wasn't cheap but well worth it, especially considering I plan on tracking the car a bit. The pedal feels great and catches nice and high. They're easy to modulate, provide excellent feedback, and stop the car much much quicker. My confidence level is much higher compared to the stock setup. Now I just need to upgrade the rear drums... sigh.

[705.0Merc]

I really like those cars. Great bang for the buck. I dig those brakes!

[DarkBuddha]

I really like those cars. Great bang for the buck. I dig those brakes!
Thanks! I've sorta thrown my original budget for this car out the window, but it's still way cheap comparatively. Hell, even with the brakes and the cosworth bodywork I just got, I'd guess I'm into the car for less than $4k. It'll be double that before I'm done, which will still be a deal versus just about anything else I could buy for that kind of money. Besides, it's one of my dream cars... I guess it really is good to have cheap dreams.

[vintageracer]

I went and looked at a good black 2 owner XR4TI last night with 153K on the clock. Actually in pretty good shape. It's been sitting for 9-12 months. Very complete. Good interior and the paint would probably buff.

At $1600 I probably should not complain but I will. I have not decided whether to buy it or not. If he will take a Grand I will probably play. Something else to work on that I will never get to!

[DarkBuddha]

I went and looked at a good black 2 owner XR4TI last night with 153K on the clock. Actually in pretty good shape. It's been sitting for 9-12 months. Very complete. Good interior and the paint would probably buff.

At $1600 I probably should not complain but I will. I have not decided whether to buy it or not. If he will take a Grand I will probably play. Something else to work on that I will never get to!
Depending on condition and location, $1600 may be about right or a bit high. It would also depend on what year it is ('85-'89), manual or auto, and if any mods or maintenance has been done. I'd say if the body is solid and rust free, it's a manual, and is in good/decent operating condition, then $1000-$1200 would be a good deal, $1500 would be a fair deal.

BTW, the paint on these cars does buff up really easily and nicely as long as it hasn't been done much. As for the interior, the biggest issues are either cracking dash pad, cracking seats (leather), and broken turn signal switch. The cloth seats are actually very durable and usually hold up much much better than the leather (which was recalled). And if you didn't know, the stock seats are designed and built by Recaro and are therefor pretty comfortable and supportive.

Also, make sure the body is as clean as possible. The fenders are welded to the chassis, so it's best to avoid front end damaged cars. Also beware of rust under the plastic cladding and bi-wing, as they both tended to trap dirt and leaves and cause rust.

The auto trannys suck and the auto cars got lower power ecus. Maintenance stuff is hit or miss as some things are cheap and easy to get (like tune-up stuff), but others (like hoses) can be pricey or difficult to locate.

BTW, just a warning... these cars are addictive. Even in stock form they have good character and are comfortable and fun to drive, especially on the highway where you can roll into the boost and get pushed back in the seat.

[vintageracer]

It's a Black/Black 88 with a 5 speed. Completely original under the hood and throughout the car including the original air cleaner box. Original jack, wheels, wheel locks, Michelin tires, nice carpet, door panels and good leather seats. One small cut in the driver's leather seat otherwise nice leather for 153K miles. Dash pad is not cracked however it is curling on the edges. All original glass in good shape, manual sunroof, power windows, short wing, 5 speed, original radio, power mirrors, gauges, etc. Gauge lights do not work, and several other electrical gremlins. Car has no rust, good clading and completely original paint. A couple of very small dents with on small crease dent down the middle of the passenger door. Turbo supposedly replaced at 90K. Head with new valves and valve joby at 152K just before he parked the car. He "says" he parked the car because of the clutch/shifter starter interupt safety switch gave problems and sometimes became difficult to find the "sweet spot" to get the car to start.

Overall a lot better car than what few I have seen still out there in this neck of the woods!

[DarkBuddha]

Sounds like a decent car. I suspect $1000 might be a bit low, but $1200-$1500 sounds fair. Let me know if you do buy it and I can point you in lots of good directions for info and parts/supplies. If you don't buy it, I know there are others that would be interested.

[vintageracer]

Looks like I now own a 1988 Merkur XR4TI. The seller called today and accepted that $1,000 offer. I will pickup the car this weekend before my trip to Scottsdale!

What have I gotten myself into?????

[Damn True]

Ok Wyatt, enough screwin around with that thing. Go auto-x it!

[DarkBuddha]

Looks like I now own a 1988 Merkur XR4TI. The seller called today and accepted that $1,000 offer. I will pickup the car this weekend before my trip to Scottsdale!

What have I gotten myself into?????
SWEET! Congratulations and welcome to the club... drop me a PM and I'll be glad to send you some forums and parts suppliers.

[DarkBuddha]

Ok Wyatt, enough screwin around with that thing. Go auto-x it!
I've got a date to do exactly that in early April. I'm hoping to have some stuff done before, like a BMW lsd install, harness bar/rear shocktower brace install, front strut tower brace, rear discs, Cossie front swaybar, and maybe new Eibach springs install. Should be a freaking good time!

[DarkBuddha]

Ok Wyatt, enough screwin around with that thing. Go auto-x it!
Well, just for you I got out to an auto-x this weekend. It was a blast and car did great! In fact, the car is better than I am. I placed about mid field of 136 cars, which put me behind lots of much faster cars, and some obviously slower cars with better drivers. But I did find myself ahead of a lot of very respectable "performance" cars and even some seasoned drivers in slower cars.

I also finally got the 28mm Cossie front sway bar installed and installed a set of hood vents to help with some of the underhood heat. Both helped, but it definitely needs the biggest rear sway bar I can find... the search is on!

Another new project is that the new LUK clutch we just installed has already started slipping, with less than 1500 miles on it. The motor is making probably 260+ ft/lbs at the flywheel and a stock clutch just isn't capable of holding it. So instead of just putting in another clutch, I picked up a World Class T5 tranny to replace the fragile T9. Hopefully it'll get installed in May.

BTW, it's official... the budget is out the window. Now I wonder if my wife will let me spend $2000 on a set of Porsche GT3 seats?

[Damn True]

NIIIIIIICE!

Glad to hear it Wyatt.

Screw the GT3 seats. Go to the wrecking yard and find some Honda Prelude or Civic Del-Sol seats. Unless you are a really big guy they will probably provide more than enough support.

[Nate_ERC]

My first "hot rod" was an XR4Ti. I really regret selling that thing. Made about 230hp for under 3,000. Great 12 second commuter. Cornered okay, couldn't stop for #$% though!

I put in a T5 transmission, saab intercooler, e6 exhaust manifold, ported upper and lower intakes, 3" downpipe and exhaust, LA3, yada yada. The thing spent more time broken than on the road though. So I sold it to some kid for a grand, I think he wrecked it and parted it out in about a month.

[DarkBuddha]

NIIIIIIICE!

Glad to hear it Wyatt.

Screw the GT3 seats. Go to the wrecking yard and find some Honda Prelude or Civic Del-Sol seats. Unless you are a really big guy they will probably provide more than enough support.
Actually, I'm down about 80 lbs since September, but I'm still a really big guy at 330. So yeah... I need some more supportive seats. I was kidding about the GT3s though... maybe just some '80s VW or BMW Recaros, or there's a guy with a set of battered Procars for $100.



My first "hot rod" was an XR4Ti. I really regret selling that thing. Made about 230hp for under 3,000. Great 12 second commuter. Cornered okay, couldn't stop for #$% though!

I put in a T5 transmission, saab intercooler, e6 exhaust manifold, ported upper and lower intakes, 3" downpipe and exhaust, LA3, yada yada. The thing spent more time broken than on the road though. So I sold it to some kid for a grand, I think he wrecked it and parted it out in about a month.
I keep trying to tell people these can be great cars, but the cars do have a reputation for breaking (especially when not cared for consistently). Too bad about yours meeting it's end...

[stealth71]

Looks like fun. Any more info on the stainless brake lines you made?

[Nate_ERC]

Wyatt are you on the mca or turboford forums? Turboford.net is still probably the best technical forum I've ever been on.

The Merkur is a good car, but only kind of. They look cool, and have a great powerplant, but other than that they suck. Almost everything else on the car has to be dramaticly changed for it to be a real performer. The OEM tranny, diff, suspension, and brakes are all biblicly terrible.

[DarkBuddha]

Wyatt are you on the mca or turboford forums? Turboford.net is still probably the best technical forum I've ever been on.

The Merkur is a good car, but only kind of. They look cool, and have a great powerplant, but other than that they suck. Almost everything else on the car has to be dramaticly changed for it to be a real performer. The OEM tranny, diff, suspension, and brakes are all biblicly terrible.
Yep, I'm on MCA, MerkurSport, and turboford forums. Tons of great info on all of them. I post under the name worked_xr over there (though I can't remember why I chose a different name now...).

You're right about needing upgrades, but really, for the most part the upgrades are easy and fairly reasonably priced. I'm doing a T5 conversion ($250), a BMW lsd diff conversion ($350), rear strut/harness bar ($250), and I've already done a big front brake kit (11.3"x1.25" w/Wilwood 4 piston FBSL calipers, $800). My front brakes are actually overkill for anything less than racing and there are really good, very cheap (under $300) brake upgrades available instead. Rear disc conversions are cheap too (under $200). Put it together with the Poly bushings ($300), Cossie front sway bar ($100), KYB struts ($240), and AVO Cossie spec springs ($220), OMP front strut bar ($150), and the chassis and driveline is really well set up. Finish it up with some basic engine mods (intercooler, ported E6, ported intakes, ported head, ecu/vam upgrade, MBC, 3" exhaust, etc.), and you've got a mighty respectable, quick-ish, good handling, excellent braking little car for under $6k. And it's not a belly button Mustang, DSM, F-body, or whatever.

[DarkBuddha]

Looks like fun. Any more info on the stainless brake lines you made?
Not much to tell really... the hose was standard high pressure stainless brake hose (cost maybe $10 for the bit we used), and a couple straight hose compression type fittings per line (like these: http://www.speedwaymotors.com/p/936,13_High-Pressure-Hose-Ends-Straight.html).

Basically you cut the hose to length, slide the female (I think) fitting on, push the compression sleeve into the end of the hose, and screw the male part of the fitting and tighten it up; no special tools needed. As long as the compression sleeve is on the end of the hose really well, it shouldn't leak. After doing a pair of 'em, I don't see a reason to pay for custom built hoses again.

Pics just for kicks:

https://static1.pt-content.com/images/noimg.gif (http://img176.imageshack.us/my.php?image=IMG_1689_small.jpg) https://static1.pt-content.com/images/noimg.gif (http://img176.imageshack.us/my.php?image=IMG_1690_small.jpg)

[Nate_ERC]

Basically, with my XR4 I found myself thinking, "what kind of gain would all of this work net if I had started with a better car in the first place?" It would be a little different if every part didn't have to be custom.

Just changing the tranny, driveshaft, and rearend is going to be a bitch and a half. (And probably wind up costing a lot more than you think after you think by the time it's drivable.)

Don't get me wrong, they are cool cars. It's just that to make it something truly spectacular you have to pretty much gut it out and start over.

[DarkBuddha]

Don't get me wrong, they are cool cars. It's just that to make it something truly spectacular you have to pretty much gut it out and start over.
So basically do the same thing you'd have to do with any older car, right? Trust me, if I could start with a new Porsche, Viper, 'vette, Mustang, etc. and get all the good stuff to start with, I might actually do exactly that. But if we all did that, we wouldn't have wicked '69 Camaros and '71 Cudas that can compete with new Porsche, Viper, 'vettes, Mustangs, etc. and do it with more soul and style!

[Nate_ERC]

You're totally right, but if I was going to do all that work I'd way rather have a Camaro or a Cuda! :poke:

[DarkBuddha]

Yeah, but you could probably build a killer XR for the cost of just a starter Camaro or Cuda body.

[DarkBuddha]

Another update... finally got around to doing the front bumper conversion I'd been planning for so long. I was never fond of the big ass, grouper mouth'd US bumper they put on these cars, so a fellow XR enthusiast and I came up with using a Mk3 VW Jetta bumper. He's actually the guy that did all the leg work and fabrication and fitting... it's good to have good friends!

Anyway, I think it looks great and really helps make the car look a bit less dated. Now I just can't wait to get the Cosworth bodywork on it too!

Now for pics.... here's before:

https://static1.pt-content.com/images/noimg.gif (http://img413.imageshack.us/my.php?image=img1379small2my8.jpg)


After:
https://static1.pt-content.com/images/noimg.gif (http://img127.imageshack.us/my.php?image=IMG_1911.jpg)


BTW, I've now got my own helmet and I'm scheduled for several more auto-x days. Should be a fun spring and summer.

[blown9746]

my buddy in high school had one of those. Fun little car that seemed pretty bulletproof.

[va72mlibu]

Slick mod! Looks good.

[DarkBuddha]

Went autocrossing at Bremerton Motorsports complex this weekend on Friday and Sunday. It was only my second time doing it and it was both very rewarding and a ton a fun. But it was also a bit disappointing and frustrating. The car was great, my driving was mediocre. Driving in the rain can be scary and sketchy, but spending time learning how the car really acts in the rain and what the limits really are is a fantastic experience. No traction means slow times, but going sideways at ~50mph through a pair of gates like a drift car doing a finely choreographed ballet is wicked!

On Friday it was raining all day, and pretty darn cold, and being that it was a Friday, that all pretty much kept attendance really really low. We were able to get 12 runs in for day, which is unusual, especially for a lousy $25. This was only my second time autocrossing, and the car was pretty much sideways all day, but I still placed mid-pack among a bunch of mostly experienced drivers, many in well prep'd autocross cars. The XR still pushed quite a bit in the really tough apexes, but a little clutch-kick usually solved that. Too much fun!

Sunday was another matter entirely. I ran first in the morning session and it was still very cold (~33 degrees) and wet from raining all night. It was also more crowded so we were down to only 5 runs per session. On my second pass I had a intercooler hose burst, sidelining me for 2 runs. I was able to half-ass fix it, turned down the boost, and returned for my fifth run, which went well if a bit slower than I wanted.

Returning for the afternoon session, I had high hopes since the sun had peeked out and the track was dry and warming nicely. Unfortunately the boost hose repair didn't hold for long and my first run was botched. The pipe had slipped out of the coupler, so I refitted it and tightened the clamps up really tight and got back in line. On the next run it happened again, so I called it a day before something went really wrong and I wouldn't be able to drive the car home.

Another big bummer about the weekend is that I demolished the front airdam boarding the ferry from Seattle to Bremerton. Absolutely destroyed it. There weren't even enough remnants to tape back together, so I have to order another one. That sucks. Oh, and somewhere along the way I lost the driver's side marker light. DAMMIT! Luckily I have a spare.

So, what was supposed to be a cheap weekend of fun has turned out to be a kinda expensive weekend of breaking stuff and being thwarted and deprived of a good run. Oh well... I'll order an airdam, some better silicone couplers, get the boost pipe ends flared, and replace the marker light and be ready for the next event.

[Nate_ERC]

Looks good. Now it really needs some Cozzy headlights. :headbang:

[DarkBuddha]

Looks good. Now it really needs some Cozzy headlights. :headbang:
They're in the closet... I'm waiting to get the balls to sawzall the bulkheads out of the way.

[DarkBuddha]

These are much belated (from February's auto-x), but my wife just got the film developed... here's me workin' the wheel:

https://static1.pt-content.com/images/noimg.gif (http://img339.imageshack.us/my.php?image=autox5xk9.jpg)
https://static1.pt-content.com/images/noimg.gif (http://img339.imageshack.us/my.php?image=autox4wu5.jpg)
https://static1.pt-content.com/images/noimg.gif (http://img339.imageshack.us/my.php?image=autox3pi8.jpg)
https://static1.pt-content.com/images/noimg.gif (http://img339.imageshack.us/my.php?image=autox2nn8.jpg)
https://static1.pt-content.com/images/noimg.gif (http://img339.imageshack.us/my.php?image=autox1wd1.jpg)

[jackfrost]

film? whatzat? :razz:

j/k. looks awesome. how's it drive?

[DarkBuddha]

film? whatzat? :razz:

j/k. looks awesome. how's it drive?
Actually, it drives pretty well except that it pushes pretty hard at the limit. I ordered a big ass rear sway bar today to help with that, and I'm going to run some wider Falken Azenis autocross tires next time out. It should help quite a bit.

That said, there are a couple other XR guys out there and they have "track" built suspensions and more experience and weren't much quicker than I was. And their cars ride really harsh compared to mine. I'll gladly sacrifice a second or so on the auto-x for a reasonable street ride.

[DarkBuddha]

Got the euro Cosworth RS upper spoiler mounted and primered. It still needs top coat, but I'm just not sure I like it quite yet... maybe I just need to install the Cosworth flares too to be sure. Here's a pic:

https://static1.pt-content.com/images/noimg.gif (http://img515.imageshack.us/my.php?image=IMG_2003.jpg) https://static1.pt-content.com/images/noimg.gif (http://img515.imageshack.us/my.php?image=IMG_2009.jpg) https://static1.pt-content.com/images/noimg.gif (http://img515.imageshack.us/my.php?image=IMG_2025.jpg) https://static1.pt-content.com/images/noimg.gif (http://img515.imageshack.us/my.php?image=IMG_2012.jpg)

[DarkBuddha]

Got the 19mm rear sway bar and Eibach pro-kit springs installed. The sway bar basically solved my understeer problems, but I'm not sure about the Eibachs yet. They're a progressive rate spring and are softer initially than the AVOs I had on the car previously. The handling has changed but the ride has improved immensely. I guess I'll see how they handle at the next autocross before deciding if I'll switch them back.

[DarkBuddha]

Ran an autocross today... tons of fun and the car performed well. The 19mm bar definitely helped, but the car still understeers a bit at the limit. It works great if I carry plenty of speed or if I slow down and let the car rotate, but there is a middle ground where it's just miserable.

I don't know how my times are in context yet, but they were respectable and I'm definitely improving as a driver. I only clipped one cone in 4 runs. I was a good 3-5 seconds ahead of regular WRXs and a late model Mustang GT and a GTO. Damn modified Civics and Miatas, two Solstices, and a bunch of EVOs ate me for lunch though.

[Beans]

Hey, I'm new here, but this thread caught my eye. A friend back home in the Toledo area is building a similar car. Scope it out for some ideas.

http://www.toledotuners.com/phpBB3/viewtopic.php?f=63&t=24365&st=0&sk=t&sd=a

[DarkBuddha]

I know Brian's car from MerkurSport. Nice work on that car, especially considering where it started. It'd be nice to have more folks recognize these cars as being great (and inexpensive) alternatives to the usual fox body cars.

[Beans]

Have you seen his Yellow Fox he's selling? That car's freakin' beautiful, sad sight to see it for sale, that car would've been nasty with the 2.3T setup that was going to go in it.

You should ask him about his Ranger, now that truck was COOL. ;)

[DarkBuddha]

Some updates...

I installed the Cosworth RS500 lower spoiler and new OEM VW Vento euro front spoiler, OMP strut brace, rehab'd the cooling system, got the turbo rebuilt with a Cosworth turbine housing and upgraded turbine wheel, new 3" exhaust with a Borla XR1 muffler, and a new VAM and cone filter. Here are a couple pics:

https://static1.pt-content.com/images/noimg.gif (http://img393.imageshack.us/my.php?image=img2469smallhg1.jpg) https://static1.pt-content.com/images/noimg.gif (http://img172.imageshack.us/my.php?image=img2474smallky8.jpg) https://static1.pt-content.com/images/noimg.gif (http://img79.imageshack.us/my.php?image=img2465smalldm7.jpg)

https://static1.pt-content.com/images/noimg.gif (http://img520.imageshack.us/my.php?image=img2426modifiedsmallek4.jpg) https://static1.pt-content.com/images/noimg.gif (http://img520.imageshack.us/my.php?image=img2423smallhu4.jpg)

[jackfrost]

certainly looks PT to me... :razz:

[DarkBuddha]

Not much progress on the car, and perhaps a bit of retrogression... I removed the upper Cosworth spoiler to repair after someone backed into it with their SUV or van or whatever. Weather has turned so I haven't been able to finish the primer and paint, but maybe this weekend. Mainly I've just been driving it a bunch, which has brought out some problems to fix... a couple bushings, bad fuel pressure dampener, bad ECU temp sensor, stuck cruise control cable, etc. Annoying crap but every fix improves the car.

Otherwise I had the opportunity to get together with some other local Merkur enthusiasts and did a run of Washington's Mountain Loop Highway, which includes a 6 mile stretch of very narrow, rough, gravel road. One guy got put into the ditch because he was hauling ass at 70+mph when a Jeep came from the other direction. No damage, but it had to be winched out. Anyway, here are a few pics of my car just after finishing that 6 miles of gravel:

https://static1.pt-content.com/images/noimg.gif (http://img519.imageshack.us/my.php?image=IMG_2850.jpg) https://static1.pt-content.com/images/noimg.gif (http://img708.imageshack.us/i/img2848v.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img833.imageshack.us/i/img2847r.jpg/)


https://static1.pt-content.com/images/noimg.gif (http://img851.imageshack.us/i/img2849s.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img519.imageshack.us/my.php?image=IMG_2869.jpg)

And some of the rest of the group:

https://static1.pt-content.com/images/noimg.gif (http://img519.imageshack.us/my.php?image=IMG_2857.jpg) https://static1.pt-content.com/images/noimg.gif (http://img519.imageshack.us/my.php?image=IMG_2852.jpg) https://static1.pt-content.com/images/noimg.gif (http://img519.imageshack.us/my.php?image=IMG_2854.jpg)

https://static1.pt-content.com/images/noimg.gif (http://img519.imageshack.us/my.php?image=IMG_2836.jpg) https://static1.pt-content.com/images/noimg.gif (http://img376.imageshack.us/my.php?image=IMG_2798.jpg)

[blown9746]

Not a big fan of the cosworth spoiler. I like the one on the black car above (i believe that's stock correct)

[DarkBuddha]

Not a big fan of the cosworth spoiler. I like the one on the black car above (i believe that's stock correct)
That is the stock spoiler. Personally I go back and forth, literally. I actually installed my Cosworth spoilers so that I can reinstall the stock spoiler(s) and no extra holes show.

[ed1le]

Love the XR4Ti's! My buddy has been into them for years and has had a few...back in the early 90's he had one running mid-13's and no one at the track quite knew what to make of it! LOL He has a white one just like yours now that he's doing a serious build with.

[DarkBuddha]

Time for an update...

Got the Cosworth arches installed. They definitely need some "fine tuning" to fit properly, typical of fiberglass body parts. The front bumper will also need to be refitted to match the arches since they are significantly bigger than the original wheel arch molding.

I also got the Walbro 255hp fuel pump installed, solving my stuttering under heavy boost when the fuel tank got below half full.

Also, the head gasket finally blew. It was way overdue considering I knew I was running too much boost and too much timing, and knew it was running lean for a long time (before the Walbro install). It went pop for a good cause though... there is some guy in a newer C class AMG still wondering why he couldn't get by an old odd, ratty looking Ford hatchback.

And since I was replacing the head gasket anyway, I did some more upgrades, including a mildly ported head, ported/knife-edged intakes, and ChuckW motor mounts. It now makes more power on less boost and feels tons better to drive. It's more linear, progressive, torquey, smooth... and it spool like right-f'ing-now!

Anyway, a couple new pics with the arch kit on the car and my painted and polished upper intake:

https://static1.pt-content.com/images/noimg.gif


https://static1.pt-content.com/images/noimg.gif

[DarkBuddha]

Engine pic from today:

https://static1.pt-content.com/images/noimg.gif

[bbcc]

That is freaking rad dude! The arches make it look a little more "complete" if that makes any sense. Defenitly some good progress on the car. If you don't mind me saying, i think the car would look a ton better with the factory spoiler in white and the black strip in the rear bumper also done in white.

But keep up the good work, truely an interesting build.

Cheers, Ryer

[DarkBuddha]

Thanks... it's coming along alright. I'd thought about painting out the black strip in the rear bumper but have instead decided I need some bump strips on the doors, so I'll be adding a black strip to the sides of the car and then extended onto the front bumper as well. The car is a driver and I'm starting to get annoyed with idiots banging their doors into my car in parking lots.

As for the spoiler, I keep going back and forth... I liked it in white, but I think the black will make more sense when I get the Cosworth upper back on soon-ish.

[DarkBuddha]

Some updates...

Got around to doing some final projects before I move (Seattle to Sarasota) in a couple weeks:

E36 BMW LSD w/custom cradle, solid beam mounts, poly arm bushings, new axles
Spax adjustable dampers and springs
new tie rods w/alignment
Rapido front sway bar (replacing slightly smaller Cosworth bar)
Rapido rear disc brakes (free from a parts car!)
ARP wheel studs (from MC2 racing)
Swapped wheels to ARE 5 stars & remounted and balanced Yokohamas

One word: transformed.

The LSD has proven itself a double-edged sword. In the dry it is great, functional, predictable. In the wet it'll bite me in the ass if I'm not respectful of rolling into boost mid-corner. The Spax are my favorite combo I've had on the car, and I've now had 4 different spring and damper combos on the car. The only place to go from here is custom coilovers... big $$$. The brakes are improved, but mainly because pedal pressure and modulation is better. Balance front to rear also seems better as well. The solid mounted rear definitely feels much better than the old worn out diff mount and squirmy bushings, and actually seems to ride better too. Sweet! And it's always nice to change the wheels for a different look. With the longer ARP wheel studs and no center caps, it looks totally race.

All in all, awesome improvements.

[ProTouring442]

Very cool little ride you have! What sort of mileage do you get with all of the mods? I think once we move I will be picking up a Thunderbird Turbo Coupe, the little turbo motor is just too cool!

Keep the improvements and pics coming!

Shiny Side Up!
Bill

[DarkBuddha]

Mileage is mediocre with my heavy foot and the kind of driving I do (85% in town, lots of sitting it traffic, lots of sitting at lights, lots of quick stop and go action)... between 15-17mpg typically. In fact, because of the kind of driving and the generally short distances I drive (under 6 miles at a time), the car just doesn't get into closed loop operation and the O2 sensor never gets properly warmed up, which means the ECU is always running richer than really necessary (which they are tuned to anyway). To help, I'm going to be switching to a heated O2 sensor. And I think the kind of driving I will be doing in Florida will be more balanced between highway and city, so I'm hoping to see mileage in the low-20s.

I have a friend with one of these motors in a '70s Volvo wagon and it gets a solid 23-26mpg in balanced driving, but it also has different gearing, an automatic tranny, and a heated O2 sensor. But you can see why I'm hopeful.

[ProTouring442]

Mileage is mediocre with my heavy foot and the kind of driving I do (85% in town, lots of sitting it traffic, lots of sitting at lights, lots of quick stop and go action)... between 15-17mpg typically. In fact, because of the kind of driving and the generally short distances I drive (under 6 miles at a time), the car just doesn't get into closed loop operation and the O2 sensor never gets properly warmed up, which means the ECU is always running richer than really necessary (which they are tuned to anyway). To help, I'm going to be switching to a heated O2 sensor. And I think the kind of driving I will be doing in Florida will be more balanced between highway and city, so I'm hoping to see mileage in the low-20s.

I have a friend with one of these motors in a '70s Volvo wagon and it gets a solid 23-26mpg in balanced driving, but it also has different gearing, an automatic tranny, and a heated O2 sensor. But you can see why I'm hopeful.


So how is this project going? I ask as I have just purchased a 1988 Thunderbird TurboCoupe.

Shiny Side Up!
Bill

[DarkBuddha]

Sorry I haven't posted an update recently... mainly because I haven't done a damn thing. We moved from Seattle WA to Sarasota FL in mid June and then spent the next 6 weeks living with family while buying and waiting to close on a house. We got in the house in early August and still aren't settled in. 75% of our stuff is still in boxes and my new garage is stacked deep and tall with all the boxes.

The one thing I did do on the XR is fix the a/c hoses so that I now have a/c while driving around (even if I did have to jury-rig the de-icing switch so it would work). So at least now the kids aren't just cooking away when I drive them to school and stuff. Oh, and I also bought another set of wheels: vintage Enkei RE92s, 16x8 with nice deep offsets. I can't run them for auto-x or daily driving, but they look killer for just cruising and preening.

I do have some short and long term plans for the car. I'm looking forward to getting involved in more track and auto-x, and some rallycross, so I think the car is headed towards being a track car even though I'll keep it street legal. In the short term I'd just like to tidy it up a bunch since it's basically a mess from the thrash to get all the work done on it before I left Seattle. And when I get some room in my garage and the weather cools a bit I'll install the black interior and Recaros I've got stashed. I'd also like to get it tinted at some point, touch up some paint, fix some trim, etc., etc., etc. The list seems to go on forever... typical project car, right?

[70Nova4dr]

I have a Ford racing camshaft and adjustable sprocket for 2.3 turbo if your interested. the part number is m-6250-a237 if you want to look up specs on it. I will sell the cam, roller followers and sprocket as a kit, that's how it came. Let me know if interested. Brandon

[DarkBuddha]

PM sent.

[mountainboy]

Here are some photos of Merkur's cousin

https://static1.pt-content.com/images/pt/2009/11/June20287JPG-1.jpg
https://static1.pt-content.com/images/pt/2009/11/June20286JPG-1.jpg

https://static1.pt-content.com/images/pt/2009/11/June20283JPG-1.jpg
https://static1.pt-content.com/images/pt/2009/11/June20284JPG-1.jpg

[DarkBuddha]

Awesome pics! Please tell me it is yours! That thing is wicked for sure. There have been a few RS200s for sale in the last year and the prices have just been going up and up... $100k+ easy. Considering the cost difference, I think I'm stuck with my XR.

[DarkBuddha]

I haven't done crap all weekend because of a flu/cold but last night I was so stir-crazy that I decided to just take some pictures of the car since I hadn't in a while. I really haven't done much to the car since moving to Florida other than fix up some nagging issues and repair some of the body work that I'd done in a rush before moving. I finally fixed the fit of the fiberglass Cosworth rear arches and tried to fit the front bumper a bit better. I also got some plugs to fill the bolt holes where the original cladding installed and installed a bump strip along the sides of the cars. And I finally got around to repairing and repainting the Cosworth RS upper rear spoiler and got it reinstalled. And more recently (as in last week), I got a nifty Ford Motorsports A237 cam/followers/cam gear shipped to me from 70Nova4dr (thanks a ton!). Anyway, just because I could, here are some pics:

https://static1.pt-content.com/images/noimg.gif (http://img194.imageshack.us/i/img5047small.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img34.imageshack.us/i/img5046small.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img69.imageshack.us/i/img5053small.jpg/)

https://static1.pt-content.com/images/noimg.gif (http://img194.imageshack.us/i/img5037small.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img34.imageshack.us/i/img5045small.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img187.imageshack.us/i/img5038small.jpg/)

And the cam and stuff:

https://static1.pt-content.com/images/noimg.gif (http://img693.imageshack.us/i/img5011small.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img256.imageshack.us/i/img5008small.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img509.imageshack.us/i/img5010small.jpg/)

[DarkBuddha]

Just a quick update... I've had some axle issues of late. I frag'd a rear CV joint (the XR has an IRS) and had to replace the entire axle assembly. Then I've been having problems where the stub axle on the other side kept popping out because of a worn retaining clip. Oh, well, it just gave me a reason to pick up another E36 BMW limited slip differential, this time with 3.91 gears instead of the cruise-tastic 3.15s my current diff has. I'm looking forward to the improved off-line performance and quicker boost.

While I was under the car, I took some pics of the BMW diff conversion:

https://static1.pt-content.com/images/noimg.gif (http://img7.imageshack.us/i/img4846small.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img8.imageshack.us/i/img4848small.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img21.imageshack.us/i/img4850small.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img8.imageshack.us/i/img4849small.jpg/)

https://static1.pt-content.com/images/noimg.gif (http://img23.imageshack.us/i/img4847small.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img21.imageshack.us/i/img4845small.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img25.imageshack.us/i/img4844small.jpg/)


Still need to pull the head, replace the valve stem seals, and install the cool A237 cam and adjustable cam gear, but I really need to get the interior in my Mach first. It's tough to do a head job when I need to be driving the car everyday.

[DarkBuddha]

I'm pretty psych'd how these turned out, so I wanted to share. I found I needed tires, which gave me the opportunity to fit the 17" Team Dynamics Pro Race 2 wheels I've had sitting in boxes for 18 months. Shoed 'em with 215/40/17 Continental ContiExtremeContacts, which is about as big a tire you can fit on these cars without coilovers or cutting/rolling the fenders (which I couldn't do with the Cosworth arches). In any case, a couple pics:


https://static1.pt-content.com/images/noimg.gif (http://img197.imageshack.us/i/img5791smallm.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img198.imageshack.us/i/img5790small.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img198.imageshack.us/i/img5799small.jpg/)

[DarkBuddha]

Not much to update... replaced yet another axle after the CV joint frag'd (again). I can't figure out if it's the crap quality rebuilds I'm getting or some issue with the rear suspension setup. I've got a pretty severe rear camber issue related to lowering the car, so that may be part of it, but everything else looks pretty good.

On an up note, in spite of the camber issues, I took the car out to auto-x with the local Porsche Club. The car did awesome... it's quick, it handles great, it's flat, minimal dive on braking, etc... truly, it's a better car than I am a driver. I ended up late mid-pack, a good 7 seconds off from FTD. My last run would've been 3-4 seconds faster (if I hadn't done a couple seriously stupid moves), which would've put me towards the front of the pack. I know the car has serious potential with a good driver and a set of good auto-x friendly tires (instead of the not-so-sticky Contis on the car now).

Anyway, here are a couple pics from one of my runs:


https://static1.pt-content.com/images/noimg.gif (http://img261.imageshack.us/i/16608508.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img94.imageshack.us/i/85122052.jpg/)


https://static1.pt-content.com/images/noimg.gif (http://img829.imageshack.us/i/73301999.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img695.imageshack.us/i/31338860.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img192.imageshack.us/i/66888812.jpg/)

[67goatman455]

wow, the new wheels made a huge improvement! now you just need to ditch the spoiler :twothumbs

[DarkBuddha]

wow, the new wheels made a huge improvement! now you just need to ditch the spoiler :twothumbs

Not digging the Cosworth RS upper, huh? Actually, I've been debating removing it again... maybe just run the Cosworth lower spoiler or go back to the original OEM bi-level wing. Or I might replace it with a roof spoiler.

BTW, that giant Cosworth RS upper actually weighs less than the stock bi-level wing.

[406 Q-ship]

I have always had a soft spot for the XRTi4 after working on one at the Firestone dealers I worked at. The car had an engine fire that only took out the upper injector harness but the other mechanics at the store could not do wiring to save there souls (like most mechanics). The shop had gotten the car to run for like 2 seconds at a time. If I remember correctly there was a change in the wiring during their model run and it required me to rework the salavge harness they got for it to make it run right. Once I had it up and running I had a blast test driving that little rocket around.

I gotta say I am not a fan of the big spoiler too.

[DarkBuddha]

Not much to update in terms of build progress other than some minor touches here and there. Because the front fascia has pretty low ground clearance (under 4") which makes it tough to get a jack under the front crossmember (which makes tire changes and servicing much easier), I decided to make the front bumper cover "quick release". Basically I installed retention pin in the middle and hood pin type pins on the sides. It still requires removing the grille (4 screws) to remove the bumper cover right now, but I will soon add two more hood pins in the front so I don't have to remove the grille. Pics:

https://static1.pt-content.com/images/noimg.gif (http://img169.imageshack.us/i/img7076a.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img294.imageshack.us/i/img7083p.jpg/)


The only other thing I've really done is take it to a couple events... an auto-x last weekend, and a rally-x today. Both were disasters but not because of the car per se. During the auto-x, I adjusted the dampers too firm which created a snap oversteer situation that I was not able to resolve until my final run. The result was that I spun the car on 5 out of 6 runs and posted embarrassingly miserable times. That said, the car was dynamite otherwise... took the abuse without complaint, including the 160 mile roundtrip drive to the event. For today's rally-x, I DNF'd because one of the front tires (my street tires) got sliced and gouged by the fiberglass Cosworth replica wheelwell arch. I've done a few auto-x on these tires and put a couple thousand street miles on 'em and had absolutely no problem. But today's outing in the dirt apparently was severe enough to create the contact. Bummer, but I'm just glad it wasn't something more significant that frag'd.

In any case, here are a couple pics from the two events:

https://static1.pt-content.com/images/noimg.gif (http://img15.imageshack.us/i/img7124cropped.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img64.imageshack.us/i/img7132croppedsmall.jpg/)


Once I get a replacement tire, I think the XR is going on hold for a bit so I can my Mach done. But then again, I can't ever seem to let things be...

[DarkBuddha]

I got bored waiting for the stupid replacement tire and fitted my old set of Yokohamas on ARE 5 stars (painted gold now):


https://static1.pt-content.com/images/noimg.gif (http://img34.imageshack.us/i/img7159small.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img543.imageshack.us/i/img7146small.jpg/)

[showa]

You truely have the "Pro-Touring" mentality.... Run what you got and have fun... Looking great and I enjoy your updates....

[DarkBuddha]

Thanks... I'm definitely building and using this with the same mentality as I would (and do) with a pro-touring car. One of the things I think really drives it is the process of "build it, bang on it, break it, build it better", so that's what I keep doing. After my recent rallycross experience, I'm actually thinking of going a bit more in that direction, but I don't see that as a departure from the pro-touring thing at all... more like an extension. In fact, I'm looking forward to getting my Mach 1 done so I can take it rally-x'ing, like Dukes of Hazzard style. Just seems a natural part of the cultural and racing heritage vibe we all seem to dig.

[showa]

I enjoy seeing the rallyX coverage in GRM.... Seems to be alot of that action in FL...... Being an X-dirt roundy round guy, I look forward to getting my car running and try it out this way too...

[DarkBuddha]

Well, I'd been driving it a bit... hard usually... and it finally caught up with me too. My custom spec super quick spool turbo suddenly and violently frag'd and I mean bad. Some of the turbo is salvageable, but it makes more sense financially to buy a rebuilt replacement right now than rebuild that one again, so I basically got the same thing but without the upgraded turbine wheel. While I was at it, I figured I'd port out the E6 log manifold and match the turbine inlet. Should increase flow and decrease spool time, which means more power when and where I need it. A couple pics...

frag'd turbo:

https://static1.pt-content.com/images/noimg.gif (http://img163.imageshack.us/i/img7392un.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img97.imageshack.us/i/img73771.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img20.imageshack.us/i/img73761.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img684.imageshack.us/i/img73721.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img269.imageshack.us/i/img73811.jpg/)


new rebuilt turbo:

https://static1.pt-content.com/images/noimg.gif (http://img18.imageshack.us/i/img7452fs.jpg/)


Pics of porting...

E6 manifold:

https://static1.pt-content.com/images/noimg.gif (http://img703.imageshack.us/i/img7541f.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img683.imageshack.us/i/img7539q.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img5.imageshack.us/i/img7546k.jpg/)




turbine before and after

https://static1.pt-content.com/images/noimg.gif (http://img36.imageshack.us/i/img7553x.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img705.imageshack.us/i/img7548t.jpg/)



I'm also going to take this time to re-do the intercooler plumbing, some of the cooling system plumbing, add an oil catch can, and install the EGT sensor (and maybe the wideband sensor as well), and clean up some other stuff. Car should be much better off for the hassle. :)

[DarkBuddha]

Got it done... newly rebuilt turbo, ported manifold, re-did the IC plumbing, added an oil catch can, fresh ignition stuff, EGT sensor installed, relocated air intake and filter to fenderwell and fab'd a stupid simple splash guard, fixed coolant hose routing, and cleaned up some wiring and vac lines. It always rewarding to fix annoyances that have been bugging me for a while, and I really hated how much stuff I'd left sorta half done because of time constraints. It's extra nice to have both a garage and tools, and an alternate daily driver so I can work on the car as I want and get it done correctly. Anyway, some pics:


https://static1.pt-content.com/images/noimg.gif (http://img716.imageshack.us/i/img7710h.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img41.imageshack.us/i/img7711e.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img838.imageshack.us/i/img7712m.jpg/)

https://static1.pt-content.com/images/noimg.gif (http://img692.imageshack.us/i/img7714y.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img837.imageshack.us/i/img7708v.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img222.imageshack.us/i/img7626w.jpg/)


And button'd back up:


https://static1.pt-content.com/images/noimg.gif (http://img808.imageshack.us/i/dsci0341small.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img860.imageshack.us/i/dsci0348small.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img5.imageshack.us/i/dsci0350small.jpg/) https://static1.pt-content.com/images/noimg.gif (http://img534.imageshack.us/i/dsci0351small.jpg/)
Now I'm just looking forward to getting it out to an auto-x event soon-ish.

[RobertGP]

Nice car dude! We had alot of them here in Germany, it called Ford Sierra.

[DarkBuddha]

Thanks... I love it. BTW, I know that there were LHD Sierra RS Cosworth 3 doors exported to Germany (and Italy, and Poland, and..), but wasn't the German "domestic" version the XR4i? I'd love to have a legit Cosworth just for bragging rights, but at this point, my wannabe version is better than a stock Cosworth in almost every way (except maybe the awesome front bumper and the big side window), and for less than 1/4 of what a decent driver legit Cosworth would cost. I can live with that, quite happily. :)

[Ash]

Was checking the GATEBIL RUDSKOGEN (http://speedhunters.com/archive/2011/07/09/event-gt-gt-gatebil-rudskogen-let-the-mayhem-commence.aspx) on speedhunters. When I saw this RS Cosworth on Custom classic-style OZ Rally's. I want one now!

Makes you wonder why ours came with side moldings.

https://static1.pt-content.com/images/noimg.gif

Any update on yours?

[DarkBuddha]

https://static1.pt-content.com/images/noimg.gif

Any update on yours?
Drool!!!:worship:

As for mine, I haven't been doing much in terms of more build progress because it's been so much fun to drive since getting the new turbo installed. Mainly I've just been banging on it a bit to make sure it's up for the rallycross this coming weekend. It's a 3 hour drive over and a 3 hour drive back, plus I expect the temps during the event to be in the mid 90s, so I really wanna know the car will handle it all. So far, it looks very promising.

As for plans, I'd like to add some proper gauges to monitor the motor, install some Recaros I have, and add a roll bar (or half cage), harness bar, and harness. I'd like to do more road race type events and since the car is capable of over 140mph, I think a bit of rollover protection would be wise.

[rab]

im picking up 2 xr's and making 1 good one and useing the other turbo motor for my ranger.

can u tell me more about the bmw diff swap?

also on the pics you post from the rally/drive on page 4 , i really liked the stripped look, ie when you had the side moldings ,ect removed. also on that same post there is a pic of a black xr front shot, http://imageshack.us/photo/my-images/519/IMG_2836.jpg/
what bumper is that a vw corrado???? it looks different from yours, i think yours is from a jetta?

[DarkBuddha]

Well, welcome to XR ownership.

The BMW diff swap isn't overly difficult, but it does require quite a bit of fabrication and the ability to do careful measurement and the like. There are other (probably better) options available now that weren't when we did the BMW conversion. For example, http://mc2racing.com/ offers a kit to retrofit an Eaton limited slip unit into the stock differential. The only issue there is that you're stuck with stock diff ratios. Another excellent, and the one that would get my coin if I were to do it again, would be JVAB's Mk3 Supra LSD diff conversion. He sells a mounting bracket and axle adapters to mount the diff, and he can give you the part number of the correct diff flange to get for the driveshaft. It's a very strong diff and readily available in junkyards, and because it's the same diff used in Toyota trucks (which are very popular in off-road circles), there's plenty of aftermarket support and lots of different gear ratios available. John V (JVAB) is the guy to talk to, but ya gotta call him... he doesn't do email. Here's a link to his picture pages: http://www.rallyrace.net/jvab/spgm/

About the "stripped" look, I too liked it for a while. I actually go back and forth on what look works best on these cars. It's hard to argue with the Cossie bodywork, but there's a leanness about the stripped look that is very appealing. And every once in a while I see a pic of a really clean stock XR that's got just the right stance and wheels, and it knocks me out too. Really, any of the looks can be awesome with the right combo.

The bumper on the black car is also a Jetta bumper... his was actually the original Jetta bumper conversion. The things that make his look a bit different is that it has OE orange turn signals and a scoop insert instead of the parking/fog lights (inboard of the orange turn signals). I actually bought those scoops to put on mine, but they looked much better on his black car than mine. The scoops used to be readily available on ebay if you're looking for a set.

If there's anything else I can help with or questions I can help answer, feel free to drop me a line. And if you're not already, join the Merkur Club of America and MerkurSport forums.

[DarkBuddha]

BTW, an update on my XR...

Not particularly interesting or significant, but I tried an experiment with a bit of white vinyl tape on the front air dam and decided I like it. Eventually I'll paint it properly. Here are a couple pics:

https://static1.pt-content.com/images/noimg.gif

https://static1.pt-content.com/images/noimg.gif


Also, I did do that rallycross event, and had a ton of fun. Car ran awesome, and in spite of the high temps (mid '90s), it never even came close to overheating. It did take me weeks before I was able to get most all of the mud off the car... the wheels still have a light coating on the inside of the barrels. A couple pics from the event:

https://static1.pt-content.com/images/noimg.gif

https://static1.pt-content.com/images/noimg.gif

https://static1.pt-content.com/images/noimg.gif


Most recently (a few weeks ago), while "testing" the XR in a parking lot in preparation for an auto-x the next day, I broke something in the driveshaft. I haven't had any time to do more than a cursory glance, but I think the rear u-joint is probably frag'd. Since the u-joints aren't replaceable from the factory, I'm going to remove the driveshaft and take it to a local shop to have it machined for replaceable/serviceable u-joints and have it balanced. It's only a matter of time and money, but eventually I figure darn near everything on the car will have been fixed, replaced, upgraded, or rebuilt.

[Tig]

Awesome build, looks amazing.
Youre doing a great job man. Everything I've done to my car/truck is basically preventative maintanence, hah. Whether I need it or not :)
I have always been a fan of XR4s, you never see them. That RS200 is just nasty. That black XR on SpeedHunters is just insane to.

[SuperB70]

Thanks... I know that there were LHD Sierra RS Cosworth 3 doors exported to Germany (and Italy, and Poland, and..), but wasn't the German "domestic" version the XR4i? Hi Wyatt! Here we have Sierra and Cossies also and for the record, first where made in UK but 4d 2wd & 4wd Cossies where build in Belgium. I have had five: '88 2d 1.6 2wd from my Dad, '85 2d 2wd 2.0 Turbo (small IHI and Weber DAT carb. 247Hp), '86 2d 2wd 2.8V6 180Hp, '86 2.8Twin Turbo 4x4 442Hp and stock '90 2.0 2wd stw. Good to drive, simple and cheap to fix
My friend has real '90 2wd Cossie 460Hp and '88 2.0 GL a "granddad-model" with 5.0 TT about 630hp. Also here is one with Explorer 4.0 V6 Twin Turbo, about 600Hp
I havent ever heard that rear diff chance you wrote about, we just use Cossie diff... Nice looking Ford you got there, keep it up...
Something to read:
http://en.m.wikipedia.org/wiki/Ford_Sierra_RS_Cosworth

[DarkBuddha]

That's a helluva list of Sierras to have played with. All of the Merkur XR4TIs were made in Belgium as well, even though Ford was daft enough to claim they came from Germany and put this one the grilles:

https://static1.pt-content.com/images/pt/2011/10/3334096951_14d82f7cb3-1.jpg

I guess they can claim that because Karmann did the US market conversion.

As for the diff, we just don't have a big enough supply of Cossie stuff stateside to conveniently find diffs, transmissions, etc. There are a few folks that have imported stuff, but it's still cheaper to do the BMW, Supra, or Eaton diff conversions.

BTW, I'd love to have a '90s Cossie 4x4 and have Reyland lean on it a bit... maybe if I win the lottery one day.