AMC Eagle Den Forum

The Shop => Project Cars => Topic started by: RallyEagle on November 23, 2018, 09:06:30 PM

Title: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on November 23, 2018, 09:06:30 PM
I obtained the 82 SX4 Rally car, raced by Dean Blagowsky in 83-84'ish.  It has an AMC 390 w/727 and a 119AM tcase.  I will not be racing it when done.  It requires complete rewiring and all new suspension components.

(http://i1255.photobucket.com/albums/hh637/RallyEagle/20181123_201850_resized_zpsyg24m8cg.jpg) (http://s1255.photobucket.com/user/RallyEagle/media/20181123_201850_resized_zpsyg24m8cg.jpg.html)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: rmick on November 23, 2018, 11:31:05 PM
Way Cool :occasion14:
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: amcfool1 on November 24, 2018, 03:47:55 AM
welcome. successful Eagle V8 conversions can be counted on one hand! good luck, gz
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on November 24, 2018, 08:27:06 AM
It's a fun car just not ready to be safely driven. A note for using 8 gauge cables in an 0 gauge apllication: DON'T!  Starter wire jacket was melted plus batteries are in rear.  Long wires, high resistance, low voltage, high amps.  All cables have been replace with hmmwv/humvee (AM General) double jacketed 0 gauge.

(https://i1255.photobucket.com/albums/hh637/RallyEagle/20181113_194412_resized_zpsraw5ssb8.jpg)[/URL]
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on November 25, 2018, 06:34:11 PM
Removed front axle and found that it is 4.10 (41-10) Has a 1/2" spacer between carrier and ring gear.  Rear is 4.11 (37-9). Both open diffs. I don't think the front has been serviced in decades. Rear was cleaner but still old oil.  Easy to drop front axle, 5 bolts and 2 half shafts. Transmission jacks worked great.  They both will get cleaned up and cover put on and refilled for now.  Need to redo front and rear shocks and suspension. That's all for now.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on November 25, 2018, 06:44:57 PM
(https://i1255.photobucket.com/albums/hh637/RallyEagle/20181125_153820_zpsrou7dsif.jpg)[/URL]
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on November 25, 2018, 06:46:27 PM
(http://i1255.photobucket.com/albums/hh637/RallyEagle/20181125_154100_zpsuetl8shd.jpg)[/URL]
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on November 25, 2018, 06:47:09 PM
One side removed.

 (http://i1255.photobucket.com/albums/hh637/RallyEagle/20181125_171232_zpsoyu8buxe.jpg)[/URL]
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on November 25, 2018, 08:09:08 PM
Three shock tower configuration.  All bad a will be replaced.  See broken center COS..

(http://i1255.photobucket.com/albums/hh637/RallyEagle/20181125_154201_zpsndzi6pcs.jpg)[/URL]
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: DAVE on November 26, 2018, 09:18:43 AM
when you get a chance would like to see how they converted to the V8
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: derf on November 26, 2018, 12:19:51 PM
(https://i1255.photobucket.com/albums/hh637/RallyEagle/20181125_153820_zpsrou7dsif.jpg)

That's certainly one way to do it.  I wonder why they didn't use the correct carrier for that gear set?
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on November 26, 2018, 07:47:50 PM
True but it works. Ring gear has a date of 2 22 80.

Engine fit snuggly, the Spirit had a v8 option.  The biggest mods are: the oil pan is custom made, the cross member cut down, and exhaust.  Snug fit.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on December 01, 2018, 08:26:54 PM
Inspected and cleaned front diff then new gasket and set cover with new bolts.  Also removed tiewraps and installed clamps. Thrrn dropped front steering control.  Pressed out all bushings and primed all parts.  New wear components will be installed.

(http://i1255.photobucket.com/albums/hh637/RallyEagle/20181201_091101_zps6vzusd8g.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/20181201_094121_zpsmo6nplns.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/20181201_194825_001_zps0lqdc6bc.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/20181201_194905_001_zps91gffqiv.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: mudkicker715 on December 01, 2018, 11:22:48 PM
You move quick, for certain.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on December 02, 2018, 07:26:19 PM
Once I start I keep going!  Cleaned up front cross member, remove pitman arm with cutting wheel. Fast and clean.. Some pictures of engine area underneath. Tight fit. Painted front axle and lower control arms.

(http://i1255.photobucket.com/albums/hh637/RallyEagle/20181202_125042_zpsp7rtetxq.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/20181202_125021_zps0ec6xr0t.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/20181202_125042_zpsp7rtetxq.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: Blip Downshift on December 05, 2018, 10:01:53 AM
Very cool, I'm building a modern take on a Spirit rally car.  I've always wondered what setups they used on the Eagle cars.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on December 05, 2018, 08:43:01 PM
Whomever was the original build on this car did professional work. I like what I've run into and easy fixes thus far.  Working on shock tower and upper a arm now as well as front spindles. Good bearings, very bad seals.

Regarding your build, why are you lowering it to Spirit  height? Seems old springs do that for us!  :rotfl:  mine were down close to thge bumper pads
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: Blip Downshift on December 06, 2018, 09:31:33 AM
I just like the spirit ride height better, aesthetically.  The way I am doing it, if I do not like the height or want to change it back I have the pieces available to do so.  I have spring setups for a 6 cylinder eagle (which I heard was the same spring tension settings as 2wd 8 cylinder cars), 4 cylinder eagle (same as 2wd 6 cylinder cars), and 4 cylinder Spirit.  I really like the way the original builder of your car did the front suspension, it has given me some ideas for my rally car build just when I thought I had my mind made up.  What is the make of the middle coilover and how was it originally attached to the upper control arm?  I am also curious regarding the modifications done to the upper shock mounts?
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on December 06, 2018, 04:24:28 PM
Nice.  I like taller eagles!   8) 

The middle coilover is unknown, tags unreadable.  I have searched and found nothing.  Anything comparable is very expensive.  It is not a gas shock, just a piston with seals and bushing.  The spring is 12" with 2.5" ID and appears to be 300 pounds with 16" extended and +-10" compressed.  I am rebuilding these and will reinstall them.  Each end has a male rod end (both ends trashed) with 1/2" Heim Joint..  At the top, they made a bracket assemble to bolt the rod end to.  They used washers as spacers, so I will have to make up a bushing to fit it better.  The guy I bought it from included a set of Hydro 7052 shocks (2 on each side) that I will mount up.  This setup of 2 shocks and one coilover keeps the front end fairly level around corners while carrying the 390 motor weight.  The lower cross bar is 1/2" round stock.  I will replace them with new since these are beat (required more that 12 tons to free them from the tube.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on December 08, 2018, 06:45:58 PM
Started installing front steering gear with all new wear parts. Will set front axel soon.  Then dropped fuel tank, rear shocks, tail pipes (dual exhaust) and brake lines. Lots of room under there!  Have to order new rear springs with lift.  Fuel tank is in great shape, has rock shields. Fuel hose really bad. Surprised it never caught fire, both fuel and electrical!!! That's all in the past now.

(http://i1255.photobucket.com/albums/hh637/RallyEagle/20181208_160152_resized_zps8c5hkgkj.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/20181208_164043_resized_zpsx0zivdct.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/20181208_170257_resized_zpsvcekjakj.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/20181208_160132_resized_zpsare2vxim.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/20181208_160108_resized_zps0e3bmzef.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: Blip Downshift on December 10, 2018, 09:00:36 AM
Was/is this car fitted with rear disc brakes?  If so, do they have the original 5x4.5 lug pattern?  Usually to get rear discs on a Eagle, a rear end swap is required.  Might explain the strange rear diff setup.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: DAVE on December 10, 2018, 09:34:39 AM
watch out for that front rock guard on the fuel tank I've seen them collect sand & gravel and trap moisture up against the tank and cause rust through
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on December 10, 2018, 06:18:38 PM
Yes, rear wheel disc brakes on 5x4.5. Same rear axle just a quality welded bracket. I'll snap a picture of the mounts.

Yes, the rock shield is actually a gravel collector. Dry between the two and tank is in great shape. I'll cut a slot in front of shield to let debris and moisture drop out.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on December 10, 2018, 09:39:37 PM
Rear disc brake brackets.  Nice easy setup.

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181210_183901_resized_zps0vm3iukz.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181210_183847_resized_zpsbvvrkibu.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: Blip Downshift on December 11, 2018, 08:07:30 AM
Do you know if the rear brake rotors are a stock part off something or did they have to make a custom brake disc hat to fit the caliper and spindle offset offset?  Also can you post a picture of the rear differential cover?
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on December 12, 2018, 11:46:46 AM
Rear on this car is the same as the front, both rotors and calipers.  Rear axle is a Dana 35 with standard cover and 4:11 gears.

New rear springs are on order!  Adding a 1" lift.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: Blip Downshift on December 13, 2018, 09:13:08 AM
Very interesting, this has once again given me some new ideas.  Keep up the good work.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on December 14, 2018, 08:58:27 PM
Rebuilt coilovers with new bushing and Heim joints. New shocks and new cross shaft on control arm.  Waiting on some parts to finish front end. Then drop rear axle and the new rear springs in.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on December 15, 2018, 06:38:09 PM
Parts relay so out came the rear axle and springs.  No rust on unibody!  Some surface rust but no cancer.  Definitely a SW car.  Springs were saggy and a 3/4" lift block was on drivers side.  Bushings shot.  All new bushings will go in. I'll pull shafts out and replace seals and check bearing/races.  Cleaned axle housing to work on.

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181215_145020_resized_zpsjsvuylwo.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181215_164914_resized_zpsnwtg13hh.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181215_164929_resized_zpsljpklecj.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181215_164957_resized_zpso7jm65ph.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on December 15, 2018, 08:35:02 PM
Coilovers and leaf springs. Plus the rear disc brake bracket and mount. AMC number.

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181215_193214_zpsso9by0go.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181215_191935_zpsreimmrr7.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181215_201407_zps11exjc76.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181215_201416_zps26fuc28s.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on December 16, 2018, 07:53:50 PM
Cleaned out gas tank with a cleaner and 5 pounds of bolts. Lots of crud came out. Rinsed, dried, primed and painted. Pressed in bushings on upper control arms. This rally car uses one long 1/2" bolt that goes through both bushings. There is a sleeve between them that stiffness up the connection plus allows the nut to be tightened against.  Very strong mount.

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181216_172636_resized_zps73srajie.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: Blip Downshift on December 17, 2018, 08:20:07 AM
Is the middle front coilover custom made or is that an off the shelf part?
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on December 17, 2018, 08:45:32 PM
It had a sticker but illegible,  so I'd say they bought them. I rebuilt them and now installed them!  I still have line them up and tighten them down. I'll set spring tension when it's on all 4 tires.  Previous owner bought the shocks, Hydro 7052.

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181217_202816_resized_zpskkfawpl0.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181217_202744_resized_zpsvtickope.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: Dan Pfeiffer on December 20, 2018, 08:37:07 PM
Excellent project and photos.  Super lucky find.  It looks like the front diff on your ralley eagle mounts to the cross member rather than the engine?  And the cross member itself looks quite a bit beefier than OEM.  Do you have more pics of that?   Is the diff mounted at the same height as oem or is there some lift there?  Are the spindles same as stock?  And what is the tire size?

Thanks,  Dan Pfeiffer
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on December 20, 2018, 09:26:25 PM
Work on fuel sending unit. Since no AMC gauges in this rally car, I'm installing a sending unit with matching gauge.  I modified the pick up tube assembly. Drilled out old broken sending unit and modified the Sunpro unit to correspond with fuel level. New ground wire soldered on using prestolite military wire.

Yes, happy I found this car. It needed saving for many reasons. The top part of the cross member has been modified and yes the axle mounts a 1/2" plate that's welded to cross member.  I don't believe the axle is lower than stock since pinion bracket and disco area bracket are in the factory location.  No real good pictures of the upper mount since a 1970 390 engine is sitting really close to it along with the lincoln log manifold. But this one shows a little more.

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181220_211039_zpshsmdagma.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/20181202_125042_zpsp7rtetxq.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on December 20, 2018, 09:31:07 PM
Forgot to add, spindles are stock and it has 215/70R15. Ill up them to 225 and use the coilovers to raise it some.  Inner fender plastic has already been trimmed...problably from articulation during racing.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: Dan Pfeiffer on December 20, 2018, 11:05:45 PM
Thanks for info.   I also see that at the outboard edges of the crossmember there is a vertcal plate that fits up on the outside of the frame rail and is thru-bolted there.  And the bottom the cross member has a much thicker plate welded all around.   And two large reinforced passages that are maybe for transmission cooling lines?  Do you think this is a stock cross member that's been modified or is it a custom fabrication?

I also see a bar (like a monte carlo bar you see in 60's mustangs) running across just fwd of the firewall.  Though it seems to me that would do more futher forward - like ahead of the shock towers (as in the mustang).

Have you discovered other reinforcing mods to the frame and unibody?

Thanks,  Dan Pfeiffer
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on December 21, 2018, 08:12:27 AM
It is definitely beefed up.  The trans lines are run on drivers side of engine.  Holes in a double plate allow extra reinforcement, there is also a thick welded bar on top of member.  I would bet that it is stock that has been modified.  Even the front supports from member to front have additional metal.  The bar behind engine is part of the full roll cage (ROPS) setup.  I have found no other structural mods to the body, just suspension.  Rear is stock though.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on December 22, 2018, 06:16:07 PM
Most of the front end is installed. Hubs done. Just need to set tie rods and halfshafts and tighten the upper and lower a-arm bushings. Repositioned the fuel tank primary filter in a safer area and need to relocate fuel pump then run new AN fuel lines. Fun!

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181222_113757_resized_zpspoftadqe.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181222_170558_resized_zps7w1tvamp.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181222_174135_resized_zpsg1meq5py.jpg)

Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on December 23, 2018, 06:22:09 PM
Installed new rear springs with extra arch, set rear axle and mounted fuel pump. When my AN hose fittings arrive, I'll plumb it all in. Installed rear shocks as well.  The upper shock mounts are reinforced with plate steel.  Nice and stout..  Exhaust system is very rusty but newer mufflers. I'll get them changed out for a better fit and kick exhaust out the sides in front of tires.  Once I set it down on tires, I'll start the rewiring and revamp the cooling system. Fun!

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181223_150303_resized_zpsaultslbx.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181223_152030_resized_zpsrayvsmbw.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181223_154522_resized_zps1cc5ftvn.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181223_150249_resized_zpswyrcxhpa.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: Taylor on December 23, 2018, 08:28:46 PM
Great rebuild. The rear brake conversion looks good. But when it was done was a parking brake added somehow?
Thanks for posting the build.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on December 24, 2018, 09:24:44 AM
There is no provision for a rear parking brake.  There is a manual "balancing/proportioning" valve near the shifter for the rear brakes.  I will be investigating using this valve or installing a micro-brake lock on the rear line.  If there was room, I would install hmmwv (humvee) rear brake calipers (they use the same mounting setup) that has a mechanical locking feature.  I am not a fan of rear propeller/pinion braking systems.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: mo.eagles on December 24, 2018, 03:48:06 PM
Nice project!!   Great work!!
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on December 26, 2018, 03:45:28 PM
Thank you mo.eagles.  It is a fun project.  I have built and restored many vehicles and this little sx4 is a blast.  It will be funner when spring arrives and I put it through its paces in northern lower Michigan.

Did more work, front cv joints, etc. Set tires to get it on ground but have not cranked up coilovers yet.. Still have fuel tank/lines to install, exhaust systems, cooling system and ALL electrical.

(https://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181225_130237_resized_zpskgbk0hvm.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181225_130320_resized_zpslp3sa7sn.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on December 29, 2018, 06:32:15 PM
Was working on fuel system and waiting on a part.  So off comes the front end.  Cowling/facia was really loose. Was not fully bolted in and some cracked metal.  Also welded studs to hold radiator, was bolted and 2 were not installed!  Removed radiator, transmission cooler, oil cooler and power steering cooler, then degreased, ruffed up metal and etched primed it.  Also, including a motor mount picture and top of cross member for reference.

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181229_144606_resized_zpsgegnc20y.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181229_143603_resized_1_zpsgpeyuvu8.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181229_123636_resized_zpstcg7uvoi.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181229_164718_resized_1_zpsurtlrybf.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181229_164655_resized_1_zpso1ajuaed.jpg)

Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on December 29, 2018, 06:36:31 PM
The area around radiator was cut to fit this rad. Don't know what rad is from but is a 3 row.  It'll get it tested and hopefully reused.  Lower cooling line used a labatz beer can for a belt protector.  Preformed hoses will replace these cruddy things.

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181229_090302_resized_zpsdvryxdqk.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: mudkicker715 on December 29, 2018, 07:36:05 PM
Sweet.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on December 30, 2018, 06:57:27 PM
Painted front end semi gloss black and cleaned out and set coolers.  New hardware for reassembly.  Cleaned out overflow reservoir buy using peastone and water. Clean as new.  Set grill to check clearance. Clean up wire harness and add back the high beams.  Might add a second horn since its wired for it.  Picture of radiator.  Sides modified and much wider than stock AMC.  The silver paint is Ford Silver Birch. Matches pretty good.

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181230_153540_resized_zpscqzekioo.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181230_153548_resized_zpswtwkioni.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20181230_153528_resized_zpsxmpkaocu.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on January 01, 2019, 07:19:21 PM
Finished making custom rear brake lines due to disk brakes. Then I cleaned out radiator, then primed and painted. The 2x 12" electric cooling fans that were set in place, barely, need to have mounts made to fasten to radiator mounting points.  I will control the fans via a coolant temp sensor.  Also started to rewire front headlight harness with all new wires and connectors. Many splices being removed, pictures when I'm done fabbing the harness.

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190101_164049_resized_zpsu91xbuua.jpg)


(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190101_163426_resized_zpsm8wf625d.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: IRON HORSE on January 02, 2019, 01:51:27 PM
Hello,

   You have found a great piece of history, priceless !!  Found the link to the SX4 at Nurburgring ... 1979.
Link:  https://www.youtube.com/watch?v=dhRzTqwuDTU  (https://www.youtube.com/watch?v=dhRzTqwuDTU)   

                                                                                                               Enjoy,  Iron Horse
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on January 02, 2019, 04:59:39 PM
Good to see that.  1979!  I remember that year.  ugh.

Yes, I believe this car is priceless and I am keep it as original as I can.  However, due to age, there were issues with electrical and fuel that really needed attending to so it would not have any shorts/leaks and destroy it.  I am almost done with the fuel system and have started the electrical rewiring.  When finished it will be very close to original but with the necessary upgrades.  The suspension is done, just need to jack up the coilovers to get it in a good front suspension range.  Can't wait to put it through it paces in northern lower MI this spring.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: rmick on January 02, 2019, 07:29:01 PM
The Nurburgring cars were AMC Spirits. 2wd sister car to the Eagle SX 4
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on January 03, 2019, 04:08:02 PM
No doubt they were Spirits given the year.  But good to see none the less. :occasion14:

Made cooling fan shroud mounting brackets.  Just need to add nutserts to shroud for brackets to attach to.  The other end of the brackets will mount to the same points as the modified radiator.  They used 3/8 bolts.  So I installed longer 3/8 bolts and welded them in to be studs for easy installation/maintenance/removal of cooling stack.  I replaced the power steering lines with new and plumbed the transmission cooler with correct hose (5/16).  There was 3/8 hose clamped to 5/16 tubing which leaked even though they were double clamped.  Next up is the oil cooler lines.  Once I get the front harness complete and the oil cooler lines in, I can set the cooling stack and connect the hoses.  Then set the headlight cans, grille and pencil lights.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on January 05, 2019, 06:09:20 PM
Drained engine oil and removed hose for remote filter. Also discarded filter.  Takes about 2 gallons of oil.  Replaced power steering lines and relocated the ps cooler.  Then set cooling stack and hoses. The lower hose has to be custom. The upper is a for a Javelin.  I thought the lower would be as well but out on radiator is pointing up instead of back..   Started the light relay panel rebuild.  Waiting on fuel stuff to finish that, the oil hose to finish that and electrical wrap to finish front harness. Fun!

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190105_170157_resized_zpsm4fkfmlm.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190105_170252_resized_zpsvazmskyf.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190105_170236_resized_zpsnolvfwsb.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190105_170139_resized_zpswx6onfw8.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190105_170128_resized_zpszoztyzvo.jpg)

Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on January 06, 2019, 04:56:44 PM
Did some odds and ends on the fuel system and removed old electrical wire from rear end.  Cranked up the coil overs and inch or so to see the rake.  The half shaft looks fine so I'll crank it up some more to decrease the rake.

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/43191_zpsq48sqxhh.jpeg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190106_144641_resized_zpspjqagagi.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/43192_zps8jmzbli2.jpeg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: Blip Downshift on January 07, 2019, 08:32:59 AM
Lookin good, when you're finished are you going to show the car anywhere or just keep as a fun toy?
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: DAVE on January 07, 2019, 08:51:22 AM
looks like the power steering belt doesn't line up to well
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on January 07, 2019, 10:32:02 AM
It will be driven, mostly in north lower Michigan and a  trip to Colorado.

Correct, the ps belt is off a bit and probably for many years.  I adjusted the alternator alignment so next is ps.  The bracket is quite the contraption so it looks like fun.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on January 07, 2019, 08:37:50 PM
Still waiting on parts. So I wrapped front harness and secured it. The set drivers headlight, buckets, and trim.  So many screws!  Halogen drive lights and they have halo leds. Add8ng pencil lights in middle on bumper as before.

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190107_202037_resized_zpsduxruvhr.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on January 08, 2019, 08:51:50 PM
Installed oil cooler lines and secured them. Filled engine with oil. That allowed me finish the passenger headlight bucket and grill.  Fuel system parts came in so that's next.

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190108_202503_resized_zps7o0qr7sb.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190108_202434_resized_zpsb9sautkf.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on January 09, 2019, 09:02:47 PM
Got the double stainless jacketed AN6 fuel lines installed. Just need to install tank and plumb the regulator, carb, gauge and final filter.  Fuel lines followed the hard lines but added extra clamps.  Also did the final brakeline connection so now I can bleed the brakes with new fluid.  Now there is no fuel exposure inside the cabin or over the exhaust system! ::)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190109_204438_resized_zpsqj3e1gmd.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190109_204255_resized_zpsrrzyysiw.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190109_204354_resized_zpscktvsjjv.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190109_203719_resized_zpsfpepuyhn.jpg)


Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: Blip Downshift on January 10, 2019, 08:33:54 AM
That fuel system looks great.  On many rally cars they would run the fuel system inside the cabin to prevent them (the lines, pump, filter, and regulator) from getting broken when the underside of the body would rub on the ground or get beat up by gravel.  The same would also be true for the braking system.  I, however, do not blame you for wanting to put it back to the standard configuration albeit with much better parts. Keep up the good work.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on January 10, 2019, 10:44:24 AM
Thank you and true about how they are/were setup.  The fuel part inside the cabin was the fuel pump and it was in an open bottom box above the right muffler!  The delivery lines still were underneath in factory position.  The rear brake line is inside with regulator near shifter.  It exits by where the rear factory brake bracket is.  So, it will still be very close to original rally but a heck of a lot safer.  The jacketed lines will offer some protection and they eliminated some connections.  I am going to remove the open bottom box (50 cal ammo can!) and patch the floor.  I will be setting the tank tonight.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on January 10, 2019, 07:59:33 PM
Set fuel tank and completed connections. Made carb fuel line with AN connectors.  I will set up another AFB carb with higher cfm rating to feed the engine. Currently it is a 500.  I also set the front pencil lights to complete front.  Now the electrical, my favorite!

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190110_171729_resized_zpsvrzsvmgn.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190110_193901_resized_zpsu4zkdqul.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190110_193544_resized_zpsq65zckfd.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on January 16, 2019, 08:10:54 PM
Started the wiring. So many splices.  I'll document and then just remove it all.  Quite the challenge.  No pictures,,,yet.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on January 17, 2019, 08:11:38 PM
Making headway in tracing leads. Have a look. Found 5 splices in 2 feet! Fun!

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190117_191502_resized_zps7uge6riv.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190116_194632_resized_zps00lycoob.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: mudkicker715 on January 17, 2019, 09:31:30 PM
Splices make life fun for others lol. I hate electrics, but even i would run a new wire to a broken section.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: Blip Downshift on January 18, 2019, 08:30:52 AM
Have you considered ripping out all the old electronics and starting from fresh?  Sometimes that is the easiest way.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on January 18, 2019, 11:30:11 AM
That is what I am going to do.  All new switches, fuse panel, wires, connectors, gauges, etc.  I first like to document what was so that I can understand it.  Here is a picture of the electrical overview I drew up.  Soon gutting will occur.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on January 20, 2019, 05:36:15 PM
I got the front leads landed and installed the heater hoses. I installed a humvee heater valve since the original setup was full heat all the time! Crazy!. I also installed a recirculation control cable to mix air.   I moved the starter solenoid away from exhaust manifold and rerouted my new battery csbles,,,from a humvee.  Since AM General was part of AMC, a lot of my hardware and parts are interchangeable.  Next up is landing the wires in the cabin and installing a new fuse panel.  Added a ground buss for all lights, cooling fan, and relays.  I'll spray it with clear coat to protect it. Fun!

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190120_171757_resized_zpsqukm0pvw.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190120_171822_resized_zpsdczdpugz.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190120_171842_resized_zpshzvletuz.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on January 21, 2019, 08:19:55 PM
Gutted most cabin wires and gauges.  Quite a pile of spliced wires and broken connections.  More gutting and then new gauges and harness.  Fuses too. Fun!

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190121_194332_resized_zpse2fvwntv.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190121_194349_resized_zpsllydxkgk.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: mudkicker715 on January 21, 2019, 10:15:50 PM
Omg gold luck. I know it will be better.. the tilt steering wheel on my 97 f150 for example had broken wires from the column bei g tilted.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on January 22, 2019, 07:45:02 AM
Thanks.  I need gold luck...to pay for this! lol  Its really not that bad to rewire it, just mark and cut.  Considering all the add on's previous owners did, it's not that bad for a race type car.  I just don't under the splices after splices in a single line.  Several wires where over heated from exhaust manifolds.  So I rerouted them as best as possible to avoid the radiant heat.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: TEagle85 on January 22, 2019, 08:34:07 PM
Sweeet! Ive been taunted by this car on the internet for years after I started digging into mine. Thanks for all the photos, really giving my inspiration for a chassis/ suspenson upgrade on mine. Also from MI (living in Chicago), maybe ill catch you on the dirt roads in Manistee forest. If not I'd love to see this car in person! 
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on January 24, 2019, 01:47:36 PM
Initially I will put it through its paces near Camp Grayling.  Whatever issues arrive I can drag it to Higgins Lake work on it there.  PM me if you are heading through Lansing area.

I removed the speedometer.  The needle was bent and being squished by the faded Plexiglas cover.  I will replace the cover with new and reseal.  Odometer says 13,221.8

Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on January 24, 2019, 08:40:59 PM
I sealed up a few holes and put some dynamat on the transmission hump and firewall to help with heat and noise then primed it. I decided to paint the instrument panel.  The transmission filler tube will be framed with a big rubber grommet and metal plate. The speedometer head should be back together this weekend.  I also snapped engine bay pictures after I cleaned up the black parts. Enjoy.

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190123_164001_resized_zpsfjnfzctb.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190124_201856_resized_zpsqglkybl2.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190123_191228_resized_1_zpsfmb5oaq5.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190124_201840_resized_zpscksvu03g.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190124_201831_resized_zpsr37zqacj.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on January 25, 2019, 08:20:22 PM
I fixed the speedometer and made a new plexiglass cover so I can see through it!  Made a new fuse panel holder and mount the new fuse panel. This will really make the wiring clean with my other new wires.  Also painted the firewall silver. Getting close to setting gauges and landing wires. Fun!

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190125_200743_resized_zpsrkiumvcg.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190125_200736_resized_zpsoxbu0nj8.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on January 26, 2019, 07:44:13 PM
Painted dash and while waiting for it to dry, I cut up a lower radiator hose and fit it in place. Installed the fan thernal switch and wired it in.  I'll start laying out the wire runs to get and idea as to what the harness will look like and where it will fit.  I also plugged some fire wall holes and sealed the front harness hole and the transmission filler tube. Used humvee harness plates and it worked really good. Enjoy.

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190126_110422_resized_zpsigltvcd1.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190126_095038_resized_zpsbzbs379z.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190126_110406_resized_zps9kvhtcny.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on January 27, 2019, 07:19:48 PM
Wrapped the fuse box wires and routed them down to tunnel. Then installed wiper motor wires, pencil light wires and broad light wires. Even though I'm not installing those lights, it'll still be ready for them in future. They ar e interlocked with high beam lighrs. And have overrides switches. Crazy wiring. Takes a lot of layout time to do this. Once a wire is cut, it's cut!  Installed temp sensor and gauge so the engine compart is really done!

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/IMG-20190127-WA0000_resized_zpsflyfxzeo.jpeg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: vangremlin on January 28, 2019, 12:20:43 PM
All those new wires are sure pretty but this has got to be a huge undertaking.  Good job!
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on January 31, 2019, 07:53:42 PM
True.  Lots of wires and a solid challenge.  So many splices!!! All being removed with minimal connections.

I forgot to check my propane level and my shop heat run out right before -17f weather. So no working on car until they fill the tank.  Bummer.  Car swap meet this weekend in Kalamazoo.  Might find some goodies.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on February 03, 2019, 07:21:35 PM
Got heat back on and now it's 45f! Outside...

Wired in the steering column and left side.  Next up is gauges, then right side.   Then test  and hopefully clean up wires with plastic wrap. Check out horn wire splices!  I also installed speedometer with new Plexiglas and wires.  Need to route Speedo cable and backup light switch wires. They were melted from left exhaust lead pipe!

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190203_154100_resized_zpsdpaanwyo.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190203_154011_resized_zpsnivhobpn.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: mudkicker715 on February 03, 2019, 11:51:21 PM
That is a sea of wires, wow. I hope to never have to do that. Your doing awesome.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on February 04, 2019, 08:14:49 PM
Keeping track and labeling is my key to stay on track.  Thank you for the comp.

I made up the gauge harness, added a power plug to modernize it and mounted it in panel. Routed wires to center switch panel where it's an octopus now! I'll mount gauges tomorrow and start the switch panel.  Once wires are landed, I'll test out the electrical then place all runs in conduit.  Fun!

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190204_195341_resized_zpsmyvjumj2.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on February 05, 2019, 08:40:19 PM
Check out the old fuse panel. Lots of splices and the main feed was just twisted wire!!! Set gauges and wired them in. Placed a ground buss behind dash for a common ground. Prepped switch panel for new wires and new switches.

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190205_194308_resized_zps9gkiawsh.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190205_165159_resized_zps9815yssb.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190205_193645_resized_zpsrdmzf9kq.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on February 07, 2019, 09:10:32 PM
Landed some new switches with boots on the control panel and terminated wires for start, alternator, ignition, gauge lights, dome lights, parking lights and head light control.  Still have Hella pencils and broad lights. Both gave override switches too. I prepped for broad lights but am not mounting them because that's a lot of light!  This car had head lights: low and high beam, pencil lights and broad lights. All capable of being on at the same time. Crazy bright.

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190207_205430_resized_zpsjcixdfvo.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on February 08, 2019, 08:31:51 PM
Wired in the pencil and broad light switches with low beam override switches.  Just a few more wires to land and it'll be ready for testing! Then if all goes good, I can clean up the wires and place into conduits.  The wiper harness is a pain. I may extend  them and place box in a better spot.

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190208_201039_resized_zpsip20sloy.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on February 09, 2019, 06:46:59 PM
Landed all the wires and tested the electrical. Seems all to be operational!  Installed the HEI distributor with new plug wires. Now I have to clean up and slide the wires into the conduits.  Getting close!

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190209_165800_resized_zpsm9p8hbpb.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on February 10, 2019, 04:39:24 PM
First thing was to clean the shop floor and pick up about 10 pounds of scap wire. Now I can wall around the car without tripping.  Started the conduit runs and mounted the Eagles on the B pillar.  Decided to clean and gap plugs and set HEI to TDC to #1.  Topped of the oil and added antifreeze.  Cranked the engine to circulate oil and to make sure it would! Fun!

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190210_161341_resized_zpsttey2t7r.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190210_161353_resized_zpsycibdytq.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190210_161447_resized_zpssfbusbss.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190210_161406_resized_zps1bq8uw6c.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on February 11, 2019, 08:55:49 PM
I got most of the conduit in. Just need to to tiddy it up a bit. The gauge light power lead for oil popped off so that will be fun getting it fixed.  Got the switch panel done done and bolted it down. I like the patina on that so I chose to not paint it.  I have to fuel it and check for leaks. To do that I want it outside.  To put it outside, it has to warm up. So it will be awhile before I fire it .

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190211_203821_resized_zpsel2bmzwd.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190211_203731_resized_zpsknogfpkb.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190211_203636_resized_zpsmhetxxpk.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on February 21, 2019, 08:22:48 PM
Been traveling and it's been cruddy weather. So not much more done. I did install the speedo cable and installed a rear view mirror.  Maybe this weekend I can bleed the brakes and put gas in it. Getting close!
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on February 23, 2019, 05:21:48 PM
Fueled it up, charged the fuel system and vroom, she started! Timed the engine and topoed off liquids. Bled the brakes, still a little mushy but they work. Might be mc. Set the hood too.  What a great rally car and fun project.  Next up is a paint touch up.


(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190223_135225_resized_zpskclticvz.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190223_135249_resized_zpsgqz4nx7y.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190223_142258_resized_zpsvccgrgk2.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190223_142708_resized_zpsnhq1tjs3.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190223_144028_resized_zps2n91ugfr.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: rollguy on March 03, 2019, 02:50:09 PM
I just read through this thread, and I am impressed!  I have not been on here in a while, as I have not had an Eagle for years. It is still fun to see what the Eagle community has done in my absence. I like seeing this type of build. I have done many of the things you have done on your car, and enjoy seeing others have as much fun as I have doing this kind of work. Keep up the good work!!!!
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on March 03, 2019, 09:36:14 PM
Thanks for your post and the compliments.  Glad you read my project. It is surprisingly quiet on this site compared to other sites I belong to, non AMC.  The stored knowledge here is priceless. Something other social media sites have not replicated.  I really like working on this challenging rally car project.  I built/restored several dozen vehicles and this one ranks high on my list.  Im trying to find people that know more about its history but not much success yet.  It's been cold in MI again so the car is waiting for exhaust work and then paint once 5he weather breaks.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: Blip Downshift on March 04, 2019, 09:49:47 AM
Great job on the resto.  Your project has inspired some of the modifications I am now implementing on my eagle.  I am trying to install rear disk brakes using the system on your eagle as a template.  Which brings me to my question.  I know you didn't design the original build, but do you know what rear axle hub they used or is it the original turned down so the front brake rotor will fit over it?
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on March 05, 2019, 06:21:36 AM
I dont know the hub number or what it is from.  It does not appear to be turned down either.  So the question is what AMC vehicle had rear disc brakes on a Dana 35 with C clips shafts?  I'm sure someone one here will know the answer and will hopefully post the answer.

Thank on the comp. Still waiting for this cold weather to end.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: Blip Downshift on March 05, 2019, 07:20:03 AM
I didn't know your dana 35 had c-clip shafts.  I thought all eagles were the bolt in style.  I know later jeeps with dana 35s and c-clips came with disk brakes but that wasn't until the late 90s and this doesn't look like one of those. Agreed on the cold weather, I'm also a Michigander and I like winter but I've had enough.  9 degrees this morning.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on March 05, 2019, 01:57:49 PM
They do but I did not post that info.  When I can, I'll take off rear tires and thoroughly search for a hub number.  I have know idea when the rear axle was installed. Could be from day 1 or ? Interesting though.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on March 09, 2019, 06:32:41 PM
Took car out for a run on the property.  Still frozen out yet she ripped through the limestone for about 300 feet with all 4 tires and some air at the hump.  Crazy fast car.  Did a doughnut too.

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/IMG-20190309-WA0000_resized_zpsp7kwgixf.jpeg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: eaglefreek on March 12, 2019, 08:54:16 PM
Thanks for your post and the compliments.  Glad you read my project. It is surprisingly quiet on this site compared to other sites I belong to, non AMC.  The stored knowledge here is priceless. Something other social media sites have not replicated.  I really like working on this challenging rally car project.  I built/restored several dozen vehicles and this one ranks high on my list.  Im trying to find people that know more about its history but not much success yet.  It's been cold in MI again so the car is waiting for exhaust work and then paint once 5he weather breaks.

This site used to be very active, but the Facebook page killed this site.

C clip Dana 35's showed up in the early 90's on Cherokee and with disc brakes on the Grand Cherokee in '96, if I recall.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on March 17, 2019, 12:38:45 PM
The rear axle hubs are stamped on the backside:
LR=  32361
RR=  23513

Perhaps this means something to someone.  They appear to NOT be machined down hubs.

I've started working on the car again,,,above freezing!

Looking for an extra matching rim and used tire. This car use to have 2 spares, but only has one now.  Mounted grab handles on ROPS and 2 water bottle holders.  Getting comfier inside.  Lol.  Mounted RR mud flap and reinforced the cracks with flex tape and 3m black adhesive. Good as new'ish.  Pictures later.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: rmick on March 17, 2019, 02:31:01 PM
I have an extra rim no center cap.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on March 17, 2019, 05:33:24 PM
Don't need a center cap.  Same type as shown in my thread?  Pm the price please.

Here some pictures of some work I've done.  Like the purple mudflap lettering!?

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190317_143043_resized_zpss1ksm1oc.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190317_124012_resized_zpselts3atj.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190317_124025_resized_zpsbul2xwsu.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190317_143015_resized_zpspen1ljnq.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190317_124051_resized_zpspouslgiz.jpg)

Might need to source this MC. 

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190317_112025_resized_zps2e1mwmsh.jpg)

Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: amarshall on March 18, 2019, 10:54:04 AM
Fairly certain the master cylinder is a GM unit.  I had a 1981 Buick Regal, it looked identical with the huge cover.

I may still have a couple "Eagle" flaps on my pile, if you want to match the fronts.  PM me if interested.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on March 20, 2019, 02:24:05 PM
Thanks for the information.  I will search.  I bled more air out of the brakes and that helped but the cylinder seems weak.

Here is a picture of this car posted by a "Mad Mike" on specialstage site.  It may be at the 1983 100 Acre Wood.  The right rear panel still has the crease.  I like the history of this car!  The stance is awesome and once again it has that stance.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: Ace2600 on March 20, 2019, 11:07:18 PM
Luckyyyyy, you have a V8 in there. I have dreams about that. But the sheer fab work and such is beyond my skill range. Really hope I get the chance to check it out this summer.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on March 23, 2019, 02:36:15 PM
No doubt. It's a machine.  I drove it this morning while the road were still frozen to avoid the mud and she screams.  3000 rpm at 50 mph if I believe the speedo.  Taller tires might now be in my future.  From 0-35, it rides up the road.  Still have fix exhaust and touch up the paint....the disco colors are, well, noxious.   
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on March 25, 2019, 09:03:01 PM
Brought car into exhaust shop. Here is before pictures less mufflers.  Dual going in with up and over then out the back.   More pix when done. 

Photo bucket not working.

Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on March 26, 2019, 07:06:43 PM
Fast working custom exhaust guys!  Better than before and a more manageable sound. Thrush turbo mufflers.

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190325_170728_resized_1_zpshgpw3vxp.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190325_170739_resized_1_zpszse87zpy.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190326_131517_resized_zpstvs4qkva.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190326_131502_resized_zpsbnfwwslo.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190326_131644_resized_zpsmqpfs8dq.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: amarshall on March 26, 2019, 08:09:19 PM
Looks great!  Random question - have you replaced the strut rod bushings yet?  They look like rubber.  For what it's worth, I put in a new rubber set and they lasted about 500 miles of dirt roads before they exploded.  I'm now running poly bushings from Prothane, much more durable.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on March 26, 2019, 08:55:25 PM
Good eye. They are rubber and I have not replaced them yet.  They are currently in good condition but when they fail, they will be poly.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on March 29, 2019, 08:52:46 PM
I replicated the rubber deflector that protects the left rear shock from rocks and then I installed anothger up by the fuel tank sender and lines.

I am now starting the sanding.  Say good bye to baby blue and purple.  It will be sprayed silver as original.   I'll have to find the paint code for AMC .

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190329_202204_resized_zpsnrtsqyjy.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190329_202237_resized_zpsu8abwegt.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190329_201601_resized_zpsrypjavxd.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190329_201400_resized_zpsaloposcq.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190329_201541_resized_zpsdod6heku.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: Draekon on March 30, 2019, 08:55:55 AM
I'll have to find the paint code for AMC .

The Eaglepedia has paint code charts:
http://amceaglesden.com/guide/1982_thru_1984_Exterior_-_Interior_Colors
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on March 30, 2019, 11:47:46 AM
Awesome! Of course this site has everything AMC Eagle! Thank you Draekon for the link.

It appears that it is Mist Silver Poly 3466.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on March 31, 2019, 03:57:08 PM
Reworked the hood. The infrastructure was removed to lighten the hood for racing.  It was all bent and twisted. I've done a bit of metal work before and I got it back into shape.  Still flimsy but now it seats properly. I installed a hood stop for front end accidents. I also prepped the tub for painting. I had to remove the old stickers that were illegible. I ordered new stickers.  I really like the stance of this car!  I posted for info on specialstrage.com for this car since it was talked about a few years ago. That site is really dead now!  Strange that these sites and others are dying.

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190331_121733_resized_1_zpsmodytn2e.jpg)

(http://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190331_125129_resized_1_zps15z3xysf.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: Blip Downshift on April 01, 2019, 08:03:10 AM
Looks good as usual. specialstage.com is likely defunct.  The only rally forum I know of that is still partly active is rallyanarchy.com.  Although most have abandoned that site as well thanks to a handful of trollish and dismissive users (if you've been on there, you can probably guess the people I'm referring to).  That is why I like the AMC forums, people here are positive and helpful.  Some of the facebook pages have taken over for some forums, may have luck there.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on April 02, 2019, 11:13:12 AM
Thanks. Car goes in Thursday for an exterior paint job.  I'll finish sanding it prior to save money with my painter so that all they will have to do is tape and paint.  It will not be show car paint job, just a good durable one for the trails.  All new and original stickers but the 99 on the door are gone.  Sad to do it but the original ones were mostly illegible heavily cracked.  If the car was still one color, I might not have painted it, but since PO hand sanded large areas, it was too far gone for me.  She will look like she did, silver and black.
Correct jebidia24, the rally sites are dead or almost dead.  This site seems to hang in there though with good people and priceless knowledge.  I was reaching out to the rally sites for information on this car and or to find someone that race in or against it.  The original 1982-85'ish owner/racer passed a few years ago so that was a missed opportunity by previous owners to get first hand knowledge of this car.  It has been talked about for many years up to 2016, and that is when most forums began their decline.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: Ace2600 on April 02, 2019, 12:46:33 PM
Ive been talking to my local exhaust shop, and they seem to thing the downpipes off of the exhaust flange is going to be difficult? What did your shop say?
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on April 02, 2019, 01:38:45 PM
For my 390V8, they just disconnected the old pipes from manifolds and with their bender made new one piece lead pipes to each muffler.  Drivers side routing was a bear for there was no easy path for dual exhaust.  The sort of followed the original but I think they improved the routing a bit.  From the mufflers back, they did a up and over bend with good clearance for the axle and fuel tank. The guy that did mine was in his 60's with lots of real world experience (hot rods, race cars, etc).  I have since paint the pipes black so they blend in better.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: Ace2600 on April 02, 2019, 01:43:09 PM
The guy at my muffler man tells me "I don't know if ill be able to make that pipe" Im really hoping he can. But I do like the sound of open headers  ;)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on April 02, 2019, 08:35:46 PM
Sanded the fender flares and as hot pink and purple appeared, my shop radio started playing a Donna Summer song really loud.  I think it was Hot Stuff!!!


(https://oi1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190402_201658_resized_zps2bfxoa9q.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on April 12, 2019, 07:09:58 PM
Last week the car went in for painting and I went out to Pinon, New Mexico to where the original owner use live and race. Fun trip and great rally roads in that area.  Unfortunately he lived there so long ago that the people I met at the town store did not remember him.  Bummer but still fun.  Lots of rocks, through the missile range and dried up river beds.  Might have bring the Eagle rally car out there!

(https://oi1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190404_083528_resized_zpslucokymc.jpg)

(https://oi1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190406_141935_resized_zpslocpgkun.jpg)

(https://oi1255.photobucket.com/albums/hh637/RallyEagle/20190406_123949_resized_zpsug6rmupf.jpg)

Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on April 18, 2019, 06:59:20 PM
Got the car home between showers. Will unload it this weekend.  The big stickers had to get removed. Unfortunately they were too far gone.  New ones are being made to replace them.   I'll start placing the others as well.  Then fill with fuel and head to the woods and sand of northern lower!

(https://oi1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190418_183714_resized_zpsifer3io0.jpg)

(https://oi1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190418_183739_resized_zpsqow0fq69.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: amarshall on April 19, 2019, 09:14:15 AM
Looking good!  Were they able to use the original silver paint code?  It almost looks matte, but that may be my imagination.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: Ace2600 on April 19, 2019, 09:55:39 AM
Gorgeous paint! Curious as to what the holes cut in the hood are for?
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: TheBirdman on April 19, 2019, 10:15:28 AM
Those are speed holes Ace, they add .5 horsepower each.

Love the car rally, you should put a video of it up on youtube, id love to hear that 390 roar from an eagle.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on April 19, 2019, 01:49:45 PM
Original paint code with urethane paint.  I did flatten it about 25% as to not be too shiny.  It is not a factory finish for there are dents, scrapes and weld mark on her.  Sort of battle scars and I though they should remain.  Plus I'll put more scapes on it...

I believe those holes in the hood were installed a very long time ago.  This engine ran hot according to po.  The real issue for that that I found was bad ignition timing, advanced too far, and crappy cooling setup.  That's all fix now and it runs around 180 now.  That cast block generates a lot of heat so the more venting the better climate inside the cab.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on April 21, 2019, 06:20:33 PM
Got to spend a short time today placing some stickers and the windshield trim.  Need the passenger side top of door trim piece. Need to find one and a mirror for the door.

(https://oi1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190421_153921_resized_zpszf0prhwa.jpg)

(https://oi1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190421_153948_resized_zpsbsh4avvp.jpg)

(https://oi1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190421_154009_resized_zpsuuhvkj6c.jpg)

(https://oi1255.photobucket.com/albums/hh637/RallyEagle/20190421_153931_resized_zpshivsly5h.jpg)

Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: Blip Downshift on April 22, 2019, 07:35:33 AM
Beautiful car, it came out great.  I've seen this thing float around on the internet for quite awhile but never had the funds to do anything about it.  I am happy that someone brought it back before it got destroyed. Good work and I look forward to hopefully seeing it in action.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on April 23, 2019, 08:11:08 PM
Thanks jebidia24.  It sure need saving. It was about burn itself to the ground from neglect.  A few more parts and off to the woods it'll go.

If anyone has a spare passenger door trim (top of door) and non remote passenger mirror,  please pm me.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on April 24, 2019, 08:01:05 PM
Placed a couple of stickers in engine compartment and set up the Hella pencil lights.  Then I installed rear hatch light switch.  The light was there but no power. I placed an LED bulb in it.
Just a few items to go!

(https://oi1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190424_194619_resized_zpsyes06vas.jpg)

(https://oi1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190424_194535_resized_zps5jgaohjm.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on April 27, 2019, 07:01:43 PM
Worked on trim and then painted the hood high-rise black.   Need to find the clips for securing the trim to the lower triangle window.  Weather still bites so no running tiday.

(https://oi1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190427_135914_resized_1_zpsqqku7sc1.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: mick on April 28, 2019, 12:12:23 PM
Digging! Totally digging it! You have taken some outstanding pictures. It was nice to see detailed front axle brackets. What's the chain for on the drivers side? I build my rear disc brakes the same way. Heavy tab welded to axle tube and use front components. 
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on April 28, 2019, 06:03:21 PM
Thanks.  There is a chain on each side of engine tying it to the "frame" and act as a safety strap  incase the motor mount(s) break during racing/jumping.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on May 13, 2019, 09:23:52 PM
I just picked up 5 - 7.5 x 15 jeep rims with 235/75R15.  Getting an extra lift. Same offset and center bore.  Goodyear wranglers with 3000 miles dated 2016.  I'll keep the AMC Rims but might sell off the BF Goodrich tires. Pictures to be posted once mounted.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on May 18, 2019, 08:36:05 PM
I've been traveling a bit but I finally got to put the 235/75r15 tires and rims on.  Noticeably different stance, look and speed.  The 4.10 axles still churn up the gravel with the 390 in front.  What a blast to drive.  Might change rear to a locker and then add a 242 tcase.  Time will tell.

(https://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190518_193301_resized_zpsn4uaqgys.jpg)

(https://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190518_194304_resized_zps6hcozafp.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on May 27, 2019, 07:17:56 PM
Since I have and early humvee  AMG 242 tcase which is 4wd only with Hi lock, High, Neutral and Low lock, I will install it in my SX4.  I split the case and removed innards. Will install new seals. Then I'll drop the AM119 and compare input shafts to see what I need to do.  The transmission is a 727 3 speed.  Novak adapter on order as well.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on June 04, 2019, 06:09:06 PM
Tore my NOS hmmwv NP242 transfer case down, replaced input drive gear and seal. Waiting on seal extender and speedometer drive gear. Then I'll set the tcase and connect the shift linkage to determine floor cutout location for shifter handle. Then I'm going to use a hmmwv rear drive propeller with slip yoke and have it fitted to length.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: amarshall on June 05, 2019, 11:36:20 PM
I’ll be interested in pictures of your shifter solution.  I hacked mine together and it works, but I need to come up with a cleaner solution for a boot.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on June 06, 2019, 09:23:05 PM
Sure, I'll post pictures once I get it fitted.  It seems the transmission shift linkage maybe in the way.  Should have progress on it next week.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: amarshall on June 07, 2019, 10:30:32 PM
If you are using the Novak shifter I posted about...I do recall that I had to modify the trans shift linkage to clear the Novak bracket.  Details are fuzzy, but I think I was able to flip the direction of the linkage 180 degrees and get it to clear.  I think the lock nut was the biggest hang up, I was able to flip that around.  It’s tight, but it works.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on June 08, 2019, 07:15:07 AM
Thanks for tip.  On this retrofit, it seems everything is fighting me! I have a 727a transmission so the seal extension requires a bushing to press into the housing correctly.  Then the Dana 35 yoke with 1330 I have has too small of a seal boss. I have to change that so that i can cut down my propeller.  Once the tcase is in I can then figure out the shifter. Fun stuff! Pictures when I'm getting close.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on June 09, 2019, 05:14:37 PM
Since its raining again, I spent time prefitting the shift adapter for the NP242 tcase and bending the shaft. Tight fit up there and the 727 linkage needed adjusting as well.  Once the tcase is installed, I hope I can get my hands in there to tighten the stuff up. Enjoy the pictures.

(https://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190609_163211_resized_zpsqhyu3ct0.jpg)

(https://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190609_163226_resized_zpse2j7risc.jpg)

(https://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190609_161540_resized_zpsjj75olgn.jpg)

(https://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190609_161520_resized_zpston52fgf.jpg)

(https://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190609_161633_resized_zpsqmc1c8jn.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: amarshall on June 09, 2019, 10:44:42 PM
Looking good!  You kept that slot really small, almost hard to believe that is enough to get the shifting done.  I cut a huge panel, maybe 8x8 and got it all tweaked by working from above.  It was still tight but at least it gave me another angle to get in there.  After everything was adjusted, I cut a slot in the panel and put it back in place with some bar stock as a flange.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on June 10, 2019, 06:58:36 AM
Thanks. It might require enlarging however the linkage is close to the cut out and as long as possible on the connecting link arm, so a smaller throw is needed. I measured as best I could without tcase in. The slot was made with a unibit and recip saw. It is going to be a challenge to tighten things in there.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on June 19, 2019, 06:52:27 AM
I finally had time and parts to install the NP242. The seal extension just barely reaches the input shaft. I had to have an aluminum bushing made for the extension to fit in to the 727a output seal location. I also had to grind off a tcase casting lug on the tcase so that it would clear the tunnel ceiling. This tcase is a bit smaller in size than the AM119.  A little more room to reach things.  The shifting adapter was a pain to connect and tighten.   The shifting throw is about right and I did not have to enlarge it.  I still need to fit rear propellor with yoke and connect front prop.  Pictures soon
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: amarshall on June 19, 2019, 01:29:39 PM
Amazing news, I had my fingers crossed for you.  I assume your custom bushing for the extension seal was due to using a 727a, or maybe because of the Hummer version of NP242?
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on June 19, 2019, 09:31:06 PM
Thanks. I need crossed fingers on this. It was close to not working. I'm a little concerned about the overlap of the output trans shaft and the tcase input shaft. It's about 1.75" but not anymore than that.  The shifter is a pia! No room to tightened the bolts without a lot of cuss words.  The 2 bolts that tighten the shifting lever are really bad. They should use nutserts or welded nuts.  Tonight I test fit the rear prop and I may have to lengthen it!  Typically on a slip yoke, you insert until bottom out and the pull it out about 1"-1.5".  I'm at 2.25" on a 5" slip yoke. My rear axle is at normal load height.  I'll install it and then test it. Fun and challenging to say the least.  Pictures as promised.


(https://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190618_200503_resized_zps1esnrqdi.jpg)

(https://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190618_200518_resized_zps8baothdc.jpg)

(https://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190618_200509_resized_zpsnbml0srj.jpg)

(https://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190618_220322_resized_zpsuzprcscf.jpg)

(https://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190618_220246_resized_zpspym74hnr.jpg)

(https://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190618_220331_resized_zpsuhdig7d7.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on June 19, 2019, 09:43:23 PM
Regarding the seal extension, it was because I could not find a longer input shaft.  The Dakota's are 5.75" ish long and these short ones are 4.25" long.   I would liked to gave found a 5" one but I don't think they exist.   So the seal had to get moved towards tcase like yours.  I'll find out about torque and shaft stripping soon!
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: amarshall on June 20, 2019, 09:21:55 AM
It was a lot easier for me to install the shifter because I cut an access panel in the trans tunnel.  Still a pain, but a little easier with another approach angle.

I had the same concerns about the shaft engagement, but I have not had a problem.  Of course, I've still got the stock 258 with maybe 100 hp these days.  Also, the extension seal was made by Teraflex - who offered it as an adaptor for their 231Low transfer cases.  These were 4:1 ratio modified NP231 transfer cases used in rock crawler Jeeps, but they only made one version with a short input shaft.  The extension seal was used with Jeep automatics, and it would be the same situation as ours - so you'd think that less engagement of the shaft would be OK.

Great stuff!
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on June 20, 2019, 09:43:25 PM
Yes, I used the teraflex but added the bushing for fitment into the 727a.  I'll find out soon!  My concern now is the the rear drive shaft may need lengthening. Anyway, I splurged and bought the sx4 stickers and put them on.  A trip is planned to western CO this summer so I have to test drive before then in northern MI.

(https://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190620_212405_resized_zpslsrisocx.jpg)

(https://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190620_212349_resized_zpsbpgozmhw.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on June 27, 2019, 08:13:58 PM
While the rear drive shaft is getting lengthened, I installed the humvee tcase shifter plate and made a rubber boot for the shifter.  Then installed dynomat in the driver compartment and painted it. The left exhaust lead pipe runs right under the drivers feet!

(https://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190626_195449_resized_1_zps3y8pr4u8.jpg)

(https://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190627_200027_resized_zpszmbh0sjk.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: amarshall on June 27, 2019, 10:12:46 PM
Looking clean, I’m jealous.  What’s going on with your gas pedal?  Looks like there is a 1/2” thick block bolted to it?
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on June 28, 2019, 07:04:34 AM
Thanks, it helps to have AMG stuff that works for AMC cars.

The pedal had 2 holes in it for a spacer block from way before. The seats are fixed position and setup for a tall person. So I put the oak block back in for better throttle response since I'm shorter than the guy that installed the seats!  The dash is a reach especially when strapped in with 5pt harness.  I have a whoopi cushion and back pad help also. These race seats are hard.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on July 01, 2019, 08:07:31 PM
Rear prop is in and test drive was awesome. 4 low lock is a creeper.   After I do final adjustments on linkage, I'll put the tcase shield back on and go tear up my back 40. Build is done. Eagle enjoyment time begins.

(https://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190701_194814_resized_zpsbda3nhzp.jpg)

(https://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190701_194851_resized_zps5ofvs8fc.jpg)

Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: amarshall on July 02, 2019, 01:53:22 PM
Congratulations!  Yes, 4 low on mine totally transformed the behavior.  I love that shot from underneath!
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on July 23, 2019, 08:26:18 AM
It is a cool picture (need to put skid plate on though), the cleanest it will ever be.  I put a few miles on this beast and the AMG NP242 is a very good choice as compared to the AM119 I removed.  With the 4:10 diffs, it goes from 0-50 like a rocket and by the time I hit 55 mph, the 390 engine is over 3,000 rpm.  Definitely a trail vehicle.  1st gear Low Lock is crazy slow, like my old M38A1 was.  The first part of August it will be in western Colorado (Ouray) riding along with modern Jeeps.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: amarshall on July 23, 2019, 12:59:30 PM
You will have fun in that part of Colorado, and no problem keeping up with the Jeeps.  Get ready for a lot of attention!  I went through that area last year in my wagon, across a bunch of the passes.  People couldn’t quite believe their eyes seeing an Eagle at 12000 feet up on a rocky pass.  The low gear in the transfer case makes these things act like mountain goats!  First gear low is perfect for coasting down steep grades, saves your brakes.  I have 3.07’s and a tired old 4.2L six, I can’t imagine the power with 4.10’s and a 390!
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on July 23, 2019, 02:46:55 PM
Yes, but I am concerned about the transmission and engine.  They are the only things I did not "go through" mechanically.  I did install a driver seat slider for the race seats it came with, I am closer but not as close as I want to be.  I would have to cut the base frame welded in and re-position it for better fitment.  But I probably leave it alone.

I will put a for sale sign on it there for fun!
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on July 29, 2019, 09:08:32 PM
Finally got time to change out the 500 cfm AFB carb to a 625 cfm AFB.  The 390 is supposed to have the 625 so its perplexing as to why the 500 was installed. It had big jets too.  It was burning very rich according to the smell and plug color.  So now I'll check the plugs after a drive and adjust from there, keeping in mind that itll be at 10,000' for a week.  I have extra jets and needles to adjust further.

I put two spare tires in it since it was setup for that.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on September 08, 2019, 06:30:11 PM
Been away for awhile.  After a nice drive there and back, the eagle ran hot and rich.  After a day, we parked it and I rode with friends.  It vapor locked once so i didn't want to wrench on the trails.  Had fun none the less.

I had to remachine the seal extender due to a leak that developed internally.  I added .75" to the adapter to reach the input tcase shaft and to seat firmly in the transmission housing.  Since I didn't find anything in a727 to 242 tcase adaption, here is what I had to do.  The o.d. of extension is 2.6850" which allows it to firmly seat in housing.  Total length is 1.823".  I inserted the adapter .6250" from face of tcase/a727  mating faces.  Always fun dropping down a new tcase,,,goes faster!


(https://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190908_123945_resized_zpsjhyrpm97.jpg)

(https://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190908_123911_resized_zpskddte4ys.jpg)

(https://i1255.photobucket.com/albums/hh637/RallyEagle/Mobile%20Uploads/20190908_125545_resized_zpsbdrtw2gr.jpg)
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: mick on October 30, 2019, 10:03:14 AM
It's way cool seeing the efforts you have put forward. Where you in Colo for FSJ Invasion?
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on November 24, 2019, 08:45:34 AM
I was not. I did see a few good looking FSJ's and a Commando.  I had a 68 v6 Jeepster Commando and a 78 Cherokee Levi back in the 70's and 80's.

Anyway, a few friends got together for a ride along, former H1 and HMMWV guys and gal that now drive Wranglers.  We will be back there next summer but the Rally Eagle will stay back in Michigan.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: TEagle85 on August 24, 2020, 08:34:46 PM
Hope you are still on here. Was wondering what coilovers we’re used on your set up? I see you listed some info on the shocks, hoping you could give me some more info on the coils. I’m going to do the same set up as this rally set up. Was going to just run one nice pair of coil overs but after revisiting your posts I like this set up better .
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on August 27, 2020, 07:42:32 PM
I'm still on here from time to time. Seems the forum has picked steam and energy! Good to see.

I could not find the make/model number of these coil overs.  The middle is a dampner, not a shock.  I forgot the range but it was hard to match and expensive. So I just rebuilt these with new springs and internal dampner parts I had to have machined.

The front suspension is awesome on this car!
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: kcinenoel on December 20, 2020, 02:13:18 PM
Hi all,
My partner and I were the 3rd or4th owners of the SX4.  We found it in a chicken coop in MO.
The "coil over" is a 3rd spring used on circle track modified no longer available from what I can tell.
The hubs were turned down to fit the front Eagle rotors.  A front Eagle caliper was used with 2 inner pads to try to compensate for the large rotor.
The radiator was from a Cherokee V8.  The compression ratio of the motor was reported to be 11 to 1.
I had the trans rebuilt with a different valve body and it will go into1st gear at any speed.  Be careful.
The wiring: it worked and we left it alone.
Vapor lock. Well not unusual, our 401 V8 Gremlin rally car had the same problem.  Look at the fuel line from the tank near the exhaust and on the firewall near the exhaust manifold.
Axle ratios were special,  Dean had an AMC connection and I believe those were provided by AMC.  I don't believe there are any 4:11 gears available.
My partner and I didn't have a lot of money to update the car most parts were used from the pullapart yard.
Expenses to rally could run $2000 for an event.
WE live in Colorado and ran the car in Westcliff Colorado, Grove OK, and Prescott AZ for about 3 or 4 years.

Nick Leone
720-289-2813
Westminster CO.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on December 22, 2020, 06:42:28 PM
Hi Nick,
Thanks for the info. Good to keep lineage on this car.  I got it from Bruce in OH.
Ted
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: kcinenoel on January 07, 2021, 06:52:22 PM
New from speedway https://tinyurl.com/y6khzy6w
similar to the unit I  used in front suspension.

Nick
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on January 07, 2021, 08:02:35 PM
Very similar and affordable.  The lower eyelets were broken at the heim joint.  Replaced with  beefier ones.
Title: Re: RallyEagle's 82 SX4 Rally car rebuild
Post by: RallyEagle on December 05, 2021, 08:40:28 AM
Update:  the Rally Eagle has been sold!  Enjoy the car Bruce!  It's ready to rumble!