How to Build a Baja Car Guide for Dummies-2008v1

16 How to Build a Baja Car Guide for Dummies First Produced in 2007 Revised by the Bush Baja Committee in 2008 Contents D) Before we begin, please remember that this document has been set up as a guide only and to consult the Bush Baja Specifications for anything that may have missed before submitting your vehicle for scrutineering. Beginners 6.4. E) F) unnecessary. Harness Seat Belts - To make you safer, mount the harnesses to the original seatbelt mounts, roll cage or floor pan according to CAMS schedule I (www.CAMSmanual.com.au/pdf/ general/0610_Schedule_I_Q208.pdf). Remember to plate both sides of the mounts if you mount them from the floor pan. The harness mounting bolt should not under any circumstances be used to affix a safety cage to the body shell. Specifications - 6.3- The beginner section is for all you rovers who would like to enter a car into Bush Baja but have absolutely no idea where to start, what to do or even what the hell an engine is. This is a step by step guide to how to transform an ordinary road vehicle into your basic Baja car to meet Baja specifications. Intermediate G) After completing the minimum steps to make your Baja car meet Baja specifications, for the brave there's the intermediate section where we will go through some ideas and modifications that you can do to your Baja car to make it something a little more special. H) By removing all Advanced Increase Suspension - Larger springs and shocks give better handling and more clearance off road. Engine Modifications - Any engine modifications are allowed. You can either modify the existing engine with a turbo or other performance mods, or you can completely swap the engine for a larger one. Please refer to Specifications - Section 11 for limitations. Lock Differential - By locking the differential or diff with either an ‘off the shelf’ mini spool locker or by welding the spider gears in the diff, you can get more traction on the slippery Bush Baja tracks. Roll Cage - To increase your safety in the car it is a good idea to mount a roll cage in the car. It also gives you good mounting points for items such as harnesses and fire extinguishers. Ensure the roll cage complies with CAMS schedule J and is properly constructed (www.CAMSmanual.com.au/pdf/ general /0611_Schedule_J_Q208.pdf). How to Build a Baja Car Guide for Dummies And for those of you who are after a challenge there's the advanced section, which will outline some modifications that will turn your Baja car into a real competitive mean machine. 2 How to Build a Baja Car Guide for Dummies Specifications - Section 4. 15 Advanced CAMS stands for the Confederation of Australian Motor Sport. This is the body that our Rover Scout Motorsport runs through and provides the assistance, guidance and insurance that allows us to run Bush Baja. It has been the custodian of motorsport in Australia since 1953. The only major changes from running through CAMS compared to the old days, is that we have to adhere to the CAMS constitution and the CAMS vehicle specifications as well as the Bush Baja Specifications (but don't worry because the Bush Baja specifications are based on and are in accordance to CAMS specifications), and the only other major difference is that in order to participate and be a driver or passenger we are each required to obtain a special CAMS drivers license. So if you would like to drive or be a passenger at Bush Baja, you will need to fill out a CAMS license form and send it off to CAMS to organize a license for you. For more information on CAMS visit their website at www.cams.com.au. So just what is CAMS? How to Build a Baja Car Guide for Dummies 14 How to Build a Baja Car Guide for Dummies So for the extremely competitive you can take your Bush Baja car to an even higher level. Your only limited to your imagination (and mechanical prowess). As long as you abide by the specifications you can do what ever you like to turn your vehicle into a real mean machine. Here are just a few things we recommend. A) Replace Battery - Replacing your original battery with a larger battery could save you if you have an electrical problem in a stage. It also makes starting the car a lot easier. B) Move Battery - By moving your battery into the back of the car, you can protect it in the case of hitting a tree. It also puts more weight in your back end, but remember, you have to run all the wires to it for power. If the battery is placed in the passenger compartment, it should be fully enclosed in a battery box, a breather fitted which expels the gases to the exterior of the vehicle and have two mounting brackets (one on the battery itself and one on the enclosure lid). If battery is located in an enclosed area (e.g. boot) the enclosure should have a vent to expel the gases to the outside of your vehicle. Specifications - 15.2-15.3 &15.8. C) Remove all extra Weight - By removing all unnecessary components of your vehicle you will create a lighter more agile vehicle. It is up to you to consult the specifications and then decide what is 3 What are Specifications? E) always goes faster! (I never got that, doesn't red mean stop?? Maybe green is a better option!?!) Rally Tyres - You can also think about getting some rally types, these would give you better grip in mud and on loose ground. These tires must not be marker “Not for Road Use” or “For Racing Purposes Only” are prohibited. Specifications - 14.8. F) Vehicle specifications are a list of important components that your Bush Baja car must adhere to in order for you to enter it in and compete in any Rover Scout Motorsport event, including Bush Baja. You can find these vehicle specifications on the Rover Scout Motorsport website: www.rsm.warovers.com.au Scrutineering G) How to Build a Baja Car Guide for Dummies 4 How to Build a Baja Car Guide for Dummies H) Service Engine – It also a good idea for you to go over the vehicle and give it a good service, changing the oil, water, radiator and putting in new spark plugs, the way we thrash around in our Bush Baja cars this could save a lot time fixing things later! Protect Radiator - You also might want to place some sort of mesh in front of the radiator to protect it from incoming sticks and rocks, but be sure not to block the air flow as you could end up cooking your engine. Secondary Fire Extinguisher - A backup fire extinguisher is always handy in case you have to use your first one. If the first one is used, you don't want to have to sit on the side lines and watch because you don't have a spare Fire Extinguisher. Specifications - 18.4. 13 Scrutineering is where a team of scrutineers will inspect your vehicle in order to see if it adheres to and meets Bush Baja vehicle specifications. If your vehicle meets all requirements you will receive a scrutineering pass to place on your vehicle so that you are able to enter events at Bush Baja, if you don’t pass don't worry you will receive a check list (vehicle scrutineering form) of the things you've done right and the things that need to be done or fixed, so that you are able to have your vehicle in ship shape condition for the event weekend. You can find the vehicle scrutineering form which is the list of components that the scrutineers use to inspect your vehicle at the end section of the scrutineering regulations. It is a good idea to use this list as a guide to see if your vehicle will pass scrutineering. Dates of these scrutineering inspections will be posted closer to the event. Specifications - 1.5. Intermediate Steps for Beginners 1. Get a Car! A) Some possible places you can find a car are: The Quokka Newspapers Family Friends Scout Groups Old Rover Crews Its completely up to you how much you spend on a car, but keep in mind that you will have to spend some money on it after the initial purchase, in order for it to meet Bush Baja specifications. B) What to look for in a car: You can make any car work but these are just some things to take into account when choosing a car that can make your job a lot easier. • • • • trucks or convertibles. Specifications - 1.3-1.4 & 2.8. Smaller cars are better for the type of events we compete in. Front or rear wheel drive, doesn’t matter. Cars with smaller turning circles are better, some front wheel drives have large turning circles so be wary of this. No 4WDs, buses, • • Auto or Manual, it doesn’t matter. Minimal rust (especially in doors pillars or roof, as this weakens the structure of the car and could mean you may not pass scrutineering inspections). • • How to Build a Baja Car Guide for Dummies So now you should have completed the basics (well enough for you to enter into Bush Baja), we have a few recommendations that you can do to your vehicle that would competitively take it to the next level. A) Bash Plate/ Sump Guard – For the kind of terrain we compete on at Bush Baja, it’s a very good idea to put a large enough metal plate underneath your vehicle to cover the delicate bits. It helps protect some very important parts of the car, that if damaged could mean the end of your racing career, and also helps you not get stuck on those pesky large rocks, rather gracefully sliding over them instead. You should place a metal bash plate mainly under the front of the vehicle, ensuring you at least cover the oil sump. Specifications - 2.20. B) Spot Lights – Placing spot lights on your vehicle could also come in handy during those twists and turns on the night events. We also recommend having a reverse spot light too. C) Strip Interior - Its also a good idea to strip the interior such as all the carpet and door trim (except front passenger compartments) etc, as it removes extra weight and you do not want all the carpet of you vehicle to get wet and muddy as this not only makes the car heavier but eventually rots! D) Paint Job – Well this ones pretty self explanatory, A paint nice paint job goes along way, you could even go with a theme, remember red No holes in floor. Preferably all components in working condition, so less to fix which means less work for you! 12 How to Build a Baja Car Guide for Dummies 5 2. Getting your car into Shape! one is used. Specifications - 2.15 & 18.1-18.4. R) Fuel - Only standard grade fuel formulas that you can buy from normal retail petrol outlets may be used to fuel your vehicle. Specifications - 13.1. S) Tires - All tires should contain only compressed air (standard in most tires), larger than 10 inch diameter and no tires are to be fitted with studs or chains. Specifications - 14.3, 14.5 & 14.7. Now hopefully you should have something that resembles a Baja Car! Now that you have chosen your vehicle, you need to modify it in order to meet Bush Baja Specifications. Below we have outlined the things you need to do to your vehicle so that it meets Baja specifications. We have also highlighted the appropriate area you can find these in the Bush Baja specifications and recommend that you read these before making these modifications: A) First Aid Kit - You need to fasten a first aid kit to the car that is easily accessible a glove box is a good place for this. Specifications - 1.12. B) Sharp components - You need to remove any sharp components on the body of the vehicle, window edges, remove aerials, rust holes and from body damage. Also placing them remove any on the you will need to somewhere sharp points vehicle. from the interior, such as door interiors, dash boards, gear shifters etc. You must retain the front door trims. Specifications - 2.3-2.4 & 2.22. C) Doors - Doors must be openable from inside and outside the vehicle (at least 15m prior to the outside the vehicle. Specifications - 2.11. D) Rust holes - Patch up all holes. This can be done with tin and pop rivets, then use silicone to seal it. For larger holes weld in new panels. Specifications - 2.17. E) Seal compartments - All holes between the engine bay and passenger compartment and the floor and 900gm tagged and fire extinguisher passenger compartment tested be sealed. This is to must protect passengers from an engine fire and hot fluids. This also needs to be done to the fuel tank to seal it from the passenger compartment. The best way to do this is to bolt metal onto the holes or use a sealant. How to Build a Baja Car Guide for Dummies F) Tow Points - You need to have two tow points on the 6 How to Build a Baja Car Guide for Dummies 11 Specifications - 2.12-2.13 & 13.4. Specifications - 13.5. vehicle, front and rear. If your vehicle already has a tow bar on the back, remove the ball and leave the tow bar. For a front tow point you can mount a bit of chain between the factory tow points. Feed chain through tow loops on each side and bolt it to itself with at least 10mm high tensile bolts on each side. The chain has to be tied up so that it doesn't drag. All tow points need to be painted yellow or red for identification. Specifications - Section 3. G) Seats - Seats need to be securely fastened. Seats also have to have a head rest. Seat belts need to be a lap sash belt or harness. There must be seats for a minimum and maximum of 2 crew members. O) Painting - You will need to choose an identification number and paint this onto the side of the vehicle, this number needs to be round about 450mm width by 230mm high. See Figure K-1 from the CAMS manual of motor sport below. You will also need to mark the battery is located by painting a blue triangle on the outside of the vehicle where the battery is located, the triangle needs to have 150mm sides. All vehicles also need to have some sort of scouting promotional advertising on the outside of the vehicle. This can be done by to remove any sharp You need painting the scout symbol on oron the body large scouting logo stickers components purchasing of the vehicle, window edges, (which can be bought from the scout shop) and placing need to somewhere sharp the vehicle. you will them remove any on points from the Specifications - 1.8, 5.1-5.2 & 6.1-6.2. Specifications - Section 8. How to Build a Baja Car Guide for Dummies Q) Fire Extinguisher compartment and mount floorfull and passenger - You will need to the one and 900gm tagged and tested be sealed. This is to fire extinguisher passenger compartment must somewhere in the passenger compartment that is easily accessible to both the passenger and the driver. It will need to attached by bolts. No self tapping screws should be used anywhere in the passenger compartment. Bringing a spare fire extinguisher as above is also useful in case the first You need to have two tow points on the 10 How to Build a Baja Car Guide for Dummies H) Windows - For Bush Baja 2008 have the choice of removing all the glass in your vehicle or keeping all of it. For future events, all new entrants will have to keep all glass in their vehicles. (Note: smashing the windows out, although fun, creates more work!) To take the door windows out all you need to do is undo the screws on the winder mechanism, which is found under the interior trim and remove the glass through the door. To remove the windscreen and other windows you will need a knife to cut around the rubber seal, then feed a piece of wire behind the glass into the passenger compartment and pull the wire around the glass to cut the seal, then pull out window. If you remove the windscreen and the front passenger compartment windows you will have to replace them with weld steel mesh in place of the windscreen and netting in place of the side windows. Specifications - 7.1-7.6. 7 P) Reflective Triangle - You will need to also carry within the vehicle a reflective triangle, so that if your vehicle breaks down at night you can inside it Doors must be openable from place and outside the vehicle (at least 15m prior to the vehicle) so that other vehicles are aware you are there. You can get these from super cheap seal it. For tin and pop rivets, then use silicone to autos for not much. This needs to be stored within the car and be easily accessible. Specifications - 16.5. I) Handles - You will need to have a front passenger door grab handle. This can be on the inside of the door. Specifications - 7.7. unless you have ripped out all the wires (not recommended). You will also need to cover the positive terminal of the battery to prevent short circuiting. Most cars come with a rubber cover over the positive terminal. These can be picked up cheap from Auto Stores. Specifications - 15.4-15.6, 15.7 & J) Steering and Suspension - You will need to disable the steering lock. You will need to remove the trim from behind the steering wheel, there will be a collar around the ignition terminal you will need to remove this. Note: leave the key hole so you are able to still start the vehicle. Specifications - 9.2-9.4. 15.9. M) Lights - All the standard lights on the vehicle need to be in working order. An orange light needs to be fitted to the top of the vehicle, so that you are visible at night. Orange trailer lights are good for this, screw it onto the outside of the roof and wire directly to the positive terminal of the battery with fuse and switch. Wire according to manufacturer specifications of trailer light. K) Tail Shaft Loop - For rear wheel drive vehicles you will need to fit a tail shaft loop, this needs to be fitted just behind the front joint of the tail shaft. The easiest way to do this is to make it out of seat belt material or chain and bolt it to the floor. Note: when the rear suspension is fully extended, the tail shaft should not touch the loop. Specifications - Specifications - Section 16. N) Fuel Tank - If there is nothing between the fuel tank and the ground, you will need to mount a metal guard between it and the ground to protect it. How to Build a Baja Car Guide for Dummies L) Electrical - A kill switch needs to be fitted to disable the engine and any electrical fuel pumps. If your car has a mechanical fuel pump simply remove the ignition wire from the ignition coil, and wire the two kill switches in series so that if either one is switched off power is removed from the ignition coil. If your car has an electric fuel pump you will need to use dual pole switches using the second pole on each switch to kill the fuel pump or rewire the ignition barrel (the bit you stick the keys in). If you are unsure of how to wire a kill switch contact the Bush Baja committee who will help you out. All electrical wiring must have circuit protection (fuse or circuit breaker) between battery and any devices. Fortunately, most of this should be done for you 8 How to Build a Baja Car Guide for Dummies 9 11.10.