I had some time this evening to spend at the shop. I pulled everything out and performed a much needed sweep and mop. While the floor was drying I got the rally car up on a lift and started looking over it like a American Airlines MD-80. The Rally Neon also has cracks in the fuselage.

Here’s my preliminary to-do list. A little bit of welding, a bunch of new parts and replaced items, and some cosmetic items. I have a little less then 2 months to get the car buttoned up for the big trip to North Nevada and Idaho.

Underbody:
Front skis need to be re-enforced and tied to the frame.
New front skidplate made out of 6061 3/16″ Aluminum.
Side sill angle iron needs to be replaced and re-drilled.
Front tow hook re-attached.
Rear strut towers cracking on fold - need to weld.
Build gas tank molded skidplate.
Add bars that support the gas tank skidplate.

Suspension:
Replace ball joints.
Replace control arms.
Check wheel bearings.
Flatten front strut towers. (Starting to bubble. If that makes sense.)
Install new Billstein strut inserts.

Drivetrain:
Replace left axle and find a right axle for spare.
Send 3.94 transmission out to be rebuilt.

Safety:
Fire Extinguisher re-certify.
Tighten bracket or replace.
SFI padding check.
New headlights.

The following is included in Episode 4 of the Stage Notes Radio podcast. Please download and enjoy the entire show! I have posted a script of the segment for search and informational purposes.

On this segment of Rally Tech, I tackle the age old question that every aspiring rally driver has to decide:
Buy it or build it?
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