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Thread: Gonzo Racing 5/1600 Post Roll-Over Rebuild

  1. #1
    Senior Gonzo 5/1600's Avatar
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    Gonzo Racing 5/1600 Post Roll-Over Rebuild

    Hey everybody, if you're reading this you've probably seen the video of our little unplanned test of roof strength at the Baja 500...

    Since the race we've been hard at work tearing down, inspecting, repairing, and replacing parts to get the car back into shape. I'm only now getting around to posting up some of our progress, I hope to show some of the problems and our solutions.

    First off here's a condensed list of the damage incurred as a result of the roll-over:
    -Crushed roof (obviously) and doors
    -Bent/kinked beam
    -Kinked and displaced beam support tubing (passenger side)
    -Engine pushed up into firewall resulting in crushed exhaust primaries, hole in intake end casting, various other things
    -Torn out lower engine/trans mounts as well as upper hanger mounts
    -Trashed rear bumper (some in front too)
    -Tweaked rear trailing arm (sheared sprinplate bolts)
    -Broke nose cone OFF trans

    On the bright side the car is still basically straight, no pan deformations! And the main cage structure appears intact.


    The mess:



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  3. #2
    Senior Gonzo 5/1600's Avatar
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    Re: Gonzo Racing 5/1600 Post Roll-Over Rebuild

    More damage pictures:

    Engine trans pushed up, bumper kinked etc:





    Bent and kinked beam:



    Trans mount torn through, whole drivetrain push way up:





    Lots more pictures of the damage; folded up wheels, broken trans etc, but you get the idea...

  4. #3
    Senior Gonzo 5/1600's Avatar
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    Re: Gonzo Racing 5/1600 Post Roll-Over Rebuild

    Work begins!

    The car is entirely torn down, basically pan, cage, and body, little more.

    Kinked footwell tube (goes to lower beam tube):



    Cutting out damage (tube shown above and other passenger side beam supports):



    Fitting up sleeves:







    I love TIG welding Sorry for the unnatural lighting



    All beam support repairs sleeved and final welded in:



    Pleased with the progress so far as we have limited shop resources and minimal man power at our disposal.

    The roof comes off tomorrow! More to come.
    Last edited by Gonzo 5/1600; June 20th, 2012 at 21:31.

  5. #4
    Ironman Ramsey_ElWardani's Avatar
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    Re: Gonzo Racing 5/1600 Post Roll-Over Rebuild

    This is the perfect time to put some of those good parts in a nice 2-1600 chassis.
    Ramsey El Wardani
    Smarter Than Dirt!
    One Man Racing

  6. #5
    Senior Gonzo 5/1600's Avatar
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    Re: Gonzo Racing 5/1600 Post Roll-Over Rebuild

    Quote Originally Posted by Ramsey_ElWardani View Post
    This is the perfect time to put some of those good parts in a nice 2-1600 chassis.
    Cough cough 1/1600, thought about it seriously haha. Maybe down the line or side project?

  7. #6
    #billsson pdailey's Avatar
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    Re: Gonzo Racing 5/1600 Post Roll-Over Rebuild

    Love it Trevor. Glad you made this thread. Good luck. Racing the 1000?

  8. #7
    Senior Gonzo 5/1600's Avatar
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    Re: Gonzo Racing 5/1600 Post Roll-Over Rebuild

    Thanks Pat, we're planning on it!

  9. #8
    Elite punchdrunk monkey's Avatar
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    Re: Gonzo Racing 5/1600 Post Roll-Over Rebuild

    Great job Trevor. Your moving along quickly. Is an external sleeve stronger than an internal sleeve?
    #1130 #30
    Pacific Fire Systems, Inc. - Fire Sprinkler Design Installation Inspections 858-722-9865

  10. #9
    Senior Gonzo 5/1600's Avatar
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    Re: Gonzo Racing 5/1600 Post Roll-Over Rebuild

    I'm sure it's debatable, but we decided this would be the best approach.

  11. #10
    Loyal MadMike1111's Avatar
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    Re: Gonzo Racing 5/1600 Post Roll-Over Rebuild

    Quote Originally Posted by ramsey_elwardani View Post
    this is the perfect time to put some of those good parts in a nice 2-1600 chassis.
    exactly!
    Ridin' Dirty Since 1979

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