Hey David, we didnt have too much time to talk when you picked up the car. Start by stripping it down to the bare pan. The floor should be in pretty good shape except for maybe where the battery was sitting. Weld in the good IRS pivots, Torsion adjuster, and truss the torsion housing. The Torsion housing is the back-bone of a 5-1600, if you bend that then the car is junk.
The SCORE rulebook requires 1.5" x.095" (at a minimum) seamless tube be used for the "required" cage elements for vehicles 2000 lbs or less (5/1600's fall into this range unless you go crazy on the cage...). It gives you the choice of CDN/4130/Seamless or 1018/1026 CDS/DOM steel, but IMO 4130 is the better of the two choices. Just make sure you use "seamless" tubing!
The questions you're asking about the torsion adjuster, truss and IRS are basic VW knowledge, and this isn't really the best place to learn the "basics". You probably need to have someone give you a "tour" of the rear suspension on a 5/1600 to really "get it"...... We currently have our car apart for some upgrades, you're welcome to come by and see it if you'd like. Or, we'll have the car at VW paradise in the next month or so for Jason to fine tune our motor - you can have a look then. We might be able to answer your questions better by "showing" you!
So I would be better off with 2" IMO 4130 seamless chromaly?
Yea thats no problem in coming by sometime...im live close to Guajome Park, N Santa fe, and the 76....
This weekend im leaving for the NORRS race in Lancaster, but next weekend or during the week is a good time for me. Im not sure about your schedule though.
Im sure that we can work somethig out.
For the "required" cage elements, you don't need to go bigger than 1.5 X .095 tubing (for SCORE, I don't know about other organizations), it would just add unnecessary weight. Parts of the cage that are not required by SCORE can use other size/wall thickness material, at your discretion (but SCORE will check the thickness of the required elements when you get it "tagged"). You really need to have a rulebook on hand when you build this, we'll bring one by for you......
The material choices are:
CDN/4130/Seamless (cold drawn 4130 seamless tubing)
1018/1026 CDS/DOM (1018/1026 cold drawn steel/drawn over mandrel steel)
When I said "IMO 4130 is the better of the two choices", I meant "In my opinion 4130 is the better of the two choices". IMO is not a steel type. You can use either the 4130 seamless or the 1018/1026 mild steel - the 1018/1026 is easier to work with (bend, grind, etc.) but isn't as strong. The weight and price is essentially the same for both types, so strength is the defining difference. Tube Service can supply just about any type of tubing you want - don't go bargin hunting when you shop for roll cage steel! Most people can't tell one type of steel from another just by looking at it (though new steel should have the type printed on it) - get it from a "known" supplier to be sure you're getting what you expect.
We are going to be in Baja for 10 days - 2 weeks starting on Friday, but we'll work something out when we get back.
Here is a feature on Jeff Sack's 5-1600. There is some good detailed shots of the car, study some of the pictures of the rear suspension.
You are completely right and I am on you side of the opinion, I do have a rulebook handy and i am reading it thouroughly.
The reason I got it.
Was to start from the bottom up. From scratch.
I wanted the challenge and thats why im doing it in the first place. I want to learn the hard way so in the future its only natural.
Im prone for mistakes but I will fix them.