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Author Topic: New XR2 Project!  (Read 4568 times)

Rocketman

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New XR2 Project!
« on: August 25, 2012, 06:32:00 PM »

I picked up a new project XR2 for me - she's in rough shape but rust free & completely salvageable!

 

116k miles. Wrecked front end, shot top and interior. Been sitting for 8-10 years now. We'll see what I can do to fix her up, came with everything I need to repair the front end so that makes life a little easier.

Hoping to get her running soon as a replacement daily driver, and then I have some big long-term plans for it  

In-transit to my shop.
 
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1.8L Turbo All Wheel Drive Capri... the "GTXR2"


Sceeter

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New XR2 Project!
« Reply #1 on: August 26, 2012, 12:10:00 AM »

Hi Matt,She looks good I know you said she came with what you need for the frount but I have a 91 parts car if you need any AC stuff or what ever. Pittsburg isnt that far away you know that. Diane is a great cook an my beer is cold.We are leaving friday morning for the meet get to the hotel that night,an bum around sat.Throw Russ a line an see If there be a get togeather that night,see you there. John
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Rocketman

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New XR2 Project!
« Reply #2 on: September 10, 2012, 04:09:00 PM »

Thanks John I will let ya know if I need anything, I think I'm pretty well covered at the moment though. Guess I could use a soft top with a decent rear window if y'all got one layin around.

Like I said the front end was buggered:

 

If there's anyone out there that's ever replaced a header panel, you know what a pain these are. I'd done one on my old XR2, but it was a crude job. I'm trying to do this one "right"

Get to play a long, tedious game of locate, punch, pilot drill, and drill out spot welds. I ground my own bit for removing the welds - they're available purpose-made but at the moment I've not the cash to throw at one.

 

It's surprised!

 

About 100 of these later

 

A note to anyone doing this: Probably best done at a pro body shop lol. If the panel's just dented, you can replace just the skin. In my case the under-structure was pretty well damaged, it's a single piece with the radiator support so all that came off too
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Rocketman

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New XR2 Project!
« Reply #3 on: September 10, 2012, 04:16:00 PM »

Old piece is off - it was even repaired once in the past prior to whatever wreck later. You can see the frame under the panel is damaged - it's the same piece of metal that makes up to the radiator support

 

Gotta clean up & remove all the extra sheet metal on the donor piece

 

Just aboot there

 

Test fitted:
 

It still needs a handful of grinding before it can be re-assembled. I've decided it needs to be welded back together, there's not enough meat on the headlight buckets or elsewhere for it to be bolted together. Everything's too thin

Scrap pile!
 

More to come once it's welded into place!
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tonlaw71

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New XR2 Project!
« Reply #4 on: September 11, 2012, 05:24:00 AM »

It's surprised! LOL Love it!
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///Tony aka Bubba Gumpshrimp\\\

///'92 Plasti-Dipped XR2\\\

Rocketman

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New XR2 Project!
« Reply #5 on: September 13, 2012, 05:41:00 AM »

I got some more work done on the XR2 - ground down all the mating surfaces of the header panel and pulled out the frame a bit. It looks like the passenger headlight frame might have been pushed in a bit, so I'm trying to straighten that out a bit before welding everything solid.

I do have it tacked into place at the moment, with everything roughly placed to check panel alignment. It's slowly starting to look like a Capri again!

 
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Rocketman

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Re: New XR2 Project!
« Reply #6 on: September 12, 2013, 02:38:10 AM »

I haven't updated this at all, lol. Not that I've done much to the car.

Our big Capri meet is coming up & I'm trying to get this ready. Things I've done

-Finished welding in the header panel & spraybombed it for the time being
-Installed a stock intercooler & intake system (stock for now)
-Spraybombed & mounted fenders
-Mounted bumper
-New wheels & brand new tires
-Replaced hardware on DS caliper. Replaced whole passenger caliper. Thoroughly bled brakes. New brake pads

-Gutted the whole interior minus the dash
-Replaced carpet with one from my old parts cars
-Took the seats out of the GTXR2 temporarily until I can locate seats. Have a set of Prelude seats but they won't swap in easily.

The car has some electrical issues I've been battling.
-Horn won't work ( bad connection at the back of the steering wheel, easy fix)
-Turn signals didnt work (ground issue at the sockets, fixed)
-No wipers (bad relay/timer module, replaced.)
-No dash lights (bad connection at the back of guage cluster, cleaned all connections in dash. fixed)
-Crossed wires from previous botched radio install (cut out & fixed)
-Burned out marker lights everywhere, replaced.

Still to do:

Foglights
New radio
New soft top


And right now she won't run, no spark. She ran fine before I started fixing other stuff... go figure.

Slowly getting there.








Bodywork & paint will come eventually.

-Rocket
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Rocketman

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Re: New XR2 Project!
« Reply #7 on: September 12, 2013, 02:38:55 AM »

Turns out someone rigged an "anti-theft" device of their own creation made out of speaker wire and electrical tape... It intercepted the signal to the ignition coil. Clever, but I disturbed it at some point working under the dash and created a two-day nightmare for me. The offending wire has been removed, burned, shot, buried, exhumed, and spat on, and buried again.
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Rocketman

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Re: New XR2 Project!
« Reply #8 on: September 12, 2013, 02:39:52 AM »

Late night caliper repair. Sound like a good idea for a business? lol. I love having machines, hate to have to use it for stuff like this.



Milled out the snapped off bleeder, along with the snapped off EZ-OUT (ez-headache might be a better name?) like it was butter. Carbide endmills rule!
Drilled it out oversize and tapped for 1/8" NPT, installed a Dorman bleeder repair kit. Works perfect now, I have brakes. Brakes are good.
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Rocketman

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Re: New XR2 Project!
« Reply #9 on: September 12, 2013, 02:40:07 AM »

Took her out on the road today. The clutch is smoked so I have to take care of that, digging into it tonight.

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Rocketman

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Re: New XR2 Project!
« Reply #10 on: September 12, 2013, 02:40:45 AM »

Clutch was toast. Pull an all nighter last night to put a new one in. I wanted to stick with a stock clutch but I decided to go for the ACT HD-SS I had brand new, and a Fidanza flywheel I picked up in a trade.

Assume the position!




Same combo I have in the GTXR2






Success! Time to break it in.



Also flushed the coolant. New t-stat. New swaybar endlinks. Have to switch tops over with the GTXR2 then I'll be set, or as set as I'm going to be for now lol

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Rocketman

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Re: New XR2 Project!
« Reply #11 on: September 12, 2013, 02:41:30 AM »

Went to move the XR2 the other day, the knocking it was making has "disappeared" I am running a slightly heavier weight oil in it...not sure if that's helping? A little confused. So I've decided to try driving it. If the stock oil pressure gauge is to be believed it's running around 30psi which seems a little low maybe? not sure they never really work.

Rear wheel bearing on the driverside is shot, so that's also on the todo list.

Took this today:

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Rocketman

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Re: New XR2 Project!
« Reply #12 on: September 13, 2013, 08:46:22 PM »

Got a shot with another unique car today:

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CapriTypeR

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Re: New XR2 Project!
« Reply #13 on: September 14, 2013, 03:03:37 AM »

Nice!
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fayzaldean

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Re: New XR2 Project!
« Reply #14 on: October 26, 2013, 10:43:38 PM »

What is the DeLorean worth in the United States? people are paying 50k for them over here.
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