TeamCapri

General => Build Threads => Topic started by: Surfnut on September 13, 2010, 03:47:00 PM

Title: Kelmark XR-2 Project
Post by: Surfnut on September 13, 2010, 03:47:00 PM
Hi,

I'll be posting updates of my Kelmark powered XR-2 project under this thread from now on so most everything will be in one spot.


My two past posts on this topic can be found by searching for,
"The Death and resurrection of my XR-2"  posted Feb. 7th, 2010 under "General"
and
"Kelmark XR2 No Crank / No Start" posted Sept.4th, 2010 under "General"
Or you can search under my member number of 1489 to find them.

In these videos, the rear of the engine/trans is facing us.  The rad and intercooler are connected as in the stock XR-2 but they're up against the wall so that can't be seen from this angle.

The first video I made about a week ago is here :

http://www.youtube.com/watch?v=CyTWw07xNhk (http://www.youtube.com/watch?v=CyTWw07xNhk)


The second video I made tonight (using my new, snazzy hi-def camcorder...) is here :

http://www.youtube.com/watch?v=UKVnIoevy7A (http://www.youtube.com/watch?v=UKVnIoevy7A)


Next I'll wrap up the newly chopped up wiring harness then start on the engine cradle and suspension mounting points.
I hope you enjoy this as construction progresses.

Peace,
Dave
Title: Kelmark XR-2 Project
Post by: Surfnut on October 10, 2010, 02:07:00 PM
I finally started building my engine cradle and frame today.

Start :  24' long, 146 lb piece of 2" X 3" steel tubing.


 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP9945.jpg)


2" X 2" lower part of the engine cradle is laid under the engine.  The stock engine support will bolt to the bottom of the rear 2" X 2" crossmember.  The lower "A" arms (I haven't built them yet) will be attached to the 2 " X 2" steel tubing that makes up the engine cradle.  

The pine 2" X 3" you see being held onto the motor mount with a C clamp is a partial mock-up of the upper frame rail which will be braced / bolted to the lower engine cradle.

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP0019.jpg)


Here you can see the real steel 2" X 3" upper frame rail clamped to the motor mount.  The upper "A" arm will be bolted to this piece.  In front the 2X3 steel tubing angles down to where the perimeter frame will go under the Kelmark body.


 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP0022.jpg)


Driver's side view of the lower engine cradle from the rear of the engine.


 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP0023.jpg)

Driver's side view of the lower engine cradle from the front of the engine.


 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP0021.jpg)


The drivetrain, engine cradle and frame will be installed from underneath the vehicle.  The 2" X 3" perimeter frame and upper frame rails will be welded to the floor and front suspension of the Kelmark to tie the new rear stuff to the existing floor and front suspension of the car.

If / when I have to pull the engine, the 2 X 2 lower engine cradle will be unbolted from the upper frame rails and then the drivetrain, lower engine cradle and lower "A" arms will come out from underneath the car.

Tomorrow I hope to build the driver's side upper frame rail and start bracing the upper frame rails and the lower engine cradle together with 1" x 1" square tubing.

I'll also have to make an upper frame rail rear crossmember.  Hopefully that will get done tomorrow.

Dave
Title: Kelmark XR-2 Project
Post by: Rocketman on October 10, 2010, 08:33:00 PM
Looking good dave. Any pics of where the engine will be ending up?
Title: Kelmark XR-2 Project
Post by: Heavensheros on October 11, 2010, 01:40:00 AM
what is a kelmark engine ???
Title: Kelmark XR-2 Project
Post by: CapriTypeR on October 11, 2010, 04:44:00 AM
Josh-
A Kelmark GT is a kit car that was styled roughly after Ferrari 246 Dino.

Kelmark Engineering was an auto shop based in Michigan, that focused on the production of rear/mid-engined kit cars. The kits were built by hobbyists or professional mechanics manually. Until 1986, Kelmark Engineering built kits and complete vehicles which were either Volkswagen-based or on tubular race car style frames.

The cars are all "rare" models, but the Kelmark GT body style was the most popular. It was featured in the magazine Car and Driver in 1977 and 1979. The car had exterior styling that was distinctive for its debut in 1969. The styling was reportedly influenced by Ferrari and a Corvette concept car. The "Independence" model was a fiberglass body kit for a Volkswagen chassis, while the "Liberator" model was more customized, and could go on a tube frame, Porsche or VW chassis, or even a custom combination.

Therefore, A Kelmark engine is whatever engine you chose to use in your kit!  Dave has chosen to use a B6T out of an XR2!
Title: Kelmark XR-2 Project
Post by: CapriTypeR on October 11, 2010, 05:12:00 AM
Dave-
Wow! You have a whole lot of work ahead of you!  I tip my hat to you, and I'll tip a Labatts in your honor!

--Russ
Title: Kelmark XR-2 Project
Post by: bhazard on October 11, 2010, 06:52:00 AM
How much is this car gonna weigh? Around 2000 lbs would be sweet.
Title: Kelmark XR-2 Project
Post by: Surfnut on October 11, 2010, 01:35:00 PM
Rocketman, I forgot to take pix of where the new engine compartment will be.  I'll do that later this week - sorry.  I had a lot to do today.

Thanks Russ, I'm digging in as best as I can !  I hope to have all the new engine / frame, etc. ready to go in by New Years.  With the aid of my handy-dandy digital angle finder I can safely tell you that I'm within a tenth of a degree on making everything level and even on each side of the engine.  And with the aid of my dollar store tape measure, I'm within a 1/16 of an inch of everything being square.  Dollar store tape measures are very accurate you know.

bhazard, I'm thinking around 2100 lbs.  My Kelmark weighs 1850 (with gas, oil, no driver and all the junk I usually carry - tools, jumper cables, etc...).  

I weighed the ready to run XR-2 engine, trans, axleshafts, spindles, rotors, exhaust manifold, turbo, about 3 feet of exhaust pipe, MY cut-down but complete wiring harness, full rad and factory lower steel engine support today.....449 lbs.  
The lower engine cradle I built is 35 lbs,

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP0027.jpg)


The upper will probably be around 60? (It's a thicker wall steel).  Subtract the weight of the VW engine and trans and I think the car'll be between 2000 and 2100 lbs.  I'd really like to be ready to run down the road with me in the car and be less than 2200 lbs.  That's a solid 500 lbs less than a stock XR-2 and light weight means more fasterness.  I think Colin Chapman said that.

Anyway, today I had some setbacks but I stayed on it and got some decent results to report.


This will give you a general idea of where the spring and shock will end up (I'm using the stock strut for a mock-up).  From this angle you'd be standing outside of the passenger door.

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP0025.jpg)


Strut mock up from rear passenger 1/4 angle

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP0026.jpg)


This is what I got done today :


 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP0034.jpg)
 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP0032.jpg)
 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP0033.jpg)

Next will be more bracing (especially across the rear crossmembers) and more upper and lower frame triangulation.  Which I'm pretty sure is a fancy word for "bracing."   (http://smile.gif)

Dave
Title: Kelmark XR-2 Project
Post by: Rocketman on October 11, 2010, 03:47:00 PM
EXCELLENT!!! MORE!!!
Title: Kelmark XR-2 Project
Post by: Surfnut on October 12, 2010, 02:13:00 PM
Thanks Rocket ~
Gotta go buy more steel....more pix in a few days.

Dave
Title: Kelmark XR-2 Project
Post by: CapriTypeR on October 12, 2010, 05:45:00 PM
Dave-
Nothing wrong with saving money on tools! I'm amazed at this project - The Kelmark is a sharp car to begin with, now your throwing a turbo at it! Imagine what it would be like with a Rocketchip and MBC!!!
I also notice your pretty clever - unless you crushed your wife or neighbor.......
  (http://photos.imageevent.com/roosport/roosportmisc/small/IMGP0025.jpg)

Nice job of improvising!
Title: Kelmark XR-2 Project
Post by: Surfnut on October 16, 2010, 01:02:00 PM
Believe it or not, it took me six stinking hours to do this:


 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP0037.jpg)

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP00401.jpg)

But I'm pretty sure it ain't never gonna move!


Note: I'm only tack welding most of the metal in at this point.  When I know everything's where I want it to stay forever I'm going to have my dad arc weld it.  He's a far better welder than I'll ever be.

Dave
Title: Kelmark XR-2 Project
Post by: Rocketman on October 24, 2010, 05:47:00 PM
Dave,

Looks like thats getting awful heavy now!

I think I've found a semi-solution. I daily drive a 1995 Pontiac Grand Prix - the transmission has been going out. I pulled apart a GP at Harry's for another tranny to put in, at the same time got looking pretty hard at a lot of GM's vehicles.

Most of them have a pretty beefy subframe complete w/ control arms, all held into the body with 4 bolts + bushings.

I saw one from a Grand Am I think, it looked like it would be a really good platform to build off of. I think I'll be using one for my mid-rear project. I might have to go with custom control arms, but at least the mounting points are already there, and I won't have to use custom bushings...

Just food for thought I suppose -

-Rocket
Title: Kelmark XR-2 Project
Post by: Rocketman on October 24, 2010, 06:32:00 PM
Here's the subframe I pulled off of my GP tonight -  (http://www.werbatfik.com/uplimg/2010-10-25_01-02-57_892.jpg)
Title: Kelmark XR-2 Project
Post by: bhazard on October 24, 2010, 11:36:00 PM
Yeah I'm gonna have to say you overbuilt that cage a bit lol. Its a B6T not a cummins.
Title: Kelmark XR-2 Project
Post by: Surfnut on October 25, 2010, 03:47:00 AM
That's a nice-looking engine cradle Rocket and I can see why you like it.  I toyed with the idea of using something like that and bolting it in but the biggest problem was --- what do I bolt it to ?  The VW floor pan is thin, somewhat rusty 40+year old metal and there's no way it's going to support anything safely.  I'd have to add some type of subframe to bolt that engine cradle to and to be honest, instead of adapting an existing cradle it's a lot easier to just build a medium duty frame to bolt to the existing "chassis" of the VW pan which torsionally, is really stiff.  At least it's a lot easier in my situation...

When you do yours, you'll most likely have to strengthen the area where the cradle will bolt to.  Especially so when you think about the crazy power you're going to be putting to the ground !  You'll have enough power to rip the whole works out of the bottom of the car.

Like you wrote, you'll probably have to either fab upper control arms and figure out where to mount them or figure out how to use a factory strut to locate the spindle (and figure out where to mount them !).  You probably remember that I originally wanted to use the stock Capri strut and spindle but as you know, everything snowballed when I realized I had a wheel adapter / wheel bearing /offset problem.


When I get a few more steps down the road with this engine cradle it'll become much more clear why I decided to do it the way I did it.  I think this is going to come together nicely.

What you're looking at in those last pictures is a combination of the engine cradle AND the frame itself.  The 2"X3" rails on top (where the stock motor mount is sitting on) - that's the rear part of the mostly unbuilt frame.  Those 2"x3" frame rails - that's where the upper control arm mounting points, spring/strut mounting, cantilever pivot points and motor mounts to.  Additionally, the lower engine cradle (the 2"x2" structure) will bolt to.  So it's gotta be strong 'cause in one way or another, pretty much everything is going to be bolted to it and when all's said and done, the whole car will be bolted to it as well !

The lower engine cradle is where the drivetrain and lower control arms will mount to.  Obviously, that's gotta be pretty tough too.

I understand what you guys are saying about weight and I COMPLETELY agree.  That's why I cheated a bit - the stuff that isn't essential for structure and strength are a much thinner wall steel.  You know those "X" braces on the back of the cradle in the last pictures ?  All that stuff weighs a total of 3 pounds.  Triangulated though, they're strong as Hell.  95% of the bracing is thin wall (like maybe .083 ?) 1"x1" steel and in total, I'll be surprised if the bracing adds more than 10 pounds when the frame and cradle are finished.  

But it's stiff, adds an incredible amount of strength and I think it looks cool as Hell.  (Which is the most important part  (http://smile.gif)  )

As it stands now, all the steel in my frame/cradle totals 72 lbs and other than finished welding, it's pretty much done.

In the end, I KNOW it'll be MUCH stronger then it needs to be, I hope it'll be cool to look at and yes, I'm sure it WILL weigh more than I'd like it to  :(     But really, it's a safety issue and you don't want to mess around with stuff like that.  Overbuild it and don't EVER worry about it.

I went on Friday and bought all my Grade Eight nuts and bolts and the guy at the store asked me if I was building a tow truck.  So maybe "overkill" is the right word...

Thanks a lot guys for your comments and for keeping up with this project.  I sure appreciate it.

Dave
Title: Kelmark XR-2 Project
Post by: Rocketman on October 25, 2010, 05:44:00 AM
72lbs - thats a lot lighter than it looks.

You're going with a dual a-arm suspension?

I'm planning on sticking with something similar to the stock front setup - control arm/strut, or dual lateral links + trailing arm and strut like the GTX rear is setup.

I'm not much of a suspension guru... so I don't know exactly what the benefits of dual a-arms is going to offer. But I'm looking at it as far as real estate goes - trying to make the best use of the little space available to me back there. It looks like dual A-arms will be quite bulky.

(I looked into using a Miata rear suspension for either RWD or AWD, and the rearend on them is GIANT compared to stock or that of the 323 GTX...Miata is dual a-arm.)

And yes, the one unfortunate thing will be having to frame out the rear of the car. But I'm pretty much going to have to do so regardless of what frame I use. I think I can get away with leaving the stock framrails untouched - probably end up reinforcing them.

I'll have to get back out to the junkyard at some point and start measuring. I'd rathing be able to recycle, or use somehthing pre-fabbed, and use that instead of building completely from scratch.
Title: Kelmark XR-2 Project
Post by: Surfnut on December 16, 2011, 01:14:00 PM
Long time, no post.
I hope everyone's doing well and having good luck keeping those Capris on the road.  I miss mine a lot - they were great cars for me.  Lots of fun and good times...


Anyway, I thought I'd post to let everyone know that I haven't given up on my XR-2 transplant.  I've been slowly working away on my sub-frame but I've got to get another car in the garage over the winter so I moved the frame out today.  Here are some pictures I've taken over the last couple of weeks :


 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1065.jpg)

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1066.jpg)

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1071.jpg)

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1069.jpg)

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1067.jpg)

The sub frame (not including the A arms and cantilevers weighs 115 pounds.  Not light but not crazy-heavy either.


This part of the sub-frame's about 80% done at this point.  I plan to get back at it in April but just for shiggles, I decided to fire up the engine before I put it away :

http://www.youtube.com/watch?v=Vr4EXn2J2cE (http://www.youtube.com/watch?v=Vr4EXn2J2cE)

Sorry the video's so poor but there wasn't much light when I shot it.  The engine hasn't run for about a year and a half.  It fired up after about 5 seconds of cranking - can't complain about that!

Here's a picture of the engine sitting in the frame :

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1111.jpg)

Interestingly, with the XR-2 drivetrain installed, I had a heck of a time lifting the front of the frame.  
I put a scale under one of the 2"x2" 's sticking out the front and there's 120 pounds on it.  Which for my purposes is great because it moves the weight farther forward and will help to equalize the almost no-weight-on-the-front-end problem my Kelmark has now.  It'll help a lot with weight distribution.


I'm pretty sure I'm going to end up with Shockwaves instead of coil springs but these will have to do for now.

Anyway, I just wanted to post to let everyone know I'm still at it, just moving a LOT slower than I'd planned.  

I hope everybody's doing really well.


Dave
Title: Kelmark XR-2 Project
Post by: Rocketman on December 16, 2011, 01:30:00 PM
I was just about to bump your post to see how you were doing - great to see the progress!

The frame is looking great. Really dig the cantilever suspension. Was that an OEM design on the kelmark? Also, what are "shockwaves"?

Winter break, then back to work huh!
-Rocket
Title: Kelmark XR-2 Project
Post by: Surfnut on December 16, 2011, 01:47:00 PM
Hi Rocketman

It's great to chat with you again!

Most Kelmarks came with a standard VW Beetle (late '60's, early '70's era) rear end - torsion leaves etc...  That's what's in mine right now.
I'm going to cut the bottom rear of the car out from underneath and lift my sub-frame into place then tie the whole works to the front suspension and reinforced areas of the floor (amongst other places).

Shockwaves - are shock absorbers with integrated air bags (or specifically, air springs).  Here's an example :

http://www.jegs.com/p/Ridetech/Ridetech-ShockWave-Lowering-Systems/751900/10002/-1 (http://www.jegs.com/p/Ridetech/Ridetech-ShockWave-Lowering-Systems/751900/10002/-1)

There are a lot of different kinds and I don't have any idea which kind I'm going to go with but my end choice will have to do with vehicle weight and ride quality.  Essentially, I have to figure out how much weight is going to be over the back half of the car so I can get the correctly rated air spring.  That'll have to wait until the car's pretty much finished.

Great to hear from you.  I hope your awesome Capri is still tearing up the roads !


Dave
Title: Kelmark XR-2 Project
Post by: rcdraco on December 16, 2011, 03:19:00 PM
Saw those on TV once, they're pretty scary when tuned correctly.  Makes a '69 camaro handle like a '98 corvette, without sacrificing ride quality.
Title: Kelmark XR-2 Project
Post by: CapriTypeR on December 16, 2011, 04:03:00 PM
Nice job, Dave! I can't wait to see this thing when it's done!

--Russ
Title: Kelmark XR-2 Project
Post by: Surfnut on December 16, 2011, 10:31:00 PM
Rcdraco - yeah, they're super expensive but pretty much the pinnacle of spring / shock technology for the general aftermarket.  I gotta save my bucks for a while so I can buy a pair of those things!!


Thanks Russ - like you, I can't wait to see this thing when it's done either.  The project's really dragging on but realistically, I only need another week or so to finish this part of the frame, then the rear half of the car will be just about done.

Phase two of the project will be cutting the back of the car out and installing the sub-frame.  (Yes, that makes me VERY nervous ~)

Phase three will be making it all work.  Who wants to bet that this part is going to be the REAL headache?  Between axles, shifter linkage front-mounted rad and A/C condenser and larger intercooler...oh, my aching head.


When I'm done though, I might just be able to run with you big boys and your high-powered Capris  (http://smile.gif)

I still think I can have this thing on the road and fully loaded (with me in it) for around 2200 lbs - that's an honest 500-600 pounds less than a stock XR-2.  Hopefully that weight difference will make up for a pretty much stock engine / trans.  (Currently have a 2.5" mandrel exhaust & Rocketchip.  Still gotta up the boost.)

If it's not power to keep up with you guys, maybe I can sweet-talk Rocket into building me a hot engine....  (http://graemlins/big-biggrin.gif)
Title: Kelmark XR-2 Project
Post by: Rocketman on December 17, 2011, 01:12:00 AM
Getting everything to work should be the easy part! Intercooler, piping, etc should all be straightforward  (http://smile.gif)

Regarding weight - a stock Capri weighs 2400lbs so at 2200 you've got a 200lb advantage. My AWD beast weights in at 2750 after all my mods, the AWD bits + 1.8 and fuel cell, rear end reinforcements, etc all weigh quite a bite more it seems.

Your real advantage is going to be being able to put the power down - and weight balance. You'll probably be able to run laps around your FWD brethren  (http://tongue.gif)

We can build you a hotter motor - but I'd really suggest going to a 1.8 - it's an inch longer but can make some serious power with a basic setup, compared to the same for a 1.6. And they're relatively common even in Canuckland!
Title: Kelmark XR-2 Project
Post by: Surfnut on December 19, 2011, 04:42:00 AM
You're the power man so what you says goes.  When you mention that it's an inch longer - do you mean the engine itself is an inch longer side to side?
Does the 1.8 use the XR-2 transaxle ?

I built the frame specifically to fit my 1.6 and there's less than an inch from the crankshaft to the frame and on the other side, I actually had to notch the lower frame rail for the transmission so I don't know if a 1.8 will fit.  
Guess I shoulda thought ahead  (There's something I'm getting real used to saying....)

And the way I drive, I don't think I'll be running circles around anybody.  If I can follow you and keep you within sight at all times, I'll be very satisfied !!
Title: Kelmark XR-2 Project
Post by: Rocketman on December 19, 2011, 04:56:00 AM
Yeah the 1.8's block is about an inch longer due to the increased bore spacing. It requires framerail notching to fit in a Capri but it's well worth it.

Yes, it will bolt to the XR2 g-type - but the stock BP g-type transaxle might be a better option for you. It uses a hydraulic clutch actuation setup, as opposed to cable. And it tilts the engine forward 15 degrees, which would put your center of gravity a hair more forward compared to the 1.6
Title: Kelmark XR-2 Project
Post by: Surfnut on December 19, 2011, 05:09:00 AM
Geez, I wish I would have known that before I started - a hydraulic clutch would make life SO much easier for me and the extra weight in front sure wouldn't have hurt either.

Oh well.  I still think this car will be great with the XR-2 drivetrain.  I've got that 5th gear set so that'll help with revs on the road and when you think about it, I paid $800 for the XR-2, drove it without an issue for 3 or 4 years, (with ice cold working A/C!!) and now the engine'll be powering the Kelmark.  It sure don't owe me nothin' !!


When I get the car all squared away, I'll probably come bugging you for an updated drivetrain.  If you can find the time to build me something, I'll have to find someone to make me a snazzy fender emblem that says, "Powered by Rocketman"  

Coooooooooooolllll    (http://smile.gif)
Title: Kelmark XR-2 Project
Post by: Surfnut on March 15, 2013, 05:44:00 AM
Hi Guys,


I thought I'd drop a quick line to say hello and tell you I'm still slugging away at my new frame for my XR-2 powered Kelmark.

I've made some significant changes to my original plan and have decided to build an entire frame instead of just installing the subframe (pictured earlier in this thread)into my Kelmark's existing frame.  
Of course this means a lot more work but I've no doubt the end result will be far superior to the original frame.

Some pix soon, I promise.

I hope everybody's doing really well and having continued good luck with your Capris!


Dave
Title: Kelmark XR-2 Project
Post by: Surfnut on March 25, 2013, 01:53:00 PM
As I wrote earlier, I've decided to fabricate an entire frame instead of melding my new frame to the Kelmark's existing floor pan.  For the front end, I'm going to use a Mustang II front suspension.

Here's a picture of my rear subrame with the spare tire sitting in the approximate area it's going to be mounted :

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1810_zps78848e79.jpg)

Mock up of center frame rails with front suspension roughly in place :

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1811_zpsb7ed3fae.jpg)

Driver's side of Mustang II front suspension :

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1910_zps7c82b667.jpg)

3/16" plate I'm using to reinforce the suspension:

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1911_zpsbff06602.jpg)

Lining up the rear subframe :

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1866_zps37c9a6f5.jpg)

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1865_zps27b4d996.jpg)
Title: Kelmark XR-2 Project
Post by: Surfnut on March 25, 2013, 02:02:00 PM
Picture of the center frame rails.  From this angle, you'd be standing beside the passenger's front wheel.

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1906_zpsf94d59c3.jpg)


Center frame rails from the front :

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1905_zpsf7a7219a.jpg)

Perimeter frame rails added :

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1907_zpse99e7297.jpg)

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1909_zps6366201b.jpg)
Title: Kelmark XR-2 Project
Post by: Surfnut on March 25, 2013, 02:07:00 PM
Front end roughly located :

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1915_zpse5896009.jpg)

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1918_zps2b457ede.jpg)

In the process of lining up the rear wheels (which I already aligned to the rear subframe) to the front wheels.  Two days of measuring and adjusting allowed me to get the front wheels square to the rear wheels and the overall wheelbase dead nuts to where I wanted it.

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1917_zps933fe5e2.jpg)

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1916_zps19571ebd.jpg)

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1919_zps2188e03a.jpg)

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1920_zpsf1e1b308.jpg)
Title: Kelmark XR-2 Project
Post by: Surfnut on March 25, 2013, 02:10:00 PM
First attempt at cleaning up and mounting the extremely cut-down wiring harness (the plywood is temporary) :

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1894-1_zps81e0e325.jpg)

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1893-1_zps3c348412.jpg)

Does anyone know what this thing is and what it does?

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1897_zps384c7481.jpg)

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1895-1_zps93895d99.jpg)

 (http://i880.photobucket.com/albums/ac9/Surfnut74/IMGP1896_zps0e8f2be6.jpg)
Title: Kelmark XR-2 Project
Post by: Gostlrs on March 25, 2013, 04:04:00 PM
Is it one of the ABS Sensors?
Title: Kelmark XR-2 Project
Post by: Surfnut on March 27, 2013, 12:19:00 PM
I don't think my '91 XR-2 had ABS.  I'm 99% sure but I can't recall.
Title: Kelmark XR-2 Project
Post by: azgtx on March 27, 2013, 02:27:00 PM
That is the knock controller for the ecu and distributor
Title: Kelmark XR-2 Project
Post by: Surfnut on March 28, 2013, 12:23:00 AM
Ahhh!  So don't cut it out of the wiring harness~

I'll find a nice place to hide it.  Thank you very much!


Dave
Title: Kelmark XR-2 Project
Post by: Surfnut on April 07, 2013, 01:26:00 AM
Quick update:

After much consideration, I concluded that I needed to redo my rear suspension.  I've trashed the '96 GMC Jimmy front spindles and hubs that I was using and am now planning on playing with '95 Mercury Cougar XR7 (same as T-Bird) rear knuckles.
 
The Cougar knuckles will allow me more suspension travel and no bumpsteer issues.  Additionally, Cougars have a rear caliper E-brake system so I won't have to screw around trying to fabricate some kind of custom E-brake.

I hope to still use the pushrod/cantilever spring system but at the least, it'll have to be reworked.  
All this equals much more time  :-(

To make matters much, much worse, my 18 month old niece has to have open heart surgery and we'll all be concentrating our efforts on her and her recovery so I probably won't be doing much or updating anytime soon.

But I will be back and I'll post again when I have something interesting to report.
Stay well Capri brothers.

Dave
Title: Kelmark XR-2 Project
Post by: Gostlrs on April 07, 2013, 11:40:00 AM
Good Luck....
Title: Re: Kelmark XR-2 Project
Post by: Surfnut on February 11, 2014, 01:11:22 PM
Hi Guys,


Long time no updates.....I hope you all have been well and have had good luck keeping your beautiful Capris on the roads.

Since the good moderators here were kind enough to move my build thread to the snazzy new forum, I thought that the least I could do would be to update it!


The build is still on (and ongoing) but there have been a number of changes.  First and foremost, my lovely neice had her open-heart surgery, survived it and her heart has apparently healed almost completely so thanks very much to all those who sent good thoughts her way.  Your good vibes were MUCH appreciated.

Secondly, I've changed cars.  I came out of the grocery store one day and a guy was walking around my Kelmark.  He said, "I've got one of these!  But it's a bit different than this one..."
After much conversation, I concluded he did not have Kelmark (like mine), he had a much rarer "Karma GT."

He also told me that after 20+ years of storage, he'd like to sell it.  We went to his house, spent 1/2 an hour digging the car out and this is the first view I got of it :

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma%201/MyNewCar_zps5aa5a33a.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma%201/MyNewCar_zps5aa5a33a.jpg.html)


We struck a deal and the next day my old dad showed up with his trusty tow dolly and :
 
(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP0014_zps30da5f0a.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP0014_zps30da5f0a.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP0026_zps04abdb15.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP0026_zps04abdb15.jpg.html)

Believe it or not, the Karma was less than 2 miles from my house.  I'll bet I passed by that car 100 or more times over the years and never even knew it was there!

The Karma was in need of a total redo.  The engine was seized, brake master cylinder was completely empty (it had 4 wheel drum brakes anyway) and he told me that he'd slid under the back of a transport one time, cracked the front fender and had it repaired.  They did a decent job repairing the damage but there's a lot more work left to do to fix the accident damage.

I quickly concluded that the Karma was the PERFECT candidate for my in-progress frame so I decided to ditch ripping my Kelmark apart and focus on the Karma instead.  When the Karma's finished, I'll sell the Kelmark.

Here's how it looked the day I brought it home :

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/DSCF1785_zpsa781df5c.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/DSCF1785_zpsa781df5c.jpg.html)

I had to winch it into the garage :

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP0190_zps25f45e31.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP0190_zps25f45e31.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP0192_zps70ddf985.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP0192_zps70ddf985.jpg.html)


(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2084_zps52e30f88.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2084_zps52e30f88.jpg.html)



Time to get to work.


I pulled the doors and hatches off in an effort to decrease the body's weight as much as possible:

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP0207_zps795a797b.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP0207_zps795a797b.jpg.html)


After I gutted the interior, I made up these steel braces to tie the "A" pillars to the "B" pillars :

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2113_zps73a18ad7.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2113_zps73a18ad7.jpg.html)


(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2112_zps6552e8e9.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2112_zps6552e8e9.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2111_zps426834c2.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2111_zps426834c2.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2110_zps57aa1f28.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2110_zps57aa1f28.jpg.html)


I reinforced the garage ceiling and set up a pulley system with steel cables and a 12 volt powered electric winch :

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2041_zpsf7fcaf74.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2041_zpsf7fcaf74.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2040_zpsa069e030.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2040_zpsa069e030.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2042_zps2271b6c7.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2042_zps2271b6c7.jpg.html)

Undo a zillion bolts and separate the body from the chassis :

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2060_zps684dfa47.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2060_zps684dfa47.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2064_zps726d21e4.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2064_zps726d21e4.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2065_zps6eee8b45.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2065_zps6eee8b45.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2067_zps5a2d34c2.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2067_zps5a2d34c2.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2069_zps263f8288.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2069_zps263f8288.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2070_zpsc686b9d8.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2070_zpsc686b9d8.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2072_zpsf254efee.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2072_zpsf254efee.jpg.html)

Old Chassis :

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2086_zps113432e7.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2086_zps113432e7.jpg.html)


Bare body on the lift :

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2080_zps1af92801.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2080_zps1af92801.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2081_zps0c20bdd1.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2081_zps0c20bdd1.jpg.html)


Here's the rear subframe I'd already made (with the XR-2 drive train in place)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP0255_zpsac63e0a7.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP0255_zpsac63e0a7.jpg.html)


I had to do some cutting to make room for the XR-2 drive train :

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2147_zps6d1460b1.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2147_zps6d1460b1.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2149_zps9ddafc2f.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2149_zps9ddafc2f.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2150_zps44e4def8.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2150_zps44e4def8.jpg.html)


This is the piece I cut out:

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2151_zps6d0fbfe3.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2151_zps6d0fbfe3.jpg.html)


I lowered the body :

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2164_zps7e9e93ad.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2164_zps7e9e93ad.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2166_zps34c7c843.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2166_zps34c7c843.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2168_zpse617dbc4.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2168_zpse617dbc4.jpg.html)


And here's how it all sits in the Karma :

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2170_zps6b214580.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2170_zps6b214580.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2184_zpscc9bf49b.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2184_zpscc9bf49b.jpg.html)

Kind of messy but for a first time fit, it'll do!

I got some snazzy new wheels and popped them into place to see how they'd look :

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2193_zps2775d45d.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2193_zps2775d45d.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2192_zpsdaa5d763.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2192_zpsdaa5d763.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP0276_zpsbd163b99.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP0276_zpsbd163b99.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP2194_zps53620323.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP2194_zps53620323.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP0238_zps973e723d.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP0238_zps973e723d.jpg.html)

From there I started building my new rear control arms using the Cougar / T-Bird knuckles but those pix have to wait 'cause I have to get myself to work!

Obviously,there's still a ton of work to do but I just wanted to update everybody on what's going on.  These pix bring us up to July of 2013.  I'll post more pictures of what I've done since then. 
I just didn't want you to think I'd given up!

Thanks again for moving my build thread to the new forum.

Dave
Title: Re: Kelmark XR-2 Project
Post by: Rocketman on February 11, 2014, 10:18:52 PM
Dave,

Boy what an update! You've been quite busy.

Looks great. So new chassis, new body? What was the original motor in these things?

Can't wait to see this thing running.
Title: Re: Kelmark XR-2 Project
Post by: Surfnut on February 12, 2014, 01:09:33 AM
Hi Rocket,

It's nice to hear from you.  I hope you've been keeping well.

I had to do so much trimming on the frame I had already built that I was only able to salvage about 1/2 of it for the Karma.  The rest of it was modified to fit.

The Karma is VERY crooked - the underneath of the car isn't straight and every wheel well is shaped and sized differently.  I had to do a lot of tweaking to get the body to sit right on my new frame and it still isn't "right"....kinda more like a bunch of happy mediums!

Through plenty of internet digging, I've found that the first Karma GT was a heavily modified Kelmark GT.  While they are extremely similar, they are definitely different animals.  Here are some side by side comparison shots :

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma%201/IMGP0066_zps7790ef8f.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma%201/IMGP0066_zps7790ef8f.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma%201/IMGP0067_zps44c32a59.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma%201/IMGP0067_zps44c32a59.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma%201/IMGP0071_zpsc731fb13.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma%201/IMGP0071_zpsc731fb13.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma%201/IMGP0072_zps3fbb3d88.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma%201/IMGP0072_zps3fbb3d88.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma%201/IMGP0065_zps916702df.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma%201/IMGP0065_zps916702df.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma%201/IMGP0064_zps1c0fc30a.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma%201/IMGP0064_zps1c0fc30a.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma%201/IMGP0063_zpsd44d2dfd.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma%201/IMGP0063_zpsd44d2dfd.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma%201/IMGP0062_zps0946c624.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma%201/IMGP0062_zps0946c624.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma%201/IMGP0061_zps474d4e8c.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma%201/IMGP0061_zps474d4e8c.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma%201/IMGP0060_zps44797b7b.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma%201/IMGP0060_zps44797b7b.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma%201/IMGP0077_zpsb3c66616.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma%201/IMGP0077_zpsb3c66616.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma%201/IMGP0078_zpsc5f6ae68.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma%201/IMGP0078_zpsc5f6ae68.jpg.html)



As far as I know, all Karma GT's were true kit cars.  They were specifically designed to sit on VW Beetle floor pans.  Kelmarks were also designed to sit on Beetle pans but Kelmark Engineering sold turnkey cars (mine is one of them) as well as Kelmarks built on V8 powered mid engine frames.  (Many of which used a VW front beam!)  So to answer your question, the "original" motor in Karmas and most Kelmarks was most likely an air cooled VW engine.  I know there are a bunch of guys with built VW engines in the 150+ hp range, a couple of guys with 911 six cylinders and a couple of guys with Subaru engines.  All of those engines fit nicely into the Karma and Kelmark's rear engine bay.  There are a bunch with 6 cylinder Corvair engines too.  They're nice because they'll put out 180 horse and weigh only 30 lbs more than a VW 4 cylinder.

The Kelmark body is far superior to the Karma body.  It's tougher, stronger, straighter, and finished to a much higher standard BUT, the Karma body is lighter.  I weighed my Karma body - with doors, all glass and trunk lids, the entire body is only 466 pounds.  The XR-2 drive train is 449 lbs.  With luck, this whole thing will be less than 2000 lbs ready to run.   8)
Title: Re: Kelmark XR-2 Project
Post by: Rocketman on February 12, 2014, 11:57:07 AM
I would take either one, they both look cool as hell!

So you're going to sell the kelmark now? No plans to finish it?

Tossing a Subaru STi engine in there with the right transmission/adapter plate & you have a 300hp monster, that would be a lot of fun!

Waiting for it to warm up here. I have a lot of work to do on my cars, heh.
Title: Re: Kelmark XR-2 Project
Post by: Surfnut on February 12, 2014, 12:19:27 PM
It's been terribly cold here too. 

(http://i880.photobucket.com/albums/ac9/Surfnut74/NEW%20STUFF/thermometer_zps1c1f18f5.jpg) (http://s880.photobucket.com/user/Surfnut74/media/NEW%20STUFF/thermometer_zps1c1f18f5.jpg.html)

I know the picture's blurry but it says, "-11 F".  That was the temperature of the lift one day when I was working.  I have to wear two pairs of gloves, two pairs of socks, two pairs of pants, ski masks, insulated coveralls etc...  I've really been suffering out in the garage this winter but thank God I HAVE a garage!  It may be cold but at least there's no wind - that makes a big difference.

My Kelmark is a finished, drive-anywhere car.  I can't really store / license / insure two vehicles that are almost the same.  I don't have the room or the disposable income for that luxury.

I really do love that Kelmark but I'm building the Karma to MY specifications for ME.  In this configuration it might not be right for a lot of people but if all goes well, it'll be really right for me.
Once the Karma's done and finished (two different things!!), I'll have to kiss the Kelmark goodbye.  It's made 2 trips to Pennsylvania at better than 35 mpg and been a very reliable, very enjoyable car for better than 5 years but unfortunately all good things must come to an end at some point. 

I still want to meet up with everybody at your yearly Capri gathering - but I want to do it in a Capri-powered car!

I know a lot of guys are running those Subie engines and everybody I've talked to is CRAZY about the power and performance.  Pulling the air-cooled VW and going to a flat Subaru is definitely the way to go!
Title: Re: Kelmark XR-2 Project
Post by: Rocketman on February 12, 2014, 12:23:58 PM
Would love to have you down here for one of the meets. You should come down capri-power or not. Do you still have one of your capris? I thought you had an N/A too

Lucky you have a garage! I have a small shop I rent that's big enough for some of my machines and equipment, but not for a car. Boo.
Title: Re: Kelmark XR-2 Project
Post by: luvit on February 12, 2014, 06:23:54 PM
i saw this thread on my phone.. i didn't know what i was looking at, but it was awesome.
i dig your projects!
Title: Re: Kelmark XR-2 Project
Post by: Surfnut on August 04, 2014, 07:12:59 PM
Rocket, I had to sell my N/A a few years ago.  It was a good, good car and I miss it.

I just wanted to give a quick update.  The frame's finished and I've spent the last 2 months doing bodywork, body mods and paint.  I'm at the point that I'm quite confident with fiberglass work now.  (Not necessarily good at it but I know I can do it  :D)

This body was in rough condition.  There was damage to the front and back as well as a lot of stress cracks in the fiberglass.  Also, it was wavy as can be.  It must have come out of a second rate mold when it was made.  At best I'm an okay bodyman but luckily I'm a pretty good painter.  I'd say there's a real 200 hours of bodywork into this car (I work slowly  :( )
Painting in the driveway in the sun is challenging.  Between bugs, floating fluffies in the breeze and the burning sun, it's hard to lay a good coat of paint on.  This paint turned out acceptably well for the conditions. 
This is some of the stuff I did :

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP1496_zps42dbc7f3.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP1496_zps42dbc7f3.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP1495_zpsc8aeeed1.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP1495_zpsc8aeeed1.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP1497_zps72d576cd.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP1497_zps72d576cd.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP1741_zps7c7aa4b2.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP1741_zps7c7aa4b2.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP1759_zps5f869567.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP1759_zps5f869567.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP1782_zps667b3a8f.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP1782_zps667b3a8f.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP1754_zps45558888.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP1754_zps45558888.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP1767_zps24ed4385.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP1767_zps24ed4385.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP1756_zps13d4f7a8.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP1756_zps13d4f7a8.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP1771_zpsee75aaa5.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP1771_zpsee75aaa5.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3031_zps7aadd441.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3031_zps7aadd441.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3029_zpsfc2ac177.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3029_zpsfc2ac177.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3034_zps2fac0c27.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3034_zps2fac0c27.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3203_zpsb84aaf5f.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3203_zpsb84aaf5f.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3205_zps222e2412.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3205_zps222e2412.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3204_zps8ab5df66.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3204_zps8ab5df66.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3129_zpsa7e6ef11.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3129_zpsa7e6ef11.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3418_zpsf4b30d93.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3418_zpsf4b30d93.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3416_zps166d2dfd.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3416_zps166d2dfd.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3397_zps7ef4040e.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3397_zps7ef4040e.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3029_zpsfc2ac177.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3029_zpsfc2ac177.jpg.html)

I mixed my own paint from cheapo quarts I've purchased over the years :

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3012_zpseff63848.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3012_zpseff63848.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3016_zpse9e9c6c2.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3016_zpse9e9c6c2.jpg.html)

The results of two solid months of bodywork :

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3453_zps92a0ea16.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3453_zps92a0ea16.jpg.html)

I did things like modify the front turnsignals.  Here are the front turnsignals the day I bought the car:

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMGP0012_zps465d1809.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMGP0012_zps465d1809.jpg.html)

I had four of these swap meet specials in my parts stash :

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP2355_zpse715f75f.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP2355_zpse715f75f.jpg.html)

I cut up a couple of paper towel rolls and taped them up to fit the diameter of the lens :

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3268_zps5970f809.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3268_zps5970f809.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3269_zps6396fc46.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3269_zps6396fc46.jpg.html)

Cover with packing tape :

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3270_zps487f4832.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3270_zps487f4832.jpg.html)

Lay some fiberglass over it :

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3271_zpsea1cfb28.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3271_zpsea1cfb28.jpg.html)

When it cures, remove the paper towel roll :

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3273_zps1438a746.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3273_zps1438a746.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3276_zpsf5ec4e2e.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3276_zpsf5ec4e2e.jpg.html)

Open up the hole in the body to fit the new fiberglass tube:

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3279_zps089f45d4.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3279_zps089f45d4.jpg.html)

Cram it in there :

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3280_zps31f5c21c.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3280_zps31f5c21c.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3282_zps7c17b487.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3282_zps7c17b487.jpg.html)

Start glassing it in:

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3291_zps089d97cb.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3291_zps089d97cb.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3294_zpsee42c8ed.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3294_zpsee42c8ed.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3295_zps45543057.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3295_zps45543057.jpg.html)

Cut the excess off:

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3298_zps237ff129.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3298_zps237ff129.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3299_zps8723d29d.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3299_zps8723d29d.jpg.html)

Grind, sand and fill the low spots with fiberglass matt and resin then top with fiberglass reinforced bondo (and do that a few times):

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3299_zps8723d29d.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3299_zps8723d29d.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3307_zpse53cde85.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3307_zpse53cde85.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3309_zpsf5471b7f.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3309_zpsf5471b7f.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/IMGP3311_zps8fd975e2.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/IMGP3311_zps8fd975e2.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/frontend2_zps34bb5e0f.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/frontend2_zps34bb5e0f.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/frontend3_zpsa6fe62f2.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/frontend3_zpsa6fe62f2.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/frontend4_zpsaf766652.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/frontend4_zpsaf766652.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/frontend6_zpsfffbe3f4.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/frontend6_zpsfffbe3f4.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/frontend5_zpse72588d3.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/frontend5_zpse72588d3.jpg.html)

It's stuff like that that has sucked up my time.  I modified the mid-hatch, the rear trunk, the front turnsignals and the rear panel. 
While I was waiting for the paint to dry, I started messing with the XR-2 engine.  I changed the water pump, timing belt, tensioner pulley and the thermostat (I FOUND IT!!   ;) ).  I fired it up and started fooling around with the exhaust but that my friends is a story for another time!

https://www.youtube.com/watch?v=JBVGz2WIgSc

At this point, I'm over a year into this build, have worked like a dog and spent almost $8000.   :'(
 
Title: Re: Kelmark XR-2 Project
Post by: greywolf27030 on August 05, 2014, 10:54:49 AM
You're an inspiration man.  Saving a vintage kit car is always a hassle, but you're doing the people at Karma proud.  In those days poor molds and wavy bodies were par for the course and was a major reason many were never finished.

Keep it up man, Jack Byrd
Title: Re: Kelmark XR-2 Project
Post by: Surfnut on November 25, 2014, 12:18:23 PM
Thanks Jack!  I appreciate your nice comment.   :D

This has been a ridiculous amount of work.  Hopefully it will all be worth it in the end...

'Cause I didn't want y'all to think I'd given up or disappeared, I wanted to post a quick update.
 
The finished (for now) body is back on the car, the XR2 drive train is installed and I'm squaring away the engine wiring now.
Next up will be half shaft fabrication.  I've elected to have this done professionally instead of trying to make / modify them myself.  I don't want to worry about busting an axle shaft so even though I'm confident with my welding and fabrication abilities, I'm going to pop the $$ and have custom half shafts made and hopefully, never have any issues with that part of the build.

To recap, I've mid-mounted the stock XR 2 engine and transmission.  The new axle shafts will be attached from the XR 2 trans to 1995 Mercury Cougar XR7 (same as T-Bird) rear uprights and stock rear disc brakes on custom made unequal-length upper and lower "A" arms. 

Here are some updated pix for you :

This picture was taken the day I dragged the poor old car home :

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/Karma%20Finished%20Bodywork/karma1_zps995454b4.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/Karma%20Finished%20Bodywork/karma1_zps995454b4.jpg.html)

Body on the new frame :

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/Karma%20Finished%20Bodywork/Karma2_zpsef05e2db.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/Karma%20Finished%20Bodywork/Karma2_zpsef05e2db.jpg.html)

Completed body on the new frame :

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/Karma%20Finished%20Bodywork/IMGP2569_zpscc664fff.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/Karma%20Finished%20Bodywork/IMGP2569_zpscc664fff.jpg.html)


Other pix :

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/Karma%20Finished%20Bodywork/karma3_zps2a56b3ff.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/Karma%20Finished%20Bodywork/karma3_zps2a56b3ff.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/Karma%20Finished%20Bodywork/karma4_zpsde09477a.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/Karma%20Finished%20Bodywork/karma4_zpsde09477a.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/Karma%20Finished%20Bodywork/PA130696_zps8484eb71.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/Karma%20Finished%20Bodywork/PA130696_zps8484eb71.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/Karma%20Finished%20Bodywork/PA130692_zps9ce27d4f.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/Karma%20Finished%20Bodywork/PA130692_zps9ce27d4f.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/Karma%20Finished%20Bodywork/IMGP2573_zps7afa2d2b.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/Karma%20Finished%20Bodywork/IMGP2573_zps7afa2d2b.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/Karma%20Finished%20Bodywork/IMGP2565_zpsb0817f1a.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/Karma%20Finished%20Bodywork/IMGP2565_zpsb0817f1a.jpg.html)

We're not using a cable operated clutch anymore so to switch to hydraulic, I came up with this :

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/Karma%20Finished%20Bodywork/IMGP3780_zpsc77be61b.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/Karma%20Finished%20Bodywork/IMGP3780_zpsc77be61b.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/Karma%20Finished%20Bodywork/IMGP3785_zpsf02b452a.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/Karma%20Finished%20Bodywork/IMGP3785_zpsf02b452a.jpg.html)


(I'll get a Grade 8 bolt next time I get to the Nut and Bolt store but this one will do for now)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/Karma%20Finished%20Bodywork/IMGP3783_zps2e9908cc.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/Karma%20Finished%20Bodywork/IMGP3783_zps2e9908cc.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/Karma%20Finished%20Bodywork/IMGP37961_zps229f654a.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/Karma%20Finished%20Bodywork/IMGP37961_zps229f654a.jpg.html)

Completed bracket - the important stuff is 3/16" plate, all the braces are 1/8".  It'll never break or bend:

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/Karma%20Finished%20Bodywork/IMGP3798_zpsab975f4a.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/Karma%20Finished%20Bodywork/IMGP3798_zpsab975f4a.jpg.html)


Right now, I'm organizing the hugely-trimmed-down XR 2 wiring harness and trying to make it look nice-nice.

(http://i880.photobucket.com/albums/ac9/Surfnut74/Karma%20Bodywork/Karma%20Finished%20Bodywork/IMGP2601_zpsdf0c3882.jpg) (http://s880.photobucket.com/user/Surfnut74/media/Karma%20Bodywork/Karma%20Finished%20Bodywork/IMGP2601_zpsdf0c3882.jpg.html)

As nasty as that looks, it all works great.  All I have to do is organize and secure the whole works, connect my ground wires and new battery cable then splice into the original XR2 wiring that attaches to the steering column.  I'm using a GM tilt steering column so I'll connect the appropriate wires from the Capri wiring loom and we should be good to go (as far as starting and running the engine in the car).

More later.    Stay warm Capri brothers!


Dave
Title: Re: Kelmark XR-2 Project
Post by: greywolf27030 on November 25, 2014, 01:32:46 PM
Cool, where are you located?

Jack
Title: Re: Kelmark XR-2 Project
Post by: Surfnut on November 28, 2014, 12:14:50 AM
Just outside Deeeeetroit.   8)
Title: Re: Kelmark XR-2 Project
Post by: greywolf27030 on November 28, 2014, 09:46:09 AM
Gosh, I hate it for you.  I hate winter.  Thinking about moving further south.

Jack
Title: Re: Kelmark XR-2 Project
Post by: Rocketman on November 28, 2014, 10:21:50 PM
Im digging the progress. The body looks amazing. Can't wait to see it under power. Soon right? ;)

Winter is upon us here in PA. Not digging that part. I despise winter.
Title: Re: Kelmark XR-2 Project
Post by: Surfnut on December 10, 2014, 04:37:41 PM
Thanks guys!

I will definitely update you as soon as I'm able to safely drive the car.  I'll be posting tonight in the XR2 section regarding some half shaft questions.  If somebody here can help me figure out what I need to do, I can get my half shafts done properly and we'll be close to driving!

Thanks again,

Dave
Title: Re: Kelmark XR-2 Project
Post by: StreetDoc on August 31, 2015, 05:44:22 AM
Wow. Just found this thread and am loving it. I wish I had those skills.
Title: Re: Kelmark XR-2 Project
Post by: Surfnut on May 19, 2016, 11:57:22 AM
We're nearing road-worthiness.  I thought you guys might like to see this picture of my XR-2's engine in its new home.

I'm not happy with the intercooler's piping but I need to make this work as quickly as possible and don't have the time to screw around with too much custom fab work.  At some point, I'd like to have a larger, custom intercooler made and then the piping will be properly routed.  For now, this seems to work okay.

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/IMG_20160518_160721685_zpsy3higj6g.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/IMG_20160518_160721685_zpsy3higj6g.jpg.html)
Title: Re: Kelmark XR-2 Project
Post by: Rocketman on May 23, 2016, 11:36:01 PM
Awesome! Glad to see you're still working on it.

You can always mess with the intercooler later. Get her movin' ! hah.
Title: Re: Kelmark XR-2 Project
Post by: Surfnut on June 17, 2016, 11:49:30 PM
(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/P6170326_zpsxpqwyago.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/P6170326_zpsxpqwyago.jpg.html)


Good news - my Karma is now legal and absolutely fantastic to drive.  It's super tight and firm and the power from the XR2 engine is a perfect match for it.

You can feel the car's lightness and you can feel how stiff and strong the chassis is.   

The shifter snicks and clicks into gear like a piece of Swiss machinery.  It begs to be shifted and downshifting with a punch of the throttle brings on a spectacular 'whoosh' from the turbo then a crackly, snarly rattle from the exhaust that sounds like angry hornets in a can. 
I can't believe how rattle free this car is!  It doesn't squeak or shimmy or creak or anything, and with the exception of needing a proper alignment, it feels completely refined.  It is absolutely rock solid.

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/P6170317_zpsduesa8qc.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/P6170317_zpsduesa8qc.jpg.html)
I'll post more pictures (and hopefully some video) in the days to come but for now, here are a few interior shots.


(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/P6080259_zps4qemufhi.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/P6080259_zps4qemufhi.jpg.html)



(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/P6150290_zpsr6i2kzuw.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/P6150290_zpsr6i2kzuw.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/P6150287_zpsu7rnppv6.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/P6150287_zpsu7rnppv6.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/P6150281_zpspjt1giec.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/P6150281_zpspjt1giec.jpg.html)

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/P6150282_zpsriy3dodn.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/P6150282_zpsriy3dodn.jpg.html)

And the aluminum underbelly pans along with the stainless cooling tubes:

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/P6170300_zpsabky4k4m.jpg) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/P6170300_zpsabky4k4m.jpg.html)

More later!

Dave
Title: Re: Kelmark XR-2 Project
Post by: greywolf27030 on June 18, 2016, 08:30:44 AM
Simply awesome.....Jack
Title: Re: Kelmark XR-2 Project
Post by: DarkAngel on June 18, 2016, 10:21:11 AM
Congrats Dave on a truly awesome project... kudos
Title: Re: Kelmark XR-2 Project
Post by: Surfnut on August 27, 2016, 10:30:26 AM
Thank you for the nice comments, I appreciate them very much.  :)

Here's the link to a video of the car running and driving. 
This is probably the only car in the world with a stock XR2 drive train running the rear wheels.
I hope you like it!

https://youtu.be/WGOxg5Po8sY

Thanks,

Dave

Title: Re: Kelmark XR-2 Project
Post by: greywolf27030 on August 28, 2016, 08:07:08 AM
Very impressive accomplishment.  Does it drive and ride to suit you?

Jack
Title: Re: Kelmark XR-2 Project
Post by: Surfnut on August 31, 2016, 08:52:57 AM
Thanks Jack!  I'm sorry for taking so long to get back to you but I work 7 days a week and I'm smack in the middle of moving so 3/4 of my life is packed in boxes right now and I don't know if I'm coming or going.   :o

The car is quite impressive to drive.  It's super tight and firm and rattle free. You can feel the car's lightness and how stiff and strong the frame is. Nothing creaks or squeaks - to be honest, it's hard to believe that a self-built car could feel this solid and refined.  I had a 2004 Crossfire and the Karma feels as solid as that car was.  The doors close with a 'clunk' and there are no squeaks or rattles or annoying vibrations.  It feels solid like the Crossfire but much, much lighter (and louder).

The shifter snicks and clicks into gear like some sort of high end Swiss machinery. The clutch pedal is FAR too hard but the travel is lightning quick and between the super quick pedal travel and the snicking and clicking of the shifter, changing gears is glorious. You WANT to keep shifting.

The power is beautiful.  I've never gone over 4000 RPM and I see no reason to unless i was looking to make a show. The exhaust is rumbly and crackly and when you really get on it, it the turbo whooshes, and the exhaust shouts and crackles like a giant angry hornet in a can. I can't tell you how fantastic it is to drive. I never would have believed a normal guy could build a car that feels this good. The XR2 drivetrain is fantastic!  You can imagine the acceleration if you took a good running XR2 and dropped a few hundred pounds.  Not a rocket ship but certainly not a slug and TONS of fun to drive.  In the future, I plan to upgrade the power (why not?  It's what we do!) but truthfully, I have absolutely no issues with the stock XR2's power.

The Karma looks good but it actually drives better than it looks.   :)

Thank you for your reply!

Dave
Title: Re: Kelmark XR-2 Project
Post by: WashiestSnake on September 01, 2016, 12:11:19 AM
First time Ive seen this thread. I love it, that is a incredible show of work! I love the looks of the Karma, it reminds me of a Ferarri 206!
Mike  ;D
Title: Re: Kelmark XR-2 Project
Post by: chrispoe on September 01, 2016, 10:32:25 AM
You did a great job with the car!

Have you taken the car to a scale yet? cuz I’m curious as to how much the car actually weighs.
Title: Re: Kelmark XR-2 Project
Post by: CapriTypeR on September 05, 2016, 11:14:19 AM
Dave-
Congrats! I'm glad you were able to finish this project up, and be happy with the results! I've been watching this build evolve for what, 6 years now?
It's a beautiful car!

--Russ
Title: Re: Kelmark XR-2 Project
Post by: Surfnut on September 13, 2016, 04:33:20 PM
Thanks very much guys!!   :) :) :)


Yes, Russ, I think I started dabbling sometime in 2010.  I found this video of the starting and running XR2 engine that I posted on September 4, 2010 :


https://www.youtube.com/watch?v=CyTWw07xNhk


I remember pulling the drivetrain out of the XR2 in the winter so to my recollection, I probably "started" in early 2010.  By late summer, the stock wiring harness was cut down enough to make the engine run.

A little more than a year later (December, 2011), I had the rearmost part of the frame "done" :


https://www.youtube.com/watch?v=Vr4EXn2J2cE


This is when I still had my pushrod suspension (eventually trashed that).  So sometime between September 2010 and December 2011 saw the start of the fabrication of the frame.  I didn't actually get the Karma until June 2013 and that's when things really started to move along.

I hope I will be able to drive the car to the Capri meet in 2017 -wherever and whenever that will be.

At some point in the future, I'm going to have to start planning on building in more power..... 8)



Thanks again guys, I really appreciate your comments!


Dave

Title: Re: Kelmark XR-2 Project
Post by: Surfnut on November 13, 2016, 08:48:24 AM
Hi guys,


Neat news - my Karma has been featured in a magazine (E-zine).  The magazine is called, "ReinCarNation Magazine" and it focuses on replica, continuation and low volume automobiles.  They included a lot of pictures of the build process, which I think is very cool.

(http://i880.photobucket.com/albums/ac9/Surfnut74/My%20Karma/Screenshot%202016-11-03%20at%203.21.40%20PM_zpsj9wih9ce.png) (http://s880.photobucket.com/user/Surfnut74/media/My%20Karma/Screenshot%202016-11-03%20at%203.21.40%20PM_zpsj9wih9ce.png.html)

Unfortunately, the author got a few of the details confused and not much is mentioned about the Capri XR-2.   :(   What is mentioned isn't correct.  I've decided that I will produce some YouTube videos focusing on the build process and one of the videos will go a bit more indepth on the XR-2 drivetrain.  Hopefully, the videos will help to set the record straight - just in case somebody out there actually cares about it someday.



Here's a link to the e-zine article
:

http://reincarnationmag.com/garage/karma-re-engineered


And here's a link to the first, general / overall build video I just finished:

https://www.youtube.com/watch?v=sK68jaMqWws


Other slideshow type videos will follow.

I hope all is well with everyone here.


Dave
Title: Re: Kelmark XR-2 Project
Post by: greywolf27030 on November 14, 2016, 08:59:56 AM
Great vision, great execution.

Jack Byrd