Not only is 2013 an exciting year for TEIN in regards to new products, but we are also prepping for a great year of racing. One of the teams we assist in Rally America, and who we are quite fond of writing about, the Sparco Rally xD team is starting to put the finishing touches on this year’s chassis.
Aesthetically, it may look to be just about the same. But, as the saying goes, it’s what’s on the inside that counts. And this chassis lives up to that saying!
Much more fabrication is going into this new car. As it is, the Rally xD team are facing some serious competition. Some of which are tried and trued platforms used internationally. The Rally xD is one of few cars that doesn’t have that sort of background. For the past 4 years, this team has been the guinea pig in getting a Scion xD into a competitive vehicle. As I’ve stated before, and as I say again, these guys are doing such a great job at it.
Although I don’t feel at liberty to cough up the details on the new car, I will say that their TEIN dampers for 2013 are a big step up from the HG-based dampers of years prior. This year, they’re using 2-way adjustable dampers based loosely off of the Group N. dampers. Basically, it is height adjustable and compression and rebound adjustable. This damper project was completed through our Specialized Damper Program- a program also available to the public!
Below are a few photos of the team’s progress on the vehicle, as well as their new TEIN dampers.
I’m sure I can dig up a few more photos of the car build. But I’m sure they’d appreciate if you gave them a follow on Facebook, Twitter, or Instagram (@RallyxD,,, easy enough to find!), which they are very active on. Tons of photos for all of you to see! So, please do so and be sure to wish this hardworking crew the best of luck for 2013!
Other than this team, we look forward to another great program of events for the year ranging from Time Attack to the Formula Drift series. As always, we’re glad to be involved!
As we previously mentioned, the Sparco Rally xD team had a rear twist beam axle failure during the last event, Susquehannock Trail Rally in PA. Once they got the car back down to California, they dropped off the rear dampers to us for inspection/repair.
Like we stated before, we knew that the dampers had some damage and broke the piston shafts. Here’s a look at the carnage
Remote hose was ripped right off. The shell case took a few hard impacts causing some dents. Now onto the piston shafts
The above picture shows the top of the shell case where the ring nut seals off the damper. The piston shaft broke midway and the remaining pieces recessed into the damper with oil coming out this ring nut portion. The top portion of the piston shaft was still attached to the shock tower.
This pic below shows the piston shaft broken towards the top, snapping right off after the twist beam axle gave way.
But after a full teardown, we saw that the inner tube (where the piston is inside of) was still intact. The outer shell case took a hit, but the inner tube was unscathed during this violent axle breakage. Here’s a pic showing the dent
The second pic from the top shows the other indentation on the shell case.
On a mono tube damper, this wouldn’t fare so well with that type of dent. Since the piston would reside right against the inner lining of the shell case of a mono tube damper any imperfection to the case will make it either impossible to function properly, or to be field stripped, or both. This is what I meant as testament to the durability of the twin tube damper structure and this case shows it well!
If you’re wondering why we would make a twin tube damper for a rally car, there’s a bit more to it than just the damage that could be inflicted to it physically. Our HG twin tube structure isn’t like a normal damper.
In a standard twin tube damper, there is still an inner tube that contains the piston shaft and piston. This area is fully submersed in damper oil. From the bottom of the damper and through the base valve controlling oil flow into the outside of the inner tube (inside of the shell case) is where there is some oil and the nitrogen gas charge. This charge is important in sufficiently providing rebound force to the damper.
What we do with the HG is fill the inner and outer tube with damper oil.
But wait. If you fill a damper full of incompressible oil and no compressible gas like nitrogen, then technically the piston shaft will never recess into the damper and it wouldn’t function at all.
That is true. But this is also why we utilize an external reservoir to keep the nitrogen charge separate. With this, we can eliminate any chance of aeration (nitrogen gas mixing with damper oil, causing it to froth, decreasing damping effectiveness) while still being able to secure sufficient rebound. The twin tube structure also allows ample stroke length for a given shell case size compared to a similarly built mono tube damper.
So why not utilize this design into all rally suspension? Mono tube dampers still have many great benefits- they dissipate heat better; when inverted, they decrease unsprung weight (you can technically invert our HG damper, btw); they allow a larger piston size; overall damper oil volume can be much higher. They also allow for us to use our Group N.technologies, which aren’t readily applicable to twin tube dampers
But mono tube rally dampers are a much higher investment as development costs are quite high. Also, they are physically much larger in length and body diameter. the pistons used in them are much larger too, which is key for precise damping control.
So in the end, the HG is still very capable and also very durable at a much more reasonable price!
Anyway, enough ranting. We went right to work getting it rebuilt with new shafts and internal seals. this time, we stuck with our shorter length reservoir hose, still giving the team the freedom to reposition the external tank for their needs.
Awwww. Looking as spiffy as it will ever be! Ready for more abuse!!!
Speaking of which, here’s a video the Rally xD team posted from their blog showing the twist beam axle breakage
If you’ve been following the Sparco Rally xD team as much as we have, then you know that they have consistently placed podium finishes. As of the Oregon Trail Rally (May 4-6), they temporarily held 1st in championship points under the 2wd class. Good stuff! That’s not an easy task, mind you!
Consistency is key. If you follow these dudes on Facebook and/or Twitter, you’ll see that they completely rework the car after every event, going down their laundry list of items to check, making sure that all components are good to go or replaced if needed well before the next race. I must add that they run a very tight ship- only a handful of guys working on this car. They not only serve as pit crew and transportation, but I’m guessing also as entertainment for their driver and co-driver Andrew Comrie-Picard and Andrew Wimpey. Geez. That’s a lot of work!
After every three or four events, they normally send their custom HG dampers to us for inspection. In some cases, they go longer without inspection, especially when they quickly have to prep for the next event. As with anything rally, these parts take a beating! In our case, it’s normally exterior coatings that get blasted off by dirt and gravel. Minor concern, i suppose.
Before the Oregon Trail Rally on May 4th-6th, Crew Chief Philip Chase brought in the dampers for a quick check. Surprisingly, nothing to really change on the front dampers.
Jon a.k.a. Sir Smiles-A-Lot Inspects The Front Dampers.
But for the rear, he requested remote reservoir mounting (tank detached from damper body), rather than the external mounting (tank attached to damper body) to give them freedom to reposition the external tank and add some needed clearance in the wheel well. Since that kind of work requires complete damper tear down, we overhauled the rear dampers for them. Now they have the reservoir attached by way of a braided steel hose, allowing them to reconfigure reservoir arrangement (they still keep the reservoir close to the damper body, just upside down and a few degrees in towards the chassis).
Still, even with all this preparation and constant rebuilding, something is bound to go wrong in the world of rally. Case in point- the Susquehannock Trail Rally (June 1-3) proved to be the breaking point for the Rally xD. This time, a fatigued rear twist beam axle gave way, pulling apart the axle and the damper assemblies. Ouch! Seven consecutive events can easily do this to a car and its parts. But seven events is also a long time of service! Seems the xD ain’t no cheapo box, afterall!
Susquehannock is no joke. check out this video showing the driving conditions they face
Fortunately, the break was at the beam. So it looks like they’ll be able to repair the car in time for the next event. Also, it seems that our customized HG rear dampers may be able to be repaired, too! That’s testament to the strong twin tube structure of the dampers that can take a good amount of punishment!
Next up is preparation for Pikes Peak, then off to New England Forest Rally (NEFR). They’ve got some time to knock out repairs.
I wish them the best this season, as these hard-working guys continue to do a great job time and again. On our end, we’ll continue to do the best we can to make sure their TEIN HG dampers are in top working order!
Keep it up, guys!
For an econobox, this Rally xD is one tough shoe!.
There’s some good recap of the events at Rally America’s website
www.rally-america.com
And of course, the dudes at Sparco Rally xD keep their blog up-to-date!
www.rallyxd.com
You can also follow them on Facebook (Rally xD) and Twitter (@RallyxD)! Oh, and you can follow us on Facebook, too (TEIN USA, Inc.)!
P.S.- if you were to look up the Finnish term “Sisu”, I’m almost positive that you’d find a picture of the Rally xD team. Look it up!
Congratulations to the Rally xD Team pulling a 2nd place win just beating 3rd place by a few seconds!
Even though the teams were faced with a portion of blindness due to high speeds and dry weather, which combined created major dust clouds affecting some of the teams on day one of The Rally of the 100 Acre Woods in Salem, Missouri which forced the Rally xD to fifth place on Day 1.
They eventually managed a second place finish but not without battling their way through the ranks.
Nice shot of their custom TEIN Suspension.
Good Luck on their next event! Keep up the Good Work Rally xD Team!
January 27th 2012 saw the start of the Rally America Championship series, and the TEIN sponsored Sparco Rally xD is off to a great start.
The Rally xD team managed to nab a 2nd in class win in spite of the frigid temperatures of Atlanta, Michigan and the subsequent snowy/icy/slushy road conditions they faced.
Andrew-Comrie Picard and Jeremy Wimpey returned once again as driver/ co-driver, piloting the xD expertly against the likes of Fiestas and Focuses, and even some Evo’s and STi’s.
After the event was finished and the team returned to sunny SoCal, the Specialized HG Dampers were removed from the xD and brought to us for a tear down and refresh before the next event.
Close, in-house repairs are definitely an advantage when you need your products back ASAP.
The next Rally America event will be February 24-25th in Salem, Missouri.
Check back for more coverage and results of the TEIN sponsored Sparco Rally xD in future Rally America events.
Video from 0-60 Magazine. All footage was taken at the Oregon Trail Rally held on May 14-16.
Rally Scion xD is using TEIN HG coilovers made using our Specialized Damper program. You can see in the video that it easily absorbs the rough conditions and even a jump. Throughout the three day event the suspension worked perfectly and after a little cleaning it will be ready for the next event.
This past weekend I attended the Oregon Trail Rally as a crew member/ mechanic for the 0-60 Rally xD. This was my first rally ever and it was a eye opening experience.
Arrived in Portland on Thursday night for our first ever team meeting. This was the first time that the entire team was able to meet at one time. Going into this event everything was new: new unproven car, new transporter, new crew, new co-driver, etc…
On Friday we were at Portland International Raceway for the entire day. For the first half we were setting up the car and making changes so that we could pass tech inspection. My job was to fabricate rear rubber guards to protect the suspension, brakes, and shocks (little did I know that I would end up making about 5 sets of these throughout the weekend). Rally competition started around 7PM which were Special Stages designed for spectators.
Saturday had us in Dalles which is about 1.5hrs from Portland and then in Dufur for the second half of the day. We would stay in Dufur for the remainder of the Rally which ended Sunday afternoon.
There were basically four mechanics for the car which included Lenny and Ben from Design Craft, and Mr. Nakai and myself from TEIN. Gordon and the 0-60 crew were cleanup and kept the car clean for the entire Rally. Other crew members included photographers, videographers, and volunteers willing to help anywhere needed.
(picture is missing three crew members who were hiking back from the best photo spot – pickup 0-60 magazine to see the amazing photos)
During each day we had 1-2 services between the stages. This is when the cars come back into the service park for crew members to repair, clean, refuel, adjust the car. Most services are about 40mins which was enough time to:
Remove and inspect all 4 wheels, Rotate wheels, check all fluids, repair any damage, inspect and torque check all suspension components, inspect and clean brakes, clean the entire car inside and out, refuel and get the car back out.
Each service is organized chaos. It must look like a swarm of bees attacking from a spectator point of view. Any delays in service and the car is hit with time penalties. At the end of every service I was covered in dust/ dirt but I was glad the rain held off until the rally ended – mud would have REALLY made it messy.
At the end of every night we performed a longer more thorough service which added changing fluids, bleeding brakes and more extensive repairs. A Rally car has many components which preventative like the mud flaps, inner fender liners, underbody body guards, etc… During service these parts all need to be inspected, repaired or replaced to ensure nothing is damaged in the following stages.
Crewing for a rally car definitely has its stresses. While the car is out running you have no contact so you never know what is going on. Then when the car arrives it is a rush to get all service completed. Once the car leaves it is time to cleanup and prepared for the next service or grab a bite to eat. At the end of the day there is service and then teardown of the pit for the night. The next day it all starts over again.
The underpowered 1WD (due to open differential) almost all stock xD SHOCKED many teams and spectators alike with its quick times which were mainly due to driver Chris Duplessis (2007 & 2008 2WD Champion) and co-driver Ron Zaras (0-60 editor, 2nd Rally ever).
Driver, Chris with the helmet hair. Co-driver, Ron with the Sparco suit, and 0-60 girls.
The attrition rate of the rally was high with about half the field out or slowed due to damage. The durable and reliable Scion completed the entire Rally with no incident. Stock engine, stock transmission, stock brakes = no problems. Yes, more power, clutch type differential, upgraded brakes, shorter gears, etc… would all make the car faster but the goal for this first event was to finish. With the hard charging Duplessis behind the wheel the car was able to finish 2nd in 2WD, losing to a veteran turbo charged Ford Focus.
Visit 0-60 Magazine’s website for videos and a complete story of the event.
Just got back from Portland Oregon. Myself and Mr. Nakai went out to support 0-60 magazine rally entry for Rally America – Rd. 4 Rally Oregon. The three day event started Friday and ended Sunday afternoon.
Gordon T. of 0-60 had a Scion xD modified for Rally competition. It features custom TEIN HG dampers which are designed for rally usage.
The kit features external reservoirs, two-way adjustment, extra large piston shafts, and other internal parts made to handle the harsh conditions.
The team was quite large with many support personnel who are here to ensure this experiment is a success. This is the first time the car has been run. It was completed by Design Craft only a few days before the event and put on the trailer immediately after. The support team is comprised of Rally virgins besides Mr. Nakai who has supported rally worldwide for the past 3 years.
The car has a stock motor, stock transmission and no testing. Major modifications are the roll cage, HG dampers, Volks, and plethora of Sparco parts. The car was kept simple for a reason – so that it would finish.
I will post a more detailed account of the weekend in the days to come.
Here is a short video clip found on YouTube. Not bad considering the car is one wheel drive (open differential).
