Saturday, Day 2 of the Rally
I woke up early and immediately pulled to battery out of the RX7 and swapped it into Chief's auxiliary battery spot to charge, letting the truck idle to bring the battery back to life. I had tried to check the voltage but of course my multimeter was dead.
I then swapped the spark plugs and gave everything a once over while Sara cleaned the dust out of the air filter- the plugs didn't look fouled, so I wrote off the possibility of any major fuel or ignition problems. None of the electrical connections, sensors, etc. looked bad either, so my hope was that the low battery voltage had cause all of our issues from the night before. Just in case, I bought some jumper cables at the local parts store as well.
We put the battery back in the RX7 and cranked it... and cranked it... and, dammit, what is wrong with this thing, I know this battery is charged fully now! It finally fired up and I turned the idle up to ensure that it couldn't stall- this was not appreciated by the motels non-rally guests, one of whom was yelling at me as I packed the car, which drew my attention away from the task at hand enough that I accidentally slammed the hatch shut on my GoPro, breaking the lens (although I didn't know it was broken at the time). Oops. We cleared the hell out of there before people started throwing things and got to the Parc Expose, which for day 2 was in Seney about 20 miles up the road.
The car ran well on the way there, although we noticed that our diff was leaking upon arrival. Why? Oh, maybe it's the exhaust superheating the fluid in the thing:
Luckily it was overfull to begin with and the gas tank was staying cold, so I wasn't too worried. We decided that, thanks to the mysterious starting annoyance, we would only shut the car off in the service park, and keep Chief oriented in such a way as to facilitate use of the jumper cables. I checked tire pressures and Seth crafted an exhaust sling from some wire to prevent the remainder of the pipe escaping.
We then left our crew, with Chief in prime jump start position, and headed out to SS7.
SS7 was a stage called Danaher, and we were told it was the other car killer of this rally, with 9 miles of the same sort of nasty garbage as Two Hearted but with less trees so that you'd be lured into driving too fast for the terrain. It was all of that and more.
We launched off the start line and settled into a fast pace, slightly less conservative than our run at Two Hearted the day before. The exhaust is already broken, right? How bad can it really be?
Maybe 6 miles in, it got bad. The car began sputtering, the gauges were going nuts, and we were slowing down all too fast in a section with no room to pull off. Then the car fully died, shutting down so quickly that I only got it half way off the road- I tried the starter, the fuel switch, everything, and not a single thing had power.
We were stuck, around a blind corner, blocking half the road, and there was another car coming. I shouted "Traingles triangles TRIANGLES!" as we dove out of the car, and Sara took off running with one while I dug another out of the back. We got them set up just as the first car arrived, and they squeezed their way around us. Sara got the third triangle set up and I went back to the car. A couple cars went by, but they had fragile looking light bars that I didn't want to risk- then the Celica showed up.
I flagged the Celica down, slapped the RX7's rear bumper, and hopped in- getting the message, they shoved me the rest of the way off the road. Now I was clear of the race line and could work on things.
When I opened the hood, I was greeted by a geyser of coolant (did you know rotaries overheat when you shut them off at race pace? Surprise!) and saw the problem immediately. The battery had ripped free of its' mounts and the power steering pulley had sawed through the positive cable- it threw sparks all over the place as I yanked it away from the engine, leaving little bits of cable welded to the pulley. How the hell do I fix this?
JUMPER CABLES! I grabbed the brand new jumper cables we had bought that morning and a ratchet strap and got to work; jumpers connecting what was left of the positive battery cable together, ratchet strap holding the battery and mess of cable in position, perfect. I got back in the car and it had power! Then followed the longest starting procedure of my entire life- the car was flooded, hot, and didn't have the best battery connection, but we apparently have the most resilient starter motor in all of history because seriously, 10 minutes straight is not an exaggeration.
I was still cranking the engine when sweep showed up; the first sweep vehicle saw that we were OK and drove on, and the second asked if we needed a tow as Sara packed the triangles back into the car. "I will work on this until you tell me you need to pull me out of here" was my response, and after another 2 or 3 minutes, the car fired again- YES! Sara strapped in as I closed the hood by smashing it with my knee, as it now had to clear an extra 4 inches of ratchet strap and jumper cable.
This picture is from later, jumper cables not included:
We took off- I wanted to catch the lead sweep vehicle so we could exit the stage before it officially closed, and catch him we did- only a mile or so from the finish. He let us by and we posted over a 32 minute time for the 9 mile stage- but not a DNF! We were still in it!
I wanted desperately to check my repairs but we didn't even stop other than to get our time- we had to transit SS8 to get to SS9, and had very little time to do it. Technically SS8 was now an open public road but I'll admit, I pushed it a bit... for the purposes of statutes of limitations and such, lets leave it at this: we made it to SS9 with no time penalties, showing up ON OUR MINUTE somehow. I still don't fully understand how that was possible.
It was becoming painfully obvious at this point that the car was losing power- anything below 5k rpm wasn't really an option for acceleration, and it was not particularly strong from 5-8k either.
SS9 was a road called Carlson Camp, and was VERY fast with the odd "caution" and "don't cut" thrown in for good measure. When I jumped out of the car on Danaher I had broken my intercom wire, forgetting to unplug it before sprinting up the road, so we had no intercom- the car was quiet enough for Sara to yell over the exhaust, so we still had notes, although I really had to strain to hear her at times.
I ran somewhat conservatively for this stage- I wasn't sure of my repair or what was happening to the car. We were slow but didn't lose a ton of time, and the jumper cables amazingly held on the entire time. The added stress of the oddly bent hood also broke the passenger side hood hinge as we came over a jump. We transited back to service to hopefully make our fix a little more permanent.
Service was 20 minutes, and I nearly passed out (did I mention it was like 90 degrees?) as I tried to fix the battery, drink a bottle of water, and eat an energy bar at the same time. The conversation was as follows:
Me (mouth full and staring at the battery): "Hey Brian you're an electrical engineer or something right?"
Brian (while fueling the car): "Electrician actually"
Me: "That's even better- do you think rivets are a suitable replacement for battery cable?"
Brian (not missing a beat): "Steel or aluminum rivets?"
And so, we had a positive battery cable spliced together with two hose clamps holding the ends of a cluster of 6 steel rivets, and wrapped in electrical tape. Sara duct taped the broken hood hinge back together with some zipties for extra reinforcement, and I got back in the car to start it with one minute before our service time was up.
Even with the jumper cables hooked up to Chief, it took forever, and by the time the car came back to life we were 3 minutes late to leave service. In my haste to get out, I ran over one of our jackstands and my wiring box, which Brian then had to yank out from under the car before we could leave. This is why we can't have nice things.
Guess what SS10 was? Yeah, we were transiting back to Danaher. We still had no intercom, and Sara was saving her voice, but still made sure to stress that we need to survive, not go fast on this next one. Boy was she right.
It was Baja 1000 rough, Safari Rally rough, "why would anyone do this to a car?" rough. Sara is yelling notes and we're hauling ass, because I know damn well if we slow down we'll get stuck. In some of the slow corners I have to slip the clutch in first to keep the engine in the powerband. We pass a broken car, then a crashed car, then come upon a bit of comic relief.
The Subaru Legacy team suffered a mechanical, and they were out of their car displaying the "OK" sign like everyone else we passed, but they were basically doing this:
Except the guy with the sign had it above his head, with his pants down, and his back to us. Rally people are, by definition, nuts, but it comes in all flavors.
Then we came upon the CRX, stuck in a huge sandy corner- we tried to pass and got stuck as well, but as soon as they saw us bogged down the CRX guys ran to us and pushed the RX7 out while I bounced it off the rev limiter to avoid bogging down and stalling.
Free again with a couple miles of stage to go, we kept moving as fast as possible while a banging noise under the floor got louder and louder- what was left of the exhaust was finally giving out. By the finish of Danaher, we had a noticeable exhaust leak but the car was still somewhat muffled, and Sara could still yell over it somewhat (remember, intercom is broken!).
We transit SS11 to get back to Carlson Camp again, and I take a look at the intercom issue- we're not fixing it without a soldering iron, that's for sure. Sara and I work out a system of hand signals in case it gets too loud to communicate- number of fingers for the severity of the corner, a wrist flick for the direction, and a closed fist for a caution.
I haul as much ass as this car is still capable of hauling on SS12- the power issue is getting worse, it's incredibly hot in the car, the exhaust fumes are coming into the cabin, we know this stage, and we have one more service to get to. Maybe 5 miles in the exhaust finally breaks fully at the header.
IF YOU HAVE NEVER HEARD A ROTARY WITH OPEN HEADERS AT WIDE OPEN THROTTLE LET ME PAINT A PICTURE FOR YOU. THERE ARE WARRING FACTIONS OF MECHANIZED BEES, ARMED WITH CHAINSAWS, IN YOUR EAR CANAL, AND THEY ARE REALLY GOING AT IT, RICOCHETING OFF THE WALLS AND E36 M3. THAT IS WHAT WE LISTEN TO FOR THE REMAINDER OF THE STAGE, AND SOMEHOW SARA STAYS ON THE NOTES AND I KNOW WHAT THE HELL SHE'S TRYING TO SAY USING THE HAND SIGNALS WE CAME UP WITH A MINUTE BEFORE.
WE TRANSIT BACK TO SERVICE AND DEAFEN EVERY RESIDENT OF THE UPPER PENINSULA OF MICHIGAN AND SOME OF CANADA.