Breslau Adventure Rallye

Couch Off-Road Engineering was the first American Team ever to Run this Race.

11/21/2011

U1200 – 1984 – FOR SALE!

Sandy @ 1:26 pm

We’re BACK!

As you can imagine, it’s been insane since Jay arrived home from Breslau. There’s some great things happening, and we’re almost ready to tell you about our two biggest projects, LandArk and GROC.

In the meantime, Jay’s ready to part with a few of his favorite Machines to clear some space for new projects. The first, is his 1984 U1200 Unimog, he’ll sell for $46,000. For those of you who know Jay, this machine has everything it takes to accomplish some serious work (or play!) If you’re interested, just give Jay a call at 888.X.UNIMOG (888.986.4664).

- 24 Speed
- 3,200 Engine Hours
- 26,500 Miles
- 135 HP
- 4 Circuit Hydraulic System with PTO-driven Ultra High Capacity System for Crane or other High-Demand Hydraulic Implements
- Front Schmidt Quck-Hitch System with Front and Rear 3 Point Hitch
- Fuses are Re-settable breakers
- Electric Heated Winshield
- Optional Sliding Rear Windows
- Atkinson Voss Cab Sound-Deadening Kit
- New Continental 14.5 MPT81 Tires
- Wide Track Rims
- Schmidt FL4 Front End Loader with Incorporated Brackets into Front 3 Point Hitch
- New Clutch
- All 4 Portal Gear Boxes Rebuilt
- Front and Rear Differential Locks re-sealed
- Front and Rear Live PTO’s 2 Speed with Shafts
- Auxiliary Transmission PTO
- Completely Gone Through and READY TO WORK!

07/13/2011

The Photography of Robert W. Kranz

Medulla @ 10:38 am
The photography of Robert W. Kranz

Photo of Bam Bam in the Prologue at Breslau 2011, by Robert W. Kranz

Our lack of resources and vantage points at the Breslau made for some less than spectacular photographs. However, our new friend Robert W. Kranz has been so generous to share his photographs with us. Behold! (more…)

07/03/2011

Results

Medulla @ 2:57 am

We’ve found our rankings online at Breslau Rankings. They should be updated soon. As of last night we were told that Jay finished 11th in the big truck class, out of 36.

We missed the party last night in order to prepare everything for a ride back to Frankfurt without us this morning, putting the smaller tires on Bam Bam to fit him into the trailer and sorting through tools. There will be more of that when we arrive in Frankfurt on Friday. In the mean time, we’re renting a car to do some sight seeing.

07/02/2011

We did it

Medulla @ 6:30 pm

Preparing for the off road portion of Stage 2

I’m happy to report that Bam Bam has successfully completed the Rallye Breslau #17. However, our final place doesn’t do justice to the champions on our team. We could not have succeeded at completing this race without the extremely hard work of Alois and Josh who volunteered their time to this venture, the calm and orderliness of Maura who made sure that head sets were charged each night, kept an eye on the time, drove us around each day for errands and such and made sure the crew had snacks in the cab, the preparation and planning from Gus who arranged registration, and service transport and pointed us in the right direction when we were in the dark as we made our own plans, and the experience and direction from the passenger seat of Tobius, the German navigator lent to us by team “Natalie”. We have many others to thank including Ian and the Gigglepin Team, Team Blitz from Holland, Dominique and Fritz for transport, Sabrina for her helping hand and many others who jumped in with the tools and the skills needed to complete our repairs. Jay is extremely honored to have such tremendous support behind him. (more…)

07/01/2011

Happy Rallye Day

Medulla @ 11:20 am

Preparing Bam Bam for the trip to Dresden... through water sand and mud

The last I posted, we were preparing for the arrival of the new axel. The old axel was removed after midnight and hauled onto the service truck by 7 men, who even together, needed all of their strength to lift it. Alois and Josh discovered that the joint or collar where the axel connects to the truck was broken and when they removed it, it lay in 3 pieces. Made of cast iron, we needed special equipment to do the repair and Michael from the Dutch team from across the way used his stick welder to get the job done.

Traffic and other delays for the delivery truck kept Alois and Josh waiting until 5:15am for the arrival of the new axel. This left them less than 5 hours to install it and get Jay to the starting line by the 10 am cut off time. Installation went very smoothly, with the help of some Red Bull and support from Maura who stuck with them until morning. Their work continued to the last minute and unfortunately, just beyond. Seventeen minutes late, we didn’t make the start of the first phase of the race. Josh said, “Oh well, we wouldn’t have done anything differently.” The job was still done in record time and we’d be in good shape once Jay was able to start at phase two, unfortunately at the end of the line with any others who didn’t start or finish the first part of the race that day.

Planning over breakfast

A page in the road book

The rest of the team, including myself, were headed to our next camp, just west of Dresden in Poland. Just after we arrived that evening, we got a call from Jay. We all waited anxiously, as a call from our driver in the middle of a race isn’t usually a good thing. He gleefully reported that things couldn’t be going better. He finally felt like he was racing. He was hitting corners hard, set into his seat by the smoothness of his acceleration and his trust in the suspension.

The next call we received was from another member of the press who informed us that an accident at one of the checkpoints caused the attendant to rush to the aid of the competitors involved. Since there was no way to know who had passed during his absence, the organizers had decided that they would call it the end of the line, cutting short what was expected to be the longest day of the entire rally.

Film crew gets a view from overhead

Film crew gets a view from above

Today at the drivers’ meeting, the results were posted. We learned that we had climbed up from to #98 among the 136 remaining contestants. Three days ago we would start at the bottom of the list to find our ranking and each day since we’ve moved up to find ourselves looking for ourselves on page three. More than half of the 300 who started were gone. The most prominent piece of advice we received, early on in the race was to take it slow at the beginning. Many competitors make the mistake of pushing too hard early on and breaking their vehicles, never giving them the chance to reach the final days where real speed matters. We’ve reached that point now and are in good shape to give it our best go possible. Couch got some good sleep last night and Tobius studied the Day 6 road book, highlighting each of the key directions all through breakfast. The film crew finally got their chance to ride in the helicopter which circled the starting line as we waiting for Bam Bam’s turn. They are following overhead and will continue to until they loose him in the trees.

06/29/2011

Breslau Rallye updates finally

Medulla @ 10:59 am

Loading Bam Bam in Mainz

We’re on day 5 of the rally and things could have gone better so far. I’ve been doing some writing, but what’s interesting to read as it’s happening is less exciting to post days later. The Rallye has not been able to provide internet until today and still the press is disappointed because it’s not enough to upload photographs. I’ve sent a memory stick into town and hopefully will have a few photos to share soon. In the mean time, here’s what’s up:

We arrived in Frankfurt on Wednesday morning, a week ago today. We had an interesting time connecting with the service team arranged by the co-driver who wasn’t to arrive until later that day. Once we found them we immediately got down to business. We picked up the truck and totes at Lufthansa Air Cargo and headed to a nearby city where we loaded everything, including Bam Bam for the 8 hour drive to Breslau, actually Wroclaw, Poland. Breslau is an old name for the same town, as of 15 years ago. The crew arrived at different times; we were split up handling different aspects of business before leaving Frankfurt.

The cars line up at the start of the Prologue

Our crew consisted of Alois (a co-worker from Jay’s previous work with Spiderplow/Fokersburger) and Josh, the mechanics. Gus, the co-driver. Sabrina, Jay’s intern. Maura, our sponsor, Magpul’s representative. Four from the film crew hired by Magpul to document the adventure. And of course Jay and myself. Jay and Josh rode out with the service team, who had a stop on the way and a lot more to haul, so they didn’t arrive in Breslau until 5:30 am. They went strait to camp, while the rest of us spent the night in a nearby hotel. Since the sun was already coming up, the guys decided to just start their work. The new tires had to go on Bam Bam as it was shipped with smaller ones for clearance. There was work on the cooling system still to be done… hydraulics, and a million other odds and ends (I’m sure I’ll leave out a lot of wonderful gearhead details as I’m just the girlfriend, but look for updates later after Couch gets his eyes on this).

After only a few hours of sleep for the crew, the work continued the next day and included a parts run that me and a couple other ladies were sent off to do. Finding specialized parts in a foreign country was a challenge that began only after spending 3 hours looking for the first auto parts store. Maura was our leader these first few days, keeping everyone on task and bringing a bit of order to the chaos.

The Maiden voyage of Bam Bam

The race began on Saturday morning. The rig was outfitted with five tiny cameras, helmets were wired for audio, fluids and belts were checked and it was time to start, ready or not.

Day one went well, probably the best day so far. I’m not certain on where we placed exactly, but it was respectable and was somewhere just above average in the list of 180 or so cars and trucks. I spent the day with the most of the film crew tracking down viewing locations, but only found one and only after Bam Bam had passed. It was interesting, however to watch some of the other competitors on moguls, steep hill climbs, and a steep decent, on the dusty terrain. Another member of the film crew had gone with the press that morning and was able to get some good footage, sending reports to us by text. It was an eventful day for some. A photographer’s leg was broken by a jeep. Some of the motorcyclsts were supposedly arrested when they were caught doing 100KMH in a 30 zone. We learned a lot that day. We’ve often struggled getting our information ahead of time, as most of it is given in German with an abbreviated version in English. Among what we learned was about the format of the race, road driving vs off-road. The road driving portions of the race are timed, but the speed limit must be followed. Too slow and you loose points, too fast and you are also penalized. (more…)

06/20/2011

Bam Bam Flies Away!

Medulla @ 11:21 pm

(more…)

06/17/2011

Delivered to the airport

Medulla @ 10:13 pm

I dropped Bam Bam off at the Chicago O’Hare Airport Lufthansa Terminal on Thursday. We cleared customs rather quickly, thanks to our savvy shipper. Our carne for customs had 296 individual items: tools, spare parts and camping gear. We had to install the baby tires for transport, putting the big mothers on a palate which added another $4.5K to the bill! The shipment departed from Chicago this morning. We’re working on some super secret spy photos from the loading process. Stay tuned!

06/08/2011

Decal placement has begun

Medulla @ 1:51 am

05/31/2011

Rally Base Camps

Medulla @ 10:07 am

See the Base Camps at Google Maps.

05/27/2011

Bam Bam

Couch @ 10:21 am

The race truck has been named. Bam Bam will now be flying into Poland, which gives us an extra 2.5 weeks to complete and perfect our work. The attached pictures show its current state, near finished. One major difference will be that the bed will have a printed canvas cover on it… and of course the entire truck will be covered with our sponsors’ brands. Stay tuned for more!

05/23/2011

The end is near.

Bryan Taylor @ 6:31 pm

Time is getting short, as you all know. Jay has had the truck running several times now, shaking out the bugs. He has found that the clutch he had built was insufficient to handle the power to weight ratio that exists, so another is being built to resolve the problem. Overall, the truck is fast and gets airborne easily from all the power under the hood.

Jay is trying to resolve an IP timing issue – it’s a strange one that makes no sense, so it is extremely irritating!

The tires and wheel are both in, and mounted. Boy do they look nice! The CTIS is plumbed up and the setup is very slick.

The truck has to be taken to NY instead of Houston now, so that is going to add a bit to the timeline as well.

Check out the pics!

05/17/2011

Test Drive

Medulla @ 2:25 pm

Roaring Beast emerges

Couch @ 10:54 am

05/09/2011

New Additions

Bryan Taylor @ 1:50 pm

Jay received the shocks for the mog the other day, and boy are they sweet, although a bit pricey! The guys had to cut the front mounts, lengthen them, and retool them to fit the new shocks – and the rear will require a bit of fabricating as well. The finished product is very nice (see pics below).

A lot of time has been spent on the cooling system. Jay was able to complete the hydraulic fan for the stock radiator in the front, and the guys are plumbing the two additional radiators as I type. The rear two have electric fan setups with shrouds. There will be an auxiliary pump to circulate the coolant as well, but the location has not been finalized yet.

I have included some better pics of the turbo as well. It looks very well done. The exhaust is complete as well. It is setup to dump just behind the cab as you can see in the pic. Check out the size of the inter cooler!

The front bumper is coming along nicely. Jay is planning to turn it into a 3 piece bumper, to allow for easier cab tilting, etc.

The overall progress is good, but time is getting short!!!

04/26/2011

Start your engines.

Bryan Taylor @ 8:31 am

The very latest word regarding the prototype winches is that they will NOT be completed before the mog has set sail for Europe, so Milemarker is sending out a mockup so Jay can fab the front and rear bumper/mounts. They should be completed the second week of June, and will be shipped to the truck, and installed at that time.

Jay is cutting down the factory 1700 bed by 11″ in order to provide clearance for a spare tire/wheel and fuel tank.

The methanol injection system is almost fully plumbed and can spray around 1 liter of meth per minute at full capacity (which shouldn’t be very often). Ya, that’s a lot! He has (2) 7 gal tanks for the fluid…

Jay is working to increase the alternator output to get into the 180 – 200amp range. It’s proving to be a bit of a challenge though, and a custom alternator may be the final option. More to come on that…

Due to the large electrical load, Jay may add another Odyssey flat plate drycell battery, but he has completed the battery box, sans Rebel flag on the lid.

Wheels and tires are looking like May 5th or so – I’ll get some pics when they arrive.

Take a look at the engine pic. Everything is looking really good. The engine was fired up today as well, but only briefly since the cooling system is not in place. There is a good possibility the mog will be driving by the weekend, so expect video soon!

04/20/2011

Ch Ch Ch Changes

Bryan Taylor @ 8:19 am

So the truck is progressing along – but there are lots of inputs coming from different sources, and some are being re-worked to make everything mesh together. For example, the clutch input shaft is being milled down a few more millimeters, because of a conflict with the ID of the bearing it goes through. While not a huge deal, the milling is not being done in-house, and so there is a delay…

Other changes: the original turbo was to be a variable vane turbo, but an Aurora 3000 non wastegated turbo has become the final choice.
The original winch choice was a prototype (REALLY nice), but it may not get completed before the truck has to go – so dual hydraulic 15,500 lbs winches may be riding up front, with one in the back. This is still very TBD…
Stazworks is going to be fabricating the beadlock wheels, and that will start soon – Jay is just making his final “bling” selection for the center cut-outs. He was considering opening this up to a poll on the forum, but he was concerned that the winner might go this way, and he didn’t want to represent the USA quite like that… Ya, thanks Jay, you’re a true Ambassador… So the final choice may be something more simplistic and industrial, which will actually go very well with the mog as a whole.

The Bell intercooler should be coming next week, as well as the tires – I’ll get some pics up when they get here.

Below are a few more pics for you all. The first one is of the engine/transmission adapter plate. It is all aluminum and about an inch thick. It can be replicated for future Cummins conversions, so get that check book out! I also attached a pic of the exhaust manifold and turbo.

Time is getting short as you all know, for finishing everything up, and Jay is running as fast as he can right now, so if he doesn’t answer his phone, you’ll know why. I personally like to call him and suggest he fabricate something ridiculous for the truck, as a distraction – like a 3 foot stainless steel guinea pig. As soon as you mention fabricating anything, he starts thinking about it and it’s just fun to watch him wander off into fabrication land!

04/15/2011

Progress

Medulla @ 8:16 pm

04/12/2011

Couch Off Road Race Truck Build Notes

Couch @ 2:13 am

The project truck is a 1985 U1700 that had a stock 170HP motor, which has been replaced with a Cummins 24 valve diesel. The new motor, ATS turbo, intercooler, and P7100 IP setup should push 450HP. This Unimog platform was chosen because it has the heaviest chassis and should be the most stable platform, and not flex too badly after being launched into the air. The total race weight of the mog will be about 16,500 lbs, or 7,484.27411 kilograms. (more…)

03/24/2011

Intro to the Rally – Video

Medulla @ 7:37 pm