Build Dakar rally BJ71 Project

[DKRBJ71]

Having begun this with a brake booster thread I thought perhaps a build/rebuild thread would be more appropriate where I can maybe still get comments advice.
So here is my new to me 1988 BJ71 13BT Dakar classic rally car in the 2025 race. 3rd twice, almost third in 2025, I am upgrading and modding it to be safer, hopefully, more reliable and supportable for the future to compete in many more Rally raids.
We are doing Dakar Classic 2026 starting 3rd Jan.
It’s currently having a new FIA spec rollcage fitted.
It has an upgraded hybrid turbo and an intercooler fitted, new remote reservoir Oram racing dampers, modded leafs, upgraded and strengthened axles, casings, CV’s and 30 spline shafts.
Awaiting Braid wheels and a clutch booster.
Hoping to swop out the current OEM brake booster for 80 series dual diaphragm and also to upgrade the steering box and to add an OEM clutch booster.
Toying with the idea of some more progressive leafs.
I’ll post more pics as we progress with the prep.
It’s a blank canvas now as the previous sponsors have been removed.

 

[CRZR45]

Post some pics of your intercooler setup. I’m looking for plumbing ideas for my 13bt .

 

[DKRBJ71]

Post some pics of your intercooler setup. I’m looking for plumbing ideas for my 13bt .

Here you go. The steel pipes will be replaced and the path smoothed, we have replaced the tank. It seems to make a big difference.
The radiator is an OEM but from a n other vehicle.

 

[CRZR45]

Thanks! Does the water cooler cool well? Nice setup!

 

[DKRBJ71]

Thanks! Does the water cooler cool well? Nice setup!

It does. Very noticeable.

 

[NYIronPig]

bad ass!

 

[cruiserloco]

....So cool

 

[DKRBJ71]

A few updates. The OG roll cage and seat mounts were not up to the job despite passing scrutineering 3 times. Not tied to the chassis/suspension load points, some junctions not fully welded, some mount plates inadequate. I made the decision to upgrade to essentially FIA spec and add wheel carriers and a storage box frame and provide more space for driver and co driver. Photos are the build process.
CustomCages in the UK have done a stella job and tho its taken longer and more $$$, your life is not the place to cut corners.
The wiring of accessories is now correct for the 12/24v system.
Next is to rebuild the interior, refit the fuel tank, fit the Braid wheels, brake and clutch boosters, underbody protection, side bars for jacking and add the supporter logos and try to replicate the 1989/90 ACP Dakar LC entries with similar logo’s etc. then load up the car with the race kit so food, medical kits, recovery gear, spares/fluids/tools, water, tents etc.
Then Morocco for testing.
Follow on @thattoyotabj71 on insta and we will set up a YouTube channel for the race…not long now! 28th Nov the car ships for the race.

 

[DKRBJ71]

Some more

 

[DKRBJ71]

Last ones for today

 

[Tennessee Jed]

Love this thread. The thing that stands out to me: stock radiator!

 

[Felde]

Love this thread. The thing that stands out to me: stock radiator!

Agree. The thing that stands out to me: She did very well on the Dakar Classic even before @DKRBJ71 applied the improvements listed here.
I'm very much looking forward to the reports on the rally events to come it's being build for.
Cheers Ralf

PS @Dkrb: Could you share some details & dates on the events you plan to attend with her?

 

[DKRBJ71]

Agree. The thing that stands out to me: She did very well on the Dakar Classic even before @DKRBJ71 applied the improvements listed here.
I'm very much looking forward to the reports on the rally events to come it's being build for.
Cheers Ralf

PS @Dkrb: Could you share some details & dates on the events you plan to attend with her?

Of course. Starting with Dakar 3rd to 17th Jan 2026. There is an official you tube and highlights daily plus insta. Formal entries should be listed with cars from 20th Oct I think.

 

[Felde]

Great.
I'm however generally disappointed with the Dakar media coverage, i.p. with the less focused series like classics and trucks.
If there will be any own documentary by your team or so, please share.
Good Luck Ralf

 

[DKRBJ71]

Great.
I'm however generally disappointed with the Dakar media coverage, i.p. with the less focused series like classics and trucks.
If there will be any own documentary by your team or so, please share.
Good Luck Ralf

We are going to try and do a youtube channel as well as insta from when we start testing. Not sure how successful we will be during the race/live but we will record the event for us and take the official media package.

 

[DKRBJ71]

Brief update as we push to get the car done for some testing..

Wheels and tyres on the way now, electrics now done. Awaiting updated spots. Roof scoop in progress. Decal design almost complete ready for printing and fitting. Driving positions sorted.

Things to do..Build storage between the wheel bays and at the sides for medical kit, recovery gear and food. Fit brackets for sandboards, camelbacks and jack. Remake instrument plate to be adjustable and to take all the electronics needed; irritrack and trippyk supplied by Dakar, Blunik, Raid intercom, electronic roadbook mount, phone mounts, and roll cage camera mounts. Fit additional rock protection underneath and suspension stantion guards. Make a vacuum resevoir and mount. Then testing fully laden with all mandatory kit and 2 spare wheels/tyres.

Hopefully another 10 days.

 

[DKRBJ71]

more

 

[ryaneddy16]

This is sweet! Keep at it!

 

[Meshal]

keep up and excited to meet you in saudi during the race.

 

[DKRBJ71]

More progress this week. Navigation and speed management instruments. Fire extinguishers mounted. Made up some camel back holders for hydration while driving. We will make up some more holders for another 20 litres in the back.