Pavlo

For your first cage install, it's a really good job, well done!

the_msp

Cheers Paul


Rear LSD removed:



Gearbox removed:



Strong helper very useful.. who says you can't drop the box out on your shoulder?



Just need to find a TY754 donor box now and the lots being sent to API for a straight cut PPG rebuild with DCCD.

Cold!



- PG

Peter 300

Hi mate


Are you putting in a 6-speed or kepping the 5-speed???

pete

the_msp

5 Speed, 1-4 straight cut PPG with billet selectors, standard JDM 5th, TY754 casing, DCCD...

- PG

Peter 300

Whats the damage £? on that mate?

Pm if you like...

super_ted

iTrader: (30)

looking good.

the_msp

Gearbox and diff back from APi last Tuesday, gearbox installed Tuesday night (3.5 hours by myself) and rear diff, exhaust etc installed Friday night, wee run on Saturday to check everythings working...

"Taylor"

iTrader: (2)

Great read. How come you didn't go for a version 5 gearbox after? I'm looking into changing my gearbox as it's the early classic wrx box and is going to go eventually. I was thinking about either a P1 box, as i'm led to believe it has a longer ratio 5th, or a PPG helical cut box with a P1 fith gear.

the_msp

Bigger pics:







Taylor, I did go for a TY754 casing for the new build, you can see the extra mounting holes etc in the bigger pics. Speak to David @ APi he can sort you out

the_msp

Back in the shed for the next bit of work, which will include rotating the inlet manifold, converting the turbo to front entry, new lateral FMIC & radiator, and porting the exhaust manifold...



Old wiring loom scrapped and rewired:




Last time the engine bay will look like this:


2 hours later:

CRonson7

iTrader: (4)

liking the work mate where did you get the remote power steering kit from if you dont mind me asking

the_msp

Remote power steering kit is a DIY job, made up from an oil catch can from ebay, braided hose and angle anodized fitting from local motorsports supplier, and I made the tank bracket and pump inlet converter myself...

the_msp

So, a year after starting this thread and this phase is nearly complete... the car is booked in with Michael White (OMA Performance) for Simtek fitting and mapping on the 20th May, and is also booked in for its 1st track day at Kirkistown on the 31st May.

Turbo converted to front entry by Michael for a very reasonable £150



Exhaust manifold DIY ported... before:



After:



Gauges killed the radio star:



Lateral Performance alloy intercooler/radiator and reverse inlet manifold work started:














Still on the to do list is; finish the manifold, make intercooler pipes and sort out the induction, fit a baffled sump, fit camber bolts to the rear suspension, finish all the fuse/relay wiring... Will see what its like on the track before changing any more suspension. Hoping to get it on the road for a month or two during the summer, I'll be 21 in July so that might increase my insurance options...

- PG

the_msp

Nearly there, but still a lot on the to do list, so doesn't look like I'll be making it to Kirkistown this month...

740cc flow matched injectors, adapters, and a 71 degree zero sports thermostat:



Hyperflow Baffled Alloy Sump:







Gasket-less Insulated Manifold Spacers:



Sump fitted:



Start made on intercooler piping, belt tensioner, induction, and oil catch can tubing:

trails

iTrader: (41)

looking good, hard piping is coming along nicely

the_msp

Update is a bit overdue....


For one reason or another, things dragged on a bit... I had dropped the car off in June to get mapped but there were a few issues that prevented that, mainly a dodgy power steering pipe (from pump outlet to rack inlet), rad fans weren't working (blowing fuses), alternator belt tensioner not in perfect alignment etc etc. So I picked the car up again and sorted all these out during July. Dropped the car back down again at the end of July, again there were a few small issues that delayed progress a bit (ECU not getting full voltage and a few other things).

The engine was mapped and the suspension setup and was ready for me to collect on Thursday 19th of August. I was booked into my 1st trackday for Sunday the 23rd of August. I still had quite a few things to sort out, mainly tidying things up, adding a hand held fire extinguisher, intercom, engine oil change, there was a lot more that I now can't remember, but I worked on the car from 5pm Friday until 10:40pm Saturday without any sleep (16 hours straight) to get everything sorted. The car was on the transporter with all tools, helmets etc loaded and ready to go the next morning. By the time I got home and cleaned up etc I got to bed at circa 1:30am Sunday...


... up at 6:30am Sunday, and departed with the Scoob at 8am, 2 hour journey to Kirkistown... got there unloaded the car, checked over things, warmed it up, safety briefing, helmets on, and off we go...


The scoob was going really well, handling was great (still on road tyres), huge improvement on power compared to when I took it for a run with an almost standard engine in March to test the gearbox, brakes were working really well... not sure what speed I was doing down the straights, still in Kilometres so needle was off the clock at around 115mph in 4th gear. EGT peaking at around 800 degrees, oil temp peaking at 95 degrees (no additional oil cooler added).

A few photos from the 1st session:










So everthing was going well, until, 10 mins into the 1st session, accelerating out of the hairpin, changing from 2nd to 3rd, circa 7k RPM... a loud bang, engine stopped, clutch pedal stuck solid about half way... .

Coasted to a run off section and waited for the 1st session to end, got towed back into the pits and started stripping things to see the damage...


The clutch pivot and fork were sitting at an angle... worked at the car for about 2 hours, thought I had it sorted, went for a transmission warm up round the inner pits... working ok so far... all gears still selecting and working, went back to my pit, got helmets on again, went to reverse out to join the queue for the next session, and clunk... broken again So game over for the day (an expensive 10 mins!), winched back onto the transporter and off home. Scoob used 1/4 litre tank of petrol in the 10 mins I was on track, bout 5mpg... ~2 litres per minute? Even with a full tank I was getting some sort of fuel surge at various places, so fuelling is going to need to be looked at in future. (Currently standard series feed rails, 740cc injectors, walbro 255 in tank pump, standard FPR).


So back home and I pulled the engine out on Monday night, I needed to take it out anyway as on braking the engine is moving forward around 15-20mm, and the alternator belt is rubbing into the fans on the radiator, so I need uprated mounts. Some pics of the unveiled damage...








All the broken bits from the turbo side of the gearbox were still there, however the starter side was mainly shrapnel scattered around the casing… after talking to a few people about either re-casing the box or welding it I decided it would be cheaper and quicker to get it welded, so I bought a scrap box for £100 to cut out the section I needed for the starter side. I also got a Carl Davey inlet manifold wedge welded when the gearbox was being done. Got a used clutch and release bearing aswell as both mine had taken a battering.

Gearbox welded:



Uprated engine mounts:




Just about got everything back together in time for the next trackday on the 20th September, got the radiator bled at 1am on the day, took it for a short run down the road to check the gearbox was ok, which it was. Engine was reconnected in a bit of a hurry, so a bit untidy, a few pics of how it currently is:







So off again in the morning, fingers crossed that I would get more than 10 mins driving this time... Couldn’t of asked for better weather, sunny and dry yet not too warm. The car went really well all day, the fuel surge I was getting at the 1st trackday disappeared after the 1st lap so still not sure what’s causing it. Got 5 15 min sessions before my quick release exhaust clamp joining the downpipe to centre section became a “super quick release” – the clam decided to loosen itself going flat out down the straight. Oops. Got back into the pits and one of the rad hoses on the header tank started to hiss, a small crack was appearing, so I called it a day and loaded it onto the transporter. Managed to basically destroy a set of Pirelli Rosso tyre’s in one day (50 track miles). Going to try some Dunlop x12’s or similar for the next track day (15th Nov).

Still haven’t got the anti-lag or launch control setup, or a diff controller installed yet. Need to get some higher/stronger springs for the front too as the drivers side front wheel is rubbing the inner arch during hard left cornering and also bending the wing arch a bit…







YouTube - Kirkistown TrackSkills September 09

YouTube - Kirkistown TrackSkills September 09

scoobwrx94import

hi mate can u pm me that phone number for ricky evans motorsport for front windscreen ta

the_msp

http://www.youtube.com/watch?v=-wjbFUhFiuE

the_msp

360 Degree drivers view of inside

http://360.io/bS9fME

the_msp

Kirkistown short circuit sprint, 1st in class

scoobwrx94import

very nice any more stripping coming ie lightweight panels subframes windows keep up good work

the_msp

Hi yes the car is going on a small diet this winter. The biggest weight saving will probably come from removing the fuel tank, which I always run full due to getting chronic fuel surge anywhere near 1/2 tank and replacing it with a sprint cell located in the spare wheel well. Also the rear doors are being stripped of their electric window motors and mechaincs but at the minute I am keeping the glass, I don't think plexiglass works well with the doors being frameless at the top?

I am also moving the battery to a small in car one located behind the passenger seat (which I might also remove!) and also moving my washer bottle to the rear, both of these for more even weight distribution and also to give easier access to the spark plugs on the passenger side as it has a nasty habit of wetting them now and again.

lankey555

Nice thread Patrick ur engine bay looks good u going to join us on the hills next year?

the_msp

Cheers Ian. Might dabble in one or two hills but my initial plan for 2013 is the full sprint championship

the_msp

So a little tidy up last winter. Pulled the engine out to fit a new clutch and fit steel head gaskets, stripped it to long block and found it already had steel gaskets so if it's not broke don't fix it rule applied...

Bought a red top 40 battery and located this behind the passenger seat (or where it used to be, as I'm running just the driver's seat this year). Got rid of the screenwash reservoir for now, going to make a new one and mount this behind the drivers seat. New power steering pipes for reservoir-> pump and pump -> rack. New catch can fitted as the old one needed manually drained and was breathing oil mist over my bulkhead. Fitted a slightly more uprated clutch friction plate, this is as high as I can go without going twin-plate.




Some new stack gauges as my old ones had all broken. New harnesses as mine were out of date at the end of last year.




Some new graphics:






Bought 2 sets of 17" tyres, just need some rims now that will fit over my brakes.

Also treated myself to a new camera:

adz556

iTrader: (5)

Looking really good mate!!

the_msp

This was timed run 2 (Dry) a week ago


Was another 0.54s quicker in run 3, which was wet (Havn't processed video yet)



Regards,

- PG

Rick2014

iTrader: (3)

Some good driving there mate .When you did the power steering mod from the classic to the newage pump did you make up a new hose your self from the steering rack connection and what bits did you use

the_msp

There's nothing new age in there for PAS. I made an adapter that goes from the classic pump to 1/2" BSP female. Then from that it changes to the goodridge. Then over to what originally was a catch can you see mounted on the left.

On the pressure side I welded on a 1/2" bsp male to each end of the original steel pipe. Then joined this with high pressure hydraulic hose.

Rick2014

iTrader: (3)

You didn't mig weld it did you?or did you use an alloy welding rod of some sort.I really like your engine bay lay out I was trying to look at all your pictures from your build but there gone