IanPaskin

yeh that looks nice Tim, I may get a sheet of ABS and have a play on the switch console.

JonMc

iTrader: (51)

That looks a lot better

Hol

iTrader: (1)

Ian,
I have to admit that I am impressed.

I have AWD EVO running gear in a Proton hatch shell! but mine was much easier as I only needed the rear floor section.

This is soo much better IMHO.

I can't wait yo see the finished product.

IanPaskin

Cheers Jon, was one of those do I don't I !!!

Cheers... Any pics of yours?? Sounds interesting...

Hol

iTrader: (1)

Nowhere near the same amout of welding work as yours:

Proton basically bought all of the right to Mitsubishi's older bodyshells in 1999 and this 2002 GTI is effectively a Colt, with a few modern updates





The front half of the floorpan to the front seats is effectively the same as the Evo (except for the brackts and holes for the intercooler and propshaft etc), but the rear floor is different as the rear diff needed to sit where the rear wheel well would be (trial ftting shot shown).



So at the end of the day, you only end up with just space for tyre weld.
It now has the entire rear evo floor seam welded in both sides.


The front wings were a bitch though, as the both the front oif the door lines and the swage lines did not match. I had to weld an Old Colt wing and an Evo donor car wing together - using an old Colt shell as a guide.

JonMc

iTrader: (51)

That's a tidy looking project

IanPaskin

yeh very tidy... the rear cradle looks like it was made to fit there, and good work on the wings.

I bet it shocks a few off the lights...

trails

iTrader: (41)

A blast from the past

Colt-Evo thing look like lots of fun

IanPaskin

A little more progress on wiring, welded some earth points in by the fusebox and used some rivnuts to mount the live junction box (can’t believe it’s the first time I’ve used rivnuts – they’re really good ) however I forgot to take a picture!!

Then wired up the steering column/wheel buttons for the horn and various other things
I was going to buy a sparco switch bracket but as I had some switched thought I’d have a go at making on so started off with some card this was the 3rd attempt and looked good so I went with it





Then made it out of 3mm alloy plate, it sits behind the quick release so wheel can be removed without having to unplug anything



And in place (need to get two more switches only had 4)



Also started to think about the exhaust

These tubes are 90mm diameter and 500mm long, I then have some 51mm perforated tube, for wadding I have some acoustafill and they will be re-packable, hopefully that will be enough to get the sound level down if not I could fit a box under the car but will try this first,

JonMc

iTrader: (51)

That steering wheel switch panel is neat - I'm toying with one myself to remote the switches on my PSI3 data monitor

IanPaskin

I will probably cover it with some carbon wrap or paint it, also could do with something on the back to tidy it up as you can see the wiring...

JonMc

iTrader: (51)

I'll spray mine with some plastidip and use this cable with some heat-shrink

http://uk.farnell.com/jsp/displayPro...oss_price=true

IanPaskin

Realised today that I have had the car/project for 2 years this weekend 
I thought I’d be driving it by now and would have cost half as much!! But I suppose I have changed my mind a few times on the way, main thing is, it’s still going and I’m still enjoying the build

So this weekend I have started my exhausts well one of them as I needed more 51mm tube for the second,

Started to build the fixed end of the can





Then the piece that will slide in



And it fits like this





Quite pleased with it I need to chop some of the main tube down where the slits are and add a fixing point to hold the middle in but I will do this when I have done the second can as they will be welded together,

Then underneath I will make a ‘Y’ piece and bend to join up using a small flexi pipe with the center section which comes somewhere by the red dot below



Just hoping it will keep it quite enough!!!

Then as I couldn’t finish the second exhaust I had a play with the intercooler, bumper and front cross member mainly in case I need to mod the bumper as it will be painted soon, the cross member ran across the middle of the bumper intake making the intercooler sit too high and would be blocked by the bumper,

so I chopped it off…



I was thinking of getting a tube bent into a sort of wide ‘U’ shape and weld that in but the towing eyes either side are sturdy and near enough the correct height so I will just add a tube or box straight across then add a towing eye to that,



With it fitted…



And still plenty of room for a Rad and fans

IanPaskin

Not a huge amount of visible progress over the past week or two, so a quick update with a lack of pics…

I added a new tube for the front lower cross member, for added strength I notched the ends of the tube and used the porta-power to open up the towing eyes so I could get it in place,

Then welded it in (not sure whether to weld the ends up of leave open I have drilled a drain hole in the middle)





Intercooler now fits nicely and will fix to the new cross member probably with a rubber exhaust bobbin, top bolds to the bumper bar,



Finished off the other bonnet catch so they are both bolted in and working now, while I had the welder out I added a bracket for the rear towing eye,



Built up the second exhaust box and got a second hand 3” system from an impreza so I will use that up to where mine come out the side, but need a turbo and downpipe so I can bolt on in position,

Also started the wiring on the engine loom and up to the clocks a bit of head scratching but think I’m getting there…

I've decided if I have any chance of getting it done for PVS I will have to compromise on a few things so I have decided to run it as a pretty std uk impreza, main reason for this is financial but will save a bit of time, so I will run a stock td04 turbo and ECU this way there is no mapping required and safer while I’m running in the engine, doing it this way I will save probably around £500 which will help out on other bits,

I have purchased quite a few parts last week, (Rose Joint Track Rod Ends, Gel Battery, Braided brake hose and some fittings, td04 turbo, coil pack and leads, boost solenoid ect, correct Alternator, starter motor, clutch slave cylinder, impreza STi clocks) so will start getting more fitted over the next week or two,



Go to wait a few weeks for my mate who is going to paint it as he has a lot on so will push ahead with the wiring and exhaust ect so might be running soon….

tim@rallytech

iTrader: (8)

Nice tow hook

Good work as always mate, keep it up!!

cookstar

iTrader: (6)

What a great project.

But... a bonnet scoop?

IanPaskin

Cheers Tim, tow hook looks great, thanks....

I know.... it actually looks better when you see the car (which I have had a few people say), and without it would just look like a boring Astra this gives it some attitude and once all in the same colour it will be less in your face,

going forward I will have an oil cooler up there and will be using some of the air flow for cooling the turbo and cyl 3

IanPaskin

Think I have got my head around the Subaru wiring, still have a few wires going up to the clocks that I can’t find on any wiring diagrams, but nothing that will stop it running (I hope)

So I started to tidy up the wiring on the engine bay side, the ECU up to the clocks I will leave unwrapped as I will need to join to the Astra loom and run the power to the main relay for the live to the ECU,

I picked up the braided hose I got for the brakes to show a mate and then got carried away and fitted from the pedal box to the rear wheel and then on the front I just ran out of hose for the N/S I had about 140mm left but really need 160 – 170mm to keep neat and have enough to route nice to the calliper,

Then I need to run from the reservoirs to the pedal box with some AN4...

Also got some up some proper bell housing bolts and a starter motor so I pulled the engine back out and checked the clutch bearing as I wasn’t sure I had it fitted correctly so now the engine is bolted in, and then changed the turbo inlet pipe as the one that came with the engine had a tear











Not a bad weekend…

JonMc

iTrader: (51)

Some good work - a productive weekend indeed.

rentonone

iTrader: (1)

Coming on nice Ian, that exhaust is going to be mental love it, don't keep it to quiet, I'm making two exhausts for mine, one with a silencer and one straight through ***** out noisy as ****/ flames lol

IanPaskin

Cheers Jon, wish I had more time to paint and detail it like yours but that could take it passed the summer so I will come back to that, might do the inlet manifold thou as that looks a bit scruffy.


Remember mine is going on the road thou so can't be to loud, but I will be disappointed if I don't see flames lol

JonMc

iTrader: (51)

I wish I'd never started TBH, I don't have a lock up and with the weather progress is slow

IanPaskin

Know what you mean where mine was before on the farm although it had a roof the front was open and in bad weather it was a nightmare, now in the unit it's much easier to work on...

IanPaskin

Anyone got opinions on hydraulic handbrakes, I need to think about a handbrake, it will need to pass an MOT too...

So do I run with the std cable setup or go hydraulic the car will mainly be for track day use to start my look at hill climbs later... will a hydraulic setup gain me anything, other than saving some weight on the handbrake shoes.

c.lyra

Go hydro... The cables will work the first two times, and then start to stretch..

AS Performance

iTrader: (4)

bear in mind for a lot of "production" or road legal classes a cable operated h/brake is a requirement to pass scrutineering/eligibility

an extra Hyd lever can be added in a lot of cases but check your regs first

rentonone

iTrader: (1)

Deffo just leave the standard handbrake in place for now while you get the car finished and just add one into the rear brake line at a later date if you still want one!

IanPaskin

Had a couple of other jobs on this weekend helping out with patching up the rear valance and arch on an MGF and a sill on a golf,

Did get a bit done on mine I made a heel/foot rest for the pedal box, used an alloy rectangle section, I did start with it closer to the pedals but decided to move back 25mm so the nice profile I added on the right is now slightly out but it will be fine….

I used my new favourite fixings ‘Rivnuts’ in the alloy box then bolted up through the floor,



And some more pipe work I now have a pipe to each corner, I have ordered some banjo’s but they not arrived yet, then the feed pipes from the reservoirs I wasn’t sure whether to use straight, 45 or 90 degree fittings so I ran the pipes up and have now decided to use 45 degree, but all three are in the master cylinders and run up.

I’ve fitted the Reservoirs in the scuttle tray…

Also fitted bulkhead power fitting…



And just won an exhaust down pipe off of eBay so I should be able to get that finished over the next few weeks,

JonMc

iTrader: (51)

Rivnuts are great until the tool packs up - making some progress through despite the distractions which is always a bonus

IanPaskin

More small jobs done, nothing to exciting but will share anyway…

Brake reservoirs now bolted up and piped up down to the pedal box decided to run them straight inside then across to the pedal box to save them going near the turbo,





Then a bit more tiding of the engine wiring, re-routed it slightly from how the Subaru loom normally runs so had to modify the grommet to allow more cables through…



Cleaned up and put some paint on the front calipers, fitted new banjo and bolt, need to get some new caliper to hub bolts, so only on loose at the moment, also fitted some rose jointed track rod ends,



On the rear I have cleaned up my single pot slide calipers and painted them, I don’t want to use them as I want some 2 pot rears but they may have to go on for a while.

Then had an hour spare so I fitted my air vents and a drain tap and then fitted it to the car, I’m thinking of getting a van headliner to help stop any condensation dripping…