Astra 4wd subaru powered track/rally car
07 July 2014, 09:50 AM
#362
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I got the astra originally to RWD it and I had a Subaru rear cradle and diff which I was thinking of using with a vx c20xe lump but then things got out of hand and decided 4wd would be better so I chose the Subaru option rather than the normal vx cav or calibra conversion...
and it's nice to do something different...
Last edited by IanPaskin; 07 July 2014 at 09:11 PM.
09 July 2014, 08:24 AM
#363
WOW!! Just spent the past 45mins reading this and what a build buddy... Very different as you said the common heart surgery is a LET not and EJ20 haha... Look forward to seeing it running.... Id lose the VXR decals though on your paint work as it doesnt flow...
09 July 2014, 10:01 PM
#364
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and I agree on the vxr decals I just added them from an earlier design,
13 July 2014, 05:59 PM
#365
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Not had a huge amount done this weekend had some other jobs on Saturday to do so mainly just todays efforts with was to finish mounting the fuel pump tray which I used some rubber mounts, then some more pipework which except the filler and vent is all done now,
Also got James’ Subaru powered 205 over at the unit for some paintwork which is nice to see again
Also got James’ Subaru powered 205 over at the unit for some paintwork which is nice to see again
13 July 2014, 08:51 PM
#366
Haven't really got an answer for you!!!
I got the astra originally to RWD it and I had a Subaru rear cradle and diff which I was thinking of using with a vx c20xe lump but then things got out of hand and decided 4wd would be better so I chose the Subaru option rather than the normal vx cav or calibra conversion...
and it's nice to do something different...
I got the astra originally to RWD it and I had a Subaru rear cradle and diff which I was thinking of using with a vx c20xe lump but then things got out of hand and decided 4wd would be better so I chose the Subaru option rather than the normal vx cav or calibra conversion...
and it's nice to do something different...
14 July 2014, 08:29 AM
#369
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29 July 2014, 09:18 PM
#370
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Had some time on Saturday to do a few jobs, so I added a rollover valve and then vented it up to the fuel cap, may add a second filling vent into the filler pipe...
Then added some foam into the tank as I’m running a sender I chopped a square out to let the sender operate
Then made up a wiring loom for the two pumps and sender unit back to the relays
Also picked up a saxo vtr power steering pump so trying to find the best place for it, options are
1, behind the passenger headlight but that will cramped and may need that space for later additions
2, inside the car in the passenger foot well
3, behind the bumper under the drivers headlight (picture below)
4, same as 3 but passenger side just means re-locating the horns
I’m steering towards option 3 or 4 as it’s out of the way, 3 is closest to the rack, the pump is the type with a remote reservoir,
It weighs 5kg so possibly not ideal in one of the front corners plus will have to make a guard in case of leaks, but I’m not sure I want it in the car…
Then added some foam into the tank as I’m running a sender I chopped a square out to let the sender operate
Then made up a wiring loom for the two pumps and sender unit back to the relays
Also picked up a saxo vtr power steering pump so trying to find the best place for it, options are
1, behind the passenger headlight but that will cramped and may need that space for later additions
2, inside the car in the passenger foot well
3, behind the bumper under the drivers headlight (picture below)
4, same as 3 but passenger side just means re-locating the horns
I’m steering towards option 3 or 4 as it’s out of the way, 3 is closest to the rack, the pump is the type with a remote reservoir,
It weighs 5kg so possibly not ideal in one of the front corners plus will have to make a guard in case of leaks, but I’m not sure I want it in the car…
24 August 2014, 06:59 PM
#371
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So nearly a month since an update – I’m still going just been doing little jobs that haven’t really warranted photos and updates,
Inlet manifold is now bolted on and some of the boost and vacuum pipes fitted, also finished most of the battery cables just a couple to make for the cut off switch.
I picked up an exhaust manifold at a good price as the flexi was damaged on the up-pipe so I fitted a new flexi and heat wrapped it, although I’m not happy with the front joint so I’m going to redo that…
I’ve ordered the paint
And the body work is now being prepped so should see some paint in the next couple of weeks, which will be a real milestone, so now back on its wheels so it can be moved into the booth.
I’m also very close to firing it up, mainly now just need a few breather pipes, some oil and spend a good few hours checking some of the engine wiring loom before I join that up to the power circuit.
Inlet manifold is now bolted on and some of the boost and vacuum pipes fitted, also finished most of the battery cables just a couple to make for the cut off switch.
I picked up an exhaust manifold at a good price as the flexi was damaged on the up-pipe so I fitted a new flexi and heat wrapped it, although I’m not happy with the front joint so I’m going to redo that…
I’ve ordered the paint
And the body work is now being prepped so should see some paint in the next couple of weeks, which will be a real milestone, so now back on its wheels so it can be moved into the booth. I’m also very close to firing it up, mainly now just need a few breather pipes, some oil and spend a good few hours checking some of the engine wiring loom before I join that up to the power circuit.
24 August 2014, 07:48 PM
#372
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So nearly a month since an update – I’m still going just been doing little jobs that haven’t really warranted photos and updates,
Inlet manifold is now bolted on and some of the boost and vacuum pipes fitted, also finished most of the battery cables just a couple to make for the cut off switch.
I picked up an exhaust manifold at a good price as the flexi was damaged on the up-pipe so I fitted a new flexi and heat wrapped it, although I’m not happy with the front joint so I’m going to redo that…
I’ve ordered the paint And the body work is now being prepped so should see some paint in the next couple of weeks, which will be a real milestone, so now back on its wheels so it can be moved into the booth.
I’m also very close to firing it up, mainly now just need a few breather pipes, some oil and spend a good few hours checking some of the engine wiring loom before I join that up to the power circuit.
Inlet manifold is now bolted on and some of the boost and vacuum pipes fitted, also finished most of the battery cables just a couple to make for the cut off switch.
I picked up an exhaust manifold at a good price as the flexi was damaged on the up-pipe so I fitted a new flexi and heat wrapped it, although I’m not happy with the front joint so I’m going to redo that…
I’ve ordered the paint
And the body work is now being prepped so should see some paint in the next couple of weeks, which will be a real milestone, so now back on its wheels so it can be moved into the booth. I’m also very close to firing it up, mainly now just need a few breather pipes, some oil and spend a good few hours checking some of the engine wiring loom before I join that up to the power circuit.
if it was me I would have left the scoop of for the stealthy look 
24 August 2014, 07:58 PM
#373
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25 August 2014, 07:23 PM
#375
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I was going to run 6mm cable to the pump but that really is over kill as that's rated around 50amp
Also every terminal has been soldered so all joints are solid.
25 August 2014, 09:46 PM
#376
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Hi, yes it's a Bosch 044, wiring is 4mm which is rated at iirc is 38amp, distance from the relay is about a meter so voltage drop will around 0.8v, wire up to the relay is 6mm and about 200mm from main 35mm distribution point so should be ok,
I was going to run 6mm cable to the pump but that really is over kill as that's rated around 50amp
Also every terminal has been soldered so all joints are solid.
I was going to run 6mm cable to the pump but that really is over kill as that's rated around 50amp
Also every terminal has been soldered so all joints are solid.
Now get it finished
25 August 2014, 09:54 PM
#377
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Cheers, To be fair I looked back at a couple of photos and the wire does look thin but that must be the pics,
Yes trying to get it finished... Once it's painted and fired up it should give me a boost.
Yes trying to get it finished... Once it's painted and fired up it should give me a boost.
25 August 2014, 11:20 PM
#378
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Be prepared for a few teething problems. Mine has decided it likes eating fan belts.
Recon it was the idler pulley being to small making the radius of the bend to tight.
New pulley going on will see how it goes
26 August 2014, 08:28 PM
#380
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I think you'll be done way before mine, I have so much to do still...
How's yours looking?? I popped in last week before it went back looked good...
14 September 2014, 09:57 PM
#384
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A few bit and bobs done,
Wasn’t happy with the conical flange on the header to up-pipe so I changed it to sleeve over and bolt up with a new flange I will add an extra flange and couple of gaskets to seal it up in case the sleeve leaks as it only goes in about 20mm
Next I tackled the throttle cable or cables as I decided to use two, I have been trying different cables and ideas and ended up using a couple of karting cables, but my other problem was getting enough travel so I had to modify the pedal box a little, (and I had to take it back out of the car which was a pain as I had brake fluid in) luckily I managed to take the master cylinders off and leave them in the car.
Not very good pics I’m afraid
Bought Tyres!! Maxxis MA-Z1
The cam belt covers we’re not the tidiest and had the odd crack so I cleaned them up got the Q-Bond out and gave them a coat of plastic primer to start
Then decided to go for blue look a lot better not perfect, but a lot better.
And with the pulley and alternator belt fitted
Also been doing some body work
I’m off on holiday this week, so the plan is for when I get back it will be in white base coat then on the Saturday we will add the grey and orange, then lacquer it
Wasn’t happy with the conical flange on the header to up-pipe so I changed it to sleeve over and bolt up with a new flange I will add an extra flange and couple of gaskets to seal it up in case the sleeve leaks as it only goes in about 20mm
Next I tackled the throttle cable or cables as I decided to use two, I have been trying different cables and ideas and ended up using a couple of karting cables, but my other problem was getting enough travel so I had to modify the pedal box a little, (and I had to take it back out of the car which was a pain as I had brake fluid in) luckily I managed to take the master cylinders off and leave them in the car.
Not very good pics I’m afraid
Bought Tyres!! Maxxis MA-Z1
The cam belt covers we’re not the tidiest and had the odd crack so I cleaned them up got the Q-Bond out and gave them a coat of plastic primer to start
Then decided to go for blue look a lot better not perfect, but a lot better.
And with the pulley and alternator belt fitted
Also been doing some body work
I’m off on holiday this week, so the plan is for when I get back it will be in white base coat then on the Saturday we will add the grey and orange, then lacquer it
27 September 2014, 09:59 PM
#386
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Some progress on the paint work, not as much as I wanted but some at least…
It was outside for the first time in nearly a year so I took the opportunity to take some pics…
Then after some final flatting down and a good clean off it was masked up.
Then into the booth for a couple of coats of 2k primer.
Spotted a few small areas to do a bit more work on, but all in all pretty good
It was outside for the first time in nearly a year so I took the opportunity to take some pics…
Then after some final flatting down and a good clean off it was masked up.
Then into the booth for a couple of coats of 2k primer.
Spotted a few small areas to do a bit more work on, but all in all pretty good
28 September 2014, 08:07 PM
#390
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Thanks Tim will be built up soon with some of the RallyTech parts on...