DIY Classic Rally Car Build
09 December 2013, 05:45 PM
#95
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Location: oop north in a spec-c.Now sold and starting on a classic ra track/sprint/road car
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BTW Rob,Peter is chuffed with the twin scroll he got off you……even after he rolled while leading in the Manx so much so the car is now rebuilt he wishes he had gone twin scroll years ago finds it much easier to drive.
. Thanks for letting me know. Twin Scroll is definitely on the cards for my next venture 
18 December 2013, 09:01 PM
#97
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nice one for the pics and info rob
and a HUGE thankyou to AS Performance for the advice
I bought this
well happy with it, apart from the colour.... but hey, it's a rally car and built for speed not looks! on that note, I got some maxsport soft rb5's fitted and bolted on
cars dirty, no front bumper and half stickered, but you get the idea....
and a HUGE thankyou to AS Performance for the advice
I bought this
well happy with it, apart from the colour.... but hey, it's a rally car and built for speed not looks! on that note, I got some maxsport soft rb5's fitted and bolted on
cars dirty, no front bumper and half stickered, but you get the idea....
Last edited by tom-r33; 24 December 2013 at 06:19 PM.
19 December 2013, 08:44 AM
#98
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Looking good Tom ,,, here is one we built if you fancy a look
http://www.ebay.co.uk/itm/SUBARU-IMP...item3a88f4f828
http://www.ebay.co.uk/itm/SUBARU-IMP...item3a88f4f828
19 December 2013, 11:00 AM
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It's getting there. Work is holding up progress!
Car looks nice, really good looking shell/cage
What undercar protection do you guys use on tarmac cars?
Car looks nice, really good looking shell/cage
What undercar protection do you guys use on tarmac cars?
19 December 2013, 06:59 PM
#100
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Rallying is fairly new to me but the chap doing all the work has been doing it for a while now ,,, iv seen mostly kevlar stuff when iv been over there but like I said I'm not sure so would have to ask
24 December 2013, 06:18 PM
#102
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Found some time to spend on it today 
I was never happy with the front mount intercooler and where the pipework ran, even after spending time and effort trying to get it to work how I wanted, so I measured up, did some calcs regarding intercooler volumes etc and ended up buying a forge motorsport off the shelf cooler, with a view to modifying it slightly to work. It was less than £70 delivered so I thought I'd give it a go.... Anyways, here some pics of how it's coming together
I was never happy with the front mount intercooler and where the pipework ran, even after spending time and effort trying to get it to work how I wanted, so I measured up, did some calcs regarding intercooler volumes etc and ended up buying a forge motorsport off the shelf cooler, with a view to modifying it slightly to work. It was less than £70 delivered so I thought I'd give it a go.... Anyways, here some pics of how it's coming together
29 December 2013, 07:22 PM
#104
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Merry Xmas Iain!
Got the TEG restrictor pretty much fitted, had to slot out the holes in the turbo and shave abit off the exhaust support bracket so it would rotate enough so that the restrictor and hose cleared the inlet manifold! PITA
Mocked up boost pipes, intercooler end tank, air filter location tweaked and pipework sorted
I'm happy it's neat and tidy, nice and short and out the way now
Got the TEG restrictor pretty much fitted, had to slot out the holes in the turbo and shave abit off the exhaust support bracket so it would rotate enough so that the restrictor and hose cleared the inlet manifold! PITA
Mocked up boost pipes, intercooler end tank, air filter location tweaked and pipework sorted
I'm happy it's neat and tidy, nice and short and out the way now
Last edited by tom-r33; 29 December 2013 at 07:34 PM.
12 April 2014, 07:14 PM
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I lied, I wasn't happy with the intercooler/radiator setup atall! So I took a step back, did some thinking (and a lot of measuring!) and came up with this:
RS500 intercooler, MGTF aluminium radiator, 2 x 12inch fans and my existing oil cooler
I had to swap my existing oil cooler for a smaller one but I think the one I have now will be sufficient, and the right hand fan hit the exhaust manifold so that had to be moved upward, which isn't all bad as it blows through part of the oil cooler now
after that was sorted it was just fluids, a final tidy up and off to interpro
and this was the result
anti lag and launch control setup
throttle jacked open about 15-20% as I don't have an idle control valve, so it idles like a pig, but damn its responsive
RS500 intercooler, MGTF aluminium radiator, 2 x 12inch fans and my existing oil cooler
I had to swap my existing oil cooler for a smaller one but I think the one I have now will be sufficient, and the right hand fan hit the exhaust manifold so that had to be moved upward, which isn't all bad as it blows through part of the oil cooler now
after that was sorted it was just fluids, a final tidy up and off to interpro
and this was the result
anti lag and launch control setup
throttle jacked open about 15-20% as I don't have an idle control valve, so it idles like a pig, but damn its responsive
Last edited by tom-r33; 21 May 2014 at 11:59 AM.
21 May 2014, 10:45 AM
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I've been slack updating and havnt made a massive amount of progress due to finding a workshop, moving in and setting it up, whilst still working best part of 60hr weeks and starting another project! I'm well happy with the workshop and splashed out on a ramp and a load of racking too! Should make working on the cars a lot easier from now on
I thought it about time I washed the rally car, first time since owning!
I had enough of rubbish idle, so I added an idle control valve off a bm under the throttle body, not sure if it's visible in this pick, but it's there! Re-routed some engine bay wiring so that it can stay in place when the inlet mani is removed, to save some time if it needs removing again. Moved boost control solenoid closer to the turbo so the pipe is nice and short. And a little bit of tidying here and there
I also replaced the screw type brake bias adjuster for a lever type as it's much easier to set in defined positions and adjust on the fly. It lives next to the gear stick if you're struggling to spot it!
The rear end feels abit 'loose', almost like it has rear wheel steer! So I'm going to try locking the subframe solidly to the chassis as I think that's the issue.
The front tyres catch the inner arches, so they need lifting and securing, I'm looking into some stronger guards here as there are electrics running through the wings! Urgh!
On the whole I'm fairly happy with the car, it's not perfect, but as they say 'Rome wasn't built in a day' so I will continue to develop it, and will probably never stop as I'm never 100% happy with my cars
First meeting is looking likely to be Bournemouth on 22nd June! Now I just need to sort the logbook, which will require a few things changing on the car but nothing significant, and then onto the rally barge which needs timing up and MOTing and we should be good to go then! Only 10months after my target date for my first event!
I thought it about time I washed the rally car, first time since owning!
I had enough of rubbish idle, so I added an idle control valve off a bm under the throttle body, not sure if it's visible in this pick, but it's there! Re-routed some engine bay wiring so that it can stay in place when the inlet mani is removed, to save some time if it needs removing again. Moved boost control solenoid closer to the turbo so the pipe is nice and short. And a little bit of tidying here and there
I also replaced the screw type brake bias adjuster for a lever type as it's much easier to set in defined positions and adjust on the fly. It lives next to the gear stick if you're struggling to spot it!
The rear end feels abit 'loose', almost like it has rear wheel steer! So I'm going to try locking the subframe solidly to the chassis as I think that's the issue.
The front tyres catch the inner arches, so they need lifting and securing, I'm looking into some stronger guards here as there are electrics running through the wings! Urgh!
On the whole I'm fairly happy with the car, it's not perfect, but as they say 'Rome wasn't built in a day' so I will continue to develop it, and will probably never stop as I'm never 100% happy with my cars
First meeting is looking likely to be Bournemouth on 22nd June! Now I just need to sort the logbook, which will require a few things changing on the car but nothing significant, and then onto the rally barge which needs timing up and MOTing and we should be good to go then! Only 10months after my target date for my first event!
Last edited by tom-r33; 21 May 2014 at 12:04 PM.
15 December 2014, 11:51 AM
#108
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About time for an update!
Fitted tank guards and while I was there removed the exhaust flange and replaced with a slip joint style joiner so it wouldn't get caught on anything and cause damage
Replaced the old sump guard with one i made
Moved swirl pot and high pressure pump to the boot and made a firewall/bulkhead
Tidied up the engine bay and heat wrapped a few things
Then finally after a few years of building it I got it logbooked!!!
Fitted tank guards and while I was there removed the exhaust flange and replaced with a slip joint style joiner so it wouldn't get caught on anything and cause damage
Replaced the old sump guard with one i made
Moved swirl pot and high pressure pump to the boot and made a firewall/bulkhead
Tidied up the engine bay and heat wrapped a few things
Then finally after a few years of building it I got it logbooked!!!
15 December 2014, 11:59 AM
#109
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First event was recency stages which had a few night stages so I bolted some spot lights to my spare bonnet, stickered the car up and was ready to go...
15 December 2014, 12:47 PM
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So never done a rally before, 100 entries and I got seeded 98th.
1st stage I thought I'd take it easy and was 15th fastest overall, did a fair bit of overtaking it felt more like a track day! Lost a fair bit of time behind enyry level 106's and the like.
Stage 2, I know what I'm doing now, 3rd fastest, beat an ex WRC car, co driver reconed we would have been fastest stage time if we hadn't been held up so much by the slower cars.
He asked if we could be re-seeded and we got moved up to around 20th on the road.
Stage 3&4 I got my crazy head on thinking I was the next mcrea and made a few mistakes, almost destroyed the car several times, outbraked myself into tight 90right and decided I wanted to hit the hay bale on the outside of the bend sideways instead of forwards, so both doors and rear quarter took a wack, sheared the rear spoiler off and lost that, but recon we only lost a second or 2. Outbraked myself again on slippery section as throttle cable got stuck due to turbo heat melting the outer and sticking it to the inner, we got to the end though.
Stage 5&6 were good, stage 6 was dark and showed we could be quick at night too setting consistently fast times, slowly moving up the order, sitting 7th overall now. 3 ex WRC cars and some pesky evo's infront!
We're getting noticed now, microphone shoved in my face as soon as I come off stage, feeling like a proper rally driver! What is going on?! I*dreamt of this but now it's happening for real! So surreal!
Stage 7, properly dark now, lights essential, was clean, tidy and fast. I knew we would be right up amongst the big boys again, until I hit a curb and bent the rear right wheel over and spat the rear shaft out. If I'd had a DCCD controller then I couldve locked it and limped back to service, but I didn't so that was us out. Stuck on stage for over 2 hours waiting to be recovered. We watched another Impreza do exactly the same thing as we did. And the corner take another few victims. It appeared to be getting slipperier as the temps dropped. Little consolation to be honest.
We had a few issues throughout the day:
Car suffered from overheating all day so I was short shifting to try and minimise it, i later found out the cause was a faulty thermostat which was wedged closed. I can't believe the engine lasted so long, every stage we came off it was 115°+ oil and water
Launch was being funny and cutting in even though it was not enabled so off the line it wasn't pulling properly
One of the front calipers was only pulling up on one side
I kept pulling the normal handbrake instead of the hydro so the hairpins were messy and slow
But damn wasn't it fun!!! I'm hooked!!! What a buzz!
So now I've sorted the bodywork out, as much as I can be bothered to, moved the hydro, replaced all the rear arms and inspected the front caliper but can't see any reason for it not to work. The only thing that needs doing now is sorting the launch issue.
Here's some pics
Massive thanks to everyone who has helped me and spurred me on, you know who you are
Bring on 2015
1st stage I thought I'd take it easy and was 15th fastest overall, did a fair bit of overtaking it felt more like a track day! Lost a fair bit of time behind enyry level 106's and the like.
Stage 2, I know what I'm doing now, 3rd fastest, beat an ex WRC car, co driver reconed we would have been fastest stage time if we hadn't been held up so much by the slower cars.
He asked if we could be re-seeded and we got moved up to around 20th on the road.
Stage 3&4 I got my crazy head on thinking I was the next mcrea and made a few mistakes, almost destroyed the car several times, outbraked myself into tight 90right and decided I wanted to hit the hay bale on the outside of the bend sideways instead of forwards, so both doors and rear quarter took a wack, sheared the rear spoiler off and lost that, but recon we only lost a second or 2. Outbraked myself again on slippery section as throttle cable got stuck due to turbo heat melting the outer and sticking it to the inner, we got to the end though.
Stage 5&6 were good, stage 6 was dark and showed we could be quick at night too setting consistently fast times, slowly moving up the order, sitting 7th overall now. 3 ex WRC cars and some pesky evo's infront!
We're getting noticed now, microphone shoved in my face as soon as I come off stage, feeling like a proper rally driver! What is going on?! I*dreamt of this but now it's happening for real! So surreal!
Stage 7, properly dark now, lights essential, was clean, tidy and fast. I knew we would be right up amongst the big boys again, until I hit a curb and bent the rear right wheel over and spat the rear shaft out. If I'd had a DCCD controller then I couldve locked it and limped back to service, but I didn't so that was us out. Stuck on stage for over 2 hours waiting to be recovered. We watched another Impreza do exactly the same thing as we did. And the corner take another few victims. It appeared to be getting slipperier as the temps dropped. Little consolation to be honest.
We had a few issues throughout the day:
Car suffered from overheating all day so I was short shifting to try and minimise it, i later found out the cause was a faulty thermostat which was wedged closed. I can't believe the engine lasted so long, every stage we came off it was 115°+ oil and water
Launch was being funny and cutting in even though it was not enabled so off the line it wasn't pulling properly
One of the front calipers was only pulling up on one side
I kept pulling the normal handbrake instead of the hydro so the hairpins were messy and slow
But damn wasn't it fun!!! I'm hooked!!! What a buzz!
So now I've sorted the bodywork out, as much as I can be bothered to, moved the hydro, replaced all the rear arms and inspected the front caliper but can't see any reason for it not to work. The only thing that needs doing now is sorting the launch issue.
Here's some pics
Massive thanks to everyone who has helped me and spurred me on, you know who you are
Bring on 2015
15 December 2014, 05:43 PM
#113
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Well done sounds like you had a good day - you will never forget the countdown on the first stage I remember it was a right buzz, the next big memory will be finishing the last stage on the first one you finish!!
if i would give you some advice - it would be not to follow my route, keep the car as it is - its obviously fast enough, spend your money on doing events and tyres.
you will gain more speed by being in the car than trying to buy it with parts!! (that is of course unless you can afford to do both!!)
if i would give you some advice - it would be not to follow my route, keep the car as it is - its obviously fast enough, spend your money on doing events and tyres.
you will gain more speed by being in the car than trying to buy it with parts!! (that is of course unless you can afford to do both!!)
15 December 2014, 09:38 PM
#114
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Well done sounds like you had a good day - you will never forget the countdown on the first stage I remember it was a right buzz, the next big memory will be finishing the last stage on the first one you finish!!
if i would give you some advice - it would be not to follow my route, keep the car as it is - its obviously fast enough, spend your money on doing events and tyres.
you will gain more speed by being in the car than trying to buy it with parts!! (that is of course unless you can afford to do both!!)
if i would give you some advice - it would be not to follow my route, keep the car as it is - its obviously fast enough, spend your money on doing events and tyres.
you will gain more speed by being in the car than trying to buy it with parts!! (that is of course unless you can afford to do both!!)
I wish I had a load of money to throw at it, but like you say the best thing now is to get out there amongst it and get some seat time and make the most of what I've got, which as you say, is a pretty fast and conpetetive car, driven properly I'm sure I can get some good results with it
15 December 2014, 10:06 PM
#115
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you will -
mate had a basic RA with everything ripped out really lightweight and a management system on it - bog standard he did 10 events over 18 months at the end he was alot faster than me
he run on 15 inch wheels little brakes but new tyres every event water spray onto a top mount intercooler which was just a windscreen washer jet - the car never missed a beat and it was absolutly thrashed
I went the other way big wheels big brakes engine upgrades etc spent more time messing with the car than driving it its nice but dont have as much money to do the events - there fore not as quick
without doubt make it light spend time in the car and leave some dents in it
PS what are you using for an induction pipe - I need somthing plane?
mate had a basic RA with everything ripped out really lightweight and a management system on it - bog standard he did 10 events over 18 months at the end he was alot faster than me
he run on 15 inch wheels little brakes but new tyres every event water spray onto a top mount intercooler which was just a windscreen washer jet - the car never missed a beat and it was absolutly thrashed
I went the other way big wheels big brakes engine upgrades etc spent more time messing with the car than driving it its nice but dont have as much money to do the events - there fore not as quick
without doubt make it light spend time in the car and leave some dents in it
PS what are you using for an induction pipe - I need somthing plane?
Last edited by Bomber633; 15 December 2014 at 10:10 PM.
16 December 2014, 08:08 AM
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you will -
mate had a basic RA with everything ripped out really lightweight and a management system on it - bog standard he did 10 events over 18 months at the end he was alot faster than me
he run on 15 inch wheels little brakes but new tyres every event water spray onto a top mount intercooler which was just a windscreen washer jet - the car never missed a beat and it was absolutly thrashed
I went the other way big wheels big brakes engine upgrades etc spent more time messing with the car than driving it its nice but dont have as much money to do the events - there fore not as quick
without doubt make it light spend time in the car and leave some dents in it
PS what are you using for an induction pipe - I need somthing plane?
mate had a basic RA with everything ripped out really lightweight and a management system on it - bog standard he did 10 events over 18 months at the end he was alot faster than me
he run on 15 inch wheels little brakes but new tyres every event water spray onto a top mount intercooler which was just a windscreen washer jet - the car never missed a beat and it was absolutly thrashed
I went the other way big wheels big brakes engine upgrades etc spent more time messing with the car than driving it its nice but dont have as much money to do the events - there fore not as quick
without doubt make it light spend time in the car and leave some dents in it
PS what are you using for an induction pipe - I need somthing plane?
If I was to do it again there isn't much I would do differently in all honesty. The main difference would be to start with a seam welded, tubed shell that has a fully welded in cage that picks up on the front turrets.
Induction pipe is a bent steel tube, with silicone joiners either end, there is no chance of it collapsing. I'm on the fence as to whether it's a good idea to heat wrap it or not. I think some of that reflective gold tape might help keep it cool
You can see it in post #108
Last edited by tom-r33; 16 December 2014 at 08:10 AM.
16 December 2014, 08:45 AM
#118
I was watching the rally, a couple of friends were doing it , your car seemed to be going well , it looked a very slippy rally with cars skidding everywhere , so 4WD definitely helped on the day.
Whats your next event ? you doing Brean ? I might put an entry into that to get a bit of seat time as hopefully my gearbox issues should be fixed and the active diffs should be working now
Whats your next event ? you doing Brean ? I might put an entry into that to get a bit of seat time as hopefully my gearbox issues should be fixed and the active diffs should be working now
16 December 2014, 09:01 AM
#119
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I was watching the rally, a couple of friends were doing it , your car seemed to be going well , it looked a very slippy rally with cars skidding everywhere , so 4WD definitely helped on the day.
Whats your next event ? you doing Brean ? I might put an entry into that to get a bit of seat time as hopefully my gearbox issues should be fixed and the active diffs should be working now
Whats your next event ? you doing Brean ? I might put an entry into that to get a bit of seat time as hopefully my gearbox issues should be fixed and the active diffs should be working now
I'm trying to get into brean but it's looking unlikely, regs have been out for 2 weeks and already over subscribed so they've stopped accepting entries. A big fish may get a run if they make a big enough wave
Any ideas on the brakes? The pistons are all free, the pads are new and not binding, but one side does not appear to be putting pressure on the disk, it is the inside which is fed directly from the brake line too which eliminates the link pipe as the issue. I'm stumped! I havnt got anybody to press the pedal to confirm the pistons push out yet, that is the next thing, just need someone to be around at the stupid times I am!