Hi All,

Well thought it would give me some motivation if I were to document the build of our Hill-climb car. After seeing the other great projects on here though it shows me just how much work we need to do!

Anyway..

What we have is a 4 Door GC8 WRX that I used as a runaround until about 2 years ago when the engine finally lost the will to live and went 'pop'.

Since then, with opening the rolling road etc just have niot had any time to play with it, but now things have settled, and I finally (just about) have weekends to myself, I thought it time to start playing with the Subaru again!

The idea is to build a hill-climb car (we are very close to gurston down and castle combe etc so hill climbs and sprints are ideal for us.

To start with, last year we supplied several ECUs to a company in Scotland called Scottish Subarus, and in return they sourced for us a low mileage EJ22 block from a broken 22B with forged internals, STI heads and a few bits and bobs. This has gone off today to the engine builders to be acid dipped and cleaned up as it really is a bit of a mess at the moment!

Onto the car...

The car is an MY94 GC8 4-Door. At the moment it is painted in our (old) company colours of silver/red, and is currently stripped to just a rolling chassis so I can get on with prepping and painting all of the interior white, as well as prepering for instalaltion of a Custom Cages GrpN cage, and fitment of the rear firewall and fuel cell.

The suspension is a tired set of Bilstiens, and as for brakes, well they are the standard single pot items.

The car is fitted with an FMIC, but other that is standard.

So what to do:
1. Finish prepping the interior.
2. Send dash away to be flocked.
3. Polycarb the windows
4. Strip the doors down and sheet the inner skins
5. Install the roll cage, and final painting of interior
6. Install fuel lines, brake lines etc
7. Decide on and install suspension setup. (advice please! )
8. Decide on and install Braking setup. (advice here agin lol!)
9. Wire the car loom (lights, horn etc)
9. Clean up and install the engine+gbox (this requires a section of its own!)
10. Wire up engine loom, install ECU + Map
11. Repray extenral to new colours and apply gfx etc
12. Compete in the thing!

I will put up pics asap, and I am trying to do the project on the reasonably 'cheap' (not extremely, happy to spend moneywhere it counts, but unfortunately with us being a kit car tuning company I can't really put this thing down as a demonstrator (we have 3 of those already!) so its all out of my pocket lol

Cheers, and hi to everyone

Matt

 

hi,look forward to the pics

 

Prior to us getting the roll cage in, I thought as the car is now gutted, it may be a good time to seam/stitch weld some of the interior floor plan together. I will be attacking the engine bay later this week

 

Got some of the welding done this afternoon will post pics tomoz

 

After stripping back the joins to expose metal, we then went about stitching up the gaps. The idea was to do a 25mm weld, then psace 75mm and weld and so on. This allows some flex, as otherwise if the car is involved in knock the chassis can never be straightned again.


We also patched over the press holes as well wholst we were at it...

 

Ok,

Well we finally have our custom cages multipoint cage installed, will post up pics ASAP.

I also need to finish priming the interior before it gets painted.

The EJ22 engine is now built up, with reversed inlet.

Looking to get the interior and caged finished and painted, then I will be installing dash, seats, harnesses, fire suppression and make a start on the wiring. I also need to start thinking about brake system routing and fuel system/tanks etc.

All good fun!

Matt

 

pics, pics,pics!

 

Good stuff Matt, shall follow with interest

 

Any pro's in seam welding all the seams?

Will be watching this as it might give me some ideas lol

 

sounds like a good project!!

 

Cheers guys.

In terms of seam welding, just tightens trhe whole shell up. When we did the rear end you could just rock the thing so solidly if that makes sense, the cage has made it completely different.

Of course its not powered as of yet so havent been able to to test it as such. With a hill coimb being about 40 seconds if not less at high speed ona very smooth tarmac, a nice solid ride it what your after.

In regards to the above, I have just managed to get my hands on a set of Cuscos

Matt

 

Could you point me in the direction of the pipework supplier for your turbo setup? I was thinking rotated top mount turbo, but after reading about these front mounts... well...



Matt

 

I bought mine off a member on here.
Gazzasti, he's also done the twinscroll stuff on the Lateral Car.

What I would say is it's alot of bloody work and you have to cut pretty much all your front end away. I'm hopefully going to fabricate all the rad and intercooler mounting hardware tomorrow.

I would probably say to stick with Rotated as it's that much easier. I'm committed now so have to see it through, would I do it again? probably not.

I would like to compare with a traditional rotated setup when I am done

 

Ah ok mate cheers for the heads up!

I'll keep to rotated

Matt

 

Pics of the cage as it arrived, the mounting points, and how it looks now. Need to finish prepping and priming the interior before its painted diamond white









Cheers,
Matt

 

Looking like good progress there! What gearbox you thinking of running?

 

sounds like a very tidy peoject mate.

 

Cheers guys, in terms of box, either a PPG setup or JDM 6 Speed

 

I have a 5 speed PPG dog box (all 5 gears are dog, its not a 4+1 box) that's surplus to requirements now as I've taken a break from motorsport as works been to busy.

Its done very little work, has over select stops, interlockers, 20kg centre diff and a front plate LSD. Though I can swap the centre diff for a electronic one if you want. Its 4.44 ratio

If you're keen let me know..thanks

 

6 speed gets my vote and i prefer the jdm over the uk 6 speed, they are bullet proof I have never heard of one need replacing but as far as I know the ppg's need rebuilding every so often.

 

^^ You are biased though

TX.

 

What kind of turbo you aiming for? I am getting a twin scroll VF37 fitted to mine next week, as use mine for our hill climbs, and they are very twisty, so hoping for good low down power.

If the engine is out, worth thinking about a baffled sump? Especially if you run slicks

 

Grant, Yes was planning on baff;ling the sump before it all goes back together, and jave decided to go JDM 6 speed

 

Made some progress today Most of the interior now painted







Getting there...

I also went over to Merlin Motorsport and picked up some sidemounts for the sparco buckets

Next plan is to get the inside paitning finished, then put in the ally plate for the firewall between passenger compt. and boot....

 

are you making the firewall or is it purchased?

 

Looks like some good work! Not tempted by a pretty carbon firewall? lol

 

Matt, you know those 550 injectors arent going to be big enough so you might as well sell them to me!

 

lol!

Well Im actually going to be fresh building a new EJ20 block as the EJ22 is too big capacity for my series.

I have a UK EJ20 block, is this the same as the JDM item (MY96)

Just so I know the base I'm strting from!!

hmmm Carbon :P

 

So when do you reckon you will do the first event in the car? Our first is on 5 April, and as long as the car is running properly (few ecu issues at the mo), then will take an in car video.

Be good to get a few in car hill videos I reckon

Carbon firewall is virtually the same price as ali- whats stopping you Few about if you type into Google

 

Grant,

Hopefully should get it up to gurston this year, am now building a fresh engine that will hold me up, but looking forward to the road test

Matt