American Rally 86 UPDATE

[dazed_driver]

And here are some more pics...

This is the axle after some clean up


Basically, I've just cut off the stock 4 link brackets but left the pan hard and sway bar mounts. I've also been grinding the remains down to the axle level and wire wheeling away the rust. It was only a lot of flakey surface rust, so nothing too bad

Heres the "artistic rally parts shot" haha

[Jan Pedersen]

Nice project! Thats going to be a sweet rally car

[dazed_driver]

Thanks! I forgot to make a general overview of whats going on, so here's one!


Engine:

Port blended small port head with over sized intake and exhaust valves
Web Racing cams, Grind 110- 256 duration at .050 lift. The lift is a little over 10mm.
Toda valve springs
Shimless buckets
Wiesco forged aluminium pistons, 12:1 compression
Balanced internals
No idea about the flywheel or clutch yet. All I know is I want a 4 puck cerametallic disc.
Fully deburred block
GSX/R 600 throttle bodies
No idea about exhaust yet. I think I may just pull a Group A and bore out the stock manifold and the down pipe... allthough to save wieght, I might just dish out some money for a nice header

Transmission:

For now, just the stock T50, I'll see how that does and/if/or I break it, I'll get a Ford Sierra's Type 9 with a close ratio gear set

Rear Axle:

Celica Supra axle with a 5.3 final drive and LSD

Brakes:

Eventually will be
Dual master cylinder set up with a hydraulic handbrake.
Wilwood powerlite calipers in the front
Wilwood 2 pot dynalites in the rear
10x.810in (254x20.57mm) discs up from, slotted and vented
Stock supra rear discs, 10x.38in (254x9.65mm) flat unless I can find slotted and solid rotor

Body and chassis:

Seam welded from strut towers to turrets
Rear turret kit
Full roll cage
Lowered seat mounting postions

Suspension:

JVAB 40mm Bilstein based coil overs
Reinforced lower control arms
Equal length extended 4 links (aiming for around 30 inch (76.2 cm) links without the length of the rod ends
Cage reinforced front strut towers

Fuel and Ignition:

Duel electric fuel pumps
Fuel Safe 15 gal fuel cell, enduro
Autronic or Haltec ECU
Some form of CD ignition, maybe MSD
Push button ignition
Optima red top battery
Master cut off switch

Interior:

Sparco Corsa seats
Custom carbon fiber dash
Custom gauge set
Custom CF pedal kit (heel toe & LFB better!)
Undecieded racing wheel w/ two buttons (either stock or added buttons) for killswitch and horn



That should be most of it, I'm sure I'll remember some more later. Also, I'll try to get the newest version of the cage uploaded (I've designed it in 3d)

And, I'll get the pictures taken of my 4 link mock up and the work I did today on the floor.

[banpei]

Wow... That's a huge project!
The rear axle is Celica Supra Mk1?
Thought that Mk2 had IRS like the AA63.

[Ivan141]

Hi! I like the way you went to work on that coupe, no holds barred! Keep up the welding, I'm sure you'll learn to do great welds in no time, otherwise, check this site out for informative instruction video's: http://www.mig-welding.co.uk

Looks like you used to a bit too little shielding gas, or maybe worked in a windy area.

Keep us updated!

[dazed_driver]

It was actually the wrong gas IT was pure argon... that guy is fired from welding the cage...

And the axle is from the 79-81 celica supra, so I think mk1? I've been slightly kicking myself for not seeing how hard it would be to swap on a later gen's IRS onto the car.

[banpei]

Yeah, that's the Mk1 alright.

[mc68]

nice build, im very jealous that you have a coupe, id much rather one.

So, i have the same problem with my cage being in the spot the blower mounts...soo, do you want to attempt it first or should I?

is this going to be a gravel rally car or a tarmac? ah how i want to lighten mine up with lexan and fibreglass panels...but not allowed

[dazed_driver]

Well, I've pretty much realized that I need an aftermarket heater... so thats what i'll be running. As for the type of rally car, it will be gravel spec, as not many tarmac rallies are run around here. However, it will see its fair share of any event I can afford at the time

[dazed_driver]

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Heres a bit of an update...

Ask questions if you want I'll answer

Ok, these are the strut tower reinforcements. The plate on the side is for the roll cage tubes that come through the firewall. (Take that Jesse! haha) The other peices are to help with the constant pounding the tops will take.




These are the 30 inch links... There are also some shots of the brackets (I'll get better ones later)





Here is the rear turret. I've only got the right side done so far



And the boxed control arm

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