American Rally 86 UPDATE

Posted: Mon Jan 28, 2008 5:30 am Post subject: American Rally 86 UPDATE

Hi, Im new to this forum, although I have asked some questions here. This is what I've been working on!

So everything here is very old, like 4 months. I just realized I can copy my thread from hachiroku.net and paste it here.... yeah... haha.

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Ok, Heres the car as I got it, and the engine bay...

And finally, the one action shot my brother got....

The death of sound deadening... hurray for 4 inch chisels!

Oh yeah, heres the supra rear end

The JVAB coil overs I'll be getting

Custom made to application coil overs using bilstien inserts, valves to the spring rate, which is all chosen by vehicle weight, and driving conditions. John Vanlandingham is the guy who makes these, and is super crazy.

Posted: Mon Jan 28, 2008 5:31 am Post subject:

Heres some of the car before the gutting. Luckily that didnt take too long, as there wasnt much of an interior to begin with.

And here are the "gutted" pics. And yes, if it's visable... I know I missed that one bracket behind the drivers door. haha. I'll get it!

Posted: Mon Jan 28, 2008 5:33 am Post subject:

Ok, time for an update, and some more pics!

This is the usual steering lock/ignition bracket on the steering column. Note the little "Bridge." This is where the lock lug lives. Well, to steal a corolla, erm, I mean, to disable it for legal purposes, you can just cut the bridge, and pop the lug out.

Well, in rally, you cant have the steering lock, and as I'm too lazy to turn a ket to start my car... I've modified that bracket a bit.

Presto Chango we have-o a steering column *spacer* as the turn signal lever bolts to this peice.

As you can see, I no longer have the "bridge" or the turn key section. Who needs that, anyway?

On a completly different note, some of the new(ish) parts I picked up from the Pull-a-Part are one the car now.

hurray for the latching trunk and tail lights. Right now, they're just on to keep rain out, till I get my garage cleaned out enough to shove a car in it. Smile

here are my ITBs...

Posted: Mon Jan 28, 2008 5:36 am Post subject:

Ok ... I've actually been doing work! Unfortunently, I dont have the before pix... I was a bit preoccupied sand blasting all my front suspension parts to take pictures. Why? Well, for one, I like inhaling the dust and getting that wierd feeling in the back of my throat (just kidding). The other reasons are one, its good to be rust free and protected and two, they are gonna look sweet freshly painted black. I also scored the entire suspension assembly out of an 86 in the pull a part. Struts (for the spindles to make spares for the my coil overs), control arms, caster tie rods, cross member, and the steering rack. And yes... the engine is still standing! *takes cheesy bow* Thats pretty much it for suspension stuff.

Onto..... Weight stuff!

I've been trying to reduce this thing as much as possible as I have to put a really heavy cage in it (something like 230 pounds Sad

). To make it seem a bit less like a loaded school bus, I've been doing some house cleaning. And parts swapping. Obviously its gutted. I mean SUPER gutted. There is NOTHING on the shell but the rear end and the front crossmember. Not even the wires. Well, there is glass... but not for long. The doors arent even on it. Here is the list of weight savings.

Race seats, no sound deadening, MAYBE lexan side windows, CF hood, racing wheel (does that count? lol), door bars are being removed as I have the 3 cage tubes which actually mount to SOLID points, versus being contained JUST in the door. plus physics tells me that things gonna have inertia when it smacks the side of my cage.... Lets see... I think that may be kinda sorta it. Besides the unsprung weight savings!

I'm replacing the brakes on the car with some Wilwood goodness, as being able to stop would be nice. Here is some random information I have found. The stock Unsprung weight (meaning rotors, calipers for the whole car [and hubs for the front]) is 61#. With the Wilwood Dynalight 4 pot calipers up front and 2 pot in the rear running Bigger front rotors on aluminum bells and stock supra rear end width rotors on bells in the rear its 43.8# unsprung weight for the car. That includes the stock hubs. Now obviously this doenst include the half control arm, half strut, and half tie rod. This is stuff that I can manipulate at the moment. this also doesnt have the custom mounts I have to machine for the calipers. (I bolded and underlined stuff if you dont want to read it all! hmm... too late... oh well)

And finally, I picked up some Toda valve springs from Bob at Drift Office! I got my head back from Rob at Action to do a bit of port clean up then it goes back to him for the final valve cut. Pics on that later. Pics on other stuff too.

Posted: Mon Jan 28, 2008 5:39 am Post subject:

Ok... well, the garage is finally cleaned up to where I can get my car in it. Unfortunently, its about 2 months too late. What does this mean? My car wont be done in one huge "swoop?"

Febuary 23-25 is the NASA sactioned Doo Wops Rally.

Oh snap.

Crunch time.

So, now that the car is FINALLY able to be welded and ground upon (as my garage is heated, and the humidity is more easily controlled then outside Very Happy

) I have been busily (is that a word?) wire wheeling away at seam sealer, paint, the mysterious bondo covering crash damage??? But luckily the damage is only cosmetic at this point Smile

So, for your view pleasure... pictures!

The only bad rust

Your jealous that you don't have a Champs karting suit you got for free to use as coveralls... right?

And with the conclusion of the pictures, here is the "slimfast" rally car diet

The engine will be the crazy one
The suspension will be done
The Supra axle will be in with the custom 4 links and turret rear
Obviously a cage, im not sure why im putting this line Wink

Custom dash (As I have none....)
Stock tranny
stock brakes

And I think thats the main of it. I'm not really sure, too much to remember. I just look and do, hahaha. Who needs that organizational stuff anyway? Have you seen my ITB's anywhere? erm, I mean yeah.

Any questions?

Posted: Mon Jan 28, 2008 5:39 am Post subject:

God? Is that you?

More coming...

Posted: Mon Jan 28, 2008 5:40 am Post subject:

Questions? Coments? Hate mail? Death Threats? Donations?

Posted: Mon Jan 28, 2008 5:42 am Post subject:

Oh yeah, there is the engine

12:1 compression, Weisco Pistons
Clevite 77 bearings
81.5mm bores
Balanced bottom end
Toda valve springs
31.5 mm in valve, 27.5 ex
Ported Small port head
Web Cams Grind 110, approx 284* (256 at .050)
Shimless lifters
For now, stock flywheel4 puck race clutch

Yeah..... Evil or Very Mad

Posted: Mon Jan 28, 2008 5:43 am Post subject:

Here's some of my stitch welding. DONT LOOK AT THE WELDS!!! I erm... need some practice..... and no, I am NOT welding my cage. I'd like to live, thank you. When I roll it, my co drive will probably be appriciative that I didnt weld the cage!

Now, as ugly as they look, they do have penetration, each and everyone of them, so, I'm not too worried about them. They're were a few in the begining that were just too cold that I had to grind off and do again.

And this is a cage teaser pic. Its my main hoop.

This is where all the problems have started. Front bars didnt work right, the tube notcher was all screwed up, it was terrible. Rather then wasteing time, effort, and patience with trying to rectify bad equipment, I just said screw it and went on to work on other areas. Also, in all the bad came some good. Because of the notcher just sucking balls and making me have to keep notching to get one good clean notch, the tube ended up to short. So I rebent both to be SUPER tight against the cage, I'll get some pics of that later when its all tacked together.

Posted: Mon Jan 28, 2008 5:44 am Post subject:

Here I am, clearly hard at work

*ahem* After very strenuous and scientific methods, I determined the correct seating postion for optimum driver performance. Very Happy

Those are Sparco Corsa seats, btw. Also, these are just the prelim positioning. Theres no brackets, and to get the seat lower (for CG reasons) I removed that lateral reinforcement thing. The seat mounts will re strengthen the area.

And now, here is the evil heater box problem!

So there lies the problem. If its possible to move the blower those few inches inward, I would just do that, but I dont know how feasible it would be... I think instead of trying to fab a new hole, or make a duct I would rather just get a smaller, lighter, heater for the defrosting purposes.

Oh yeah, sorry for the GIANT pics. I just caught that, and I *really* dont want to go back and edit them all. Sorry. Im lazy.

Posted: Mon Jan 28, 2008 5:45 am Post subject:

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 Smile

Heres the "artistic rally parts shot" haha

Posted: Mon Jan 28, 2008 8:49 am Post subject:

Nice project! Thats going to be a sweet rally car Thumbsup

Posted: Mon Jan 28, 2008 10:47 am Post subject:

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.

Posted: Mon Jan 28, 2008 11:48 am Post subject:

Wow... That's a huge project! Shocked

The rear axle is Celica Supra Mk1? Blonde question

Thought that Mk2 had IRS like the AA63. Wink

Posted: Mon Jan 28, 2008 7:53 pm Post subject:

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: 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!

Posted: Mon Jan 28, 2008 9:09 pm Post subject:

It was actually the wrong gas Shocked

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.

Posted: Mon Jan 28, 2008 10:20 pm Post subject:

Yeah, that's the Mk1 alright. Smile

Posted: Tue Jan 29, 2008 4:05 pm Post subject:

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? Wave

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 Sad

Posted: Tue Jan 29, 2008 10:32 pm Post subject:

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 Thumbsup

Posted: Fri Mar 28, 2008 8:14 pm Post subject:

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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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Posted: Fri Mar 28, 2008 8:15 pm Post subject:

[COLOR="Red"][SIZE="5"]Ok, here's what im doing to get my seats lower. As you can obviously tell, I chop giant hole in floor... and insert new floor pan i bent up.

I took my LSD apart, time for a rebuild and some shimming

And a random pic of my stitch welding. This is with my TIG Smile

PS on the A piller Wink

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Posted: Fri Mar 28, 2008 8:15 pm Post subject:

Ok, so the pics have captions now...

Basically lately there has been a lot of designing and not so much doing going on. The cage is sort of in limbo, and may be getting redone.... again.... But hey, soon I'll be able to build the engine!

Posted: Fri Apr 25, 2008 8:43 am Post subject:

Man i forgotten this project