nzae86's AE86 Levin Tarmac rally car build Project 1

I thought I would share one of my project builds that I started after destroying my Rally car on tarmac. I managed to salvage the engine , gearbox, and diff center and front brakes, the rest went to the dump!The seats broke , the dash was destroyed, it was easier to start again!

After finding another good shell my panel beater cut and butt welded any areas of rust to end with a rust free body to start building a new cage into, all the fabrication work i have done myself.

The shell was then sent in and media blasted back to bare metal, the sprayed with PPG DP40 etch primer

The cage did it's job ok last time but I added a bit more to it for the new car

The shell then went to the painters to have the top coats sprayed in a oven

Posted: Tue Jan 01, 2008 7:08 am Post subject:

While the shell was away for paint I rebuilt all the other components, sand blasting everything and repainting, i also thoght it was time for a new engine as well , the other needed pulling apart to check for oil starvation while end for ending down the road, so a bit more power was added with new pistons and balanced bottom end.

All new bilstien suspension was fitted and the springs were replaced with TRD.

After building a new fuel system for the car I had just finished when Motorsport New Zealand changed the rules on surge tanks and fuel pumps inside the car, so i had to redesign how it fitted and mounted it all in a sealed box

Posted: Tue Jan 01, 2008 7:24 am Post subject:

My ae86 toybox! where it all happens (as you see I do have a few spare parts!!)

Finally after many months I had the car almost complete

As you can see some head restraint seats help hold me in place now!

Posted: Tue Jan 01, 2008 7:35 am Post subject:

The engine is a smallport , with Wisco pistons , 20v ITB's ,lots of head work, Link computer, TRD gearbox, TRD LSD with a 4.8 crown wheel and pinion

Underneath the car is as (was) as well painted as the outside

Looking a bit naked without any signwriting!!!!

Posted: Tue Jan 01, 2008 7:51 am Post subject:

And for the finished article in action !!

One of it's first events, just to get it dirty ! at a rallysprint in the rain

A small video, suffering from a nervous driver and very slippery conditions

http://www.youtube.com/watch?v=b_lD1ooVwqU
and another after passing the GT4 Celica
http://www.youtube.com/watch?v=bgusB5tF3M8

Tarmac rally in New Zealand

At a recent trackday enjoying the sunshine

I am now running the car on 15 inch wheels and it suits the car very well, the rims are from a Dastun 240RS rally car , if anyone knows where I can find some more of these 15 x 7 let me know

And at a recent Tarmac hillclimb, those Dunlops are fantasic, you can push them to the limit and they still hang on !

And yet another Tarmac rally in the rain !! Finished 16th O/A won 1400 - 1800cc class by over 2 minutes , take that you Honda's !!!!

Posted: Tue Jan 01, 2008 9:30 am Post subject:

thats sick... i luv 86 rally cars Smile

how come u decide to use struts and springs instead of coilvoers?? and what brakes are u using???

Takumi Joined: 19 Apr 2005 Posts: 443 Location: EIRE

Very nice build, youve been at this game a while?, had a pic of your colourscheme on an 86 a few years ago now. Keep up the good work Thumbsup

Posted: Tue Jan 01, 2008 2:57 pm Post subject:

Very nice.. great looking build.

Iketani Joined: 13 Oct 2005 Posts: 46 Location: ireland

Great job,best of luck in the future

Posted: Sun Mar 23, 2008 11:20 pm Post subject:

And just to prove that ae86's are not slow on tarmac here are the results from a recent 9km tarmac hillclimb , loosing the final run due to fuel surge from trying to run too light a fuel load!!

http://www.hamiltoncarclub.org.nz/Results_This_...imb%20Results.pdf

The conditions changed from damp to dry from the bottom of the hill to the top.
Who said 4wd was fast???

Posted: Sun Apr 27, 2008 11:30 am Post subject:

awesome build!

how did you paint your cage black with the rest of the car being white!

how good do starion 14" wheels look on sprinters Very Happy

defiantly the rally wheel of choice.

Posted: Wed Apr 30, 2008 1:03 pm Post subject:

Posted: Thu May 01, 2008 1:28 pm Post subject:

god damn, starion wheels are like hens teeth here in perth..

i need a couple of sets Sad

Posted: Mon May 05, 2008 6:51 am Post subject:

I pmed you but wondering if you have the part number for the bilsteins and the trd springs you use??? also im guessing you still use the standard ae86 struts??

Posted: Mon May 05, 2008 10:48 am Post subject:

Posted: Mon May 05, 2008 10:49 am Post subject:

Posted: Mon May 05, 2008 2:24 pm Post subject: