dougmo

Some of you will know my car from other forums but I have never felt it was worthy for EvoM, getting there now though.

Now that the car is very near to completion I thought I would share it here.
cliffs;

bought the car as a stocker in 2006 with the intention of being a tarmac rally car
built the engine, fitted suspension and cage
finally got it out in 2009 and blew the engine first time at winton
2012 is here and almost done...finally

Ill add photos of the progress

when I bought it


fitted the cage


DMS suspension

First incarnation of the engine (grenade)

At this stage I ran outlaw(wilwood) front calipers with evo 4 rotors

Had a nice exhaust

Had some suspension bits too

Front looked like this


Ended up looking like this under the bonnet


Made 270kw at all 4, lots of torque too........
enough to do this

electrical issue, conrods removed the alternator and the starter motor from the engine promptly







And from here is where it began(got out of hand)...........
The kicker was I drove a friends evo 7 at WTA last year and that made me change the build direction dramatically.

dougmo

Next stage was engine rebuild

Engine now has a 100mm knife edged crank (12mm longer stroke), JUN conrods and teflon/ceramic coated supertech pistons




Light weight pulleys


enlarged baffled/trap doored sump, twin windage trays and custom crank scraper




Polished and painted inside the block, all galleries radiused etc, water system modified




short motor



Complete motor with TD06 and steamer manifold, this was meant to be it but it went alot further from here

dougmo

Next stage was the suspension and the next stage of the cars development, even though it has not been out of a shed for a few years
I also changed to front and rear brembos and 5 stud

New fabricated front lower arms, and front and rear crossmembers from racefab in NZ

arms


front crossmember



rear crossmember


Modified original rear lower arms to allow track/toe adjustment



Rear end



Lightened front uprights/knuckles


front brembos


Rear brembo brackets




rear trailing arms with brembos


At this stage I had gone alot further than I had anticipated but was pretty happy

Mistaken

iTrader: (20)

Wow!

Love the older evos.

dougmo

This is the point where I drove the other evo at wta in 2011 made me change direction and want the car to be a full blown time attack car.

The main issue with my current setup was too much weight and a lack of power potential.
The main hurdle is the cage that I fittd which is a big CDS job and will always be extra weight I dont need, but worth it I guess.

So then the new path started with a full new turbo and manifold set up and a gearbox/clutch rebuild/upgrade.

Gerabox components were all isotropically? polished and any uneeded weight removed from parts, such as the front crownwheel and
the transfer case shafts



Transfer case shaft machined out


A heap of meat taken off the inside of this also


Water blasted cases


then

New inlet manifold and 80mm throttle body


Borg warner S259 turbo with new manifold and 44mm external gate, 3.5" dump




I still may fall a touch short on the power I need but Im a touch worried about the driveline at the moment

dougmo

Then it was onto the weight reduction on the body
Please be prepared as i have gone to silly lengths to save grams not kgs

Shifter hacked and ground up


doors were prepared (still steel at this stage)


other unused bits removed


Hinges trimmed (more than in this pic but you get the idea


Rear rotors lightened


Radiator support removed and a new setup fitted
The rods on the front mount on the bar

dougmo

not enough love for the old girls these days

dougmo

The weight reduction work continued with a motec PDM and custom interior loom and switch panel







At this stage I still have the stock engine loom due to the plug and play autronic ecu that i have, this will change in the long run

dougmo

Then the fuel system

this consists of twin 044 pumps, a carter lift pump, 1600cc injectors, magnafuel reg, 6 litre surge tank and 24 litre fuel tank...all custom.

Tank almost done


surge tank and pump cradle



in place

dougmo

The weight reduction and upgrades contined

new larger,lighter front brake calipers and rotors with custom alloy dog bones


the supplied ones were steel and heavy


front hubs modified


New very fat wheels (well for this car) now a 17x9 +12 with 255s all round


Rear crossmember modified more to reduce more weight


New pedal box, needed a lot of extra bracing to be stiff enough and still a work in progress

dougmo

By this stage I had a car with large wheels that didnt fit under the car.

looked like this



So work began on the body, due to nothing being available off the shelf a custom kit was decided on and then to be moulded in
fibre glass in the long run. It was all hand made from steel!

Started in the rear, the aim was for it too look similar to a evo 7-9 as it would be a bit more slippery through the air (in theory)




Side skirts were also fasioned up




also the front guards




A long time later it looked like this





The front bar i purchased from NZ and added 50mm to get it closer to the ground

dougmo

All of the parts were then sent off to be moulded and made front glass including the doors

I had them done in black also but they have a brown tinge under lights




also had these airguides made up


Its fairly wide now


I dont have any more pics of it with the front bar and skirts but it looks a lot nicer than in the steel/bog

dougmo

After that work continued on the suspension and other bits like the exhaust etc ....still a work in progress

rear lower arms


A few more pics of the front end





exhaust comes up over the rear crossmember (edo helped me here)


extra supports from the rear towers added




Home made rear wing

dougmo

finally a few under bonnet pics, I have stacks more but Im trying to do a brief run down as such .
This is basically where the car is at now (3 years after the blow up)
















Also a bit of CDL love

dougmo

The current weight without the front bar,boot lid or side skirts (but still with the steel/bog rear 1/4s) this is with about 5 litres of fuel and all other fluids

The work on weight removal continues though

note: not corner weighted