My Rally Car Build
- Thread starter forestfighter
- Start date
irish rallying
New Member
- Joined
- Oct 20, 2009
- Messages
- 6
well i do a bit of rallying myself,and you have done a fantastic job there
forestfighter
ZR-TEC RALLY TEAM
- Joined
- Jun 13, 2008
- Messages
- 315
Hi all. Progress is on it's way....
Just spotted this though!
Build Threads
Just wanted to say thanks to 'Randall' for submitting my thread. Much appreciated. Glad people are enjoying it!
John
Just spotted this though!
Build Threads
Just wanted to say thanks to 'Randall' for submitting my thread. Much appreciated. Glad people are enjoying it!
John
forestfighter
ZR-TEC RALLY TEAM
- Joined
- Jun 13, 2008
- Messages
- 315
Hi there,
I apologise i didn't see your question untill now... The Tony Law system went from Manifold back due to me having a Janspeed 4-2-1 Manifold already...
Cheers
John
- Joined
- Jun 21, 2009
- Messages
- 2,831
Great build man, look forward to seeing the car next year at a few rallies. Hope you had a good day at Colerne, I had a blast! I've caught the trackday bug now!
forestfighter
ZR-TEC RALLY TEAM
- Joined
- Jun 13, 2008
- Messages
- 315
Right here is starts....
With the car being built to be used as a FWD rally car, i need a suitable class to run in. The class i decided on is the 1600cc category. This means the car has to be within 1401cc to 1600cc NASP.
My aim is to have the car as light as possible, have resonable power but maintain reliability. This got me thinking about engines. After reading up about the power a EK9 Honda Civic Type R made as standard (186bhp) it made me think what a cracking rally engine that would make. Then down the line again i was offered an old Rover 216 Cabrio with a Honda engine (D16) fitted. Looking at this closely we noticed the inner wings from the wedge were the same as the ZR and most things surrounding it. The D-Series found in the wedge also uses the same engine mounting arrangement as the B-Series (Type R). With this Ade persuaded me to take the plunge and buy the wedge to break for all the necessary parts for a conversion...
After a very 'interesting' journey, we got the wedge back to Ade's unit where we attacked it. I sold the engine, scrapped the car and kept all of the engine sundries/engine mounts. These are to be used in my conversion for the ZR.
Here are a couple of pictures of 'The Beast'.
Engine gone, revealing new mounts.
The mounts were drilled out and kept. I will drill out the K mounts in the ZR and fingers crossed, weld these new ones straight in.
With the car being built to be used as a FWD rally car, i need a suitable class to run in. The class i decided on is the 1600cc category. This means the car has to be within 1401cc to 1600cc NASP.
My aim is to have the car as light as possible, have resonable power but maintain reliability. This got me thinking about engines. After reading up about the power a EK9 Honda Civic Type R made as standard (186bhp) it made me think what a cracking rally engine that would make. Then down the line again i was offered an old Rover 216 Cabrio with a Honda engine (D16) fitted. Looking at this closely we noticed the inner wings from the wedge were the same as the ZR and most things surrounding it. The D-Series found in the wedge also uses the same engine mounting arrangement as the B-Series (Type R). With this Ade persuaded me to take the plunge and buy the wedge to break for all the necessary parts for a conversion...
After a very 'interesting' journey, we got the wedge back to Ade's unit where we attacked it. I sold the engine, scrapped the car and kept all of the engine sundries/engine mounts. These are to be used in my conversion for the ZR.
Here are a couple of pictures of 'The Beast'.
Engine gone, revealing new mounts.
The mounts were drilled out and kept. I will drill out the K mounts in the ZR and fingers crossed, weld these new ones straight in.
forestfighter
ZR-TEC RALLY TEAM
- Joined
- Jun 13, 2008
- Messages
- 315
Start removing K Series.
Lightweight bonnet. Needs another coat of yellow though
A rather full garage!
Ready to pull engine out tomorrow night.
Lightweight bonnet. Needs another coat of yellow though
A rather full garage!
Ready to pull engine out tomorrow night.
forestfighter
ZR-TEC RALLY TEAM
- Joined
- Jun 13, 2008
- Messages
- 315
Few progress (or lack of progress) pics... :in:
VV LOL VV
My mate Leigh looking stumped...
K mounts... GTFO. :guns:
Off. New gearbox mount offered up. Not bad at all really.
Engine mounting point offered up. Needs a tiny but of fettling but overall i'm happy.
All this hard work required a lot of fuel...
This is the base engine that's stood for a while. It has had bits done to it so i'm told, but will strip it all down and add to it. I really want 200 from it ideally.
Gearbox is the S80 Integra box with 4:79fd - nice and short for rallying. Got a KAAZ diff for it too!
Quick spruce up.
VV LOL VV
My mate Leigh looking stumped...
K mounts... GTFO. :guns:
Off. New gearbox mount offered up. Not bad at all really.
Engine mounting point offered up. Needs a tiny but of fettling but overall i'm happy.
All this hard work required a lot of fuel...
This is the base engine that's stood for a while. It has had bits done to it so i'm told, but will strip it all down and add to it. I really want 200 from it ideally.
Gearbox is the S80 Integra box with 4:79fd - nice and short for rallying. Got a KAAZ diff for it too!
Quick spruce up.
forestfighter
ZR-TEC RALLY TEAM
- Joined
- Jun 13, 2008
- Messages
- 315
This is an ex works MG ZR rally car spoiler. These are so incredibly rare, so when i finally found one, it was rude not to snap it up. Expensive and fugly - yes, cool and purposeful looking - deffo!
Spoiler sprayed up
Spoiler sprayed up
forestfighter
ZR-TEC RALLY TEAM
- Joined
- Jun 13, 2008
- Messages
- 315
A mate of mine was breaking his ZR rallycar and seen as this size tyre is soooo expensive and also hard to come by, i bought his loot. Pirelli moulded slicks in Intermediate, Soft and Hard. Will certainly give me options for Cadwell.
Gave the chassis mounts a quick blast to make welding easier.
V-TEC y0!
Got the engine lined up and then marked where they need to be. Got the shafts in the hubs and all tight - fit mint!
Got the mounts welded and then got the engine back in.
As you can see the engine is sitting slightly high on the LHS... This was as it was fouling on where i had welded the mount. I chopped part of the mount and welded it higher and then it was bang on!
Got a massive list to keep cracking with, but it's a big step forward! :headbang:
Gave the chassis mounts a quick blast to make welding easier.
V-TEC y0!
Got the engine lined up and then marked where they need to be. Got the shafts in the hubs and all tight - fit mint!
Got the mounts welded and then got the engine back in.
As you can see the engine is sitting slightly high on the LHS... This was as it was fouling on where i had welded the mount. I chopped part of the mount and welded it higher and then it was bang on!
Got a massive list to keep cracking with, but it's a big step forward! :headbang:
forestfighter
ZR-TEC RALLY TEAM
- Joined
- Jun 13, 2008
- Messages
- 315
And that's it up to date after a long while with no progress!
It's full steam ahead as the car is due at Cadwell for a trackday tester on the 11th of Oct. In this time the car needs loads doing. I will update as i go along.
I wanted the conversion on here as it;s my 1st coversion and i also have very limited Hoda knowledge - maybe i can pick people's brains along the way!
Cheers
John
It's full steam ahead as the car is due at Cadwell for a trackday tester on the 11th of Oct. In this time the car needs loads doing. I will update as i go along.
I wanted the conversion on here as it;s my 1st coversion and i also have very limited Hoda knowledge - maybe i can pick people's brains along the way!
Cheers
John
- Joined
- Jul 31, 2010
- Messages
- 149
This is a great build man!!! I love from the ground up builds!!!!! Good luck on the 11th
forestfighter
ZR-TEC RALLY TEAM
- Joined
- Jun 13, 2008
- Messages
- 315
Cheers chaps!
I'm going to do a whole lot of tidying once everything fits... Just getting the important stuff done for now.
Level
Is there a cover that goes over here to stop crud getting into clutch/fly?
Shafts all in and sitting about right. Will sit more level once rear mount is fabricated.
I'm going to do a whole lot of tidying once everything fits... Just getting the important stuff done for now.
Level
Is there a cover that goes over here to stop crud getting into clutch/fly?
Shafts all in and sitting about right. Will sit more level once rear mount is fabricated.
- Joined
- Jun 21, 2009
- Messages
- 2,831
Loving the areo-package, you should get a scoop for the bonnet too; my brother just stuck one on his car - it'll make naff all difference but it looks the business!
Great work, it'll soon be finished! Kiwi from this forum with a B16b 106 used to run a Mugen ECU (same as the Spoon one) on his rally-car, you might want to look into one as an alternative to having it mapped etc. before any big mods to the engine further down the line. For things like breathing mods it should be suitable but I'd give it a power run to be sure if you do get one - http://www.ek9.org/forum/engine/21664-spoon-vs-oem-ecu-dyno-results.html
Can't wait to see it in action!
Great work, it'll soon be finished! Kiwi from this forum with a B16b 106 used to run a Mugen ECU (same as the Spoon one) on his rally-car, you might want to look into one as an alternative to having it mapped etc. before any big mods to the engine further down the line. For things like breathing mods it should be suitable but I'd give it a power run to be sure if you do get one - http://www.ek9.org/forum/engine/21664-spoon-vs-oem-ecu-dyno-results.html
Can't wait to see it in action!