My Rally Car Build

[blinx9900]

Yes there is a piece that covers the clutch flywheel and is called a block stiffener iirc, try to get the ITR or CTR one, it is much more rigid!

 

[forestfighter]

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!

Cheers matey!

We deal Haltech at work, so looking at going down that route and mapping it here on our dyno - AET Turbos. The plan is to keep developing the engine more and more down the line so i can keep adjusting the map once i develop it.

Yes there is a piece that covers the clutch flywheel and is called a block stiffener iirc, try to get the ITR or CTR one, it is much more rigid!

Super, thanks!

 

[CR1S]

awhh man why did it have to end here ?! i was just getting into it
Makes me wanna strip mine out and i don't even rally
Are you paying for it yourself or is it sponsorship ? ( if you dont mind me asking )

 

[NickEG6]

really enjoying this thread

 

[forestfighter]

awhh man why did it have to end here ?! i was just getting into it
Makes me wanna strip mine out and i don't even rally
Are you paying for it yourself or is it sponsorship ? ( if you dont mind me asking )

End here?? Loads more to come yet...

With it being a club/national car it is hard to get full sponsors to pay for things, but i'm fortunate enough to have AAautosport in Bradford to help with the car where i need and also have some good contacts for trade parts where possible. I've pumped a lot of money into the project, but it would have cost alot more if i had of bought things instantly without waiting and if i didn't have the odd contact. My old man is a bit of rally guy who is pretty handy too, so between us all it is easy to get most things done ourselves. I work for AET Turbos in Wakefield and they are really helpful and encouraging with the project too!

Thanks for the positive feedback.

Anyone got any pictures of the rear engine/box mount on a B-Series?? That's my next major task. Also pics of the power steering setup on a B?

Thanks

John

 

[forestfighter]

A job that needed doing before i get painting bits was the bonnet...

Putting little brother Ross to good use!

Aero Gashes

Then from there was where bravery came in...

My main objective was to get the pins all fitted nicely and then over the weekend i can weld what i need to and paint the underside of the bonnet and then bolt the catches onto the bonnet and seal them. Nightmare job tbh.

Then whilst i had the bonnet on i wanted to look at a decent air intake for the filter. I'm looking at moulding an Astra GTE duct into the bonnet directly feeding the filter. It will be subtle and effective.

Here you can see where the ram needs to be from under the bonnet.

Back to bed.

 

[J-Spec]

this looks like a promising build

 

[forestfighter]

Updates...

Now for the fun part imo... Making it look pretty again!

Here you can see all the mounts welded in place so i started prep for welding seams and little strengthening bits...

It was a nightmare as all the seam sealer s***** out and slops into your weld and knacks things...

I had to shave a tad off the front subframe to give me a little more clearence for a beefy manifold... The B-Series obviously doesn't follow the same path for the maifold cut out. Plated it up and seemed it up.

The bit that sits behind the bumper used to annoy me being yellow, so he got done black. mofo.

Inner arches got a good going over too... Got all the seam sealer off and it took yonks!

Gave it a good lick of stonechip...

Then a lick of black!!

Then started priming the bay.

Did the subframes black.

First coat...

The fumes were insane. It was quite a windy day so the wind was blowing dust everywhere in the garage - had to spray with it shut and even with a mask it was terrible. High as a kite in the kitchen wobbly as hell!

Gave it a few more coats and then plenty of lacquer.

Then after it dried i could start to see why it was all worth it!

Oh yeah - got the catches all bonded in and sitting neat!

Engine bay is ready to take the engine for good now! It's been quite tough work, but the end result is pretty good i think!

 

[forestfighter]

Started cleaning bits up too...

Inlet manifold was rank! All inside was coked up to fook too with old age.

Coolant housing thingy doofer.

Took them to work where i cleaned, blasted and beaded.

Also did some other bits too...

 

[forestfighter]

Engine...

Tas "My precious...."

Me "Where is ze sik V-Tecz???"

Then it was all piled up and then off to the machine shop!

Should get it back before the weekend and then will get some build up pics

 

[phillyt1988]

Awesome work on this fella, really interesting build too!!

 

[forestfighter]

Awesome work on this fella, really interesting build too!!

Thanks bud.

 

[spy]

nice dog, nice project))

 

[forestfighter]

Even though the engine was promised as a good condition unit, i wanted to rebuild it whatever... I wasn't planning on going nuts as they are strong engines, but just wanted to ensure everything was good.

Got it into the machine shop... 2 days later back it came.

- block skim
- head skim
- Block honed
- all crack tested
- polished crank
- motorsport bearings
- Piston rings
- all new gaskets for everything
- all new belts
- water pump
- oil pump
- thermostat
- valve stem oil seals

Block

Rocker cover powder coated in crinkle black... Looks wicked in the skin.

I was going to polish the writing on the rocker, but decided to leave it all black.

Sprayed a few things up...

Started making a template for a baffled sump. Sorry i didn't get any finished pics...

Had a nice delivery... Loads of bits from Tegiwa and also some new Sabelt 6 point harnesses!

Integra Ali Rad, slim fans and hosing to suit the B.

Ade and I were working on this every night of last week untill the early hours - one night we stayed up all night. This meant that actual build up pics were non existant.

The engine is now back in and all sat in place.

 

[forestfighter]

Once the engine was back in place, we wanted to look into a strong front mount. This was inspired from a T-Series front mount.

Nice strong bracket onto gearbox/block.

Onto the front subframe.

Started to box it in.

Fitted and painted. It's lovely and strong. All 4 mounts seem awesome. Engine doesn't budge.

Dry fitted the rad too... Everything is sitting in nice!

Jonno

 

[forestfighter]

Got the rad all fixed up after some midnight hours at Adey's palace! Cheers mate!

It's all tucked up under the front slam panel - couldn't fit any better if we had one custom made. To say it's for an Integra it's bob on really! With bumper on it sits right in the mouth which is great. I whipped the bumper on but couldn't get any decent shots as it was dicky dark.

There was a tiny bit of choppy chop chop needed, but only small really.

And a shot of it sat in it's position.

Got some Magnicore Leads and Iridium plugs on order and also got my Supersprint 4-2-1 manifold which is being coated on Monday being well. Then the centre section of the exhaust can be done.

Waiting on a dizzy though and then power steering feed pipe. These are really holding me up! Grrr!

Thanks

 

[fez]

this is an awsome build all fairness !!

 

[forestfighter]

Many thanks!

 

[jordan101]

looks good mate, with a nice jap touch to it

 

[D17KDB]

That is some build thread mate.

Car looks awesome. Just wish all mg's came like that