Scottish ek race car build

[mike84]

Thought it was about time I shared my race car build .

Started off buying a ek4 (the white one) that was used all of 2011 doing track days at Knockhill it had AVO suspension full multi point custom cage and b16a2 engine with motorbike throttle bodys.

By the end of 2011 I had added a ek9 lsd and gearset into the original s4c box
and wired up a emerald ecu and had it mapped at 176bhp also fitted enkei 15" split rims and toyo t1r tyres. I then got abit obsessed with wieght and cut out the doors , tailgate and rear floor and fitted an alloy tank total wieght without driver was down to 940kg had heaps of fun in total did 7 trackdays

This is when I decided I wanted to enter the Scottish Sports and Saloon car Championship 2012 and at the end of November decided it was time to build a proper race car and re shell the white one as the cage had been welded in badly and needed to have the original floor for the class I wanted to enter .

 

[mike84]

So bought an automatic EK as the shell was good and cheap and completely stripped it fitted new rear arches cut off all unnecessary brackets and side impact bars in the doors and many more.

Welded in Safety Devices rollcage mounts for Bolt in cage with twin diagonal door bars and rear diagonal

Painted shell inside , outside and underneath (Paint and prep by my mate Martin) made bumpers removable with dzus fastners

Got really friendly with powder coaters powder coated subframe , rear trailing arms, gear linkage, front hubs and heaps of other little brackets mounts etc

 

[M!chael]

Wow doing it right, will likely see you up the hill one time

 

[Andy_redevo4]

Sweeeet! Looking forward to seeing the progress of this!!

 

[sarkel]

I like i want to see more

 

[poo_ek]

have you got any pictures of the old car?showing how and what you did to remove the weight? I'm trying to gut my Ek at the moment

 

[mike84]

Cheers for the comments

Here more pictures with my obsession with powdercoating anything that hasn't been powdercoated has been painted

All suspension , wheel bearings , bushes and ball joints have been replaced power steering , abs have also been removed and new braided brake lines and adjustable load valve has been fitted.

 

[mike84]

have you got any pictures of the old car?showing how and what you did to remove the weight? I'm trying to gut my Ek at the moment

Sorry don't have any more pictures of the old car. But basicaly cut the complete inside of the doors removed electric windows / abs pump and all wiring / airbags and all wiring / stripped down all wiring to bare minimum / cut out tailgate inner skin / carbonfibre bonnet / perspex rear quarter windows / used just top skin of dash and fitted race battery . I wouldn't cut out the doors unless you have a substantial cage fitted.

 

[mike84]

Just found some pictures of the shell before it was painted in febuary
this was after about 2 months of work as you can see I took a liking to hole saws as I want to get the weight down to 850kg is my target but anything below 900kg would do .

 

[poo_ek]

thanks...I am a bit obsessed with trying to get my car light. I have done some calculations on what I can do to removed weight to get to my ideal goal of 925 kg. I would like to get down to that weight but, not sure if I'd get there. Currently I think my car is about 1015kgs, and gutting as much as you have done on your car I'm not sure I would get down to 950kgs. I roughly worked out about a 50 kg loss if I gut the doors, lexan door and rear hatch, cut rear side panels, fuel cell, cut rear floor, remove dash, gut rear hatch, replace dash bar with alloy (should have got a bar welded to cage) and a few other bits ad bobs i'd be struggling to get 50kgs

I really need to get hold of some scales to weigh it properly. I have just dropped out the standard tank and its 11kgs with the pump. I am looking to cut the rear floor out and mount a 20 litre fuel cell, but really wonder why I am bothering only to save maybe 5 kg for the extra work.

 

[mike84]

I have just had a custom alloy fuel tank made to fit in the original space which should hold about 20 litres and uses the original filler I got it copied from an American tank I found online. As if fitted inside I believe it needs to be enclosed to have a fire wall between you and the tank. The only other things that you can save alot of weight on is the exhaust the rally boy's use a straight through from manifold with just a sports cat and no other silencers and this passes noise test.

 

[mike84]

Here is more pictures some during the fitting of the braided hoses and front brakes calipers. The front calipers have been stripped and rebuilt with new seals.

 

[poo_ek]

I have just had a custom alloy fuel tank made to fit in the original space which should hold about 20 litres and uses the original filler I got it copied from an American tank I found online. As if fitted inside I believe it needs to be enclosed to have a fire wall between you and the tank. The only other things that you can save alot of weight on is the exhaust the rally boy's use a straight through from manifold with just a sports cat and no other silencers and this passes noise test.

Yes, the tank will need to be enclosed. I was going to get a tank fabricated at work but found a new cheap aftermarket tank too cheap to pass up. I am thinking of a side exit 3 inch exhaust, which should get rid of quite a few kg's. Currently have a mugen twin loop which and its nice and quite, buts its pretty heavy. Been tempted with a titanium exhaust but can't justify the cost and I can't be guaranteed of the noise level.

 

[Andy_redevo4]

Such a Cool Build! Purple is surprisingly nice, again im looking forward to the progress

 

[wooks]

Ive left the fuel tank where it is standard on the rally car, best place for it in my opinion, it cant be any lower andits between the wheelbase, putting it anywhere else will be moving weight upwards, hardly ideal, not to mention the hassle of enclosing it.
Wish id got the hole saw out when mine was still a shell, only thing i regret not doing.

 

[mike84]

Here is more pictures of the progress decided to sell the motorbike throttle bodies and changed to 45mm Jenvey's before fitting the engine hoping for a couple more bhp with a map tweak aswell

Engine fitted ditched one of the torque mounts in favour of my home made engine brace so managed to lose a big lump of cast metal for the torque mount

Just in progress of re wiring the car not my favourite part of the build
Trying not to think how much is still to do as already missed the first race of the season and about to miss the next

Cheers for all the comments so far

 

[RyanDOHC]

kool build mate!

 

[si8pny]

such a great build, will keep a close eye on this, any more pictures of the old car?

 

[samphier]

liking the colour scheme

 

[mike84]

such a great build, will keep a close eye on this, any more pictures of the old car?

Will have a look am sure I have more somewhere . Will post them when I can find them
Cheers