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 The www.rally-tech.com circuit car

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Tim@Rallytech

Tim@Rallytech

Posts : 40
Join date : 2012-07-26
Location : Thailand

The www.rally-tech.com circuit car Empty
PostSubject: The www.rally-tech.com circuit car   The www.rally-tech.com circuit car EmptyFri 23 Nov - 2:19

OK then guys. Some of you may be aware that we bought a circuit car as a promotional tool for the company.

We bought it from a friend who had been using it for the past year as a circuit racer. He did it just for fun but raced monthly in 6 month long series.

I suppose we cheated by buying a car that was already semi race prepped, still a lot of work needs to be done for it to be actually competitive when compared to the other cars that would be competing in the same class.

So here's some pics of when we went to test drive the car before we actually bought it:
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Bit pointless having the rear seats in there, so they were the first thing to come out but the previous owner probably put them there because he was selling the car.
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I won't bother listing all the spec but basically it's a fully built 2.0 and really is a race car rather than a road car. It really just needs some serious weight reduction and it'll be just awesome!

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So we bought it and took it home. Next was to stick on a load of our products that we had spare:
WRX STI TRUNK DECAL:
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SLAM COOLING PANEL:
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TOW HOOK:
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PTFE HEADER TANK SPACER KIT:
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BATTERY TIE DOWN:
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So next was to give the car a good inspection. As with any second hand car there will be some issues and we were fully aware that were some problems with the car. Took the filter off and discovered this!
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Other problems include a broken CV boot at the front and damaged ball joints on the two front coilovers. We have the replacement ball joint, just need to fit them! Not too worried about this because I really wasn't impressed with the performance from the 20g. We will be putting a Garett GT30 on shortly but are aiming for a fast spooling, responsive car.

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Bought some other bits that are waiting to go on:
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(This has been installed already and is wired up but we just need to fabricate some sort of panel for it to attach to, also we'll have some extra switches and things on the same panel)
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Aerocatches have been marked up and should be fitted shortly.
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*EDIT*
Aerocatches are installed! Really nice piece of kit for anyone who's considering buying a set, they look much better than the standard style ones.
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So the next job was to try and sort out the coilovers. We looked everywhere and couldn't find just the top part with the ball joint and a new replacment from Cusco was around $350 a set and a 1 month wait! In the end the guy who sold us the car came to the rescue, his friend had a set but for a different car.
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So we tried to see if only the balljoint could be transferred, hey presto! Perfect fit. The new balljoints are super-stiff and have loads of life left in them.
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The we (well mostly my service guys team with a little help from me) set about removing all of the carpets, and other stuff that wasn't needed.
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First the seats and the cage had to come out.
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These seats are heavy!
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Making a start on the carpets etc.
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Almost finished:
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Carpet only:
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Top layer of sound proofing material:
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Lower layer of sound proofing material:
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TOTAL APPROX. 21KG from carpet and soundproofing alone!

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Fog lights are off as that section of the bumper will probably be cut away and used for cold air feeds to the front brakes and air filter.
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First batch of items that will be sent off to the powder coater. The inlet mani and loads of other parts will also be coming off and being powder coated. I'm going for a crazy color!

Not sure what brand these are but they're incredibly light!
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Changing the carbon strut brace for a steel one, it's a bit more sturdy. Already had the steel strut brace and the rear brace was already in the car when we bought it.
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OK so the new wheels are now white and are on!
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My HT Autos P1 lip arrived too and it's a great fit. Also because it has the extra part closest to the FMIC I was able to hide the untidy cut that was made in the bumper. I have to say for anyone considering buying this part that the fit is excellent, it's very well made and incredibly flexible. It's only bolted on, this is because we may have to remove it for certain circuits as it is quite low.
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Made the header tank relocation kit prototype and I'm currently testing it out.
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Next up was to make the panel to hold the battery kill switch, I decided to mount the DCCD control there too and have an EGT gauge. I used my 'flocking' kit to finish it off nicely. Just need to find some black screws as the stainless ones are a little to bling.
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I decided it looked a bit bare so I added another two digital gauges. One is for intake air temps, the other isn't connected to anything right now, maybe I'll put a sensor in to measure gearbox oil temp.
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Next thing to do was set up the Knocklink. The LEDs were removed from the board and I've ran a wire up to the clocks. This isn't finished yet though! I'm just testing it out to see if I like this positioning, then I'll mount the LEDs in the plastic shroud for the clocks.
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Tim@Rallytech

Tim@Rallytech

Posts : 40
Join date : 2012-07-26
Location : Thailand

The www.rally-tech.com circuit car Empty
PostSubject: Re: The www.rally-tech.com circuit car   The www.rally-tech.com circuit car EmptyFri 23 Nov - 2:20

Made some panels to close the gaps that are at the rear of the car. It's really hard to see them but they've been
flocked in black. I also sprayed the surrounding area with matte black paint.
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One thing that was really bothering me was that the windows weren't tinted. This causes a real problem living somewhere as
hot as Thailand so it was the next job on the list.
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We've done the all of the windows apart from the windshield, I got them to make a small sunstrip
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Next job was the jigsaw puzzle:
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Next was to tackle the horrible wiring that has been done on the passenger side footwell, BEFORE:
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Tidied up all of the wires nicely and found an aluminum footwell panel, AFTER:
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How the gauges were, Profec B, shift light and knock link have all been relocated.
Kinda like the blue gauges where they are but the Profec is not practical in this position.
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Well, this is what happens if the wiring loom is too close to the headers!
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Took ages to rewire all this, soldered and heat shrinked:
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Loom all repaired.
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Wrapped up with some electrical tape.
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Finished!
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Got a new radiator as the old one had a tiny hole in it causing a slow leak.
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Test fitting -
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Fans on.
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In the car.
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Now this is something that's been bugging me a lot and is one of my pet hates. I just can't stand crappy wiring.
An absolute mess underneath the steering column.
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Slowly getting there! Pedals are fully visible now!
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Crappy sidelight and turn signal wiring, BEFORE -
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After:
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Tim@Rallytech

Tim@Rallytech

Posts : 40
Join date : 2012-07-26
Location : Thailand

The www.rally-tech.com circuit car Empty
PostSubject: Re: The www.rally-tech.com circuit car   The www.rally-tech.com circuit car EmptyFri 23 Nov - 2:20

Also wired up some more switches
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Had a catch can/washer sprayer tank made up
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Water injection tank and I/C spray tank

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Tim@Rallytech

Tim@Rallytech

Posts : 40
Join date : 2012-07-26
Location : Thailand

The www.rally-tech.com circuit car Empty
PostSubject: Re: The www.rally-tech.com circuit car   The www.rally-tech.com circuit car EmptyFri 23 Nov - 2:21

OK so here's some updates. We've been super busy with the PU mudflap project so the car has had to go on the back burner for a while now.

So, decided that the engine bay was just too bad.
Got the inlet mani out and stripped it ready for some new paint. Got to work with some paint stipper.
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Let this stuff work it's magic:
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Looks like some kind of horror movie:
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Rinsed it off with some fresh water and hey presto!:
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Now on with some Rustoleum:
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It actually said 'black' on the tin so I'm not too sure why it's come out gunmetal silver, still I think it looks quite nice anyway!
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After a couple of coats it looked like this:
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So while that was being painted I set about sorting out some of the wiring in the engine bay:
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So the engine bay looked like this:
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It was also very dirty:
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Cleaned up the engine bay as best I could:
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Test fitting the mani:
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Quick before and after shot of the HT leads:
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Mani all bolted back in:
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Now it was time to start bolting everything back together again!:
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Coil pack back on:
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Alternator cover fitted:
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Battery all cleaned up:
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Tim@Rallytech

Tim@Rallytech

Posts : 40
Join date : 2012-07-26
Location : Thailand

The www.rally-tech.com circuit car Empty
PostSubject: Re: The www.rally-tech.com circuit car   The www.rally-tech.com circuit car EmptyFri 23 Nov - 2:22

Quick interior shot as it stands now:
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Changed the silver screws over to powder coated ones:
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Brake upgrade, K-sport 8 pot 356mm at the front and GD Brembos at the rear:
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Here it is in all it's glory, took about 5 days working in my free time to get this finished:
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And here's a quick before and after comparison from when we picked the car up to how it looks today:
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Tim@Rallytech

Tim@Rallytech

Posts : 40
Join date : 2012-07-26
Location : Thailand

The www.rally-tech.com circuit car Empty
PostSubject: Re: The www.rally-tech.com circuit car   The www.rally-tech.com circuit car EmptyFri 23 Nov - 2:23

another thing - here's the prototype hood scoop delete plate we're working on (still work in progress)

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phil555

phil555

Posts : 2461
Join date : 2010-03-16
Age : 47

The www.rally-tech.com circuit car Empty
PostSubject: Re: The www.rally-tech.com circuit car   The www.rally-tech.com circuit car EmptyFri 23 Nov - 5:24

Great job. Looks amazing.
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locky@HYDROtek

locky@HYDROtek

Posts : 1597
Join date : 2011-08-26
Age : 40
Location : chester le street

The www.rally-tech.com circuit car Empty
PostSubject: Re: The www.rally-tech.com circuit car   The www.rally-tech.com circuit car EmptyFri 23 Nov - 7:30

Looks awesome Wink
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StickT

StickT

Posts : 2607
Join date : 2012-07-26

The www.rally-tech.com circuit car Empty
PostSubject: Re: The www.rally-tech.com circuit car   The www.rally-tech.com circuit car EmptyFri 23 Nov - 19:36

Engine bay looks really nice and alot better BUT now the oil cap, brake fluid bottle clutch resivour look left out ...
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Tim@Rallytech

Tim@Rallytech

Posts : 40
Join date : 2012-07-26
Location : Thailand

The www.rally-tech.com circuit car Empty
PostSubject: Re: The www.rally-tech.com circuit car   The www.rally-tech.com circuit car EmptySat 24 Nov - 3:23

Funny you should say that, we're waiting for a batch of these to come back from our CNC machinists within the next couple of days!

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StickT

StickT

Posts : 2607
Join date : 2012-07-26

The www.rally-tech.com circuit car Empty
PostSubject: Re: The www.rally-tech.com circuit car   The www.rally-tech.com circuit car EmptySat 24 Nov - 15:17

HAHA, very coincedentalthen ...

Much are them beauties to the public ?
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Tim@Rallytech

Tim@Rallytech

Posts : 40
Join date : 2012-07-26
Location : Thailand

The www.rally-tech.com circuit car Empty
PostSubject: Re: The www.rally-tech.com circuit car   The www.rally-tech.com circuit car EmptySat 24 Nov - 15:31

Stick wrote:
HAHA, very coincedentalthen ...

Much are them beauties to the public ?

We're hoping to get them on sale for about 35-40 gbp (it'll be around 30 for NESF member though)
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martyp1970

martyp1970

Posts : 724
Join date : 2011-05-12
Age : 49
Location : 50 shades of northumberland

The www.rally-tech.com circuit car Empty
PostSubject: Re: The www.rally-tech.com circuit car   The www.rally-tech.com circuit car EmptySun 25 Nov - 9:45

Love the changes you have made Wink
Into the cosmetic and cleaning aspect as well as performance. Cool
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Tim@Rallytech

Tim@Rallytech

Posts : 40
Join date : 2012-07-26
Location : Thailand

The www.rally-tech.com circuit car Empty
PostSubject: Re: The www.rally-tech.com circuit car   The www.rally-tech.com circuit car EmptyMon 26 Nov - 2:22

martyp1970 wrote:
Love the changes you have made Wink
Into the cosmetic and cleaning aspect as well as performance. Cool

Thanks, I like a clean engine TBH. Can't stand it when you go to adjust something for 30 seconds and your hands are covered in oil.
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Mark_Type-R



Posts : 187
Join date : 2011-10-29

The www.rally-tech.com circuit car Empty
PostSubject: Re: The www.rally-tech.com circuit car   The www.rally-tech.com circuit car EmptyThu 29 Nov - 21:53

nice build:-)
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