PDA

View Full Version : gen 5 rallycar



tctech
12-07-2013, 09:30 PM
theres a bit of a backdrop to this long story so here goes
After a flat in 5th moment on the rally of the midlands I took the view that to stay competitive with the rest of the pack I needed to go 4wd so once I gathered my senses and repaired this
http://i835.photobucket.com/albums/zz276/tctech/cars/064.jpg (http://s835.photobucket.com/user/tctech/media/cars/064.jpg.html)
http://i835.photobucket.com/albums/zz276/tctech/cars/cars008.jpg (http://s835.photobucket.com/user/tctech/media/cars/Car38_011.jpg.html)
http://i835.photobucket.com/albums/zz276/tctech/cars/Car38_011.jpg
repaired
http://i835.photobucket.com/albums/zz276/tctech/cars/Car38_011.jpg (http://s835.photobucket.com/user/tctech/media/cars/Car38_011.jpg.html)
I bought a totally stock gen5 celica

tctech
12-07-2013, 09:39 PM
here it is when it arrived with me, just a road car but not the run of the mill Subaru cos I like to be different
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/SAM_0080.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/SAM_0080.jpg.html)

tctech
12-07-2013, 09:42 PM
so work began 1st by stripping the car down to its bare bones
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/SAM_0086.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/SAM_0086.jpg.html)
inside and out and I mean bare
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/SAM_0090-1.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/SAM_0090-1.jpg.html)
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/SAM_0104.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/SAM_0104.jpg.html)

tctech
12-07-2013, 09:51 PM
once stripped a bit of fabrication. new seat mountings which also serve as cross bracing to the bodyshell and seamwelded the bodyshell
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/SAM_0128.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/SAM_0128.jpg.html)
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/SAM_0388.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/SAM_0388.jpg.html)
roll cage mountings welded in to the shell
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/SAM_0394-1.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/SAM_0394-1.jpg.html)
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/SAM_0395.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/SAM_0395.jpg.html)

tctech
12-07-2013, 09:57 PM
then dummy fitted the roll cage and got all the multipoint bosses welded into the bodyshell
http://i835.photobucket.com/albums/zz276/tctech/SAM_0384.jpg (http://s835.photobucket.com/user/tctech/media/SAM_0384.jpg.html)
pulled the whole lot out and repainted the inside of the car
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/SAM_0403.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/SAM_0403.jpg.html)
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/SAM_0405.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/SAM_0405.jpg.html)
and the cage
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/SAM_0415.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/SAM_0415.jpg.html)

tctech
12-07-2013, 10:06 PM
a bit of reassembly then started ,note by now I am about 16 weeks into the build ,I had to wait for the specially made roll cage to arrive from Italy ,only because I wanted a homologated cage so I could use the car on international events in the future
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/SAM_0419.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/SAM_0419.jpg.html)
dashboard pre built as were a lot of bits due to the waiting time for the cage
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/SAM_0121.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/SAM_0121.jpg.html)
and fitted
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/SAM_0426.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/SAM_0426.jpg.html)

tctech
12-07-2013, 10:12 PM
fire system/wiring/pipes etc was then installed
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/SAM_0440.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/SAM_0440.jpg.html)
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/SAM_0441.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/SAM_0441.jpg.html)
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/SAM_0443.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/SAM_0443.jpg.html)
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/SAM_0444.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/SAM_0444.jpg.html)

tctech
12-07-2013, 10:15 PM
brake bias pedal box and carbon floor panels were fitted
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF2080.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF2080.jpg.html)
battery and carrier position
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF2083.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF2083.jpg.html)

tctech
12-07-2013, 10:21 PM
moving on ,the hubs were rebuilt with new bearings and drive flanges trued up in the lathe and new motorsport extra long studs fitted
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/SAM_0175.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/SAM_0175.jpg.html)
bc racing tarmac dampers and springs
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/SAM_0168.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/SAM_0168.jpg.html)
all the suspension cleaned checked repainted and polly bushed
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/SAM_0172.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/SAM_0172.jpg.html)
then assembled and the ap 4 pot brakes and larger front discs fitted
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF2091.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF2091.jpg.html)
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF2227.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF2227.jpg.html)

tctech
12-07-2013, 10:30 PM
meanwhile the engine side of things was underway ,turbo stripped and inspected and 34mm restrictor fitted unfortunately a requirement
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF2530.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF2530.jpg.html)
and as can be seen a lot had been going on under the bonnet as well
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF2558.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF2558.jpg.html)
electric pas and dry break for fuel sample
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF2526.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF2526.jpg.html)
variable boost controller
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF2517.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF2517.jpg.html)

tctech
12-07-2013, 10:39 PM
fuel tank guard made ready to fit
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/SAM_0143.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/SAM_0143.jpg.html)
front sumpguard and rear diff guards made (no pics of diff guard)
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF2563.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF2563.jpg.html)

tctech
12-07-2013, 10:48 PM
new seats for the fitting, same as the ones I used to make all the seat mountings but new
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF2398.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF2398.jpg.html)
http://i835.photobucket.com/albums/zz276/tctech/DSCF2448.jpg (http://s835.photobucket.com/user/tctech/media/DSCF2448.jpg.html)
http://i835.photobucket.com/albums/zz276/tctech/DSCF2452.jpg (http://s835.photobucket.com/user/tctech/media/DSCF2452.jpg.html)
better picture of the office with the old mock up seats in
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF2200.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF2200.jpg.html)
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF2202.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF2202.jpg.html)
systems check ,,,everything worked
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF2386.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF2386.jpg.html)
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF2388.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF2388.jpg.html)

tctech
12-07-2013, 10:51 PM
at this point it was stickered finished on the floor and out the door ,only seems like 2 minutes but took the best part of 2 years
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/035.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/035.jpg.html)
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/039.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/039.jpg.html)

tctech
12-07-2013, 10:53 PM
loaded and ready for its very 1st stage rally
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF3075.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF3075.jpg.html)
and there we are from clean to filthy in a heartbeat
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/untitled12.png (http://s835.photobucket.com/user/tctech/media/celica%20gt4/untitled12.png.html)
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/untitled17.png (http://s835.photobucket.com/user/tctech/media/celica%20gt4/untitled17.png.html)
in service mr co-driver doing his thing
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/untitled23.png (http://s835.photobucket.com/user/tctech/media/celica%20gt4/untitled23.png.html)
last corner of the last stage on its very 1st rally which it finished with a blown head gasket but it finished
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/untitled21.png (http://s835.photobucket.com/user/tctech/media/celica%20gt4/untitled21.png.html)
more to come in the next few days

UtahSleeper
12-08-2013, 02:08 AM
VERY COOL!!!! Need more!

The Captain
12-08-2013, 03:55 AM
Jealous!!!!

MCcelica
12-08-2013, 07:57 AM
Wow dude, you came out of nowhere with a sweet build thread...

Get that HG fixed and stick around!

tctech
12-08-2013, 12:13 PM
so here we are the end of august 2012 and the car finished its 1st rally with a blown headgasket ,so the engine was pulled and a new engine build started new forged pistons
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF3139.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF3139.jpg.html)
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF3144-1.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF3144-1.jpg.html)
eagle rods
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF3146.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF3146.jpg.html)
replacement block bored and 3 stage plateau honed all threads tapped
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF3092.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF3092.jpg.html)
crank lightened and balanced

tctech
12-08-2013, 12:23 PM
high capacity baffled sump under construction
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF3129.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF3129.jpg.html)
baffled around the pickup so the oil cant climb out under hard cornering
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF3172.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF3172.jpg.html)
new water pump/oil pump /thermostat
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF3161.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF3161.jpg.html)
block ready for assembly
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF3209_zpsc47c8542.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF3209_zpsc47c8542.jpg.html)
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF3205_zpsf2ea38b4.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF3205_zpsf2ea38b4.jpg.html)
rings gapped to 16 thou for high boost and bottom end completed
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF3206_zps8c6efe9d.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF3206_zps8c6efe9d.jpg.html)

tctech
12-08-2013, 12:36 PM
the turbo was then inspected for wear/damage and reprepped with a new impeller wheel fitted as we found a small chip out of the impeller wheel
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF3191.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF3191.jpg.html)
zorst manifold heavy duty wrapped and thermal barrier coating applied
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF3186.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF3186.jpg.html)
tvis setup gone and intake runners matched to tvis spacer plate
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF3097.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF3097.jpg.html)
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF3169.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF3169.jpg.html)

tctech
12-08-2013, 12:44 PM
modified cambelt cover for two reasons 1st is cooling ,can you guess the other
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF3164.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF3164.jpg.html)
550cc injectors on bored fuel rail 8mm
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF3157.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF3157.jpg.html)
stealth modified ecu mapped to run 1.6 bar of boost
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF3150-1.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF3150-1.jpg.html)

tctech
12-08-2013, 12:50 PM
and all assembled ready to put in second reason for modified cam belt cover now apparent
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF3211.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF3211.jpg.html)

tctech
12-08-2013, 01:01 PM
this is where it all starts to turn pear shaped
so engine was installed and the car was ready to go so off we go to do some testing ,anyhow the car ran faultlessly for 40 minutes and then it began to smoke ,so we cut short the test and returned to the workshop suspecting turbo failure ,not so ,,after a csi moment and a complete engine strip down we found the cause ,it turned out that the rings supplied were the wrong rings ie they were for chrome bores and not cast so 40 minutes of machining and that was it game over the block was worn by 3 thou and unsalvageable without another rebore ,worse still all the machined particles had picked up on the pistons rendering them scrap as well
oh well back to the drawing board

tctech
12-08-2013, 01:22 PM
right that's the end of engine number 2 so engine number 1 was brought back into service with a new headgasket and all the salveageble bits from engine2 and bolted back in so we could do the horiba d'isis rally
we were flying
http://i835.photobucket.com/albums/zz276/tctech/60_zpse93a18e1.jpg (http://s835.photobucket.com/user/tctech/media/60_zpse93a18e1.jpg.html)
and then the unimaginable happens ,,,engine number 1 seized on the second stage ,no warnings just siezed

tctech
12-08-2013, 01:30 PM
now its march 2013 right more csi moments this one didn't take much really as the exhaust manifold had failed on no1 cylinder and set fire to the oul filter collapsing it in on its self and causing loss of oil pressure as you can imagine the bottom end is absolutely toast .
so the scores on the doors so far 2 rallys 1 test = 3 engines

tctech
12-08-2013, 01:36 PM
another engine built not to the same spec as the all singing and dancing one just new rings /oil pump/ends and mains and steel head gasket ,remote mounted oil filter and mahoosive oil cooler .oh and a eye melting led warning lamp and oil pressure guage
what can go wrong
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF3808_zpsa5b961cd.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF3808_zpsa5b961cd.jpg.html)
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF3824_zpsf32222f9.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF3824_zpsf32222f9.jpg.html)
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF3823_zpsca293747.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF3823_zpsca293747.jpg.html)

tctech
12-08-2013, 01:47 PM
September 22nd 2013 and off we go to the woodbridge stages hopes are high and we are flying coming out of stage 1 we are 15th over all and 4 seconds away from being in the top 10 out of 90 competitors ,famous last words I CAN GO FASTER THAN THAT
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/TheMEMWoodbridgeStages13_zps6fb66959.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/TheMEMWoodbridgeStages13_zps6fb66959.jpg.html)
well truthfully I can ,but 6 miles in to stage 2 the tyres decide THEY CANT we were about a minute up on our stage time to this point when total loss of grip from the rear tyres occurred and a talent failure resulted in going off 3 times in one stage ,now they were 11 mile long stages ,but they were brand new dunlop cr311 x12 cut slicks so this was somewhat unexpected to say the least ,so we exit stage 2 undamaged but about a minute and a half slower than ss1 and 54th over all ,,bugger
a quick inspection of the tyres in service reveals wire sticking out of the tyres and a new set required
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/TheMEMWoodbridgeStages10_zpsc84ff78a.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/TheMEMWoodbridgeStages10_zpsc84ff78a.jpg.html)

tctech
12-08-2013, 02:01 PM
the big fight back begins and we slowly but surely start to climb back up the leader board and as we go into the start of ss6 we are 22nd overall and looking for about 30 seconds to get back to 17th easy peasy as we are now up to full speed albeit having to do a bit of tyre management
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/39_zps77fee66a.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/39_zps77fee66a.jpg.html)
can you guess whats coming next
yep 3/4 of the way through ss6 the car looses boost and slows ,instant reaction is to check the gauges ,oil preesure is 4 bar ,boost pressure is strangely 1.4 bar ,fuel pressure is 56 psi or there abouts and water temp is mid point on the stock guage (IT LIES LIKE A CHEAP CHINESE WATCH by all accounts) .
lift off the throttle for the next corner and that's it game over the engine seizes,,,bugger ,,again
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/39_zps77fee66a.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/39_zps77fee66a.jpg.html)

tctech
12-08-2013, 02:35 PM
here we go again csi on engine number 3 so before removal the fluids are drained and the oil is burnt beyond comprehension ,also interestingly we only get 2.5 litres of coolant out of it ,it was full before the start of ss6 on the woodbridge stages (I checked it myself and only put the coolant cap on just before departure ) so the engine was pulled and methodically stripped no signs of head gasket breach ,no signs of turbo core failure and definitely no external water leaks ,the whole engine was scrap not a bearing anywhere was really intact and the oil had degraded to such a point that it became a fluid and no longer a lubricant
the big question was just where the f**k had the coolant gone
so not willing to use any of it I bought a bog standard engine but it was the same block (after a bit of research )that tte used in the gen5 rally cars ,this had my sump remote oil filter and the good parts of what I had left injectors manifolds etc fitted and was installed
we then proceeded to do some analysis and testing and found the cause of this particular failure ,this time it turns out that the high capacity thick cored alloy rad might have well just have been an ornament ,there was nothing high capacity about it ,in fact it was so restrictive that it could not cope with the increased flow at high rpm and stalled the water flow causing the cooling system to pressurise ,thes forcing the water out into the expansion bottle and over prolonged rpm empyting the cooling system ,once down to about 4 ltrs of coolant that was it sianara
so yet another mod ,a cosworth rs500 single pass motorsport rad was made to fit and installed and an alloy header tank fitted ,the cosworth rad needed a bleed fitted to the top of the end tank so it could bleed any air back to the header tank and we plumbed in the fill pipe to the heater return ,we also disconnected the turbo water cooling as this just pumps heat into the cooling system and doesn't actually work anyway,tte also ran there turbos without the water cooling.
cosworth rs500 rad with its mounting brackets chopped off the ends
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF3865_zps0db3f865.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF3865_zps0db3f865.jpg.html)
Chinese celica radiator ,,,worse than a good standard rad
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/DSCF2514.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/DSCF2514.jpg.html)

MCcelica
12-08-2013, 02:39 PM
I spoke too soon. This car has an amazing history... staying tuned for the next chapter.

tctech
12-08-2013, 02:41 PM
how the cossie rad fits ,note no bleed fitted at this point ,we just fitted a 10mm outlet at the top above the top hose ,I need to get some photos of this for reference
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/photoJPG1_zps36a4e3cc.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/photoJPG1_zps36a4e3cc.jpg.html)

tctech
12-08-2013, 02:53 PM
nearly up to date now so cooling system modified and the only way to test it was to go and drive it in anger ,so I entered a rallysprint in the end of November 2013 (last month),the entry fee was cheaper than booking a test day somewhere and a competitive event so I knew I would push it as hard as I should so I fitted the lamp pod as its nearly dark a 4pm this time of year and anticipated still running at 5pm
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/photo_zpsfdc49c6c.jpg (http://s835.photobucket.com/user/tctech/media/celica%20gt4/photo_zpsfdc49c6c.jpg.html)
and off we went to Oxfordshire to a very slippy airbase for the rallysprint ,this consisted of 8 runs northbound and 8 runs southbound on the same stage with very little time between the stages so a pretty fair test for the cooling system
on the start line for a northbound run
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/1455199_419679421492554_192996906_n_zps6b7566fa.jp g (http://s835.photobucket.com/user/tctech/media/celica%20gt4/1455199_419679421492554_192996906_n_zps6b7566fa.jp g.html)
used it as a general test really with spring changes and tyre testing going on so a bit inconsistent in stage times but it still got a good kicking through the day it is fair to say
guess what .... cooling system issues solved ,,engine stayed in one piece
it finished 10th overall and 2nd in class
I am never happy though and could have done better as I was 9th overall before the last 2 stages so I lost out at the end ,and was leading the class at one point as well ,so must try harder
now heres my excuse the car is not geared right as it has still got the 3.9 final drive in
I do however have a built gearbox with the rav 4 4.9 final drive and gearing in it ,,so watch this space
http://i835.photobucket.com/albums/zz276/tctech/celica%20gt4/1455199_419679421492554_192996906_n_zps6b7566fa.jp g (http://s835.photobucket.com/user/tctech/media/celica%20gt4/1455199_419679421492554_192996906_n_zps6b7566fa.jp g.html)

BlueDragon
12-08-2013, 03:05 PM
Wow... that weak link saying really is true isn't it? I bet every failure you had was in some way due to that cooling issue. You can put on every performance part you would like if you cannot get that heat out of the engine its useless. I hope everything works out on the next build! Awesome project, and amazing perseverance on your part. This type of thing is my dream, but if I had gone through everything you have I would probably consider it a nightmare! I bet flying down those roads was all worth it though.

tctech
12-08-2013, 03:09 PM
my fingers hurt from typing now ,I will keep this thread updated as we make any more modifications/improvements ,,but for now I hope you guys enjoy the read

Nitro_Alltrac
12-08-2013, 04:50 PM
Great store. It's really cool to see one of these cars being used for what they were designed for.

spitfiremk16
12-09-2013, 01:22 AM
Oh my. I think i have the same radiator in my celica alltrac. Hasnt ever run hot on me but i might throw it in the scrap pile and gets omething else after reading this! Thank you for sharing the story of your car with us. It was a good read. Please keep us updated on your progress!

Shadowlife25
12-09-2013, 02:30 AM
Fantastic build thread as well as history with the car. Thank you again for sharing with us and I admire the work you put in to this. :)

tctech
12-10-2013, 07:45 PM
well the gearbox has now been changed today and back up and running ,all I can say is " oh my word" this is a must do for anyone who wants lower gearing for sprinting/circuit racing etc ,it has transformed the car from a sluggish 330bhp beast into a turbo nutter screaming machine ,the rav4 gearbox may well turn out to be weaker in the long run ,but while its working ok its a real flyer

Shadowlife25
12-10-2013, 11:49 PM
Fantastic about the change in performance with the Rav4 transmission. Though I agree it may not last as long.

METDeath
12-11-2013, 02:27 AM
Well, you can always get the transmission built to take the power and have those gear ratios. Which... I mean, it is a race car.

Lonestag
12-11-2013, 04:21 PM
Wow, what a build!

I'm so glad to see some one using this platform for competition, and it sounds like it is on its was to being a demon!

andy
12-11-2013, 05:45 PM
Props man this is great! Keep the updates coming, and mount a gopro somewhere

Nitro_Alltrac
12-11-2013, 11:22 PM
Love the updates.

Shadowlife25
12-12-2013, 02:17 AM
Love the updates.

Me too! It's exciting to see it's progress.

junctrac
12-14-2013, 07:42 PM
Yes!!! about time to see a build thread like this. I wish we had the rally following and all the race organizations you have over there. Im assuming you have a lsd in the rear?

Doowstados
12-14-2013, 10:47 PM
I don't think I could have handled the second and third engines taking a shit like that. This is a great thread, super happy to see a proper Celica rally car!

tctech
12-14-2013, 11:16 PM
I don't think I could have handled the second and third engines taking a shit like that. This is a great thread, super happy to see a proper Celica rally car!
little things are sent to try us ,,and i wont be beaten

tctech
12-14-2013, 11:21 PM
Yes!!! about time to see a build thread like this. I wish we had the rally following and all the race organizations you have over there. Im assuming you have a lsd in the rear?
yes lsd in the rear which may be coming out soon though ,makes the car push on from the rear in the low speed stuff causing too much understeer ,i have just put a new torsen in the front though ,found that it was unusually tight when we stripped the box last week .so holding off the rear diff incase it was the front diff having issues
http://www.inmotionimages.co.uk/imgs/gallerylarge/122_12117_19922625.jpeg
collosal understeer here

Tecker184
12-15-2013, 12:25 AM
What axles are you running for the rav4 transmission?

spitfiremk16
12-15-2013, 12:47 AM
^what he said. And what year rav transmisssion? Im assuming your using an e250f transmission out of a 94-99(1st generation) rav4? Everything bolt on mountwise and everything? A friend of mine was thinking about putting a rav transmission in her alltrac because of the taller final drive=stronger acceleration with a more stockish engine. Also please let us know how it holds up under race conditions.

buffalohunter7321
12-15-2013, 02:22 AM
I love this, as a old man, this would keep me young. Can hardly wait for more.

junctrac
12-15-2013, 08:17 AM
yes lsd in the rear which may be coming out soon though ,makes the car push on from the rear in the low speed stuff causing too much understeer ,i have just put a new torsen in the front though ,found that it was unusually tight when we stripped the box last week .so holding off the rear diff incase it was the front diff having issues
http://www.inmotionimages.co.uk/imgs/gallerylarge/122_12117_19922625.jpeg
collosal understeer here

yeah i could see that if you're doing primarily tarmac stuff but damn do i love how predictably those torsion type diffs lock up in the loose stuff. Are there many dirt stages around you or mostly road?

tctech
12-15-2013, 11:02 AM
What axles are you running for the rav4 transmission?
use the e250f rav4 gearbox out of the 94-99 sx10 model to do it properly you need to split the gearbox and fit a gt4 front diff to the rav4 crownwheel ,fit a new gt4 left hand driveshaft oil seal and then the gt4 left hand output shaft fits ,then simply use the stock gt4 transfer box and it all bolts straight in ,dont need to change the axle ratios at all as the final drive is pre transfer so no issues ,the only fiddly bit is the rav4 5th gear which is multi piece so you have to be really careful when the 5th gear is pulled off or it comes apart and is a bit of a bitch to reassemble ,no you cant use the gt4 5th gear before anyone asks , it doesn't fit

tctech
12-15-2013, 11:10 AM
yeah i could see that if you're doing primarily tarmac stuff but damn do i love how predictably those torsion type diffs lock up in the loose stuff. Are there many dirt stages around you or mostly road?
i am by no means a tarmac specialist and frankly more at home on the loose ,unfortunately there are less and less gravel events over here now ,everthing seems to be moving toward single venue tarmac rallys ,mainly due to cost ,this car has been built with that in mind really and would need suspension and brake changes etc to be useable on gravel

grimmythereaper
12-16-2013, 04:19 PM
amazing build, it amazes me how rally racing has more veiwers then nascar but its still a pain in the ass to get it on tv here in states. also what celica gauge cluster are you using that only reads up to 110 mph with a boost gauge in it?

tctech
12-16-2013, 07:49 PM
amazing build, it amazes me how rally racing has more veiwers then nascar but its still a pain in the ass to get it on tv here in states. also what celica gauge cluster are you using that only reads up to 110 mph with a boost gauge in it?
hardly any rallying on tv over here now ,as for the dash cluster its a jap import car but i have no idea how it managed to come with a 110mph speedo, never seen another like it myself either
well spotted

andy
12-17-2013, 03:13 PM
less talky more pictures

underscore
12-18-2013, 09:44 PM
All I can say is wow, you're doing something many of us could only dream of. Beautiful car and outstanding determination good sir!


yes lsd in the rear which may be coming out soon though ,makes the car push on from the rear in the low speed stuff causing too much understeer ,i have just put a new torsen in the front though ,found that it was unusually tight when we stripped the box last week .so holding off the rear diff incase it was the front diff having issues
http://www.inmotionimages.co.uk/imgs/gallerylarge/122_12117_19922625.jpeg
collosal understeer here

Is that a typo, or do you really have a torsen front LSD? If so, where on earth did you get it?

tctech
12-18-2013, 11:23 PM
All I can say is wow, you're doing something many of us could only dream of. Beautiful car and outstanding determination good sir!



Is that a typo, or do you really have a torsen front LSD? If so, where on earth did you get it?
no typo it came out of a gen 4 gearbox that was bolted to an engine that i bought for spares ,others that i have stripped in the past only have a vc in but i have no idea where you can get one

Tecker184
12-19-2013, 02:52 PM
use the e250f rav4 gearbox out of the 94-99 sx10 model to do it properly you need to split the gearbox and fit a gt4 front diff to the rav4 crownwheel ,fit a new gt4 left hand driveshaft oil seal and then the gt4 left hand output shaft fits ,then simply use the stock gt4 transfer box and it all bolts straight in ,dont need to change the axle ratios at all as the final drive is pre transfer so no issues ,the only fiddly bit is the rav4 5th gear which is multi piece so you have to be really careful when the 5th gear is pulled off or it comes apart and is a bit of a bitch to reassemble ,no you cant use the gt4 5th gear before anyone asks , it doesn't fit

So you just put the gt4 diff in with the rav ring gear and run the gt4 transfer-case? So in theory you could put the rav diff in a gt4 transmission and run the rav transfer-case? I ask this because people use the rav transmission to clear a v6 block. I'm doing research to swap in a v6 but afraid the rav transmissions gear ratios may be too short.

tctech
12-19-2013, 07:50 PM
So you just put the gt4 diff in with the rav ring gear and run the gt4 transfer-case? So in theory you could put the rav diff in a gt4 transmission and run the rav transfer-case? I ask this because people use the rav transmission to clear a v6 block. I'm doing research to swap in a v6 but afraid the rav transmissions gear ratios may be too short.
yes that will work but if you are then putting it in a celica you would need to modify or make a bespoke rh driveshaft which is different on the rav4 ,it may fit but would be something that needs checking, also you need the cast iron rav4 transfer case ,which is smaller than the alloy version and gives you the clearance to fit it behind a v6 ,hope this helps

celica9303
12-20-2013, 05:45 PM
Very cool project! Will keep an eye here.

As far as axles for using the rav gearbox, hybrid axles are nothing new here for swappers.

tctech
12-26-2013, 01:05 PM
this is what a torsen front diff looks like ,not mine but I found a picture of someone else's just to show it can be done ,it is essentially a rear diff modified to incorporate the transfer box output ,when I build up a spare rav4 tranny for my car I will build up a new front torsen to fit it ,and do a how to ,but not today
http://i835.photobucket.com/albums/zz276/tctech/oms%20autocare/1502169_622209437837708_1667833263_o_zpscea0c0c4.j pg (http://s835.photobucket.com/user/tctech/media/oms%20autocare/1502169_622209437837708_1667833263_o_zpscea0c0c4.j pg.html)
I have just bought an emerald standalone remappable ecu to go in the car so when it arrives that will be the next little mod for this car

MCcelica
12-27-2013, 03:16 PM
This guy is a walking dictionary. We should bribe him with cookies and "exotic company" to keep 'em around.

Love this build, and I never knew that using the rav4 box was possible.

Tecker184
12-28-2013, 06:53 AM
A how to would be a great piece of knowledge. I'm eagerly awaiting this how to.

tctech
12-28-2013, 11:48 PM
A how to would be a great piece of knowledge. I'm eagerly awaiting this how to.
i will do it, but not right away as i will need to source some more bits 1st /gearbox /diff etc, so next year sometime .

tctech
01-03-2014, 07:46 PM
next event ,brands hatch winter stages we got a very late entry on this so have been given a start number of 54 but will be reseeded through the day if we are being held up ,its not where you start but where you finish that counts
http://brandshatchstages.co.uk/node/25
dont know if you guys get motors tv over there

cms-gt4
01-09-2014, 06:16 PM
Subscribed. I definitely want to see how to build a front torsen for our car. I imagine you would have to pull one out of another car as the front diff is quite small.

tctech
01-14-2014, 07:58 PM
http://youtu.be/Ih5Ju5um-Ck
did not go well at all on this one ,i had 4 very fast spins on the first stage and lost a load of time in the process
then the car went underpowered and we could not find it no matter what we changed
to add insult to injury the co driver wrong slotted on a split junction getting us a stage maximum for stage 7 costing around 4 minutes over the time i could have actually done the stage in so end result was 49th overall ,not a result i am happy with but at least the car finished the event
found the fault with the car now its back in the workshop ,it was staring us all in the face but no one spotted the actuator bracket had bent and was causing variable boost when the actuator bent it in and out, recon we were only running about 0.4 of a bar of boost all day ,,,,bugger

Shadowlife25
01-16-2014, 02:30 AM
Ouch!
Glad you found the cause and sure you will do much better on the next go-round. :)