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Discussion Starter #1 (Edited)
Hi everyone, this project is to convert an ek4 into a stage rally car using a k20 engine.

The brief was a bullet proof and reliable car. Spec is as follows,

Engine and gearbox
k20a1 with dc5 type r cams
Jenvey taper throttle body kit
hytech exhaust manifold
2.5inch exhaust
Sadev st82-14 6 speed sequential box
quartermaster twinplate 7.25 inch clutch kit
3kg steel flywheel.
all new braided fuel lines

Brakes
Brembo 4 piston front calipers with 300mm diameter 25.4mm width disc
Brembo 2 piston rear calipers with 280mm diameter discs
Tilton 600 series floor mounted pedal box
all new stainless steel braided teflon hoses
hydraulic hand brake

Suspension
3 way damper adjustable proflex coilovers
rose jointed rear toe and camber arms
rose jointed front wish bones
hard race bushings
all new ball joints and steering arms.

anyway, i'll let the pictures do the talking.

How the bare shell landed.




Shell fabrication:








seat mounts

second spare wheel mount



dummying in an engine core and new sadev St82-14 sequential box.


 

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Discussion Starter #3
suspension and brakes:

due to the bumpy nature of irish tarmac roads for rally a 3 way damping adjustable damper is required. A set of Proflex dampers are going to be fitted to this car



my own design rose jointed camber and toe arms, and front track control arms with castor adjustable compression struts





carbon parts
 

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Wow! Excellent fabrication on the shell and rollover protection. Lookin' good. :nod:

When do you expect to have the car finished and ready for testing?

Peter
 

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Discussion Starter #5
Wow! Excellent fabrication on the shell and rollover protection. Lookin' good. :nod:

When do you expect to have the car finished and ready for testing?

Peter
thanks!

ASAP! lol, in 3 weeks it will look very much more like a car, i'll be updating this thread regularly!
 

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Awesome build !!

More pics of the removable front core support :)

I remember you did one on your other build, the EG one if I recall.
 

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Discussion Starter #12
Thanks!

Will get a few pics tomorrow, ya I did use the bolt off front on the green EG. I use it on all builds because it makes life easier!
 

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Discussion Starter #16
Man love these builds! Here in Holland it's very rare to see a honda in Rally sports...

How are you going to do the rear suspension setup?

Looking forward for the end results.
The standard trailing arm will be used in conjunction with Proflex 3 way dampers, hard race bushings and some rose jointed toe and camber arms.

Wow! very nice man.

More info on that sequential box, is it available to the public?
Yup the sadev box can be bought from http://www.swrmotorsport.com/

Woah, this build escalated quickly.
:like:
 

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Discussion Starter #17

Will finish off the fuel lines once the engine and box is in




All the interior plumbing is done, fuel, brake and fire extinguisher lines
 

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Discussion Starter #19
Front suspension and brakes built up. Hope to have the clutch next week so I can fit the engine and gearbox!

 
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