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EJ20G RX Leone Rally Car Build

Posted: Tue Feb 12, 2008 12:11 pm
by ToyRX
I thought a few of you may be interested in my project.

SPEC LIST: Adding to as I go!

Brakes/Clutch:
- Wilwood brake box with Wilwood brake balance bar.
- Replaced brake booster and single MC with twin Wilwood MC's for F to R bias control via balance bar.
- Hydro handbrake - Hilman Imp MC.
- Front BC Leggy twin pot calipers and vented disk.
- Crossbred Preformance rear brake kit.
- Rear BC Leggy single pot calipers and vented disk.
- Metal King Pads - for now
- Early WRX Hydro clutch conversion.
- WRX Flywheel.
- Twin Turbo Clutch and preasure plate.

Body:
- Group A rally spec strengthing plates between tower and A Pillar
- Slotted engine Xmember to fit EJ20G
- 6 Point Rollcage
- Custom seat mounting frames 25x25x3 RHS
- Modified gearbox xmember.
- WRX bonnet vents
- Custom IC scoop using Isuzu Bighorn (Rodeo Ute) scoop.
- Bonnet Pins
- Bonnet mounting fabrication for light pod.
- Roof vent for positive cabin preasure
- Painted in Dulux Dulon 1k, untinted white.
- 6mm Ali front sump guard.
- 2.5mm steel fuel tank guard.
- 3.0mm steel diff guard
- 3.0mm Ali underbody protection - sill to tunnel, both sides
- 6mm Rubber underbody protection over rear trailing arms, brake and fuel lines.

Engine/Exhaust
- EJ20G Turbo.
- Possum Link Computer.
- VR4 aftermarket FMIC used as TMIC.
- TDO5h Turbo (V3 STi).
- Bosh fuel pump.
- 3" Grp A simese front pipe with flexijoin into 2.5 Coby resonater and 2.5" exhaust to 2.5" Coby hotdog muffler and 2.5" tip.
- Custom radiator and twin front mount fans.
- Twin Turbo Alloy Rad header tank

Gearbox/Drivetrain:
- BC5 RS Leggy 5 spd, centre VLSD, open front.
- BC5 RS Leggy rear VLSD
- Shortened prop shaft.

Suspension/hubs:
- Five stud conversion, Leggy hubs/brakes.
- Modified rear subframe - inner arm mounts rotated 10mm down and 5mm out.
- Crossbred Preformance 5-stud conversion kit on the rear.
- Custom Bilstein suspension, Front 40mm insert competition valving height adjustable 300 pound progressive springs. Rear 12mm insert competition valving height adjustable 220pd/inch linial (need replacing with progressive springs)
- custom adjustable front strut top camber plates.
- Rear strut top carrier plate flipped upsidedown to increase travel.
- Modified Nissan Ute radius rods with nolathane bushes, adjustable for castor.

Other:
- Chromemolly custom front strut brace
- Oil Preasure gauge
- Water Temp gauge
- IC water sprayer
- Boost gauge
- Light Pod


Ever since I crashed my old Leone I have been collecting bits and info on how to build a new better one, well now I am far enough along to not be completely embarrassed by my efforts to date.

I will endeavour to keep this thread alive with updates as I go but one thing I have discovered is it takes a hell of a long time to achieve what looks to be very little!!

Just to remind you guys this is what the old car looked like after my whoopsy..

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I then brought another near completed club car (UGLY green) with a cage and standard EA82T etc, this would be the perfect match for my Leggy bits and bobs.

So I.....
Added a couple of extra bars to the rollcage
Fabricated the seat mounts
Added a hydraulicc handbrake
Added hydro clutch and two brake master cylinders

Image

Also added strengthing plates to area between towers and a-pillar

Image
Image

Stitch welded the tower area

Image

Added bonnet scoop and vents and then had the whole thing painted so it looks like this

Image

Reinstalled the wiring but not the dash until she is all go again.

Image

I have also installed an after market Bosch fuel pump to handle the EJ20T from the old car.
I am trying to make this car look presentable so all the bolt on bits (Xmember, radius rod mounts, LCA's etc) are getting a coat of paint as I go.

Now piecing it back together and working on the Leggy strut/brake conversion.

Posted: Tue Feb 12, 2008 12:26 pm
by AndrewT
Wow very nice, I will be following this with great interest. I want my little RX to be like this one day.
For now tho I have to stick to my 4 week build schedule! :)

Posted: Tue Feb 12, 2008 12:29 pm
by BrennyV
hey mate, looks like a great build :D were did you get your dash cluster from? :D

Posted: Tue Feb 12, 2008 12:37 pm
by ToyRX
Thanks - cluster is std RX leone

Posted: Tue Feb 12, 2008 12:40 pm
by BrennyV
ahhz it looked like the jap spec :P

Posted: Tue Feb 12, 2008 1:02 pm
by brumbyrunner
Looking good Toy.
Great to see you choosing the slow proper route over the fast/easy one that we sometimes have to take.

Posted: Tue Feb 12, 2008 1:18 pm
by Suby Wan Kenobi
Great project you have there and i will be watching on with great interest

Posted: Wed Feb 13, 2008 5:20 am
by ToyRX
BrennyV wrote:ahhz it looked like the jap spec :P
sorry, I am pretty sure Jap spec is the standard one in NZ, I have three clusters all the same and at least two cars were Jap imports.

Posted: Wed Feb 13, 2008 9:56 am
by BrennyV
any for sale? :P

Posted: Wed Feb 13, 2008 4:53 pm
by PeeJay
I think the AUS clusters don't have the oil pressure and voltage gauges. Mine doesn't at least.

Posted: Wed Feb 13, 2008 5:05 pm
by BrennyV
PeeJay wrote:I think the AUS clusters don't have the oil pressure and voltage gauges. Mine doesn't at least.
yeh same. thats why my eyes lit up when i saw that one :D

Posted: Wed Feb 13, 2008 5:10 pm
by Captain Obvious
yep thats a jappy cluster!!

Posted: Thu Feb 14, 2008 8:11 pm
by PeeJay
What do the brakes feel like with the dual master cylinders with no booster?

Posted: Thu Feb 14, 2008 8:31 pm
by AndrewT
btw, my Aussie 1986 RX does not have those nifty extra gauges either.

Posted: Thu Feb 14, 2008 10:04 pm
by Subafury
wow looking good already.nice effort

Posted: Fri Feb 15, 2008 2:50 am
by ToyRX
PeeJay wrote:What do the brakes feel like with the dual master cylinders with no booster?
don't know yet!! But I also moved the pivot point up on the pedal to help counter the loss of the booster.
Typically the brakes have more feel so it is easier to know how close you are to lockup, how much fade is happening etc, on the down side they are a little heavier but that is not really a problem in a race car.

Cluster for sale

Posted: Sun Feb 17, 2008 4:31 am
by ToyRX
For those of you interested in a Jap cluster, I have listed one in the for sale section

Posted: Sun Feb 17, 2008 10:03 am
by riksta
I like the job your doing on the RX, if you take your time and do it right the first time it saves time fixing things in the service park, and you can get on with the driving and getting a good time.

Hope you have a good service crew be hind you that knows the car.

Good luck with the build, I like it.

Posted: Mon Feb 18, 2008 5:55 am
by ToyRX
riksta wrote:I like the job your doing on the RX, if you take your time and do it right the first time it saves time fixing things in the service park, and you can get on with the driving and getting a good time.

Hope you have a good service crew be hind you that knows the car.

Good luck with the build, I like it.
Thanks - had a good weekend on it but the wife has the camera so no photos yet. Will update hopefully Friday
I have decided to add a spec list at the top of the first post to list everything as I go, this will also make it easy to remember all the mods when it comes time to certify it for the road.

Posted: Mon Feb 18, 2008 6:21 pm
by Matatak
lovin this thread mate.
keep it up coz ill be reading