EJ20G RX Leone Rally Car Build
Posted: Tue Feb 12, 2008 12:11 pm
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..
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
Also added strengthing plates to area between towers and a-pillar
Stitch welded the tower area
Added bonnet scoop and vents and then had the whole thing painted so it looks like this
Reinstalled the wiring but not the dash until she is all go again.
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.
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..
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
Also added strengthing plates to area between towers and a-pillar
Stitch welded the tower area
Added bonnet scoop and vents and then had the whole thing painted so it looks like this
Reinstalled the wiring but not the dash until she is all go again.
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.