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My rally car project build

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jimspeed
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Joined: 05 Mar 2010
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PostPosted: 21:42 - 04 Jan 2013    Post subject: My rally car project build Reply with quote

Very Happy Ok I know its a bike forum but I figured a few of you may be interested?
not sure if I should put it here or show and tell so if you feel its in the wrong place I'm sure someone can move it for me?
I work for a Skoda specialist hence the choice of car lol

I am building a Fabia for stage rallying, I'll sort some pics out soon.
basics
take 1 fabia 1.4MPI in white with blown headgasket.
add 1 sparco rollcage. https://i265.photobucket.com/albums/ii223/felicia16v/FABIA%20RALLY%20CAR%20BUILD/DSC_0407.jpg

and a polo gti AVY 1.6 16 vvt engine and mate it with the Skoda MPI gearbox (which is by far the best box to use out of the petrol fabia box's btw)
mix in some decent suspension and vrs brakes and see what we have.
so far the cage is done and I'm at the stage of chopping the dash to fit around it, I have an engine along with the ecu and polo loom,immo box and key so its just a matter of comparing the polo ecu pin outs with the skoda ones so it should run as standard for now until I have sorted a the rest of the car and the engine is 125 bhp standard so a good start.
I already have front suspension legs from my felicia rally car so they will be adapted to suit and have some spax from a mk2 golf that look ok for the rear with a bit of messing with.
I have vrs front calipers and disks BUT can't find any front hubs anywhere, bought a pair that were supposed to be fabia but are actually octavia ones .
that will do for now as pics tell a thousand words..
https://i265.photobucket.com/albums/ii223/felicia16v/FABIA%20RALLY%20CAR%20BUILD/DSC_0427.jpg
https://i265.photobucket.com/albums/ii223/felicia16v/FABIA%20RALLY%20CAR%20BUILD/DSC_0425.jpg
https://i265.photobucket.com/albums/ii223/felicia16v/FABIA%20RALLY%20CAR%20BUILD/DSC_0426.jpg
.
few kg's of tar removed from the floor pans https://i265.photobucket.com/albums/ii223/felicia16v/FABIA%20RALLY%20CAR%20BUILD/DSC_0428.jpg this was a back breaking job and took ages to do even with 2 of us 1 heating it up and the other scraping.
my assistant is the 16 yr old apprentice from work who will also codrive for me on the cars 1st event which is at Brean Sands caravan park jan 26/27th so no rush then lol.

I needed to modify the flywheel to suit the clutch I had to use and also lighten it as much as was practical, so I spent a couple of evenings on my miller doing this
https://i265.photobucket.com/albums/ii223/felicia16v/FABIA%20RALLY%20CAR%20BUILD/DSC_0434.jpg
https://i265.photobucket.com/albums/ii223/felicia16v/FABIA%20RALLY%20CAR%20BUILD/DSC_0430.jpg
the flywheel went from 7.5 kgs to 5.0 kgs and also balanced up ok (it was 10 grams out in 1 place according to the bloke that balanced it)
anyway I'll just stick the new pictures up on photobucket in this album as I do them to save space on this thread
https://s265.beta.photobucket.com/user/felicia16v/library/FABIA%20RALLY%20CAR%20BUILD
____________________
Hyosung cruise 125(passed test on, sold) Kawasaki el 252 (better than expected but sold on) Kawasaki GPZ500S first "big"bike.(sold) ZZR600 E5..Z750 2007,ER5, currently on a 2008 Enfield bullet electra x and loving it..
,"Alpha-9: Is there any correlation between dyno rod and dyno kits?"


Last edited by jimspeed on 21:54 - 04 Jan 2013; edited 1 time in total
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jimspeed
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Joined: 05 Mar 2010
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PostPosted: 21:52 - 04 Jan 2013    Post subject: Reply with quote

currently the car is running and has its mot tomorrow Laughing then I can strip it all back down to make some more mods and finish bits off, I seem to have lost a few pictures so Ill retake them and update this as I go along ,
the wiring was easy in the end the skoda car loom and the polo ecu utilized the same pins but with different colour wires Rolling Eyes so it was almost plug and play to get running.
unfortunately one of the VRS front hubs I bought is bent badly and the strut won't fit it properly so another is on order which is a pain and setting things back a bit but front brakes were bedded in tonite mintex 1155 pads in golf mk5 calipers using fabia vrs disks and hubs lol whic is what makes the fabia a good base due to VAG compatibility thru the ranges stuff like 288mm brake upgrades can come from a scrapper etc rather than machining bespoke parts like my last rallycar.
front suspension is Ford escort cosworth 909 front bilstien casings shortened 2 inches and bespoke 40mm inverted AVO insert with adjustable bump and rebound
https://i265.photobucket.com/albums/ii223/felicia16v/FABIA%20RALLY%20CAR%20BUILD/DSC_0453.jpg
https://i265.photobucket.com/albums/ii223/felicia16v/FABIA%20RALLY%20CAR%20BUILD/DSC_0454.jpg
all built up
https://i265.photobucket.com/albums/ii223/felicia16v/FABIA%20RALLY%20CAR%20BUILD/DSC_0456.jpg
.
____________________
Hyosung cruise 125(passed test on, sold) Kawasaki el 252 (better than expected but sold on) Kawasaki GPZ500S first "big"bike.(sold) ZZR600 E5..Z750 2007,ER5, currently on a 2008 Enfield bullet electra x and loving it..
,"Alpha-9: Is there any correlation between dyno rod and dyno kits?"
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neatbik
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Joined: 27 Jun 2007
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PostPosted: 21:58 - 04 Jan 2013    Post subject: Reply with quote

Good stuff.
Always fancied a go at doing something like this myself. Let us know how you get on.
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