WRX Track Hack

[danew]

Hi I'm Dane from Melbourne and I thought i'd do a quick post about my car, apologies for it not being a liberty, but I did start my car modifying days in an RS liberty.

Originally the car was from NSW and was used as a track car for a few years, then it was sold onto another car club member and all the good parts stripped off it. It was bought as a complete car minus gearbox and engine.

I co-own the car with another mate from the club as we thought it would be the best way to go racing and minimise the costs as much as possible.




Original plans for the car was to use the built 2.2 from my road car and build it to be reliable as possible. (well as reliable as a track car can be)

First round of mods were:
- completely stripped shell
- closed decked, sleeved built 2.2
- TD06H
- JDM MY02 6 speed
- 4/2 pot combo with DBA5000's
- Cusco Coilovers
- Microtech LT8
- 24mm front sway bar and 27mm rear
- Whiteline RCK
- GDB alloy front control arms
- GDB rear cradle + lateral arms

A few progress photos:




EJ22 dropped in



First TIG attempt





Ready for a shakedown event at Phillip Island



First shake down run went well with no big issues besides a small vibration at speeds over 200 kph (loose bumper) and the turbo oil feed line deciding it no longer wanted to hold oil.

[danew]

Update (13/4/12):

Ran the car at PI with only a few small teething issues and then raced at Winton in December last year.

After 3 sessions the engine decided to let go in a massive way, didn't spit a rod or anything. Just decided it didn't want to rotate any more and thought it would be better to weld itself together.

So at the moment we have the engine (257 with CP's) from Pete's Outback, which has just been honed and prepped with new rings etc and some HPC coating on the pistons (had clearance issues).

Hopefully by the end of the weekend I will have the long motor together minus a few things.

Some pics:













So Engine specs after I finish will be:

- EJ257 Block
- EJ257 rods
- EJ257 crank
- CP 99.5mm pistons (HPC coated)
- MY98 WRX heads
- ARP head studs
- Twin scroll sump with killerB re-enfoced pickup + windage tray
- TD06H
- MY99 440cc inj de-capped
- E85

Based off a quick cal that Hodge did for us, we should be getting CR to around 9.1 or 9.2:1 (with 0.6mm head gaskets). So it should go ok on E85.

We've also stolen the Brembos from the Outback too (DBA5000's and Ferrodo pads) so it is truely a bitsa car now

[danew]

Massive Update (22/6/12):

Finally managed to pull my old 2.2 down, I think the pictures speak for themselves...

Centre thrust bearing:


And corresponding Big end:




And corresponding Rod:


It's fair to say things got a little hot.

All of the big ends were buggered:



257 build pics:





Engine went together smoothly and was of course working on it during the dying hours before I needed to leave for Mallala.

Had it booked in for a tune the day before we left for SA and got a phone call in the middle of the day saying my engine had died on the dyno....

Initial thoughts were i had fkd something up along the way and after ringing the tuner directly I had a bit more insight on what had happened. It stalled whilst in between power runs and he didn't try to restart it as it sounded a bit odd. He tried to turn the motor over by hand and heard a bolt come loose, then took off the passenger side timing cover and noticed the small ideler pully had come off and the timing belt had jammed in between the cam wheel and the inner timing cover.

I pulled all of the timing gear off the engine and retimed it whilst it was on the dyno, did a leak down test and it came back fine. So managed to dodge a massive bullet!?! It turns out that the bolt holding the small timing ideler in (which was removed from the same location) was too small and didn't have enough thread holding itself in. So even though I used loctite and the correct torque, it must have worn enough of the thread away to work its way loose. (after previously being there for over 30k klms)

Engine ended up making 260kw atws at 17psi and around 450Nm of torque with the bulk of that being between 3000RPM and 6000RPM.

A few photos from Mallala:




Things I need to sort now are:

- surge tank
- better designed catch can setup (was throwing massive amounts of oil out each session)
- tyres that can handle 260kw atw's with a 1200kg car
- suspension setup needs a lot of work

So my DIY motor has lasted a day on the dyno and a days racing at Mallala. Just need one more full track day before it has lasted longer than my 'bulletproof' workshop built 2.2...

[swingn]

Welcome

[Boostaddict]

Welcome mate


Sure looks like your having fun at least!!!!