Go Back   Mitsubishi Lancer Register Forum > General Stuff > Picture & Video Gallery

Reply
 
Thread Tools Rating: Thread Rating: 288 votes, 5.00 average. Display Modes
Old 26-06-2009, 01:55   #1
Clivew
Transmission Dynamics
 
Clivew's Avatar
 
Join Date: Feb 2001
Location: Bedford
Car: Highly Modded E6 T04Z/2.2ltr, E91 325D Ohlins/M3 bushes, Renaultsport Megane RS250 Cup.
My Car
Posts: 7,034
Evo 6 Trackcar Build......Lots of Pics.

Where do I start..........

A few people have asked to see some pics of my car and it's build progress so here goes. I haven't got pics of everything as I get engrossed in what I'm doing and forget about the camera

I've done everything myself including a full engine build, gearbox rebuild, front and rear diff build, all fabrication, infact everything apart from mapping, welding in the cage and paint work.

The engine was finished last year and I carried out shakedown testing of many bespoke parts and a new suspension set-up during the summer, and then the car was taken off the road this winter for a complete stripdown for cage fitment and to lighten the car as much as possible without compromising safety.

As the many people who have done this know, it's a big project, including a full strip and rewire of the loom

I think the last pics of the car I posted on this forum were in 2002, so some more are a bit overdue.....

Hopefully you'll enjoy looking as much as I do at other builds such as RossW, Barry, Norris, Daz, etc.

I'll start with a pic of the car last year at Norris, carrying out a mapping session.
Attached Images
 
Clivew is offline   Reply With Quote
The Following User Says Thank You to Clivew For This Useful Post:
boom_boom (21-03-2013)
Old 26-06-2009, 02:04   #2
Clivew
Transmission Dynamics
 
Clivew's Avatar
 
Join Date: Feb 2001
Location: Bedford
Car: Highly Modded E6 T04Z/2.2ltr, E91 325D Ohlins/M3 bushes, Renaultsport Megane RS250 Cup.
My Car
Posts: 7,034
Ok, going back in time, pics of the engine build in my workshop.

Arrow conrods and JE pistons with gudgeon pins, rings and bearings, balanced in positions 1&4 and 2&3 to less than 0.1 gram by mixing and matching everything except the piston positions which have already been postioned to match the bores to gain optimum clearance in each bore.
Attached Images
   
Clivew is offline   Reply With Quote
Old 26-06-2009, 02:12   #3
Clivew
Transmission Dynamics
 
Clivew's Avatar
 
Join Date: Feb 2001
Location: Bedford
Car: Highly Modded E6 T04Z/2.2ltr, E91 325D Ohlins/M3 bushes, Renaultsport Megane RS250 Cup.
My Car
Posts: 7,034
Block with Tomei crank fitted, crank was balanced on it's own (And needed no machining as was above race spec balance from new) and then balanced again with flywheel, clutch and pulley fitted.

Last pic is tightening the conrod bolts by the stretch method as this is much more accurate than torqueing as it takes friction out of the equation. The stretch tolerance was .01mm in this case
Attached Images
     
Clivew is offline   Reply With Quote
The Following User Says Thank You to Clivew For This Useful Post:
Evosick (14-02-2017)
Old 26-06-2009, 02:20   #4
Clivew
Transmission Dynamics
 
Clivew's Avatar
 
Join Date: Feb 2001
Location: Bedford
Car: Highly Modded E6 T04Z/2.2ltr, E91 325D Ohlins/M3 bushes, Renaultsport Megane RS250 Cup.
My Car
Posts: 7,034
Measuring piston protrusion with a DTI to make sure the squish measurment is in tolerance for the 1.2mm HKS head gasket to be used.
Attached Images
 
Clivew is offline   Reply With Quote
Old 26-06-2009, 02:24   #5
Clivew
Transmission Dynamics
 
Clivew's Avatar
 
Join Date: Feb 2001
Location: Bedford
Car: Highly Modded E6 T04Z/2.2ltr, E91 325D Ohlins/M3 bushes, Renaultsport Megane RS250 Cup.
My Car
Posts: 7,034
Onto the head, I spent a long time on this, anyone who has done headwork will know how time consuming it is, if it's done properly.

First thing was to cut up an old knackered head, kindly donated to me by another MLR member

I then know how much material there is to play with when modifying the ports and combustion chamber.
Attached Images
 
Clivew is offline   Reply With Quote
Old 26-06-2009, 02:40   #6
Clivew
Transmission Dynamics
 
Clivew's Avatar
 
Join Date: Feb 2001
Location: Bedford
Car: Highly Modded E6 T04Z/2.2ltr, E91 325D Ohlins/M3 bushes, Renaultsport Megane RS250 Cup.
My Car
Posts: 7,034
I modified the inlet and exhaust ports by hand, got the valve seats cut at a local engine shop, and then carefully finished around the seats. I used 1mm oversize Ferrea valves. Oh and before this I replaced the valve guides with Bronze ones.

Next I modified the combustion chamber shape and squish for less port shrouding and a more detonation resistant design.

To do this I bolted the head to a milling machine and machined each chamber the same and then finished by hand.

Lastly I matched each chamber to less than 1ml using a burette, some perspex and degreasing fluid.

That's a lot of work
Attached Images
      
Clivew is offline   Reply With Quote
Old 26-06-2009, 02:41   #7
Clivew
Transmission Dynamics
 
Clivew's Avatar
 
Join Date: Feb 2001
Location: Bedford
Car: Highly Modded E6 T04Z/2.2ltr, E91 325D Ohlins/M3 bushes, Renaultsport Megane RS250 Cup.
My Car
Posts: 7,034
Attached Images
    
Clivew is offline   Reply With Quote
Old 26-06-2009, 02:49   #8
Clivew
Transmission Dynamics
 
Clivew's Avatar
 
Join Date: Feb 2001
Location: Bedford
Car: Highly Modded E6 T04Z/2.2ltr, E91 325D Ohlins/M3 bushes, Renaultsport Megane RS250 Cup.
My Car
Posts: 7,034
Ok, I then fitted the head using APR headstuds, HSK gasket, Norris spec Piper cams and springs and solid lifters.

Below is a pic timing the cams using a timing wheel I made

I used a DTI to find TDC, then adjusted the pointer to zero, and then adjusted the cam wheels to get the timing correct to the spec that came with the cams.
Attached Images
 
Clivew is offline   Reply With Quote
Old 26-06-2009, 03:24   #9
Clivew
Transmission Dynamics
 
Clivew's Avatar
 
Join Date: Feb 2001
Location: Bedford
Car: Highly Modded E6 T04Z/2.2ltr, E91 325D Ohlins/M3 bushes, Renaultsport Megane RS250 Cup.
My Car
Posts: 7,034
Found a company that does plastic coating that looks like polished alloy/chrome without the dulling/corrosion probs

My AMS manifold;
Attached Images
 
Clivew is offline   Reply With Quote
Old 26-06-2009, 03:32   #10
Clivew
Transmission Dynamics
 
Clivew's Avatar
 
Join Date: Feb 2001
Location: Bedford
Car: Highly Modded E6 T04Z/2.2ltr, E91 325D Ohlins/M3 bushes, Renaultsport Megane RS250 Cup.
My Car
Posts: 7,034
Engine completed, ready to be dropped onto my transport stand

Norris/Shearer T04Z turbo kit, exhaust manifold Ceramic coated.
Attached Images
   

Last edited by Clivew; 23-09-2015 at 11:43..
Clivew is offline   Reply With Quote
Old 26-06-2009, 03:33   #11
Clivew
Transmission Dynamics
 
Clivew's Avatar
 
Join Date: Feb 2001
Location: Bedford
Car: Highly Modded E6 T04Z/2.2ltr, E91 325D Ohlins/M3 bushes, Renaultsport Megane RS250 Cup.
My Car
Posts: 7,034
Next, pop the gearbox on

And push it round to the garage ready for fitment
Attached Images
 

Last edited by Clivew; 23-09-2015 at 11:43..
Clivew is offline   Reply With Quote
Old 26-06-2009, 03:33   #12
GUM EVO
Senior User
 
GUM EVO's Avatar
 
Join Date: Oct 2007
Location: BERKSHIRE
Car: 2008 EVO X & 2008 EVO IX
My Car
Posts: 12,217
Stunning build... that Tomei crankshaft is pure class!!! You really used the best of the best, both build methods and parts
__________________

2011 CLASS A MLRSS WINNER
GUM EVO is offline   Reply With Quote
Old 26-06-2009, 03:40   #13
Clivew
Transmission Dynamics
 
Clivew's Avatar
 
Join Date: Feb 2001
Location: Bedford
Car: Highly Modded E6 T04Z/2.2ltr, E91 325D Ohlins/M3 bushes, Renaultsport Megane RS250 Cup.
My Car
Posts: 7,034
Not really in date order, pics of the gearbox rebuild with an uprated output shaft and new bearings. The standard output shaft twists when subjected to high torque, and knackers the transfer box.

I also rebuilt the transfer box with new bearings and got the crownwheel and pinion shot peened.

A Cusco RS front diff was rebuilt with low preload and soft ramp angle, and fitted to the transfer box.
Attached Images
   
Clivew is offline   Reply With Quote
Old 26-06-2009, 03:51   #14
Clivew
Transmission Dynamics
 
Clivew's Avatar
 
Join Date: Feb 2001
Location: Bedford
Car: Highly Modded E6 T04Z/2.2ltr, E91 325D Ohlins/M3 bushes, Renaultsport Megane RS250 Cup.
My Car
Posts: 7,034
Cheers Gum, fitting cheap parts doesn't make sense on a high horsepower build

Now onto the rear diff, the car started out as a GSR, so had the weak AYC rear diff fitted. First thing to do was to strip the diff and analyse how it worked
Attached Images
 
Clivew is offline   Reply With Quote
The Following User Says Thank You to Clivew For This Useful Post:
jonnyc (10-01-2013)
Old 26-06-2009, 03:55   #15
Clivew
Transmission Dynamics
 
Clivew's Avatar
 
Join Date: Feb 2001
Location: Bedford
Car: Highly Modded E6 T04Z/2.2ltr, E91 325D Ohlins/M3 bushes, Renaultsport Megane RS250 Cup.
My Car
Posts: 7,034
Next analyse where the weak points are before designing my own uprated casing, junking all the standard internals and fitting a rebuilt Cusco RS LSD with heavy preload and hard ramp angle. Also shot peened the crown wheel and pinion.
Attached Images
     
Clivew is offline   Reply With Quote
The Following 2 Users Say Thank You to Clivew For This Useful Post:
ben10 (17-03-2015), Evosick (14-02-2017)
Mitsubishi Lancer Register
Reply


Thread Tools
Display Modes Rate This Thread
Rate This Thread:

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump




All times are GMT. The time now is 20:36.


Powered by vBulletin® Version 3.8.6
Copyright ©2000 - 2017, Jelsoft Enterprises Ltd.