Another Evo 4 Restoration Thread

[Pushpex]

I bought the car last August for a fairly reasonable price, knowing full well it needed some TLC. The inside smells herbal and there's some spot rust around along the body with some questionable repairs to the rear chassis rails, an intercooler which hardly fits and a stupid subwoofer in the boot wired in in the most chavtastic fashion however it drives OK (although needed a wheel alignment) there's no ayc light and the engine is from an evo 5 (with an evo 9 turbo)

I had a lot of fun driving it, but after being told the wheels couldn't be aligned because the tie rod end boots were perished (spoiler- they weren't) I put it on jackstands and in typical fashion the originally small job just grew.

Taking the wheels off I decided the knuckles could do with a good powdercoating




And whilst I was at it I might as well do the subframe and control arms, however it seems the subframe was mounted with some of the most spectacular welding



Having cut the weld off it seems the reason for the welding was because the bolt had been cross threaded causing the captive nut to destroy the cage, allowing it to spin freely.The only way was to take the head off with an angle grinder to get the subframe out



Whilst I was at it I got some nice evo 5/6 alloy control arms though they needed cleaning up

The tired looking N/S bar



Fujitsubo exhaust (the first mod I did to replace the drainpipe exhaust tip that had been installed) and prop shaft



More to come...

[7722adam]

Pics not working for me

[7722adam]

Ps going through same as doing full underside resto on my 6!! Back to bare metal etc

[Pushpex]

Originally Posted by 7722adam

Ps going through same as doing full underside resto on my 6!! Back to bare metal etc

Any pics? it's a massive pain without a spit but knowing it's safe from corrosion for a few more years is worth it!

[Pushpex]

Getting the intercooler mounted properly
Note the old bracketry holding the mishimoto intercooler in place






Of course the pipework doesn't fit properly and the thin gauge strips of steel holding the intercooler in place bent down into the brake ducts which caused the arch liners to shred

Made some new brackets out of stainless




(not going to show my amelinium welding )

Some 90 degree hoses to avoid the foglights and brake ducts


Not sure how the sharp angle will affect the boost

[Pushpex]

Wire wheeling down the old paint





Painted with rust.co.uk 121 Epoxy





Haven't perfected my seam sealing yet

[Mita]

Looking forward to updates

[leeslancer8]

Yeah shame about the pictures

[Pushpex]

Sorry about the pics, tried to link from onedrive but it doesn't seem to be working. Made an imgur account so stay tuned

[leeslancer8]

Have that cat back on mine it’s a nice system

[Pushpex]

Originally Posted by leeslancer8

Have that cat back on mine it’s a nice system

It's great, JASMA rated so doesn't get annoying on long drives but still excellent when you open the throttle

[Pushpex]

Had to cut the captive nut out





Made a new one on the lathe at work



Welding it back in





A bit of a challenge welding upside down



Primed

[Pushpex]

Front subframe and control arms back from powdercoating fitted with superpro bushes



Pordercoated front ARB painted over in blue, unfortunately I didn't prep the powdercoat well so the blue just chipped



Fitted with brembos and HEL brake lines




N/S bar back from powdercoating



Unfrotunately there was a crack in the rear upper control arm



Had a go at welding it but it cracked as soon as I put the bush in





So I got someone who can actually weld amelinium to do it

[Pushpex]

Mounted my new arch liners and then moulded a support in expanding foam

And then moulded them in fiberglass

however they were too rigid to be mounted. Has anyone done anything special to reenforce their arch liners?

[EvoIVCed]

I’d def like to know as I jus had to replace my driver side arch, after it being crappy for a while.