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Building a real WRC style Rally Car


cobrajetguy
Doppleganger
1886/2000


Galant VR-4 org Post #: 1197796 posted 12/31/14 08:26 PM     Remind Me!  Send Private Message   Edit Post      
This is my 3rd Galant VR-4 and I can't count how many DSM's I own/have owned. My first Galant was a nice clean low mileage street car heavily built but still a complete car with a sunroof. I didn't have the heart to tear that car up so I sold it off and looked for a donor chassis to start my project. This car was parked in front of a friends house with a blown motor and a ton of miles on the chassis. It was a little rough but was basically exactly what I needed to start this project and the best part was the car didn't have a sunroof. The project starts with the stripping of the car and installation of an FIA legal rally cage.

Before shot of the old engine bay



And the car getting ready to go to the cage builder



Pulled all the sound deadening out



Starting to put tubes in



Seat Mounts



Door Bars



Roof Bars



Main X's



Reinforcing the front strut towers



Tied the front strut towers to the main cage



Welding in the harness bar



The new cage all cleaned up and painted



Stay tuned for more (It gets better )



'91 Belize Green Galant VR-4 Sold
'92 Nile Black Galant VR-4 Sold
'91 Summit White Galant VR-4 Rally Project
'94 Red TSi AWD Rally-X + DD
'01 Red EVO VII RS-II

Posts: 407 | From: Fort Collins, CO | Member Since: 08/02/04 | IP: (75.70.64.32) | Report this post to a Moderator

cobrajetguy
Doppleganger
1886/2000


Galant VR-4 org Post #: 1197799 posted 12/31/14 08:50 PM     Remind Me!  Send Private Message   Edit Post      
Next up was pulling out some excess wiring and gutting the rear doors





Then started making a panel to block off the rear seat area



Had to pull all the old stuff out of the engine bay



Rebuilt the pedal box and removed the steering lock



New bushings for everything in the front subframe



Pulled everything out of the rear, not much will be reused



Reinforced the rear control arms



Swapped in a DSM diff housing to delete the 4WS and installed a re-stacked EVO IX diff



Ready to go back in with new boost x bushings



Also installed a jay racing active toe elimination kit



Everything back in along with 4 bolt rear axles



Edited by cobrajetguy (12/31/14 08:54 PM)

Posts: 407 | From: Fort Collins, CO | Member Since: 08/02/04 | IP: (75.70.64.32) | Report this post to a Moderator

GSTwithPSI
A hole
820/1000
1837/2000



Galant VR-4 org Post #: 1197800 posted 12/31/14 08:53 PM     Remind Me!  Send Private Message   Edit Post      
So much WIN. Thanks for sharing.



820/1000
1837/2000
1546/2000-SOLD
1813/2000-SOLD

Posts: 3299 | From: SoCal | Member Since: 01/02/12 | IP:
(72.45.2.251) | Report this post to a Moderator

cobrajetguy
Doppleganger
1886/2000


Galant VR-4 org Post #: 1197802 posted 12/31/14 09:08 PM     Remind Me!  Send Private Message   Edit Post      
To keep with the WRC theme I decided to paint the car like the old Works team cars.

Started out by wet sanding the body



Then off to get a fresh coat of white paint





And then painted on the works stripes



Copies of the old decals for the body



The EVO III rear wing just spoke to me so I had to go for it



The rear bumper beam was rusting and heavy, weighing in around 40 lbs so I decided to make a new aluminum one





Finished product on the car



Scored a Fiberglass JDM Hood



Mocking up the ETS intercooler



Fitting the bumper over the new intercooler


Posts: 407 | From: Fort Collins, CO | Member Since: 08/02/04 | IP: (75.70.64.32) | Report this post to a Moderator

coyotes
Hipster VR4
1226/2000


Galant VR-4 org Post #: 1197807 posted 12/31/14 10:43 PM     Remind Me!  Send Private Message   Edit Post      
damb. I was partial to the marlboro graphics myself but this looks awesome



1226/2000

Posts: 1544 | From: Seattle, WA | Member Since: 11/15/13 | IP: (50.97.94.26) | Report this post to a Moderator

ApexHunter
Extreme Indoor Cyclist
1951/2000


Galant VR-4 org Post #: 1197811 posted 01/01/15 01:14 AM     Remind Me!  Send Private Message   Edit Post      
Whoa

This is good.



1991 Mitsubishi Galant VR-4 #1951/2000 (SOLD)
2003 Honda S2000
2003 Evo

Posts: 1912 | From: Oceanside, CA | Member Since: 04/25/07 | IP: (2602:306:cd73:c1) | Report this post to a Moderator

vr4hotness
New Daddy
436/2000


Galant VR-4 org Post #: 1197813 posted 01/01/15 03:16 AM     Remind Me!  Send Private Message   Edit Post      
Nothing but win in here



852/2000 (sold

436/1000 rust free



(Beer is living proof that god loves us and wants us to be happy)- Benjamin Franklin

Posts: 181 | From: Chino Hills, California | Member Since: 12/02/10 | IP: (2607:fb90:281a:b) | Report this post to a Moderator

Jon Galant VR4.org Administrator
Administrator


Galant VR-4 org Post #: 1197821 posted 01/01/15 10:22 AM     Remind Me!  Send Private Message   Edit Post      
Love it!

Posts: 1433 | From: Franklin, TN, USA | Member Since: 02/21/01 | IP: (68.63.243.24) | Report this post to a Moderator

minneSNOWta
Member +
1899/2000


Galant VR-4 org Post #: 1197824 posted 01/01/15 10:56 AM     Remind Me!  Send Private Message   Edit Post      
The livery is sick! If you don't mind me asking, how much for all the vinyl? Those control arms are cool too. I was just thinking the other day how sweet they would be if they were gusseted.

Curious, what grille will you be using? If you found an '89 grille and painted it white, that would look so sick with your USDM bumper.



#1899/2000 - W09 A71 (1/111)

Build Thread

Posts: 343 | From: Duluth, MN | Member Since: 05/14/11 | IP: (75.134.150.193) | Report this post to a Moderator

89Mirageman
Senior Member


Galant VR-4 org Post #: 1197825 posted 01/01/15 11:45 AM     Remind Me!  Send Private Message   Edit Post      
Awesome job so far, can't wait for more updates.



94 Eagle Summit DL coupe
98 Mitsubishi Mirage DE sedan
15 Mitsubishi Mirage ES hatch

Posts: 2485 | From: Stantonsburg, NC | Member Since: 07/05/06 | IP: (184.3.237.217) | Report this post to a Moderator

cobrajetguy
Doppleganger
1886/2000


Galant VR-4 org Post #: 1197829 posted 01/01/15 12:47 PM     Remind Me!  Send Private Message   Edit Post      
Graphics were made by these guys:

click

Posts: 407 | From: Fort Collins, CO | Member Since: 08/02/04 | IP: (75.70.64.32) | Report this post to a Moderator

Wookalar
ignore this pathetic weasel he's just not worth the time
3/1000


Galant VR-4 org Post #: 1197843 posted 01/01/15 07:34 PM     Remind Me!  Send Private Message   Edit Post      
Nice work. This should be a sticky, How to Build a E39A Rally Car.

Great reference pictures for the next time someone asks how to remove rear subframe and 4ws.



</font><blockquote><font class="small">Quoting 89Patches:</font><hr />

Brett gstwithpsi is the nut rider!


<hr /></blockquote><font class="pos

Posts: 458 | From: Arizona USSA | Member Since: 11/27/13 | IP: (24.251.4.211) | Report this post to a Moderator

prove_it
my racist jokes aren't actually funny
715/1000
1284/2000


Galant VR-4 org Post #: 1197861 posted 01/02/15 08:22 AM     Remind Me!  Send Private Message   Edit Post      
Looks too nice to race now. Very nice. Me likey



#1284/2K NB, Totaled
#715/1K KG, Rebuilding
02 Acura TL daily duty unit

12yr+ Vr4 owner.
Honda/Acura master tech.
Family Guy

Posts: 4201 | From: Sioux Falls, SD | Member Since: 07/04/08 | IP: (24.230.93.110) | Report this post to a Moderator

MellowVR4
5" too short
372/2000


Galant VR-4 org Post #: 1197872 posted 01/02/15 12:16 PM     Remind Me!  Send Private Message   Edit Post      
F'N SWEET



89 RAIDER V6 5speed
90 GALANT GSX SOLD
91 372/2000 making it pretty again
91 578/2000 sold
92 417/1000 DIED
87 4RUNNER LS400 SWAP SOLD:(

Posts: 1621 | From: Milwaukee, Wi | Member Since: 07/25/09 | IP: (12.207.73.194) | Report this post to a Moderator

MellowVR4
5" too short
372/2000


Galant VR-4 org Post #: 1197873 posted 01/02/15 12:16 PM     Remind Me!  Send Private Message   Edit Post      
F'N SWEET



89 RAIDER V6 5speed
90 GALANT GSX SOLD
91 372/2000 making it pretty again
91 578/2000 sold
92 417/1000 DIED
87 4RUNNER LS400 SWAP SOLD:(

Posts: 1621 | From: Milwaukee, Wi | Member Since: 07/25/09 | IP: (12.207.73.194) | Report this post to a Moderator

matt92vr4
Member ++
474/1000


Galant VR-4 org Post #: 1198016 posted 01/03/15 10:42 PM     Remind Me!  Send Private Message   Edit Post      
Awesome! Great job.



474/1000 Summit White
1993 Stealth RT/TT
1995 Montero SR
1998 Montero

Posts: 676 | From: Venice, FL | Member Since: 10/03/10 | IP: (66.87.148.22) | Report this post to a Moderator

mistaVR4
Rest in Peace
484/1000


Galant VR-4 org Post #: 1198064 posted 01/04/15 08:02 PM     Remind Me!  Send Private Message   Edit Post      
Very neat/professional work! Do you have more pics of the car? Finished exterior/interior?



SteveW
484/1000 Kensington Grey - Running VERY well :-)
564/2000 Belize Green ~ SOLD
749/2000 Summit White ~ SOLD
1989 Chrysler Conquest TSi SHP ~ SOLD
2004 Saab 9-5 ARC ~ Daily Driver



Posts: 4768 | From: Boulder, CO | Member Since: 12/16/03 | IP: (2601:1:8a80:b35:) | Report this post to a Moderator

Drew84
Member
801/2000


Galant VR-4 org Post #: 1198524 posted 01/11/15 05:52 PM     Remind Me!  Send Private Message   Edit Post      
This looks great, are you going to stage rally it? You cant run Rally America events without prior turbo car experience.



1999 Montero Winter Package
1990 Talon TSi AWD
1991 Galant VR4 801/2000
#RacedInAnger
@autoofftopic

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cobrajetguy
Doppleganger
1886/2000


Galant VR-4 org Post #: 1198743 posted 01/14/15 08:29 PM     Remind Me!  Send Private Message   Edit Post      
I do plan to stage rally the car, the plan for this year is to hit local gravel hill climbs. I can run NASA events in the car as a novice and gain experience/coefficients. I have been rally crossing with the SCCA for the past few years and hold the regional championship and am second in the nation in my 1G.

Pic of the 1G for reference.



Posts: 407 | From: Fort Collins, CO | Member Since: 08/02/04 | IP: (75.70.64.32) | Report this post to a Moderator

cobrajetguy
Doppleganger
1886/2000


Galant VR-4 org Post #: 1199146 posted 01/20/15 08:26 PM     Remind Me!  Send Private Message   Edit Post      
Here are a few shots of the motor that went into the car. It was originally the motor from my 1st 1G DSM that I rebuilt and then the car was wrecked shortly after. It was also in my green Galant before I sold it, neither car was driven much so the motor is still very fresh. Since it was built a while ago I freshened it up with a new timing belt and swapped some other parts out before it went into the rally car.

Checking the cam timing using BLE solid lifters



Coated hot parts



Valvetrain



Rebuilding the power steering pump so it doesn't cut out at high rpm



Ready to drop in



Shiny transmission



Finally in the car




Specs on the engine are as follows:

.020 over Ross Pistons, Crower I-beam rods, ACL bearings, stock crank, ARP main and head studs, Buschur underdrive dampened crank pulley, new oem front case, standard balance shaft delete, BJ's Cylinder Heads ported race head, bigger valves, dual valve springs, 3mm lifters, HKS 272 cams, Kiggly HLA regulator, extrude honed intake manifold, rebuilt 63mm throttle body, external cooler oil filter housing, '90 water pipe, FP exhast manifold, FP HTA68 turbo, FFWD triple layer ceramic coating on all hot side parts, ported EVO III O2 housing.

Transmission built by Jacks Transmissions:

EVO III 1st-5th , double syncros, US final drive, Speed Design 4 spider center diff, Cusco MZ front LSD, stock viscous center for now.

Posts: 407 | From: Fort Collins, CO | Member Since: 08/02/04 | IP: (75.70.64.32) | Report this post to a Moderator

Wolfpuss
Member
1392/2000


Galant VR-4 org Post #: 1199153 posted 01/20/15 10:04 PM     Remind Me!  Send Private Message   Edit Post      
Awesome build Subscribed more more!

Posts: 156 | From: St Louis | Member Since: 07/08/14 | IP: (24.207.133.113) | Report this post to a Moderator

snohacking
Member
1342/2000


Galant VR-4 org Post #: 1199169 posted 01/21/15 09:46 AM     Remind Me!  Send Private Message   Edit Post      
lovin it



2007 mazdaspeed6
91 Galant Vr4 1342/2000

1995 Talon Tsi.. sold

Posts: 233 | From: Menomonee Falls, Wi | Member Since: 03/16/10 | IP: (63.99.16.220) | Report this post to a Moderator

jeverts
Member +
909/1000


Galant VR-4 org Post #: 1199174 posted 01/21/15 10:52 AM     Remind Me!  Send Private Message   Edit Post      
Thank you for getting your bore over size correct. Bugs the ever loving shit out of me when people say they have a .20 over bore on there engine. ITS .020 there is a big difference between .20 and .02.

Clean build by the way.

Posts: 305 | From: Hartford, WI | Member Since: 07/14/11 | IP: (23.30.240.177) | Report this post to a Moderator

christo
Member


Galant VR-4 org Post #: 1199194 posted 01/21/15 01:38 PM     Remind Me!  Send Private Message   Edit Post      
Great build!

I am curious to see how the FFWD coating does, keep us updated.



Chris Mclean

Posts: 196 | From: Fairhope, AL | Member Since: 02/07/03 | IP: (99.194.182.44) | Report this post to a Moderator

JamesFoster
Infamous BMX Master
674/1000


Galant VR-4 org Post #: 1200261 posted 01/31/15 06:04 AM     Remind Me!  Send Private Message   Edit Post   
Absolutely love it. Cant wait to see it finished. Hopefully in person someday...

Maybe you can help me with some questions I'll have when I start putting my 1g back together. I want to set it up for rallycross.



#674/1000 760hp/630tq street car, broken transmission at the moment.
Social: @Jamesfosterbmx

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