Figured the heat has died down from nasioc and it's ok to post this stuff again. Had to delete my last build thread.
Won't dig into past details too much, you know the car. Gist of the old stuff
-2002 WRX
-Dumpy frankenstein shell. Parts from 4-5 other cars including doors, subframes, decklid/hood/spoiler/glass, etc, etc
-Eg33 3.3L flat six, '05 Sti six speed, R180
-Dccd Pro
-WRX brakes machined to fit STi hubs(to clear rally wheels)
-TD Pro Rally 15x7's
-Hydro handbrake, center diff disrupt circuit
-Sti springs on AGX's
-Misc suspension bits(bushings, sway ends, etc, etc
yaddy yaddy yada
Took the car to some RX events, proceeded to destroy GpN engine mounts and a strut mount, car then sat in the weeds for a month while I gathered some parts.
Decided to tackle a few issues at once and set the car up as an RX machine for the remainder of the season, and some ice racing this coming winter.
Car had an annoying and track time killing fuel surge issue. Decided to rip the entire fuel system off the car and replace it with a full cell, surge tank setup, full AN, and twin pumps(lift and pressure).
Started first by cutting the rear trunk floor out and fabbing a new floor and rear bulkhead, as well as capping every damn hole in the rear decklid.
Next, the cell. No company offered a pre-fabbed cell to fit the location I wanted and maintain a decent fuel capacity(~15gal+), so I built an aluminum shell and contacted ATL to make me a bladder to fit inside with a black box for the intake lift pump(stock WRX pump). Built a fuel sending unit/filler neck for the cell, as well as a fuel anti-surge tank. All mounted in the trunk, with a little "cage" reinforcement, space ventilation blower(bilge shit), and all the fuel pump/filter junk.
Small container to the right is the rear differential breather tank, because last RX event result in water entering the diff's stock breather cap.
Up front I tackled a few things as well. Rewired some connections on the motor harness, new battery(red top), moved PS/front diff catch tank to a new mount off left tower. Built a completely new baffled and heated air/oil separator for the EG33. Wrapped the intake in gold foil to keep IAT's down(shit runs hot). Changed out oil cooler to higher flow Mocal unit.
Radiator modified for 50mm pump inlet and welded and inline thermostat housing up on the top tank to pull the thermo out of the pump and reduce pump cavitation above 5500rpm(big issue on this motor).
Inside got a little treatment too. Wiring was a mess and I was embarrassed to say it was my car. Typical of testing and shit when doing a swap like this on the unknown, but needed to be finalized and cleaned up. So I took a little initiative from Steve's 240 and rewired everything to a central circuit setup with all fuses and major relays in one location. Made a quick and dirty center console from sheet AL and mounted is all to that, as well as a central batt kill for good measure just incase.
Since the car has no radio gear of any kind, I took that spot and made a switch panel that controls the fuel pumps, blowers/coolsuit, and soon to be fog pod, as well as my center diff controls.
Also removed the stock cluster because it completely shit the bed and instead of going to typical route I installed a neat little gauge setup instead off my steering column. Displays tach w/ digital speedo, fuel oil and coolant temps, oil pressure(dummy light) CEL, directionals, high beam, two-stage shift light, and speed limit(a warning feature for lead footers like me). Also records 0-xxxx speed(I have 0-60mph set), 1/8,1/4, etc mile times, top speed, and has an input for a lap timer. It's a bike thing, and was cheap.
I also recently added a functional roof scoop to force air into the car, RX/rally requires windows up unlike most track events and it get fuggin hot in the car. Added to this feature, I installed another filtered blower that feeds air from the scoop into my cool suit ice box and also into my forced air helmet. Works the nuts!
Also not shown, because I haven't quite finished mounting them, are my new Wilwood front brakes for the car. Dynalites from Mike(mafdark) made to fit my WRX. I'm going to CNC the brackets I designed tomorrow to fit the calipers to my car and clear my rally wheels. Thanks to Mike for stupid cheap Wilwoods
Oh and a shot of the skid plate up front right before it took a few heavy nose shots at the last RX. 1/4" 6061 convering everything back to the front diff housing. Had to form this in the 100 ton press but it does the job of keeping shit in one piece quite nicely. Too bad it weighs more than the entire front crash bar it's mounted to, about 65lbs
For the remainder of this year the car remains as my DD and RX machine. Next year I'm replacing the floorbards and will fab a NASA spec cage and run a few stage events towards the end of the season to freshen up and work out kinks. If I don't wad it, the following year I'll go for broke in RA/nasa events until that happens
