MK1 R32 4-Motion Sport

[Dub Toffee]

Found some help with machining as I don't have access to a workshop lathe anymore
Spacers for rose joints and engine mounts just got done.
Mishimoto Radiator seems like great quality out of the box!

[Dub Toffee]

Some new progress on the exhaust
I First planed to have the 2 front O2 sensors where a bouts they would normally sit, but after that
merge the 2 1/4 pipes into one big 3inch high flow cat and then have the rear O2 sensors together.
Even getting as far as starting to build it but realised i could do a better job and also was not so sure i would get the best
out of the ECU so take 2 is looking better!
now using x2 Cats with O2 sensors all going where they should in the circuit.


TAKE 1 Ater which i scrapped the whole idea … Building the exhaust over a mock up Tailshaft ...




So After scrapping that i have gone to a more OEM approach below…
Also not using the whole space up above the tail shaft with a 3inch Cat gives me all the space i need for
-Gear Shifter cables
-Coolant Lines to rear Radiator
-Possibly stainless fuel lines as well
-any wiring to the rear from the dash










I used x2 2 1/4 flanges ground down to mount the x2 flex to, they also made it really easy to connect the 2 1/4 bends

Finished some work on the down pipe and got the engine up and running with all x4 O2 Sensors,





Who doesn't like the sound of an R32 with just a down pipe Prrrrr

[sports racer]

Very, very impressive.

When you finally finish what are your plans?

[lunchbox]

I'm not normally a fan of utes but this build is badass!

[Dub Toffee]

Had an Certifying Engineer Look at the project today.
It was a big meeting but I felt relieved and a nice sense of achievement after we were finished.
After experiencing the Engineers Approval on the build and Stepping back it looked more like a machine than something that was cobbled together.

It was a good time in the project to get an Engineer in on it as i need to
-complete brake circuit
-complete steering linkages and adapters

After His Visit it looks Like we will be going ahead and engineering it as an ICV (Individually Constructed Vehicle.)
He was very happy to see the progress so far. He determined that the amount of modification to the chassis means
its going to be an ICV.
This is a MAJOR task and will not be cheap.:face palm:

This will mean that
- The whole Chassis will end up at his workshop to be torque tested and measured for the flexibility of the chassis.
This will produce a graph showing the amount of flexibility at different pressures applied along the length of the Chassis.
Other Tests include
-Brake testing on specialised equipment (in the workshop not on the road)
-Brake Testing under failure of the dual circuit (workshop test equipment)
-Noise test at 74Db limit under acceleration (Track)
Apperently most vehicles fail this test due to induction on the air intake not due to exhaust.
So he has asked if i can use the OEM intake box to help guarantee a pass on this test.
-Brake Testing (Track)
-Stability Testing (Track)
-the list goes on …
if anyone is interested i can post a decent list and some of the engineering requirements and certification that
is produced from this project as a result.



The Good News is I am not limited as to the turbo to be used!
As the chassis will be tested and proven to handle determined amounts of power and duress that comes as a result of it.
Also I can incorporate more tubing into the cabin!
More good news i can pretty much have any track width and wheel size and width that I LIKE
So Bring it on

Other things we covered
Track Width
(I may be converting the track width to suit OEM driveshaft lengths)
(or to suit a specific steering rack)
Wheel arch construction
Fuel tank in the rear tray bed and possibility of vapours (a good reason to have a net and not a rear tray)
Steering and bump steer (their will be some modifications to the steering rack and its position even)
Brake booster location and the angle that the booster sits at so that the brake fluid volume rests is as intended in the resivour .
Turning Circle (another good reason to increase track width)
Air box location
With The steering column i need to maintain the collapsable aspect of the column
(a lot of people take columns and shorten them in the wrong place, I need to keep the collapsable part so that if in an accident the column can still collapse)
Being a Pickup this project will still be classified as an Commercial vehicle for registration and certification.
Load Rating of Tyres and Rims for a Commercial vehicle.
(the OZ Racing Rims will still be suitable for use) phew i would hate to have to pass them up .

[HaydEn]

Awesome news. Would be such a relieve to have the go ahead!

Good luck with it all mate!

[sports racer]

So it looks like this will (eventually) be registered unlike a few other long and expensive builds I've seen on this forum. That in itself is an enviable achievement considering how wild this will be when completed. Well done!

[mjv79]

This will be epic when finished... Congrats!

[abreut]

Wow that is a pretty full-on engineering process - stress testing the chassis and everything. Mine was a walk in the park in comparison. I wouldn't want anyone stress-testing my standard mk1 uni-body, it probably wouldn't even register a reading on their gauges before tearing apart. At least it now gives you heaps of leeway for customisation though.

[Dub Toffee]

I took the advice of another engineer who is a friend of my dads in Tas.
A pretty legendary Dutch Builder down their. That was to build it in accordance with the ADR's and then change
anything they are not happy with after that.
I also questioned before building on the use of Tube chassis and if a Vehicle could have a tube front end.
I kept the questions simple and aimed to build something that is not any different to a kit car in nature really.
Engineers love the use of OEM parts tho. This doesn't bother me anyway.
I got to thank my mate Conor Bates who is a very good qualified welder.
He got me going with fabrication and weld quality. He also had a good input as i made my mind up
on things as the build progressed.

Very happy that this can sport a decent turbo.
Air to air with the intercooler mounted in the front, 3inch Exhaust.
The Engine will be built by Julian Jones here in Sydney.
were looking at using Low Comp Pistons and beefing up the valve train.
OEM Computer Mapped by another mate Scot Evered were working towards 550hp.
A second Stage down the track in years to come will hopefully happen.
That would mean building a serious gearbox up and seeing what limits we can push to.

Very happy that the Engineering process is played out with progress payments thats for sure!

Aiming for a late 2016 Finish