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 Post subject: Track Weapon Chassis
PostPosted: Sat Dec 29, 2007 5:31 pm 
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Location: Perth, Western Australia
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Its been a while since I reported on the Track Weapon project. I've decided to start a separate Chassis topic as the engine one is probably big enough to slow down most peoples browsers as it loads the pics :oops: The main delay in starting the chassis build has been due to the constructor, JEMS, being saturated with work. Realistically, it is estimated that the chassis will take around a year to build. I hope to include as many innovations as time and budget allow. I'll try and include as much detail as possible on the forum so that people in the GT-Four community can benefit. There may be some 'trade secrets' that remain undisclosed but a hint of mystery is always a good thing :wink:

Build activity over the next year will not be continuous as there will need to be a fair number of bespoke components manufactured. This is not an Evo or Impreza where there are loads of parts available off the shelf but hey, thats why I'm doing this in the first place :-D Anyone can build a track Evo or Impreza but how many GT-Fours do you see circuit racing? The nearest would be the Time Attack series but even this doesn't have an ST205. Admittedly Adrian at Fensport is running his Gen7 GT4X but it hasn't been built to comply with UK MSA (Motor Sport Association) circuit racing regulations. With the shell in the state you see it here it tipped the scales at a sprightly 1,120kg including most of the engine and transmission.

JEMS were quite impressed with the Toyota design and also the general condition of the shell and say it is better than many they have had to work with. They are even thinking of buying an ST205 themselves as a project car! On another positive note it turned out to be quite easy to source a new roof panel and the coachbuilders will do the specialist job of removing the old roof (including the sunroof) and fitting the new one once the roll cage has been fabricated in-situ.


Exterior

Front

Image

Nose

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Rear

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Interior

Front

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Rear

Image

Side

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Door

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Jack Compartment

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Aerial Compartment

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Rear Suspension Turret

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At JEMS

More dismantling

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Front View

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Engine remains :-( Note the modified UK sump with the oil level converted to take an oil temp sensor

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The original 120,000 mile engine showing evidence of twelve years on salty UK roads

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Interior view after JEMS had successfully removed the heater/air con units and associated pipework.
The cross bar visible in this view will be replaced by part of the roll cage

Image

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1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp


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 Post subject:
PostPosted: Sat Dec 29, 2007 9:02 pm 
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thats great Don, i'm really looking forward to seeing your project develop. The chassis is one of particular interest as i will be looking to develop my chassis and handling rather than going for more power.

There was quite a bit of bracing on Mutley - are you planning to brace the front at all?

This does look like it's going to be an interesting year ahead!

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 Post subject:
PostPosted: Sat Dec 29, 2007 9:42 pm 
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Location: Sunny Fareham, UK
Car Model: ST205
Great pictures Don, thanks in advance for sharing your hard earned and expensive knowledge!

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 Post subject:
PostPosted: Sat Dec 29, 2007 10:15 pm 
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I know the end result will be more than worth it, but it is hard to see stormy blue stripped down past his bare essentials!

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 Post subject:
PostPosted: Sun Dec 30, 2007 1:38 am 
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Rob, the front suspension turrets will be braced to the front of the rollcage. This may include triangulating to the front rollcage crossmember as per the WRC setup. CDS will be used for the cage as T45 is more likely to break or fracture. This will incur a weight penalty of around 15kg but I'd sooner play safe with something as important as a rollcage, particularly as it will be carrying the suspension loads. The plan is for the front and rear pressed steel subframes to be replaced with spaceframes. This should reduce the weight significantly and improve the rigidity. Superstrut will be junked for McPherson struts and fully adjustable wishbones and tie rods. Again this should save a lot of weight.

Kris, you know you are always the first to hear of my secret squirrel ideas ;-)

Loosey, the toughest part was stripping the interior of Stormy Blue, particularly since he's been 'in the family' for over ten years. I felt really guilty :oops: Still, its all in a good cause and certainly better than dying a slow death on salty British roads.

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1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp


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 Post subject:
PostPosted: Sun Dec 30, 2007 10:44 am 
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Pedal box conversion??

Interesting to note that you don't have the floor mounted B pillar bracing


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 Post subject:
PostPosted: Sun Dec 30, 2007 2:17 pm 
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what are you doing with the adjustable suspension already on it - do you want a buyer - mine is starting to leak..

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 Post subject:
PostPosted: Sun Dec 30, 2007 3:56 pm 
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two_OH_five wrote:
Pedal box conversion??

Yes of course, twin master cylinder and adjustable bias via completely re-plumbed front/rear split brake lines. Probably going for AP front discs and calipers while retaining stock rear calipers and discs. From experience it is possible to warp the rear discs with the standard brake setup. Hopefully the adjustable bias will take some of the load off the rear.

Quote:
Interesting to note that you don't have the floor mounted B pillar bracing

Pics please ...is this a face lift mod? There is a surprising amount of flex in the shell to the extent that its quite easy to twist the door frame if you jack the body unevenly. This makes it difficult to close the door. All this will be sorted by fitting the roll cage as this will take all the suspension loads.
[/quote]

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Don
GT4DC Chairman
1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp


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 Post subject:
PostPosted: Sun Dec 30, 2007 4:01 pm 
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robbiemcvee wrote:
what are you doing with the adjustable suspension already on it - do you want a buyer - mine is starting to leak..

Go on then :) , I need you to eliminate the temptation to fit the KYB SuperStreet adjustable suspension to my standard white ST205WRC :twisted: . Wouldn't hear the last of it from Kris ;-) I'll PM you when its available.

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GT4DC Chairman
1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp


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 Post subject:
PostPosted: Sun Dec 30, 2007 6:04 pm 
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You can just about make it out here. There are better photos I've seen, still looking

Photo Courtesy of MrBarry on the OC
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 Post subject:
PostPosted: Sun Dec 30, 2007 6:14 pm 
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Found the little tinkers

Removed from a WRC which was broken - hence I'm suprised it's not present on yours

I wonder if it was one of the few rumoured Grp N "production" cars

Somewhat tortuosly via Gary from Mr B again
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From HERE


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 Post subject:
PostPosted: Sun Dec 30, 2007 10:47 pm 
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Hmmm, interesting. I'll need to check my white ST205WRC in the morning. TBH I'd have thought that these braces were fitted more as an afterthought on later production models but I guess that would mean they were non-WRC fittings. Have I just done a Carter loop on this :?: sorry :oops:

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Don
GT4DC Chairman
1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp


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 Post subject:
PostPosted: Sun Dec 30, 2007 10:54 pm 
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Excellent pictures Don :)

Must have been really hard - I wouldn't want to strip my car back that far, although like you say - its saving the car from a worse fate. :)

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 Post subject:
PostPosted: Sun Dec 30, 2007 11:40 pm 
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thanks Don, yes please let me know?

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"And God said, Let the earth bring forth grass, and the earth brought forth grass and the Rastafarians smoked it."


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 Post subject:
PostPosted: Mon Jan 07, 2008 10:38 pm 
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Heeee heeee,

Guess what strengtheners I've got :D :D

I rather suspect they're part of the additional side impact system rather than chassis strengthening though :(


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