My Rally Car - A long term project
My rally car is a 1981 Toyota KE-55S
Corolla, and I bought it from a guy called Edwin Heatherington back in
1986, as a rolling shell only with no engine or gearbox. It was exactly
what I was after, as a couple of months earlier I had crashed my KE-30
Corolla and written off the body, but the mechanicals were fine.
The car had excellent suspension and brakes, so I think it was a good deal.
|This is how it looked when I first picked up up (Apologies for the poor quality of the pic, but it's the only one I have) And on the right is how it looks after the new paint job. -|
The car is collecting dust at the moment, as I don't have enough time to get anything done on it, but hopefully by the end of 2005 or so, there will be some progress..
I was planning on using a Toyota 3T-GTE turbo 1800cc engine in it for some time in the car and getting a lot more power from it, but something came up that I couldn't pass by ...
I am lucky enough to have a friend that is a Japanese parts & engine importer, and one day he brought back a rather odd engine, one that I've never seen before or since. It's a Toyota 1G-GZTE, which means it's a 2 litre, twin cam, four valves-per-cylinder, 6 cylinder, supercharged AND turbocharged 450hp monster! Take a look at a couple of pictures of it -
|This is looking at it from the front, and on the right hand side you can see where the turbo bolts on to the exhaust manifold, and the supercharger on LHS the supercharger. You can also see part of the complex inlet plumbing ...|
|This shows a good view of the
inlet pipes. All of the darn things! It took me a while to figure
out how it all works, but I think I've got it under control. ;)
You also get a better view of the supercharger, and also the two inlet
manifolds - The upper one and the lower one.
(apologies for the scratch in the picture)
I changed my mind yet again, and have given that engine back to the importer I bought if off, and I am shortly to receive a Toyota/Lexus 1UZFE, four litres with quad camshafts and an alloy block. This means that they're a lot lighter than the 1GGZTE above, and also a lot shorter. With the larger capacity it should still make around the same total power as the smaller engine and even though it won't turbo's the top end power should still be quite good. Pics to come ...
HOWEVER PART TWO!!!
I changed my mind yet again, and am now going to fit it with a 2.7 litre Suzuki V-6 as after some careful measurements it was going to be difficult to fit the big V-8 into the car. The V-6 is quite a bit smaller and lighter, and so will be much easier to fit. The smaller engine will of course make less power and so to keep the performance up to close to that of the bigger V-8, I will be running more revs (~8,800rpm) and a shorter diff ratio, thus increasing the torque at the wheels to nearly the same amount. The other reason I'm using this engine is because it'll be indentical to the one in my Starlet, and so help reduce the total cost of building the engine.
|Here's the estimated power output.
The useful torque curve is quite wide, so the engine will still be
This is one part of the rally car package.
I have decided that to be able to really use 400hp+ odd in a small car like a Corolla, that I really need a proper 4WD system, and so the car is going to be fitted with the gearbox from a Ford Sierra Cosworth 4WD, thus making it a 4WD rally weapon. To do this, I will be moving the engine and gearbox back a couple feet, and this will help the car be better balanced as well. This involves cutting a rather large hole in the firewall and moving the gearbox tunnel back a fair bit, but it'll be worth it.
||Here's the only picture I have of the gearbox, will get more when I purchase an actual gearbox.|
You can't see where the transfer case comes out the rear end, as it's on the other side. Hopefully I'll be getting one from England some time in early 2004, courtesy of a friend in the UK, so I can make a little progress on that side of things.
One of the problems with having the engine sitting in the middle of the firewall and a diff sitting in front of that, is that there's not a lot of room left to put a steering rack in that area. What I really needed was to find a FWD car that had the steering rack sitting in front of the crossmember and so had the sterring arms on the bottom of the strut also point out forwards instead of rearwards like they almost always do. After a fair bit of searching and questioning, I found that such cars are rather thin on the ground ....
Fortunately, Ford Sierra to the rescue again! I dug up a picture of the bottom of the front of the car, and it turns out that they have exactly the rack & struts I'm after. Here's that picture.
#1 is the short driveshaft from the gearbos to the front diff, #2 is the gearbox itself, #26 is the transfer case, #4 is the front diff in the is case (I'll likely use a Nissan R180 diff though), #16 is the rack which is hidden behind the front crossmember, #19 is one of the front halfshafts, and #8 is one of the tie-rods on the steering.
So it's all slowly coming together ....
Hopefully it'll be on the road by late 2004 odd.
|Work has started!!!
It'll take a while, but the car is off the to a friend's workshop, and he will be doing the major mods to get the car under way. They include cutting the very large hole in the middle to fit the engine & gearbox, fitting the Sierra front suspension & Subaru rear, etc. I have purchased a standard 2.5 litre Suzuki quad-cam V-6 and hopefully to get a hold of the Sierra 4WD gearbox & other parts soon.
|After being mucked around a great dealfor
several years I got my head down and set about getting the Ford
Sierra 4WD gearbox that I wanted. I managed to find a good one on an
English Ford forum, and simply bludgeoned my way into getting the
gearbox by spending the money needed. It ended up costing far more than
it should have, but I would still be waiting if I did things on the
Unfortunately, for various reasoons, nothing else has been done on the car. The two main reasons are that the shop that was going to be doing a lot of the work has shut and my other projects have priority at the moment.
Back to the Index pagePage & contents where applicable © Bill Sherwood