hey i'm curious how much an evo costs in the UK. i hear it's like 35,000 pounds? which translates to like $60,000 dollars. that's frigging rediculous pricing. we're so lucky that the price of evo in the US is affordable. how expensive is your RA+build is gonna be? i hope it won't be too expensive so that you'll still have money for other good performance parts.
as much as the next person would like to tell you to get an evo, i can understand what drives you to take on this ambitious project. you'll practically go over every inch of the car while building it, so you'll know it like the back of your hand. everything that goes into the car will be under your control; that's a great feeling to have.
btw, are you doing this alone or with some help? on the lift or jackstands? someone else on the forum did a AWD 4g63 build of a mirage i believe, and it came out very nice, so yes it's definitely possible.
i hope this project will be mostly fun and not much frustration for you.

 

Yeah itll be fun! We do it on jackstands, with some extra safety precautions.

I have the help of up to four people, one of whom is an engineer and mechanic and is experienced with welding, fabrication, CAD design and generally good with tools.

The Evo's in the UK are very expensive - the equivalent of $60-80,000 my lancer cost the equivalent of $20,000 new, and dont forget our fuel which is currently the equivalent of $2.20 per liter makes an Evo practically a bad choice. We dont have a Lancer Ralliart, hence me turning my 1.6 lancer into a Ralliart. I probably could have bought an Evo by now anyhow, but I get bored easily and this is more than a car for me its a project, and I like projects! Im not out to get the fastest, or best, but I am out to be unique in my own country. Currently, I have the only 2.4 lancer, and soon will have the only AWD 2.4 lancer in the UK!

I have unashamedly made my car look just like an Evo IX - to me it looks great, but at least when im done when people call it a pretend Evo thinking its a 1.6 NA FWD I can say - Ah no - its a 2.4 Turbo AWD LANCER. Some of them will be fickle enough to believe that 2.4 is faster than 2.0 anyway! Either way - slightly underpowered and slightly underhandling Evo? Or kick *** lancer!?

I just waiting on delivery of my outlander shop manual - those things make everything easy!

 

I did notice between your outlander pic and my evo pic, the drive shaft looks about the same.

 

wow if this ever gets done you better believe I will take a ferry to come see this build

 

It is getting done - I've ordered the first batch of parts! I also found that the tunnel in the chassis has the holes for the propeller shafts center bearing already there, and there are holes for the outlander rear diff support bracket to.

Im hoping I'll be able to have all the parts within 3 months.

Outlander Rear Trailing Arms
Possibly hubs, however the part number is identical between FWD and AWD so maybe not - I think the FWD ones are already splined - I'll have to check.
Outlander 5-Speed Manual Transmission AWD
AWD Fuel Tank
Fuel Sending Unit
Fuel Pump
Propeller Shaft Assembly
Rear Differential Assembly
Rear Diff Support Bracket
Rear Diff Side Brackets
Left Rear Axle Shaft
Right Rear Axle Shaft
Right Front Axle Assembly
Left Front Axle Assembly
Exhaust Pipe Connect Clamps 2.25"
Custom Exhaust Pipe segment


I've got a couple of those parts on the way already. Im starting with the smaller parts first, and finally I'll order the manual transaxle. I've already check with my supplier of brand new parts that they are available.

I do also still need to find out how the Outlander Controls its AWD system. If it has an ECU, if it is controlled by the main ECM, or whether it doesnt have any control. Whatever happens there will be a way to sort it. Theres nothing really stopping me from swapping my ECM for an outlander one anyway!

 

Image from rear susp Outie 06

 

 

Can anyone tell me how the 2005-2006 outlander controls its AWD? Is it the main engine ECM? If so I may need to swap my ECM to an outlander one.

Or does it have a seperate AWD ECU - I imagine it needs info from the ABS sensors and throttle sensor to work and shift power to the rear wheels when its needed.

 

I just read that the Outlander uses Viscous Coupling to change power distribution. From wikipedia this means:

"In the viscous coupling differentials, the shear stress of high shaft speed differences causes a dilatant fluid in the differential to become solid, linking the two shafts. This design suffers from fluid degradation with age and from exponential locking behavior. Some designs use gearing to create a small rotational difference, which hastens torque transfer"

So actually it doesnt need a computer for the front rear distribution then... I just wonder how the 3 modes actually are made to work.... FWD, AWD and 4WD-Lock.

 

diavlo, all outlander AWD cant fit to the lancer frame body w/o out "major-major" modifications. you can use the evo rear crossmember w/ "minor" modification. but it has a covered holes with you have to redrill.

 

People said that abotu various engine swap issues though, I've done my research and I'm convinced I can do it, with only minor modifcations.

I'm not interested in the physical side of it now - I've done all the research I need and if I encounter problems I'll do the so-called major modifcations as we have a welder, and a brackert fabrication ability, just the electrical now Im interested in.

 

I recieved the outlander shop manual today and that has cleared up A LOT!

Im pretty much 100% convinced now, nearly everything in the shop manual matched what I'd expected and anticipated... So many of the parts are shared.

The only custom bit is mounting the rear differential - EVERYTHING else is just a straight swap.

I also seem to have found out that I was mistaken about the outlanders AWD system.

In the 2007 - it is electronically controlled.
In the 2005-2006 - it is viscous coupling (autmatically transfers power to the rear wheels depending on how fast you drive and thus how thich the fluid gets) and not electronically controlled - From what I can tell you cant select JUST FWD all the time on the 05-06 is that right?

Someone correct me there If Im wrong!

 

if there's no electronic switch in 05-06 for FWD mode, then you cannot disable it otherwise. 03-04 evos have viscous coupling as well, so that's why we can't engage ebrake, because unlike the 05+ evos, there's no computer controlled center diff disengagement.

 

i totally understand. it'll be sorta like a mitsu equivalent of a impreza RS. that's what it should be thought of as, not an evo wannabe. it's not our fault that mitsu didn't make anything like the base RS.

 

The fact that the 05-06 Outlander's AWD system has no electronic control makes this a lot simpler!