So, you all know we have collected nearly all the parts required for our AWD conversion.

We're not quite there yet. I've still to get the AWD transmission, and also I want to do the RRM head and cam whilst the engine is out of the car. We delayed the bulk of the project itself until around November. However, we are now starting some preparation, so I will document that in this thread.

So, to begin with, we have the new Outlander rear trailing arms. First things first, we cut out the rubber bushings and replaced them with Flexane ones!
























And also, I current have a 4x114.3 bolt pattern left over from when my car was a 1.6 model. This will now become 5x114.3, the same as the US ralliart with the AWD conversion.

The observant among you may notice I have a Wilwood Big Brake Kit, which they only make for 4x114.3 lancers. So - we bought a Wilwood hat that is exactly the same as the one that comes with the 4x114.3 kit, except that the center bore is too small, which means it doesnt fit on the hub. Carl used a lathe to get a precision fit by trimming the center bore to fit the hub.

So now I have the first Wilwood Kit for a Lancer Ralliart!






Finally, we will be adding a custom mounted Rear Wilwood 2-piston opposed rear caliper along with the RRM rear slotted disks. This is a custom job, but its easy for my mate carl!






I will add to this thread as things develop with this conversion.

 

beautiful! Let us know how those susbushes are!
approx how much flexane did it take to do each suspension bushing? I know they sell it in gallons, but I was hoping to not have that much left over. Also, is that blue stuff the poly primer to help it stick?

 

it took just short of 250ml of flexane 60, luckily it was a 500ml kit. we used about 160ml of resin and about 90ml of hardener. Dan told me the kit was just about big enough for two bushings and he wasn't wrong!

Please note... the first picture of the taped up bushing shows only electrical tape... the second shows a load of kidnappers tape over the top because it leaked! Top tip there is use plenty of tape BEFORE you start pouring.

And yes, that blue stuff is the primer, I spent half an hour cleaning a paintbrush only to have Dan find that there's a brush attached to the lid!

The blowtorch is a must as well, dan tried cutting the rubber off but once heated the glue sticking it to the metal simply melted and it just pealed off really easily. Don't do the blowtorch bit inside, the rubber WILL catch fire and will give off some nice carcinogenic fumes.

BTW, if you haven't guessed I'm Carl, the dogsbody Dan gets to do all the dirty jobs.

 

i soo cannot wait until this project is done....im as excited as a giddy little school girl

 

very detailed cant wait to see it finished.

 

Same here How much did you give for the Wilwood kit?

 

wow how do u have so much money to do all this to your caR??

 

are you going to do a how to? if you get this running and everything ima try to do it also.. who wouldnt want awd!?

 

im sure that the parts didnt cost a whole lot of money plus he's doing all the work himself which saves a lot.

 

Two things are on my side at the moment!

The first is the fact we do all the work ourselves!

Second is the UK-USA exchange rate, which makes everything half-price for me!

Something in the USA that costs $200, is £100 to me, but that part in the UK would also cost £200.

The wilwoods arent expensive, about $540 for a basic kit.

 

Hey Diavlo, since you're upgrading the rear calipers also, can you keep the OE brake master cylinder or do you have to upgrade it as well?

 

Can keep it, they arent huge calipers that need a cylinder upgrade.

 

when i come for vacation you show me the car

 

I made a little decision the other day. I decided to bring the Turbo kit forward, and do that before I finish the AWD conversion.

I've asked Rob at RRM if I can order one - waiting to hear from him.

Assuming all goes well there I'll get that installed in October, and finish this AWD project in December, as I only need the tranny for that now.

I'll update with Turbo progress in this thread too.

 

You my friend are a mad man! Definitely the most fun to watch on the boards!