AlchEm1st's Evo IV Coupe conversion project
Well, here's a small update on the floorpan. This is the reason I posted the car for sale as well.
In the first pic you can see a cutout of where rust had eaten through the frame rail. It was just
a small spot of breakout on the outside like all the other pics, but the inside layers of sheetmetal
are totally rotted away compromising the strength of the rail. There are around 60 spots like this
that need sandblasted out, sprayed with rust converter, and patched. It can be done and it will be
more than strong enough to hold all the power I can throw at it once it's all done, but the pan won't
even be ready to swap until Summer at the earliest and I anticipate my car needing a lot of work as
well once were get the stock pan removed. (though not nearly this much I hope) To be honest I'm
lucky as some of the damage is almost into structural bits. You'll see the spots close to mount points
in the pictures. Those almost were to the point of making the pan unusable so I'll count my blessings
there! Anyway, the upside to all this is I will be focusing on small project bits of the car here and there
now that the rear end is built and doesn't need any more money sunk into it. Getting the last few bits
to finish the interior and gonna be working on the front suspension as well. (not much to do though)
After that's all sorted the engine build will begin. :twisted:
Also, took a quick year end state of the union video which overviews the car and the parts and also gives a better idea of the interior layout. For your viewing pleasure! :thumbsup:
https://www.youtube.com/watch?v=dada8bnAkig
In the first pic you can see a cutout of where rust had eaten through the frame rail. It was just
a small spot of breakout on the outside like all the other pics, but the inside layers of sheetmetal
are totally rotted away compromising the strength of the rail. There are around 60 spots like this
that need sandblasted out, sprayed with rust converter, and patched. It can be done and it will be
more than strong enough to hold all the power I can throw at it once it's all done, but the pan won't
even be ready to swap until Summer at the earliest and I anticipate my car needing a lot of work as
well once were get the stock pan removed. (though not nearly this much I hope) To be honest I'm
lucky as some of the damage is almost into structural bits. You'll see the spots close to mount points
in the pictures. Those almost were to the point of making the pan unusable so I'll count my blessings
there! Anyway, the upside to all this is I will be focusing on small project bits of the car here and there
now that the rear end is built and doesn't need any more money sunk into it. Getting the last few bits
to finish the interior and gonna be working on the front suspension as well. (not much to do though)
After that's all sorted the engine build will begin. :twisted:
Also, took a quick year end state of the union video which overviews the car and the parts and also gives a better idea of the interior layout. For your viewing pleasure! :thumbsup:
https://www.youtube.com/watch?v=dada8bnAkig
Last edited by Alchem1st; Dec 31, 2012 at 06:28 PM.
Well, it's been a minute since I updated this thread, so here's what I've been up to! Picked up Manley's forged 100mm stroker crank!
It's installed (not permanently) in the block with Cosworth mains and thrusts and ARP main studs. I was gonna get the block align honed,
but I have around .002in of clearance which is tight, but acceptable so I'm just gonna run with it. Also, last weekend I picked this bad boy up.
It's a PTE 6262 with the dual ceramic ball bearing and anti surge housing options! Also came with a 4in intake (not sure I can use
it though as I'm sticking with the MAF) and K&N filter, what appears to be a Full Race downpipe though not sure, a Tial 38mm EWG,
and a junky but free ebay manifold. Also got AN lines for oil and coolant feed! Now I really can't wait to get the engine built! This
whole setup only has around 5k miles on it (no shaft play to speak of) and I got a stellar deal on it all locally! PROGRESS.
It's installed (not permanently) in the block with Cosworth mains and thrusts and ARP main studs. I was gonna get the block align honed,
but I have around .002in of clearance which is tight, but acceptable so I'm just gonna run with it. Also, last weekend I picked this bad boy up.
It's a PTE 6262 with the dual ceramic ball bearing and anti surge housing options! Also came with a 4in intake (not sure I can use
it though as I'm sticking with the MAF) and K&N filter, what appears to be a Full Race downpipe though not sure, a Tial 38mm EWG,
and a junky but free ebay manifold. Also got AN lines for oil and coolant feed! Now I really can't wait to get the engine built! This
whole setup only has around 5k miles on it (no shaft play to speak of) and I got a stellar deal on it all locally! PROGRESS.
Progress on the floorpan! It's still not even half way done; but it's getting there! Got maybe 4 out of twenty total patches done and each patch is
several layers deep. Some of the patches you can't even tell were patched! Here's some before and afters and some other pics:
Here's what we're doing. Bad rust spot:
Cut out. You can see the middle section is nearly gone from rust.
Sandblasting the rust out! From here we make a patch for each layer and welds them in.
So yeah lol. All of these are only one side of the pan. Haven't started much on the other side yet. Maybe another month or two before it's ready; but it's getting there.
several layers deep. Some of the patches you can't even tell were patched! Here's some before and afters and some other pics:
Here's what we're doing. Bad rust spot:
Cut out. You can see the middle section is nearly gone from rust.
Sandblasting the rust out! From here we make a patch for each layer and welds them in.
So yeah lol. All of these are only one side of the pan. Haven't started much on the other side yet. Maybe another month or two before it's ready; but it's getting there.
Haha I could use some cash! 
This thing is draining me! It'll be worth it in the end though! I think fuel system is what's next on the list. Need a pump to install the fuel tank when the floor is done (thinking Aeromotive 340lph) and a FPR kit (probably STMs) to keep it in check until the engine swap.
This thing is draining me! It'll be worth it in the end though! I think fuel system is what's next on the list. Need a pump to install the fuel tank when the floor is done (thinking Aeromotive 340lph) and a FPR kit (probably STMs) to keep it in check until the engine swap.
In the midst of the massive floorpan restoration I picked up something good for the interior...
Evo 6 blue stitched Momo steering wheel! Pretty rare and the blue stitching matches my interior! Now I just need seats and harness' and the interior will pretty much be done!
Evo 6 blue stitched Momo steering wheel! Pretty rare and the blue stitching matches my interior! Now I just need seats and harness' and the interior will pretty much be done!
Haha calm down. All in good time. Might be another engine even going in before the Evo one is done haha. A 4g64 drops in with the Evo trans to get the awd going and uses the existing 1.8L engine harness and I think even the ECU. Straight swap and I have access to one for almost free. Then the 4G63 will be a super simple swap.
All in good time. Might be another engine even going in before the Evo one is done haha. A 4g64 drops in with the Evo trans to get the awd going and uses the existing 1.8L engine harness and I think even the ECU. Straight swap and I have access to one for almost free. Then the 4G63 will be a super simple swap.
Last edited by Alchem1st; Apr 29, 2013 at 03:15 PM.
Dash is more or less done so here are a few shots. Angles and lighting are a bit off in these though. I will
do a full good quality photoshoot outside of my garage with good light when I actually feel like it LOL.
Lighting was almost on the money in this shot but the headrest was in the way and the angle was just barely off. Gotta work on that a bit more!
What I see driving:
do a full good quality photoshoot outside of my garage with good light when I actually feel like it LOL.
Lighting was almost on the money in this shot but the headrest was in the way and the angle was just barely off. Gotta work on that a bit more!
What I see driving:
Another nice interior update! Picked these up this past Saturday and just finished the install!
Evo 8 Recaro's mounted on Evo 5 Bride seat rails!
Need to get a few sections of alcantara replaced as well as some of the foam, but I have a local guy that
does racing seats for good prices that I'm gonna have redo them for me! All that's left on the interior is
to get my harness bar installed and finished and mount some harness's and a camera mount on it and that's
pretty much it!
Evo 8 Recaro's mounted on Evo 5 Bride seat rails!
Need to get a few sections of alcantara replaced as well as some of the foam, but I have a local guy that
does racing seats for good prices that I'm gonna have redo them for me! All that's left on the interior is
to get my harness bar installed and finished and mount some harness's and a camera mount on it and that's
pretty much it!
It's getting there!
Whiteline front lower control arm bushings! (The KCA429's add +5 caster too! They need heavy modification to fit though... :-/ )
Putting on the OEM Evo 4 suspension:
Note that the car is UNSAFE to drive like this. I needed it to be rollable for the time being; but the next time it sees the street it will be awd.
The bolts the hold the LCA to the trailing arm is under a lot of stress and the bushing is torqued all the way to one side. If it saw the street that
bolt would snap pretty quick I think and geometry is way off anyway.
Back on the ground! (sort of?)
Dad says the pan repairs will be done by the end of this month and I plan to start ripping the rear out of this car as soon as it's home! We're finally almost there after so many setbacks!!! =-)
Oh, got some new goodies for the fuel system on the way finally too! I think I more or less have the rest of the build planned.
Whiteline front lower control arm bushings! (The KCA429's add +5 caster too! They need heavy modification to fit though... :-/ )
Putting on the OEM Evo 4 suspension:
Note that the car is UNSAFE to drive like this. I needed it to be rollable for the time being; but the next time it sees the street it will be awd.
The bolts the hold the LCA to the trailing arm is under a lot of stress and the bushing is torqued all the way to one side. If it saw the street that
bolt would snap pretty quick I think and geometry is way off anyway.
Back on the ground! (sort of?)
Dad says the pan repairs will be done by the end of this month and I plan to start ripping the rear out of this car as soon as it's home! We're finally almost there after so many setbacks!!! =-)
Oh, got some new goodies for the fuel system on the way finally too! I think I more or less have the rest of the build planned.
New parts arrived! STM's Adjustable FPR kit and a pair of Wally 255's! Gonna build a custom double pumper setup with all AN fittings
with a -10 feed line and a -8 return. Haven't figured out how I'm going to do the return line yet though since fuel passes through a venturi
valve before returning to the tank and I can't change the size without throwing off the tanks system of keeping equal fuel in both sides.
Got some more research to do!
(You may notice a stunning lack of regulator in the pic. It's currently backordered but STM went ahead and shipped the rest of the kit to me.)
with a -10 feed line and a -8 return. Haven't figured out how I'm going to do the return line yet though since fuel passes through a venturi
valve before returning to the tank and I can't change the size without throwing off the tanks system of keeping equal fuel in both sides.
Got some more research to do!
(You may notice a stunning lack of regulator in the pic. It's currently backordered but STM went ahead and shipped the rest of the kit to me.)