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Old 09-27-2013, 05:01 PM   #1
364seehorn
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Member#: 262021
Join Date: Oct 2010
Chapter/Region: NWIC
Location: Spokane
Vehicle:
05 STI Rally Car
Aspen White

Default 05 STI Super Prodution Rally Build

I'm halfway through my build and though I would share some of my progress. This is going to be built to Super production spec for Rally America next year and I'm going to do trackdays, rallycross, and autocross with the car also.

Sold my 08 STI 30r so I could buy a cheap Chassis to start with. The Car I bought was a totaled 05 STI with only 61,000 miles on it. Bought it for $7k and had about $2k into hard parts to get it repaired to WSP inspection.


Pulling The Quarter panel, It was pushed in about an inch:


Painted:



All done and ready for inspection:


Brakes and 15" rally wheels, drove it last winter with these:



Now It came to the real build in April of this year I ordered a Step 3 T45 cage from Custom Cages.


Then started to proceed to strip the car down and put it out of service

Stripping the fenders and seam welding the strut towers:



Due to misshipments and delayed shipping of missing parts my cage took 3 months instead of the 2 week lead time they quoted. I was beyond frustrated, but they worked with me on shipping and made it right.


Starting to get bars in and fitted:



This kit fits so nice, all pre notched and bent to perfection. very little fitment was done.

With all the uppers in place and welded as much as possible, Cage went through the floor to finish the welds.





Cage back up and floor welded back in:


Strut top braces and rear bars complete



Thats as far as I am on the cage. I'm working on the forward bars and front strut towers now, I'll post more when I progress farther. This kit came with no instructions, just a diagram pic that I posted earlier. Its been a slow build doing short sprints after long days of work. I'll post more as I get along and keep updating the thread.

This is my first rally car build so if you have any input I appreciate constructive criticism. It is T45 chromoly and I'm mig welding it with ER80S-D2 wire which was specified with the cage manufacture. It'll be FIA certified when I complete the cage and send off my pics, the test sample is allready certified.

I'm located just south of Spokane. If you are an experienced builder and have any useful tips or pointers to a good rally build, please let me know and perhaps you could come check it out and point out any thing I've missed or need to do.

As far as this being my first rally car and esentially rally events, I should pass for an unlimited license with my racing background. I've talked with Mike Hurst with rally america and it sounds like he would pass me for an unlimited license, I just need to send it in writing. I've been a professional motorcycle racer for many years including: AMA Hare and hounds, AMA Road-race, Enduros, Flattrack, Motocross, and Hare Scrambles. Also since 2008 an avid autocross, rallycross, and drift event participant. If I dont get an unlimited license hopefully I can run a 32mm restrictor or just put it to NA and run the open lights class.

Thats about it, enjoy my build and hopefully you will see me out there next year if all goes well.
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Last edited by 364seehorn; 11-25-2013 at 04:59 PM.
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Old 09-27-2013, 05:58 PM   #2
imac6471
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2004 FXT "Tucker"

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Subscribed! This should be good.
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Old 09-27-2013, 08:24 PM   #3
Ryan24
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2008 Legacy GT Limited

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You will more than likely need to convert it to an NA car until you get enough coefficient points to move into Super Production or Open Class
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Old 09-28-2013, 02:11 AM   #4
364seehorn
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Join Date: Oct 2010
Chapter/Region: NWIC
Location: Spokane
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05 STI Rally Car
Aspen White

Default

Yeah I'll have to see what they decide. One guy i know got his unlimited license and we have similar resumes except I have done ama pro road racing and supermoto. I grew up racing enduros and desert on motorcycles, which I believe are very similar. Well besides we have no Co-driver and you just have to be good at reading unknown terrain. Hopefully I can start in SP, if not I guess off comes my turbo.
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Old 09-28-2013, 12:03 PM   #5
Ryan24
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2008 Legacy GT Limited

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Good luck and welcome to the sport, I sometime regret selling my old car but I am slowly getting another car built, might take me a few more years but I do plan to be out there on the stages again. Not sure if you are interested in another set of rims and tires but I have some team dynamics +40 offset 5x100 wrapped in BFG 195/70/15 that I might consider selling...too large of a tire for my RS and wrong offset rims for me to use
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Old 09-28-2013, 03:43 PM   #6
364seehorn
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Join Date: Oct 2010
Chapter/Region: NWIC
Location: Spokane
Vehicle:
05 STI Rally Car
Aspen White

Default

Some more pics of the rebuild, this car hit a bank on the right front and rolled to a stop on it's left side. Took 2 new front fenders, front bumper cover, both left doors, A-Piller section, and window weatherstriping and trim (EXPENSIVE!!)









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Old 09-28-2013, 04:01 PM   #7
364seehorn
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Join Date: Oct 2010
Chapter/Region: NWIC
Location: Spokane
Vehicle:
05 STI Rally Car
Aspen White

Default

Other bits and pieces I got so far:

Wheel:


Hand Brake, Not installed yet just playing with position.




Seats: OMP HTE


More Cage pics











This one is cool, my Dad's project and mine side by side. My Mom bought that cuda brand new in 73. He's been on that car for 10 years now, lets hope mine gets done before his!

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Old 09-28-2013, 04:09 PM   #8
Hebidoshi
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That's awesome!!
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Old 09-30-2013, 07:21 PM   #9
TCh
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Chapter/Region: NWIC
Location: Snohomish WA
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WRB

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Nice! Subscribed...
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Old 10-12-2013, 04:40 PM   #10
364seehorn
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Member#: 262021
Join Date: Oct 2010
Chapter/Region: NWIC
Location: Spokane
Vehicle:
05 STI Rally Car
Aspen White

Default

I also have all the stock interior to get rid of if anyone wants to throw offers out there. Minus the complete dash and console and seats are sold. AC compressor and components are also coming off.
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Old 10-12-2013, 05:20 PM   #11
Ryan24
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2008 Legacy GT Limited

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Just food for thought, when I ran the first Idaho rally the temps were around 100+/- and we ran our AC on transits

Sometimes a little comfort out ways a little weight savings
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Old 10-14-2013, 07:18 PM   #12
364seehorn
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Join Date: Oct 2010
Chapter/Region: NWIC
Location: Spokane
Vehicle:
05 STI Rally Car
Aspen White

Default

Okay, I was thinking the extra air flow through the radiator with the condensor removed was the reason people scrapped the AC. Do you run an aftermarket radiator with AC and have no issues with overheating? I know I had cooling issues when I tracked my 08 STI with the stock radiator, I put an aftermarket on there after but never got a chance to track the car before I got rid of it.
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Old 10-14-2013, 08:04 PM   #13
364seehorn
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Member#: 262021
Join Date: Oct 2010
Chapter/Region: NWIC
Location: Spokane
Vehicle:
05 STI Rally Car
Aspen White

Default

By the way Ryan24, your wheels wont work on my 05 I have 114 hubs. However I may be interested in the tires, are they used or new?
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Old 10-14-2013, 09:27 PM   #14
Ryan24
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2008 Legacy GT Limited

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My original car had a 1.8L motor, I wasn't putting out as much heat as a turbo car does
The extra air flow does make sense as the condensor will be out of the way, I would reccomend a roof scoop though as it does help.
Tires are new with only some pavement and one rallycross on them, the nubs on the sidewallls are still on
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Old 10-15-2013, 03:58 PM   #15
364seehorn
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Join Date: Oct 2010
Chapter/Region: NWIC
Location: Spokane
Vehicle:
05 STI Rally Car
Aspen White

Default

Okay, I'll ask around about what other guys are doing with AC, i thought it'd be nice to have while sitting at stages too.

How much are you asking for the tires?
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Old 10-15-2013, 04:47 PM   #16
Hendo783
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Location: NW US, Oregon
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2004 Sti Rally built
WRB

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We stripped our AC out, and have only missed having cool air once, at theis years Mendocino Rally (it was 108 on Saturdays stages). . . most other teams that ran AC had overheating issues on stage. . .

Nice build, see you on stage!!
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Old 10-16-2013, 03:58 AM   #17
Dragonbreak
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Location: Seattle, WA
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Black

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Awesome build! Subscribed!!

Question: Do you have a significant other? I'm wondering what I might be able to get into if I don't have someone nagging at me, hopefully my gf doesn't find this.
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Old 10-16-2013, 06:07 PM   #18
364seehorn
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Member#: 262021
Join Date: Oct 2010
Chapter/Region: NWIC
Location: Spokane
Vehicle:
05 STI Rally Car
Aspen White

Default

Haha! Yes I do, she actually is really into racing so I don't have to explain myself at all She really wants to co-drive for me next year, but I think I'm going to have an experienced co-driver for a bit till she can prove herself. I met her when I was instructing at a Motorcycle trackday, if that gives you a heads up on where to find a "new" cool girlfriend! Goodluck buddy
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Old 10-17-2013, 11:35 AM   #19
364seehorn
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Join Date: Oct 2010
Chapter/Region: NWIC
Location: Spokane
Vehicle:
05 STI Rally Car
Aspen White

Default

Getting the forward strut bars done last night, kind of a puzzle.



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Old 10-19-2013, 11:21 AM   #20
jibber
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01 allroad

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Looking good! It is nice to see a proper build.

When we were running 2L turbo Subarus. We only ran into any issues before we switched to water wetter in AZ. Once we changed out too almost full water and water wetter we had no more issues. This was a completely stock cooling system otherwise. We were running a air to water intercooler that we had converted the AC condenser for.
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Old 10-21-2013, 09:23 PM   #21
6SpeedLove
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This is cool. Nice work. Well thought out, organized and executed. I hope to have the opportunity to put something together like this in the near future.

Thanks for sharing!
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Old 10-31-2013, 12:00 PM   #22
364seehorn
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Member#: 262021
Join Date: Oct 2010
Chapter/Region: NWIC
Location: Spokane
Vehicle:
05 STI Rally Car
Aspen White

Default

Forward bars, door bars, and floor plates all welded complete. This is quite a process. The forward bars have to be tacked in, then welded as much as you can up by the firewall and on the door bars. Then you untack the strut bars and take them out and weld the T complete out of the car. Then put the strut bars back in place. Then pull the forward hoop away from the pillar with a ratchet strap and finish the door welds. Then weld the strut bars to the forward hoop as much as possible then pull them away from the pillar again and weld behind, which required a mirror on the lower welds and a lot of swearing!



Door Gussets



Fitting dash in, needs to come up a bit then weld on the column bracket

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Old 10-31-2013, 12:15 PM   #23
tazswing
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2011 STi hatch

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Very cool. I love cages. One of the main reasons I have never gone full 10/10ths on the fast parts of any track on lapping days is the lack of one on my OE safety equipment car.

Really fun to see progress documented like this. I love build threads!
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Old 11-23-2013, 03:12 PM   #24
364seehorn
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Member#: 262021
Join Date: Oct 2010
Chapter/Region: NWIC
Location: Spokane
Vehicle:
05 STI Rally Car
Aspen White

Default

More Progress, Main hoop X bars in with gussets and fitting hans bar





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Old 11-23-2013, 03:28 PM   #25
whis9
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Nice looking cage
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