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Old 06-06-2021, 02:21 AM   #201
JDwhiteWRX
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Ok mega update time! this work has been going on over the past few weeks but I was saving it for one big post.

The steering rack is finally mounted in the chassis, here is the process...

First I wanted to have the ability to raise or lower the steering rack vertically just like the inner pivots on my control arms. This will allow me to fine tune the bump steer and also adjust the bump steer if I choose to move my control arms up or down.
To do this I would need some large and long bolts and something strong to mount then to.

Materials cut to size for the mounts

https://i.imgur.com/246kxoL.jpg?1

Tacked together

https://i.imgur.com/VBCMJLv.jpg?1

Fully welded

https://i.imgur.com/pvXIlzP.jpg?1

How they mount to the rack

https://i.imgur.com/VpyY2my.jpg?1

Then I decided to cut the frame rails further back to line up with the upper control arm mounts

https://i.imgur.com/J5uFFFu.jpg?1

https://i.imgur.com/C1ICng2.jpg?1

Cut out some end caps using CAD from 3mm plate.

https://i.imgur.com/U68rFq0.jpg?1

Welded the end caps on using Tig.

https://i.imgur.com/GIsWTDL.jpg?1

Then I created a bit of a jig to align the steering rack with the existing lower control arm mounts.

https://i.imgur.com/fTN83Jp.jpg?1

Then it was just a matter of cutting and notching some tube to connect the frame rails to the steering rack. I wanted to make the steering rack removable too so the engine could come out more easily. This required some extra work and captive nuts.

https://i.imgur.com/AG7cAg1.jpg?1
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Old 06-06-2021, 02:22 AM   #202
JDwhiteWRX
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https://i.imgur.com/Vdzbo6N.jpg?1

https://i.imgur.com/g4NpAlK.jpg?1

https://i.imgur.com/iQbsTzb.jpg?1

So these bits of tube can bolt together

https://i.imgur.com/WW9iaU0.jpg?1

Then the part of the tube with the captive nut inside was welded to the frame rail

https://i.imgur.com/25O2BdP.jpg?1

Then it was just a matter of some paint and bolt it all together.

https://i.imgur.com/eMghYj4.jpg?1

Looking at the detail you can see how the rack can be moved up and down. Some spacers will be required. Note the rack now has solid bushings too.

https://i.imgur.com/GdM7LOd.jpg?1

https://i.imgur.com/kQGS0yS.jpg?1

https://i.imgur.com/sGb8Fq1.jpg?1

I've tried to keep the design as simple and light weight as possible, I am kind of using the steering rack as a large brace to stiffen up the front end some more. I do have plans to add some kind of a vertical x-brace that can be bolted on to tie the whole front end together but I need to finish mounting my oil pump first so I know what space I have to work with.

As it is now though the steering rack is mounted very rigid as one mounting face is in the horizontal plane and the other is in the vertical.
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Old 06-08-2021, 05:58 PM   #203
Homemade WRX
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Looking on the app for the first time in forever...and holy cow, I don't ha e to click each picture to open it

With that rack mounting, I foresee it being able to bend/pivot quite easily. Even if staying single shear on the rack, I think a second point coming off of the chassis to triangulate would solidify it immensely.
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Old 06-08-2021, 06:58 PM   #204
JDwhiteWRX
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Sorry about the photos but I post this in a couple of forums so I dont want to upload photos to more than one place.

I will be adding more bracing to the rack but there are a couple more things I need to mount first so I dont run into any clearance issues.
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Old 06-09-2021, 09:54 AM   #205
Norm Peterson
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Quote:
Originally Posted by JDwhiteWRX View Post
Sorry about the photos but I post this in a couple of forums so I dont want to upload photos to more than one place.
If I only had to click on each link, that'd be one thing. But I have to click on each link to get the new tab, and then I have to click again on the little scrap of the picture that comes up in order to finally see the whole picture.

Is there some way of accessing the album directly?


Norm
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Old 06-09-2021, 10:14 AM   #206
aldiaz2
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Quote:
Originally Posted by Norm Peterson View Post
If I only had to click on each link, that'd be one thing. But I have to click on each link to get the new tab, and then I have to click again on the little scrap of the picture that comes up in order to finally see the whole picture.

Is there some way of accessing the album directly?


Norm

Tapatalk (app) is your friend for these things
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Old 06-09-2021, 10:35 AM   #207
Norm Peterson
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Originally Posted by aldiaz2 View Post
Tapatalk (app) is your friend for these things
I'm afraid that wouldn't work for me.

Is there an alternative that I can use from my laptop?


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Old 06-09-2021, 09:08 PM   #208
JDwhiteWRX
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This should be a link to the entire album but you won't know which image the text in my post is referring to.

BRZ https://imgur.com/a/8j6Nw44
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Old 06-17-2021, 01:33 AM   #209
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I have put some panels back on the car so that I can measure up the available space for the cooling package.

https://i.imgur.com/W7M6aGk.jpg?1

It's nice to see it like this, almost looks like a car again.

The amount of space in front of the engine is very good. I want to try and do a side by side arrangement for the intercooler and radiator if possible, if not then stacked will be good too.

This is just an old radiator from an Impreza for mock up purposes only.

https://i.imgur.com/m1jxARg.jpg?1

The airflow will be ducted in through the bumper and exit out the bonnet (hood). Entry and exit about 1/3 the size of the cooling package I believe is best practice?

https://i.imgur.com/lpLgbCX.jpg?1

I have also received and installed a large shipment of parts from TracTuff in the USA. Not everything is shown in the photos, some of it won't go in until later.

Water pump delete with integrated alternator bracket

https://i.imgur.com/ODCfM8h.jpg?1

I'm using a small D-series alternator but I might need something more powerful eventually.

https://i.imgur.com/5RYNiB6.jpg?1

This housing cleans up the back of the engine and directs the radiator hose in a more favorable orientation for a RWD car.

https://i.imgur.com/LT7D22n.jpg?2

This one deletes the water bypass since it is no longer required with an electric water pump.

https://i.imgur.com/IxgiJzO.jpg?1

These smaller fittings give me a place to remote mount my oil temperature and pressure sensor and provide a water feed for the turbo.
The larger fitting was part of my dry sump kit.

https://i.imgur.com/Q0Y6o6W.jpg?1
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Old 06-17-2021, 03:34 AM   #210
Zefy
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wow you really got that engine far back in the bay. Nicely done! So much room for activities.

You're keeping the factory brz power steering column right? I just put one in my impreza. It works really nicely even without the oem control system. Just runs in "emergency mode" with a fixed level of assistance.
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Old 06-17-2021, 03:50 AM   #211
speedyHAM
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Looking good!!! Keep up the good work. I can't wait to see this thing out on track.
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Old 06-17-2021, 06:39 AM   #212
JDwhiteWRX
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Quote:
Originally Posted by Zefy View Post
wow you really got that engine far back in the bay. Nicely done! So much room for activities.

You're keeping the factory brz power steering column right? I just put one in my impreza. It works really nicely even without the oem control system. Just runs in "emergency mode" with a fixed level of assistance.
Thanks, Yes I plan to use just the electric motor, the rest will be custom. How much assistance do you think its giving in emergency mode?
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Old 06-19-2021, 06:48 PM   #213
ether947
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Quote:
Originally Posted by JDwhiteWRX View Post
Thanks, Yes I plan to use just the electric motor, the rest will be custom. How much assistance do you think its giving in emergency mode?
I installed one on my WRX as well. It's a decent amount of assist in failsafe mode. More than I expected at least, but not easy to drive with one hand. I went from a 16.5:1 rack to a 13:1 rack at the same time so it's hard to say 100%.

I've seen BRZ guys complain about the p/s cutting out on them on the track. I'm not sure if they figured out the problem or not. I'm not sure if they are losing all power or if it is going into failsafe mode.

Also, these guys are kinda local to you if you want to try and dial in the assist.
https://www.agtengineering.com.au/pr...ering-emulator
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Old 06-20-2021, 12:28 AM   #214
JDwhiteWRX
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Originally Posted by ether947 View Post
I installed one on my WRX as well. It's a decent amount of assist in failsafe mode. More than I expected at least, but not easy to drive with one hand. I went from a 16.5:1 rack to a 13:1 rack at the same time so it's hard to say 100%.

I've seen BRZ guys complain about the p/s cutting out on them on the track. I'm not sure if they figured out the problem or not. I'm not sure if they are losing all power or if it is going into failsafe mode.

Also, these guys are kinda local to you if you want to try and dial in the assist.
https://www.agtengineering.com.au/pr...ering-emulator
I spoke with the owner of the V-sport 86, this one


and he said they never had a problem with the factory EPAS.

I've seen that option from AGT Engineering but its rather expensive for what it does. I'm hoping my standalone ECU can control it otherwise I'll try one of these https://www.ebay.com.au/itm/14403228...53.m1438.l2649
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Old 06-20-2021, 07:00 PM   #215
ether947
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That's pretty sweet, especially with him pulling +1.5Gs. I wonder if the cutout issue is for early models.

I saw that controller from eBay. I may order it just to see what it does.
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Old 06-20-2021, 11:23 PM   #216
JDwhiteWRX
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Quote:
Originally Posted by ether947 View Post
That's pretty sweet, especially with him pulling +1.5Gs. I wonder if the cutout issue is for early models.

I saw that controller from eBay. I may order it just to see what it does.
I believe the little dial in the kit will allow you to adjust the level of assistance which sounds perfect to me. You could wind it up in the pits and then dial it back down out on the track. I think I would prefer this over a constantly changing level of assistance with speed.
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Old 06-20-2021, 11:24 PM   #217
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My new wheels should be here within a week or so and to make sure I can get them straight on the car I had to fix a problem first.

The front Mazda RX8 hubs I'm using have a different size thread than the BRZ hubs on the rear. Luckily the RX8 wheel studs are smaller so I can drill them out and press in some BRZ wheel studs.

BRZ left, RX8 right.

https://i.imgur.com/2Mk2rqw.jpg?1

To do this properly the The drilled hole should be 0.20 - 0.25mm smaller than the knurl diameter of the wheel stud being pressed in. A 14.0mm drill made my hole 0.35mm smaller but considering the holes will be drilled in a press and not using the precision of a mill this was acceptable as the hole would end up slightly larger using the drill press as some movement will occur.

Holes drilled

https://i.imgur.com/Xkzl04C.jpg?1

BRZ studs in the freshly drilled holes, I started them in the vice and then took it over to my 12 tonne hydraulic press.

https://i.imgur.com/qyVmQ9b.jpg?1

and done.

https://i.imgur.com/CboLfkX.jpg?2

So now I don't have to worry about using different size wheel nuts at each end of the car. Ultimately I will buy new front RX8 hubs and press in some ARP wheel studs, this was just a proof of concept and allows me to put some wheels on and start the body work required to make them fit. The car is at least 80mm lower than stock so there is lots more cutting to do around the wheel arches.
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Old 07-01-2021, 02:36 AM   #218
JDwhiteWRX
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Old 07-01-2021, 08:43 AM   #219
Norm Peterson
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images not found


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Old 07-01-2021, 09:25 AM   #220
whozatguy
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images not found


Norm
When you click the link, delete the dereferer.org portion of the URL and reload, the pictures should come up.


Wheels look great!
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Old 07-01-2021, 11:51 PM   #221
Homemade WRX
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Quote:
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images not found


Norm
Odd. I use Chrome on my computer and I just click the link. On my phone app they all just show up.
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Old 07-02-2021, 06:17 AM   #222
JDwhiteWRX
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Things are really coming together now!

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Old 07-02-2021, 09:29 AM   #223
Norm Peterson
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Quote:
Originally Posted by JDwhiteWRX View Post
Things are really coming together now!

Thanks . . . and just, WOW!

I've been partial to small-bore road course cars since . . . geez, the mid-1960s. And owner-built "one-offs". Your build hits both points.


Norm
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Old 07-03-2021, 08:08 AM   #224
JDwhiteWRX
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Quote:
Originally Posted by Norm Peterson View Post
Thanks . . . and just, WOW!

I've been partial to small-bore road course cars since . . . geez, the mid-1960s. And owner-built "one-offs". Your build hits both points.


Norm
Thanks Norm!
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Old 07-03-2021, 08:09 AM   #225
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