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Insanity-74s ST205 Rally Hybrid build

Mon May 07, 2012 5:47 pm

OK, this is my project build thread, I will try and make it as interesting and informative as possible but the early stages might be a bit mundane so bare with me, I will do my best.

The story starts about 6 months ago when I finally purchased a house that had its own garage……its not very big, but luxury compared to having to work on the street like my old house. This enabled me to follow my dreams and do a full on nut and bolt rebuild of an ST205…..after owning one for 8 years it was time to own another one.

After about 10 whole minutes of looking I found just the car I was after (sorry, st205s are plentiful in the UK and go very cheaply now)

After a trip in a low loader (I don’t know what they call them in the US…but a truck that is built to carry a car) I finally arrived home with this

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I failed miserably with the photograph here, I should have taken a picture of it turning up but hey ho. It had cost me £500 which is what? About $700 It is basically a complete car without an engine….I don’t need the engine because as of this time I plan on going 5sgte, but things may change, time will tell.

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So work began

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I need to strip out all the interior, the suspension, cross members, fuel & brake lines, electrical looms, glass…..etc…you get the picture.

My plan is to make a rally hybrid……what do I mean by a rally hybrid…well half rally car, half road car……it will have a roll cage, anti lag, bucket seats etc just like the rally cars did…it will also have a good stereo, carpets and some home comforts so I can drive it on long journeys and not arrive at my destination feeling like I have been beaten with a hammer.

First task….strip the interior out, plastics, carpets, seats loom the lot.

Seats arnt in bad condition, but not needed so have to go

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Carpets are good too…going to keep those as good carpets are hard to come by

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a few notes

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The interior was coming out nicely…took the screen out to make things easier

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struggling to find space to store all the interior parts

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Removed the rear crash bar (I will be using it later for a rotisserie)

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Dash out along with all the air conditioning parts

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Toyota optional extra pedals…think I will keep those too

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rest of the dash etc removed

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I removed all the sound deadening material…what a pain this was, using a cold chisel and lots of time it took me about a week to remove all the sound deadening material…….it also weighs about 7KG in total so it will save a bit of weight.

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a bare naked interior

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By this stage I had also removed most of the engine bay parts and wheeled it outside for a wash

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Pretty clean through out

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As I was relocating the battery to inside the car I no longer needed the battery tray

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there it was….gone!!!!!!

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My next task was to remove the suspension, brakes etc and gain access to the underside of the car to remove the seam sealer and underbody protection that is very badly applied at the factory.

To enble this I had to make a rotisserie

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Finally made…having not only never welded before but not owning a welding machine I had to go out, buy a welding machine and then learn to weld.

Not too bad for one of my first attempts

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rotisserie coming along well and fully functioning

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Once this was working it was time to remove the sub frames and suspension…….i sent the sub frames off to get sand blasted and upon return painted them with POR-15

Look pretty good

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same with the drive shaft (soory about the poor photo

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Stripped and refurbished the steering rack

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and polished the rear diff end plate

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time to start stripping off the underseal and seam sealer

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what a horrible jon

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after about 2 weeks work of doing nothing else but remove underseal

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oh…I did blast and repaint some more cross member sections

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same treatment for the rear suspension arms

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nearly finished

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Sooo much more to do, but that’s about where I am up to…it will be a slow process but eventually its going to be awesome.
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Re: Insanity-74s ST205 Rally Hybrid build

Mon May 07, 2012 6:03 pm

Sweet im the first post! Its gonnnnnnna beeeeeee siiiiiiiiiick!!!

Re: Insanity-74s ST205 Rally Hybrid build

Mon May 07, 2012 6:12 pm

I did have a bit of prep work to do before this build could start......as I only have a small single car garage I had to build an "extension" nothing too flash as I didnt want to fall foul of building regulations. I had to make it out of wood and it couldnt be too big.

The back of the garage with the start of the extension being built

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Finished and clad...I even added a bird feeder so the local birds could get some food

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and a bit of decoration

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from the inside

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Re: Insanity-74s ST205 Rally Hybrid build

Mon May 07, 2012 6:15 pm

Made me hungry

Re: Insanity-74s ST205 Rally Hybrid build

Mon May 07, 2012 6:15 pm

Awesome start to a quality resto and upgrade. I can't wait to see where this goes!!

Re: Insanity-74s ST205 Rally Hybrid build

Tue May 08, 2012 5:59 am

Woah, awesome start to the build.
Great to see you doing it all properly!

So what is your aim?
I know you said Rally Hybrid... but what will the car be used for?

Re: Insanity-74s ST205 Rally Hybrid build

Tue May 08, 2012 6:38 am

subscribe to this awesome thread.
that is all :D

Re: Insanity-74s ST205 Rally Hybrid build

Tue May 08, 2012 10:30 am

MWP wrote:Woah, awesome start to the build.
Great to see you doing it all properly!

So what is your aim?
I know you said Rally Hybrid... but what will the car be used for?


Basically its going to be a weekend toy.

Re: Insanity-74s ST205 Rally Hybrid build

Tue May 08, 2012 5:08 pm

I did manage to secure this with a bit of bartering.

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It'll be a long while before it gets onto the car, time to put it somewhere safe...and try not to forget about it :lol:

I have some TTE Style rally mirrors but i have already put them somewhere safe....and cant remember where :shrug:

Roll cage parts will be arriving soon so some of the more fun stuff can start soon 8)

Re: Insanity-74s ST205 Rally Hybrid build

Tue May 08, 2012 5:16 pm

Did you weight all the soundproofing and under material you removed? I am curious how much that reduces the weight of the car.

Re: Insanity-74s ST205 Rally Hybrid build

Tue May 08, 2012 5:19 pm

CMS-GT4 wrote:Did you weight all the soundproofing and under material you removed? I am curious how much that reduces the weight of the car.


I weighted the interior sound proofing which IIRC was about 7Kgs.......the under car stuff is in a nice little pile which i will bag up and weigh when I have finished.....its at least going to be a few kgs...I guestimate that both combined will weigh about 10-11Kgs

Re: Insanity-74s ST205 Rally Hybrid build

Tue May 08, 2012 5:33 pm

Insanity-74 wrote:I did manage to secure this with a bit of bartering.

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It'll be a long while before it gets onto the car, time to put it somewhere safe...and try not to forget about it :lol:

I have some TTE Style rally mirrors but i have already put them somewhere safe....and cant remember where :shrug:

Roll cage parts will be arriving soon so some of the more fun stuff can start soon 8)



I really hate you right now

Re: Insanity-74s ST205 Rally Hybrid build

Tue May 08, 2012 5:48 pm

tubasteve wrote:I really hate you right now


Sorry Steve...I'll try not to post anymore pictures that may incur more hatred :lol: :lol: :lol: :lol:

Re: Insanity-74s ST205 Rally Hybrid build

Tue May 08, 2012 6:12 pm

I like this thread, i look forward to looking at more posts in the future :)
keep at it :D

Re: Insanity-74s ST205 Rally Hybrid build

Tue May 08, 2012 6:16 pm

Ohhhhh man do I want one of those
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