Insanity-74s ST205 Rally Hybrid build

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Re: Insanity-74s ST205 Rally Hybrid build

Postby Insanity-74 » Fri Oct 24, 2014 4:49 pm

Test fit of the brake master cylinder, complete with brand new internals, the last stage of the brake jigsaw, everything is / will be brand new apart from the callipers and the master cylinder body.

I wonder how many leaks I will have first go?

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Re: Insanity-74s ST205 Rally Hybrid build

Postby Insanity-74 » Sat Apr 11, 2015 8:24 am

Back to the project :) now the weather has warmed up'

the second coat of primer.

[url="http://smg.photobucket.com/user/nialusa/media/Celica%20Rebuild/P1010940_zpsvpl2inzu.jpg.html"]Image[/url]

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[url="http://smg.photobucket.com/user/nialusa/media/Celica%20Rebuild/P1010934_zpsp3jtj05f.jpg.html"]Image[/url]

hopefully the first layer of colour next weekend :)
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Re: Insanity-74s ST205 Rally Hybrid build

Postby Corey » Sat Apr 11, 2015 2:10 pm

This is amazing. I just flipped back through the thread. Its going to be cleaner than when it rolled off the factory floor !
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Re: Insanity-74s ST205 Rally Hybrid build

Postby Insanity-74 » Mon Apr 13, 2015 7:49 pm

Got some colour put on the other day, managed to hand paint on some extra tough 2K lacquer. its not perfect but to be honest I am not that bothered, its just for protection as it will be covered by carpet etc......the engine bay is better. Some more of the 2K lacquer will arrive in the next day or so, I will then spray it onto the rest of the engine bay and finish the interior. Then i will be ready to install the brake lines, wiring and interior. Busy weeks ahead :)

My little garage with my cramped working space :)

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the interior - front

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and the back

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the boot...slight problems in the wheel well, but again it will be covered by sound deadening etc so as long as the rust protection is there i aint bothered.

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hopefully by the end of the week it will be all shiny :)

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Re: Insanity-74s ST205 Rally Hybrid build

Postby Insanity-74 » Mon Apr 20, 2015 5:52 pm

A few more parts added........

Brake & Clutch Pedals & Dash beam thing (whatever its called)

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From the engine bay

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Re: Insanity-74s ST205 Rally Hybrid build

Postby CMS-GT4 » Mon Apr 20, 2015 6:15 pm

Is that a standard st205 spare? I assume that is designed that way to clear the brakes.
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Re: Insanity-74s ST205 Rally Hybrid build

Postby Insanity-74 » Mon Apr 20, 2015 8:21 pm

Yes, it's one of those stupid space saver wheels. Utter garbage, basically a get you off the motorway wheel. Limited to 30mph and about 5 miles distance. I usually carry a ful size spare, but using four of these as transport wheels so I don't damage the alloys.
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Re: Insanity-74s ST205 Rally Hybrid build

Postby Insanity-74 » Thu Apr 23, 2015 6:16 pm

There should be a bit of progress every day now :)

Todays fun and games....brake lines. it dosent look like i have done much, but alot of time is spent retapping bolt holes and cleaning threads up.

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I am having to rebend the brake lines as they dont quite run parallel to each other, but thats an easy fix.

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I also started to fit the closed cell foam (sound deadening) to the roof, its very light, weighs almost nothing, but its a bit expensive for what it is. the floor, bulkhead, roof, door insides, boot floor will all get covered in it :)

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Re: Insanity-74s ST205 Rally Hybrid build

Postby WarTowels » Tue Apr 28, 2015 3:59 pm

Yum
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Re: Insanity-74s ST205 Rally Hybrid build

Postby Insanity-74 » Tue Apr 28, 2015 7:06 pm

tackled the recaros today....well one of them. i tried one of the ebay bolster suppliers and the quality is spot on, so i will purchase the other bolster for the other seat later.

You can see the split in the foam.

[url="http://smg.photobucket.com/user/nialusa/media/Celica%20Rebuild/P1010976_zpslibb4qcd.jpg.html"]Image[/url]

Under the foam there is a metal support ring, it is this that cuts through the foam making the split. The bolster has this bit re-inforced but i guess old age has taken its toll.

with the bolster replaced

[url="http://smg.photobucket.com/user/nialusa/media/Celica%20Rebuild/P1010977_zpsvpc8rgsd.jpg.html"]Image[/url]

its a pretty easy job to do to be honest, i was expecting it to be harder, about ten mins to do a bolster from start to finish.

I think thats it for today...i had planned on doing more but Jo has bought me some beers and the last Hobbit DVD so its feet up time :)

back on with it tomorrow :)
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Re: Insanity-74s ST205 Rally Hybrid build

Postby Insanity-74 » Tue Apr 28, 2015 7:07 pm

Painting the roll cage...this is hopefully the last bit of major painting to do until i decide to tackle the outside. Its a rubberised & textured enamel, goes on with some force, but dries nicely.

The roll cage in all its masked off glory :)

[url="http://smg.photobucket.com/user/nialusa/media/Celica%20Rebuild/P1010978_zpsxwwwadgs.jpg.html"]Image[/url]

[url="http://smg.photobucket.com/user/nialusa/media/Celica%20Rebuild/P1010980_zpsw12k7zdl.jpg.html"]Image[/url]

[url="http://smg.photobucket.com/user/nialusa/media/Celica%20Rebuild/P1010979_zpsspkjp0fd.jpg.html"]Image[/url]

tomorrows task is to finish a bit more sound deadening on the firewall then start refitting the loom which i started refurbishing at the weekend.
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Re: Insanity-74s ST205 Rally Hybrid build

Postby Mr Alltrac » Tue Apr 28, 2015 9:46 pm

Are you actually planning to rally this or is it just gonna be a street car you go have fun with on occasion?

I would never take that much care and time in a project just to take it off-road and have the paint get chewed up.
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Re: Insanity-74s ST205 Rally Hybrid build

Postby Insanity-74 » Wed Apr 29, 2015 4:28 am

It's just a weekend toy :) .......as you say, I wouldn't take this off road, I would cry too much if I ruined the paint....or crashed it :doh: the way things are here, it will be lucky to be taken out of the garage :lol:
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Re: Insanity-74s ST205 Rally Hybrid build

Postby Insanity-74 » Fri May 01, 2015 4:08 pm

Having trouble getting photobucket to work so there's an update on my facebook page :)

https://www.facebook.com/groups/EONRaci ... tif_t=like
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Re: Insanity-74s ST205 Rally Hybrid build

Postby Insanity-74 » Mon May 04, 2015 2:00 pm

Seats and carpet in :)

[url="http://smg.photobucket.com/user/nialusa/media/Celica%20Rebuild/P1010995_zps1msgierb.jpg.html"]Image[/url]

I can sit in it now and make "brum brum psssssst" noises.

There will be a full dash going back in, just need to get it all painted etc now.

[url="http://smg.photobucket.com/user/nialusa/media/Celica%20Rebuild/P1010992_zpshikmgqeu.jpg.html"]Image[/url]

Looking good.

[url="http://smg.photobucket.com/user/nialusa/media/Celica%20Rebuild/P1010991_zpsznsqtjal.jpg.html"]Image[/url]

Good clearence with the roll cage, even with the seats as far back as they will go :)

[url="http://smg.photobucket.com/user/nialusa/media/Celica%20Rebuild/P1010994_zpsowlivbpk.jpg.html"]Image[/url]

Brum brum.........yes yes, dont laugh, I hate having my photo taken at the best of times.....but theres a face that says "If my wife takes any longer to take this photo, my smile muscles are going to give up"

[url="http://smg.photobucket.com/user/nialusa/media/Celica%20Rebuild/P1010993_zpskogkx35s.jpg.html"]Image[/url]

Time for a well earned rest, got some decorating to do. might give this project a rest for a couple of weeks and catch up on the household chores.
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