Rallysport ST165 Build

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Rallysport ST165 Build

Postby texturboII » Mon Aug 26, 2013 2:08 pm

Hey there everybody, I'm starting this thread to document the building / resurrection of a nice little st165 I found local to me. A couple of my buddies and I decided to get into Rally Racing and were looking for a proper machine to throw around turns and I found it, a black 1988 Alltrac. Our goal is a full race-rebuild and we've got a lot of work ahead of us. Here she is when we picked her up:

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and we'll be attempting to turn it into something like this:

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SO, we've got a lot of work to do. The engine bay is a wreck, the exhaust manifold is off, nothing is connected and the exhaust ports have been uncovered for god knows how long, the harness is just laying in there, air box and ducts are non-existent, etc... but we got it into it's new home: my tiny ass garage.

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and we started by stripping the interior...

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We were going to pull the engine this last weekend but years of "moving attrition" has stolen a lot of my tools, so we spent the weekend getting a hoist put together and buying jack stands and other needed tools. We did manage to clear the engine bay a bit. Pulled the radiator, and a few other accessories.

Here's the team, other than myself:

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My friend and his little brother, we are going to turn him into a pro WRC driver, lol. It's going to be a learning experience! I've never worked on an AWD platform before, heck I've never worked on a piston engine before, lol! I'm a rotorhead myself and moved to the alltrac after building 4 rx-7's over the past 7 years or so. Hopefully I'll have some more images and updates over this week, I'll be getting her up in the air and inspecting everything underneath. From what I can tell, rust isn't an issue and everything looks pretty good so far.

Thanks for looking, I'm sure I'll have a hell of a lot of questions and I look forward to any input y'all may have.
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Re: Rallysport ST165 Build

Postby texturboII » Mon Aug 26, 2013 2:09 pm

Looks like I'm going to have to work on properly sizing my pics too, lol.
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Re: Rallysport ST165 Build

Postby Redrkt01 » Mon Aug 26, 2013 8:37 pm

Welcome!

Over in the UK and sometimes here in North America you can find the "Repsol" Body kit floating around. I think there is one guy in Canada who has it and at least two in the UK. One was up for sale about a year ago. It might still be around.....if you were to get one you'd have the look going for you.
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1988 ST165 Red Parts Car
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Re: Rallysport ST165 Build

Postby klue » Mon Aug 26, 2013 10:01 pm

welcome good luck with your build!
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Re: Rallysport ST165 Build

Postby fussellbug » Tue Aug 27, 2013 11:47 am

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Re: Rallysport ST165 Build

Postby MWP » Tue Aug 27, 2013 1:53 pm

I think stickers will be the least of their worries :rofl:

Have you guys rallied before?
Make sure you check rally regulations for what is required.
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Re: Rallysport ST165 Build

Postby texturboII » Tue Aug 27, 2013 6:09 pm

Haha, yes. Stickers are the last thing on the list, lol. However, I do appreciate the enthusiasm...
The Factory Service Manual came in last night and I spent the whole evening reading through it. Wonderful reading material (sarcasm) with lots of pictures though...

And no, I've never rally'd before. I've done plenty of racing though, just never in the dirt. We've got access to a piece of land out in the middle of nowhere to hone our skills. As far as regulations go, the group we will be racing with is pretty lax. As long as it doesn't leak they'll allow it... Maybe later on we'll have to worry about WRC regulations, lol. (ya right)
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Re: Rallysport ST165 Build

Postby Sluice Box Hero » Wed Aug 28, 2013 12:04 am

im working on a stand along harness for my 165. once i get it figured out and tested ill post up my wiring diagram if youre interested. there is about 50lbs of wire and bullshit controllers you can pull out of that car. with a simple chassis harness, ignition on, and a push button start you should be good to go.

good luck with the build.

also. . . anyone else notice in the rally pic it looks like the rear tires are quite a bit taller than the fronts? i wonder if this was their solution for a rear wheel power bias these cars lack. . . . .
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Re: Rallysport ST165 Build

Postby texturboII » Wed Aug 28, 2013 12:19 am

That would be a great help! We are debating between standalone or not right now, REALLY leaning towards a standalone EMS... Which are you using?
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Re: Rallysport ST165 Build

Postby Sluice Box Hero » Wed Aug 28, 2013 1:30 am

I'm just stripping the stock harness to the bare minimums. I'm running 90% stock right now, so no need for a after market fuel management system yet.
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Re: Rallysport ST165 Build

Postby texturboII » Wed Aug 28, 2013 4:43 am

Gotcha, yea please let me know what you've figured out. If it doesn't help me it will help others!! I'd like to keep it as stock as possible, but it seems a lot easier to just rip it all out and start from the beginning... But I'd never learn these cars that way, right? Lol.
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Re: Rallysport ST165 Build

Postby texturboII » Mon Jan 20, 2014 2:04 pm

Alright! It's been too damn long, finally got off our lazy asses and had some decent weather this weekend and got back to work a bit. Moreso organizing than anything else, which is an important step, really. But we made progress and set goals. A few pics:

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Considering that the front-end of the car was hanging from a Cherry Picker for 3 months and you couldn't even walk into the garage until yesterday, I'm stoked!

So, now we're going to get the engine over to my buddy's place to start tearing it apart and rebuilding it. That happens Wednesday. Then it's deciding on an EMS, getting a harness wired up and installed, etc... New bushings, shocks and springs, clean it up real nice and re-install everything. We're not going real big right now, just planning to max out the stock turbo and engine; we're hoping for 280hp or so, which I think is very plausible.



Yea, buddy :icon_tup:
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Re: Rallysport ST165 Build

Postby texturboII » Fri Jan 24, 2014 2:10 pm

Okay, so we ripped the engine apart last night. And it was a damn good think we did! The pics can tell the story.

So the water pump came off and we saw this mess:
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Gross.

Next, the head came off and we found at least one valve that didn't look quite okay.
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Hmmmmm, something doesn't seem quite right here:
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Something went wrong.... hmmmmmm....
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Popped off the oil pan and sure enough:
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Check this one out, ouch! :owned: :
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Our guess is that somebody upped the boost and ran the shit out of it. It possibly overheated as well, the oil smelled pretty bad and there was a little coolant where there shouldn't have been. Ugh, come to think of it I don't remember seeing a head gasket at all! So I guess the next step is checking to see if the head is warped or not, and get a bottom-end rebuild kit. Jeez, what a nightmare. :pissed:

Oh well, marching forward... New bushings for the suspension have been ordered and I'm waiting on some feedback as far as shocks and springs go. We've got a quote to get the transmission rebuilt, because racecar, and I definitely don't want to have to pull the powerplant out again for a busted transaxle, lol.
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Re: Rallysport ST165 Build

Postby rallygarage » Fri Jan 24, 2014 6:04 pm

Best of luck and beware that other then suspension, rear diff and engine computer there is virtually no Celica specific rally parts available for this car. You will be fabricating everything yourself if you want it right. Some items are cost prohibitive. It looks like you are serious. You will be better off with Subi or Mitsu.
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Re: Rallysport ST165 Build

Postby texturboII » Fri Jan 24, 2014 7:25 pm

I've thought of that, but I really like what we've got going so far and for the racing we will be doing there isn't too much that we'll need to get the car up to par other than basic suspension components and getting the thing running. The dream pic of the old toyota car is what we'd like to look like but not near the level that we would be competing, lol. However, if we get more and more interested and more experienced in rally we may go another direction in the future, who knows. Thanks for the input!
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