I know what you mean but it would still be a great attraction
Project ZR Evo
12
Some of you will have seen the evo bits in the workshop recently, but now it's time for the build. I'll just go through the pics and explain along the way.
The donor car was a front and rear smashed (spun) Evo 9 FQ300 (with only 3000miles on it!!). I only got the running gear, and not all of it, the interior and chassis was returned to the seller. The front brakes were missing and a few of the rear suspension arms were bent and the hub carrier broken.
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The floorpan was cut out for all the rear suspension mounts and prop mounting.
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Picture taken for reference.
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The ECU's removed, and you'll see the full wiring loom attacted to the engine still.
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Before anything else can be done, the broken parts that need to be used would require fixing.
The timing belt cover was broken, as well as a chip out of the bottom pulley, so this week i got a new timing belt cover from a dealer.
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Ive fitted the bottom cover, but also need to sort out the powersteering pump and an aux belt idler which both have bent pulleys.
The gearbox also had broken where the front mount bolts on, so the gearbox was removed, and welded up, then refit to the engine.
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Work also started on the rear hubs, i removed one from the broken carrier to use as a test. the holes were welded up, then the face shall be machined flat again, and the center machined for the wheel center as well as being redrilled.
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#
I also gave some parts to nathan25 as he's going to work his magic with them.
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Rocker cover removed.
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Next job is to start fixing the rear suspension, get it bolted up into the floorpan and make some fixed bars instead of the springs and dampers so i can get the height and wheel angles set up.
I'll be updating this thread every few days/week with progress as progress happens, but it's also on other forums, so you may want to check these too.
Adrian
AAautosport
www.aaautosport.co.uk
The donor car was a front and rear smashed (spun) Evo 9 FQ300 (with only 3000miles on it!!). I only got the running gear, and not all of it, the interior and chassis was returned to the seller. The front brakes were missing and a few of the rear suspension arms were bent and the hub carrier broken.
The floorpan was cut out for all the rear suspension mounts and prop mounting.
Picture taken for reference.
The ECU's removed, and you'll see the full wiring loom attacted to the engine still.
Before anything else can be done, the broken parts that need to be used would require fixing.
The timing belt cover was broken, as well as a chip out of the bottom pulley, so this week i got a new timing belt cover from a dealer.
Ive fitted the bottom cover, but also need to sort out the powersteering pump and an aux belt idler which both have bent pulleys.
The gearbox also had broken where the front mount bolts on, so the gearbox was removed, and welded up, then refit to the engine.
Work also started on the rear hubs, i removed one from the broken carrier to use as a test. the holes were welded up, then the face shall be machined flat again, and the center machined for the wheel center as well as being redrilled.
I also gave some parts to nathan25 as he's going to work his magic with them.
Rocker cover removed.
Next job is to start fixing the rear suspension, get it bolted up into the floorpan and make some fixed bars instead of the springs and dampers so i can get the height and wheel angles set up.
I'll be updating this thread every few days/week with progress as progress happens, but it's also on other forums, so you may want to check these too.
Adrian
AAautosport
www.aaautosport.co.uk
21 - 40 of 57 Posts
5
Got all the rear suspension built onto the rear floorpan.
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Onto the driveshafts, the replacement for the goosed one, as mentioned earlier has a different end on it (not fitted with reluctor ring). It has not been machined for the ring either, which poses a bit of a problem. The plan is to try to use the end off the broken shaft, as is still in brilliant condition, but i'll need a new reluctor ring, as the original has a tooth missing.
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So, need to get the reluctor ring sorted, the hubs and disks sorted for 4x100 PCD, the get the height set and the damper replaced with solid bars so the rear geometry can be set before getting on the car, then small adjustments can be made once all welded in.
Adrian
AAautosport
PS, sorry about the early pics, i'm having to use the companies account to host the latest pics till i sort a better hosting method.
Onto the driveshafts, the replacement for the goosed one, as mentioned earlier has a different end on it (not fitted with reluctor ring). It has not been machined for the ring either, which poses a bit of a problem. The plan is to try to use the end off the broken shaft, as is still in brilliant condition, but i'll need a new reluctor ring, as the original has a tooth missing.
So, need to get the reluctor ring sorted, the hubs and disks sorted for 4x100 PCD, the get the height set and the damper replaced with solid bars so the rear geometry can be set before getting on the car, then small adjustments can be made once all welded in.
Adrian
AAautosport
PS, sorry about the early pics, i'm having to use the companies account to host the latest pics till i sort a better hosting method.
3
Update.
After trying to weld the old hubs up for redrilling, it was decided that it was a bad idea with the amout of stress these will take, after how the original metal didn't take too well to welding. Along with this and the fact that one breaking could have serious implications on safety, i decided to get some made.
I picked this up from the machine shop today, it's not quite right, of which i will comment on when i have the finished articles. (let's just say i'm not a happy chap).
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After trying to weld the old hubs up for redrilling, it was decided that it was a bad idea with the amout of stress these will take, after how the original metal didn't take too well to welding. Along with this and the fact that one breaking could have serious implications on safety, i decided to get some made.
I picked this up from the machine shop today, it's not quite right, of which i will comment on when i have the finished articles. (let's just say i'm not a happy chap).
Thanks for the Update
3
Finally got the hubs, on the third attempt at getting them right.... at least now they are.
Nathan came over with a caliper for trial fitment and all's perfect, didn't take any pics of it as he's not finished yet.
Anyway, the hubs,
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hubs and disks fitted, and even a rover 4x100 wheel. 300mm disks on the rear.
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The original problems i had when i picked up the first hub was that the bearing seat was not the correct distance from the disk seating face, changing the disk offset and the radious of the curve between the bearing seating face and the hub central shaft was too large, so the bearing would not go all the way down to the seating face.
Nathan came over with a caliper for trial fitment and all's perfect, didn't take any pics of it as he's not finished yet.
Anyway, the hubs,
hubs and disks fitted, and even a rover 4x100 wheel. 300mm disks on the rear.
The original problems i had when i picked up the first hub was that the bearing seat was not the correct distance from the disk seating face, changing the disk offset and the radious of the curve between the bearing seating face and the hub central shaft was too large, so the bearing would not go all the way down to the seating face.
Rover wheels were just used to make the rear end moveable around the workshop.
Thread bump!
There is progress... Been down last night to lend a hand and we got the rear of the Evo tucked into the ZR shell. It's by no means in place yet, but the hard work of getting the rear end anywhere near a ZR is done. :cigar:
21 - 40 of 57 Posts
