Race-Certified Rally Car Project

Overview

Co-builder/designer/owner of a 2005 Subaru Impreza WRX race-ready rally car. The vehicle was initially purchased from a salvage yard in totaled condition. It turned over and drove, but would smoke and leak a significant amount of coolant. After two years we restored the vehicle to its stock operational condition, and have done a multitude of modifications required to rally race.

To aid in the construction and fabrication of the project we ordered a car lift to our home and installed it in our garage. This was a learning experience on its own.

Features and Modifications

Roll cage:

  • Full-sized, painted yellow

  • Certified and approved for American Rally Association specifications

  • Improves the chassis rigidity

Aftermarket water pump, radiator, and timing belt:

  • Water pump and radiator resolved the smoking and leaking issue

  • New timing belt reduced the risk of engine failure

  • Large surface area of aftermarket radiator keeps the engine cool at high RPM

Fire suppression system:

  • Designed and installed the layout for a fire suppression system

  • When activated, a pressurized canister sprays fire retardant through nozzles located throughout the vehicle

Hydraulic handbrake and ABS delete:

  • Removed the automatic braking system and parking drum brakes, improving car-to-driver feedback

  • Installed hydraulic-actuated hand brake on the same closed system that feeds oil to the from and year brakes

  • Painted brake calipers to maintain a sleek appearance

Materials and Method

Battery shut-off system:

  • Installed a simple circuit breaker loop to the battery

  • When flipped from the outside of the vehicle, the batteries continuity is terminiated, ensuring that electrical fires do minimal damage

  • In addition, the battery was rewired behind the drivers seat to move the vehicles center of mass farther back

Control pannel and intercom:

  • Installed and wired and panel that houses the switches for the battery, blower fan, lights, intercom, fuel pump, and ignition

  • Installed and wired a intercom system to enable co-driver to driver communication

Control pannel and intercom:

  • Installed and wired and panel that houses the switches for the battery, blower fan, lights, intercom, fuel pump, and ignition

  • Installed and wired a intercom system to enable co-driver to driver communication

Aftermarket struts:

  • Installed aftermarket struts, increasing stiffness and ride height

Chassis/Mechanical modifications:

  • Shaped and formed the sheet metal sub-frame that had significant damage

  • Manipulated various body panels and features that were damaged

  • Added hood pins for safety

  • Replaced several doors that were in unusable condition

  • Stripped the entire interior to reduce the overall weight as much as possible

  • Fabricated and installed an acrylic skid plate to protect the underside from roost damage