Proton Satria GTi Road Rally Car Build - FINISHED - Saxperience

rick_VTR · 30th December 2012, 18:27

Hi guys, this is the build progress of my GTi thats taken place over the last couple of weeks.

Started off like this,
Bought the car for £550 with 70k on clock, 11months MOT and 2 Months tax.
Ran mint no problems at all.
Bit of a pocket rocket too with the 1800 DOHC 4g93 Mitsi lump!

took the standard 16's off and ran on cheap 14" wheels bought for £50 off ebay.

then ran it like that for a while, took it down the lanes gave it a good testing seeing where improvements are needed!

First problem was ground clearence, with the lotus set up suspension its far to low at the front for the lanes, so splitter got chopped off.

chucked some harnesses on the standard seats

and fitted rally wheel.

then picked up a tired looking roll cage for the grand sum of £90

engine bay shot, brace was fitted when i bought it.

took skirts off cause they were full of mud.

undersealed the sills

at this point i had bought some 15" fox racing alloys off a mate for £60 to use as road tyres and keep the 14" for nobblers etc.

i started to gather up my parts for the build, roll cage, sump guard, tank guard, evo suspension, bucket seats etc.

finally finished work for christmas so the car went in the garage!

rick_VTR · 30th December 2012, 18:27

stripped out

welded plates in for cage

fixed rails for buckets

made up some solid spot light bars

bolted up the tank guard

undersealed the hole car today then mocked up the bargain £50 corbeau seats, holes drilled so can be fitted after interior is back in

cage is bolted in place after i painted it black.

Should be 99% done by tomorrow.

Plans are:
Refit interier and bolt seats in
Refit radiator and re build front end
Bolt spots on and wire in
Fit and wire in my LED interior nav light.
will eventually get the sump guard on but ran out of materials to make up and weld the mounts on so probably do that one weekend in the new year.

EVO 5 suspension is on the way so that will lift the front end a couple of inches and stiffen it up!

Waiting for some 3" red TRS 4 point harnesses from my mate out of his stage rally opel manta.

all in all i worked it out the build has cost me around £900 so far including the cost of the car, well chuffed!

Scott83 · 30th December 2012, 18:36

Ah....now I know your name....

Forgot to ask, what brakes are you running/planning to run?

rick_VTR · 30th December 2012, 18:54

Quote:

Originally Posted by Scott83

Ah....now I know your name....

Forgot to ask, what brakes are you running/planning to run?

ahh hi scott!

running standards for the time being, was thinking about goin evo but want to be able to use 14" wheels.

and to be honest i think the standard brakes feel awsome on this.

when it comes to the time to fit my hydraulic handbrake, probably just remove ABS and have braided lines throughout with standard calipers, standard disks and some good uprated pads.

should be fine.

Aly · 30th December 2012, 19:08

I love the look of this and for £550 you really can't complain, the shell looks really solid too no rust underneath

Scott83 · 30th December 2012, 19:10

I always thought the original brakes were decent, but then the FTO/EVO ones were just awesome. Look for FTO Mivec ones, they are just the same but go for cheaper. I have 280mm discs on the 172 but only single piston caliper that's smaller overall and the proton rakes out the Clio ones to shame.

Saying that, I used Clio discs last time and had them machined down to 276mm.

They will fit under 15" wheels and 15" tyres aren't too bad price wise.

Scott83 · 30th December 2012, 19:14

For rallying, ditch the air con, the pump weighs loads. Just buy a PAS belt for a non aircon Coupe, they fit when the air con pump is removed.

If you need a reg plate for parts, just use the one i've just scrapped V263 EKS, it'll still show up as a Coupe on the parts websites.

rick_VTR · 30th December 2012, 20:54

Quote:

Originally Posted by Aly

I love the look of this and for £550 you really can't complain, the shell looks really solid too no rust underneath

yeah its a nice clean shell, there was a tiny bit of rust at the rear of the left hand sill, it had split the seam where somebody had jacked the car up on the sill in the past but straightened it out welded that up and undersealed it and its solid now!

Quote:

Originally Posted by Scott83

I always thought the original brakes were decent, but then the FTO/EVO ones were just awesome. Look for FTO Mivec ones, they are just the same but go for cheaper. I have 280mm discs on the 172 but only single piston caliper that's smaller overall and the proton rakes out the Clio ones to shame.

Saying that, I used Clio discs last time and had them machined down to 276mm.

They will fit under 15" wheels and 15" tyres aren't too bad price wise.

Quote:

Originally Posted by Scott83

For rallying, ditch the air con, the pump weighs loads. Just buy a PAS belt for a non aircon Coupe, they fit when the air con pump is removed.

If you need a reg plate for parts, just use the one i've just scrapped V263 EKS, it'll still show up as a Coupe on the parts websites.

cheers for the info scott! will keep it in mind!

rick_VTR · 23rd January 2013, 16:22

few more up to date pics.

Evo 5 front struts on (rears being moddified to go on)
spot lights on
front end back together
new radiator
removed aircon system
changed oil and filter
new silver boot lid.
boot floor treated and painted gloss black.
all interior back together and back on the road.

just waiting to hear back from my mate whos getting me a harry hockley motorsport brake line kit cheap so i can plumb my lines through the car and fit the hydraulic hand brake and bias valve and then it will be somewhere near.

just sumpguard to fit and rear struts wont take long.

rick_VTR · 1st March 2013, 17:53

bit of progress on this.
gave the old girl a quick wash and put original number plate on as evo style one looked shit.

i had been running on the 14" rim for a while to burn of the shit tyres, so did that and have put 15" wheels back on now.

so now tyres are of the 14's ive started refurbing them, flourescet orange

the light in the garage makes it look a odd colour but it actually flourescent orange, wel it will be after a few more coats!
once there done goin to fit some decent rubber to them (be a few months yet) ready for a rally im doing in july at Sweetlamb!

now im off to cyprus on tuesday with work for 3 weeks, and when i get back i got a few jobs to do on the BMW so i can start driving that on the road again then this can come off road for some more work consisting of:

alteration to seat positions
different harnesses with eye bolts
sump guard fitting
repair work to front cross member (some rot)
tank guard alterations
fit braided lines and handbrake inside
and finally get the evo 5 struts on the back!

rick_VTR · 29th April 2013, 20:19

been so busy I haven't had time to update this, or take photos yet.

done a fair bit more work on the car the last few weeks.

-fabricated sump guard mounts.
-cut out some rot from front cross member and plated up.
-modified the tank guard so it sits closer up to the tank.
-stripped interior back out and laid down braided brake lines with hydro handbrake.
-fitted evo 3 rear struts
-fitted new rear toe control arms
-removed rear ARB and brackets
-removed front ARB and brackets
-modified seat base mounts
-fitted eye bolts and backing plates for new harnesses.
-removed all original brake lines including abs pump
-removed aircon and pump, fitted shorter belt off non aircon model.
-fresh gear oil and engine oil + filter
-covered fuel lines under car with heavy duty plastic
-fitted navigators foot rest.
-fitted rear mud flaps.

thinks that's everything, just a few bits left to finish off now before I do the Eagle road rally on 1st June.

I need to finish off the handbrake install, bleed brake system, bit of wiring, and get a new timing belt and water pump fitted, I will hopefully get more pictures this weekend if I get chance!

greyjasper51 · 29th April 2013, 21:12

fair play good effort mate!!

rick_VTR · 29th April 2013, 22:42

cheers,

getting there slowly, its a lot more work than I first thought it would be!

rick_VTR · 14th May 2013, 21:38

Well finally the car is finished!

done all the wiring for spots and interior lights etc, spots on separate relay with separate switch inside for independent use.

sump guard is on, proper padding for the roll cage, decent harness in with eye bolts

ready to rally on the 1st June!
heres a few pics.

and heres one of my stealth hydraulic hand brake set up, all covered by centre console nobody will ever know

and handbrake works mint, locks rear wheels up goin straight with warm tyres on dry tarmac

Slyboogie · 14th May 2013, 21:58

Considering it's a Proton I quite like these. But I also like Hyundai and the new Gen Kia's so I have a thing for non-mainstreamish brands

rick_VTR · 14th May 2013, 22:09

Cheers, but I didn't buy it for its looks (although its grown on me and a quite like the look of them now) that's what I have my road car for.

I bought it solely to build a road rally car, they are at home in the lanes these Malaysian missiles and I cant wait to get out competing in it

probably more of these used as rally cars than actually used as road cars.

Mike_Roberts · 14th May 2013, 22:36

Looking good! Awesome road rally car in relatively standard form! Becoming a popular choice! See you at the eagle ;-)

rick_VTR · 14th May 2013, 22:48

Certainly will

what car are you competing in? 106 xsi?

Slyboogie · 14th May 2013, 22:55

Yeah I used to have a Gen 1 Hyundai Coupe. Maybe a little low on power but had enough, and certainly good fun all around! Was alot better built than people have ever given them credit for as well.

Mike_Roberts · 14th May 2013, 22:55

Yeah out in the xsi again! Need to get some big championship points! You running in novices or got an experienced nav?