WRX rally car build – Part 1

It’s actually been quite a while since we’ve done a WRX rally car build from scratch. The last few Imprezas that we’ve had in the workshop have been second hand rally cars. We’ve only had to modify and re-prepare them before taking them onto the stages. That all changed late last year when a customer…

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2019 Fire Extinguisher Rules

Many seem to trip up on the requirements for this simple yet mandatory safety equipment. Let’s take a look at the 2019 fire extinguisher rules for motorsport. Hand Held Fire Extinguishers Testing How often does a fire extinguisher need testing? The straight answer is every three years. This is determined by the date stamped into…

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Fitting a Hydraulic handbrake to a Ford Fiesta rally car

R1 Spec Ford Fiesta Effectively the R1 spec Ford Fiesta is an entry level into the Word Rally Championship (WRC). The class was developed by Ford and M-Sport based on the production model car. Many of us are probably familiar with the Fiesta World Rally Car or Ken Block’s Gymkhana machines. Ford wanted to include a…

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Daihatsu Applause rally car build part 3

Snatched from the jaws of the crusher post 3. Rear Brakes Now the suspension was sorted, the rear brake fittings could be completed. First task was to remove the obsolete factory cable handbrake and blank off the cable openings in the tunnel. A new hydraulic handbrake meant making up and welding in a mounting bracket as…

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Daihatsu Applause rally car build part 2

Saved from the crusher post 2. Our attention then turned to the interior of the car. We set about completing some minor seam welding around the rear towers, tidying a few areas and removing the factory seat mount brackets. The owner wanted different race seats from those already in the car so we also added some…

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Daihatsu Applause rally car build part 1

Rescued from the jaws of the crusher post 1. This story started with a casual chat at our end of year car club presentation in November 2015. As with any motorsport function, the conversation got around to cars and particularly what may be available to use for the Clubman Cup. At that time there weren’t…

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Nissan Silvia rally car build part 4

We were down to the last few weeks before the debut rally and some long hours were being spent on the Silvia. With the major mechanicals and the exterior sorted it was onto the list of smaller items to get the car ready for competition. The owner had found a set of used Velo race…

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Nissan Silvia rally car build part 3

As we started to put the car together we tackled a few tasks simultaneously. A new fuel tank, Warlbro fuel pump and filter were fitted and plumbed in. We received the car with the original tank removed and inspection inside revealed plenty of rust from exposure to the elements. A HDPE fuel tank guard was…

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Nissan Silvia rally car build part 2

The next step was to tackle the wiring loom. As the car originally had a CA18 engine, the loom was different. Adding to that, the wiring had been chopped and reduced to only the functions required for circuit work so many parts required for rally were missing. The easiest solution was to use the loom…

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Nissan Silvia rally car build part 1

During our busy rally season we started the build of a new gravel rally car for a customer. The brief was short and clear. Build a rear wheel drive rally car that could be used for gravel and tarmac. With a relatively short list of cost effective rear wheel drive cars available the decision to…

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