The Rocky Rebuild Thread

[MMT]

Well, the rebuild of Rocky is underway. I blew up the motor at Calabogie a couple years ago, and the car sat for a while, while I collected parts and planned a rebuild. The time has come to get it back together, with pretty much every part of the car being upgraded or changed.

Here is how the car sat before:

The car was run as a T1 Canadian Touring Car Championship car, and as a GTB Ontario Regional Race Series car. The car will now be an Ontario Regional Race Series car and 3 hour enduro series, running in either GT3 or GT4. Will have to wait and see just how much faster it is.

It is a 92 Civic Si H/B, with Intregra Hype R powertrain that was at 240 crank HP before the rebuild. Fairly stock inside except TODA cams, AEM intake, DC Sports JDM header, comptech race exhaust, upgraded T/B, RC 440 Injectors all being run by an AEM EMS with wideband. The brakes were stock ITR with Hawk Blue up front and Hawk black out back and ITR master. Suspension is custom valved JIC Magic coilovers with 700# front springs and 900# rear springs, rear comptech bar and removed front bar, all bushings were Mugen. Power steering was properly removed with the install of a true manual rack, and proper new subframe for the manual rack (the rack mounts are different on a car with a power rack) Has a Spoon CrMo flywheel and a street Excedy clutch (stage? who cares...) Motor mounts were just Energy suspension inserts, which caused all sorts of trouble and I am glad they are gone. Car weighed in at 1900 lbs and would run 37's at Mosport with 205/50/15 Toyo RA1's.

http://i459.photobucket.com/albums/qq314/mightymousetech/Race%20Car%20Pics/after1.jpg?t=1300992561

The powertrain, and fuel system have been removed, along with several items to make welding inside the car easier.

As the car sits today...

http://i459.photobucket.com/albums/qq314/mightymousetech/Rocky%20Rebuild/7022274e.jpg

http://i459.photobucket.com/albums/qq314/mightymousetech/Rocky%20Rebuild/cf149496.jpg

http://i459.photobucket.com/albums/qq314/mightymousetech/Rocky%20Rebuild/4170b74b.jpg

http://i459.photobucket.com/albums/qq314/mightymousetech/Rocky%20Rebuild/61c04894.jpg

http://i459.photobucket.com/albums/qq314/mightymousetech/Rocky%20Rebuild/c2219ce0.jpg

http://i459.photobucket.com/albums/qq314/mightymousetech/Rocky%20Rebuild/ac5c12df.jpg

http://i459.photobucket.com/albums/qq314/mightymousetech/Rocky%20Rebuild/c608e58f.jpg

http://i459.photobucket.com/albums/qq314/mightymousetech/Rocky%20Rebuild/36d3240c.jpg


First step is taking the car to my fabricator to have the new 120L fuel cell with intank pump and swirl pot installed and new drivers seat mounts fabricated. Along with some small modifications to the roll cage to allow more room in the drivers seat, and to install a passenger seat with proper mounts and harness mounts. Many people want to go for a ride in this thing around the track, so I thought I would make it as safe for a passenger as the driver.

120L Fuel Cell:

http://i459.photobucket.com/albums/qq314/mightymousetech/Rocky%20Rebuild/9e39fa5f.jpg

http://i459.photobucket.com/albums/qq314/mightymousetech/Rocky%20Rebuild/b4f62a93.jpg

New Drivers seat with head supports:

http://i459.photobucket.com/albums/qq314/mightymousetech/Rocky%20Rebuild/7643c8f1.jpg

New HANS specific harnesses:

http://i459.photobucket.com/albums/qq314/mightymousetech/Rocky%20Rebuild/c0647a47.jpg

Loaded in the trailer and off we go.........

http://i459.photobucket.com/albums/qq314/mightymousetech/Rocky%20Rebuild/6a530b78.jpg

[The Grey Area]

I love this build. Are you just refreshing the type r or doing some upgrades to it?

[MMT]

I love this build. Are you just refreshing the type r or doing some upgrades to it?

The motor is getting Wiseco 13.2:1 pistons, Carrillo Pro-A rods, TODA VTEC killer cams (305 deg) with matching springs and CrMo retainers, TODA cam gears, TODA 50mm ITB's, HyTech longtube header, opened up ports in head, larger valves. Hoping to be making about 270 crank HP running Pro Mark 2 110. Also hoping to get the car down below1800 lbs.

[The Grey Area]

All the right bits! Thats sick man. Love the lumpy idle of those todas and those headers are of insane quality. Mint build right hurr!

[MMT]

All the right bits! Thats sick man. Love the lumpy idle of those todas and those headers are of insane quality. Mint build right hurr!

Thanks. Ya, I will let the street cars play with VTEC. LOL.

[MMT]

Fuel cell supports are roughed in.

http://i459.photobucket.com/albums/qq314/mightymousetech/Rocky%20Rebuild/8e872c25.jpg

Only one bar had to be cut from the cage to slide the cell in:

http://i459.photobucket.com/albums/qq314/mightymousetech/Rocky%20Rebuild/ae3378b0.jpg

http://i459.photobucket.com/albums/qq314/mightymousetech/Rocky%20Rebuild/c7f32929.jpg

Coming along nicely.

[1point3Lturbo]

whoa thats a big fuel cell. Is this needed for the endurance races? Are you not allowed to re-fuel? Seems like a shitton of weight to be hauling around.

[PDP]

^^ I thought the same thing, does it work on a bladder system as well, even at half full that thing would slosh around quite a bit no?


AND I LOVE THE CHAIR BEHIND THE SPARCO!!!


Love the build!

[JettaRacer]

That's going to be very interesting to get a filler neck plumbed to that so that it actually fills at any speed - it's definitely doing to have to go in to the hatch pillar.

He wants to be able to go for 3 hrs without refueling. I still think he won't be able to do it, based on the motor he's building. There is still a mandatory 1 minute pit stop during the 3hr race - so the car will just have to pull in to the pits before the 90 minute mark (as the rules require the pit stop to be made before 90 minutes is up) and change drivers, wait for a few seconds and then drive off. A full driver change from the moment the car comes to a full stop should take less than 45 seconds without any issue.

The best tactic would be to have enough fuel to run the whole race on board (along with tires that will last as well), Ironman the race with one driver. Pit as soon as there is a yellow flag because of a crash... because most guys share rides, they will all mostly pit at either half distance or at the 1 and 2 hour marks if they need to refuel twice. That would definitely put you ahead of most of the crowd. Also, with refueling, most pitstops take much longer than a minute - so you're way ahead of the rest of the field.

[MMT]

Yes, the tank has a bladder and anti-slosh foam, so no worries there. Having the cell that big "should" allow me to run a full three hours, may have to short shift a bit to do it though (or pray for several yellow flags that do NOT involve me.. :) ) It does allow me the flexibilty to either try the full three hours or refuel once near the halfway mark, and refuelling a proper fuel cell is a hell of a lot faster than filling a stock gas tank.

[MMT]

AND I LOVE THE CHAIR BEHIND THE SPARCO!!!

Thanks, just got it a few months ago, in the new Santos Palisander Rosewood, which they just started to make available again (Herman Miller would not sell it in rosewood until they found an environmentally sustainable supply of the wood) and is how Eames originally designed it in 1956. Holy crap is it comfortable, I have fallen asleep in that chair, many, many times in front of the fireplace with a big honking glass of port.

This is pretty close to the exact leather/wood combination I have, the leather is just slightly different, Black Coffee instead of Black.

http://www.hermanmiller.com/MarketFacingTech/hmc/products/Eames_Lounge_Chair_and_Ottoman/hero_eames_lounge_1.jpg

[G-PWR]

Thanks, and yes it is genuine!! :) Holy crap is it comfortable, I have fallen asleep in that chair, many, many times in front of the fireplace with a big ole glass of port.

That's in way too good shape to be a real 1970s Eames chair... $2000 reproductions are awesome though.... which is what that appears to be. if it's really a legit one, you should consider selling it... in that condition you could get over $10k I bet.

Where'd you buy it? I was eyeing the ones at Van Leuwen in the market... on sale for $1750

[MMT]

That's in way too good shape to be a real 1970s Eames chair... $2000 reproductions are awesome though.... which is what that appears to be. if it's really a legit one, you should consider selling it... in that condition you could get over $10k I bet.

Where'd you buy it? I was eyeing the ones at Van Leuwen in the market... on sale for $1750

It is genuine, Herman Miller still produce it today. They have never stopped making it from the 50's when it was designed.

http://www.hermanmiller.com/Products/Eames-Lounge-Chair-and-Ottoman

Got it at Alteriors in Westboro, they are a Herman Miller dealer.

[G-PWR]

huh, I always thought they were reproductions - what'd you pay if you don't mind because I am buying one for my new house :D and sorry for speaking out of ignorance :D

[MMT]

huh, I always thought they were reproductions - what'd you pay if you don't mind because I am buying one for my new house :D and sorry for speaking out of ignorance :D

Well, your 10k estimate is close ..........

[G-PWR]

lol fuck that shit! REPRODUCTION HERE I COME! lol

[PDP]

10K OMG!!!!

Why must I have expensive taste =(

sick car sick chair fuck you! lol!

jokes

[G-PWR]

like I said Pete - $1800 gets you a replica... they're very comfortable; I'm sure just as much so.

[MMT]

New Tilton floor mounted pedal box. (good-bye power brakes!) The ITB's do not really have an attachment point for brake vacuum, so this makes it a little easier to install, plus, power brakes only really belong on a street car, they make braking variable between each pedal application. Along with a Tilton 3 chamber brake resevoir (one for each master cylinder) which will be mounted on the dash inside the car. Allows you to view the brake fluid levels while driving which will show pad wear during longer races. Also, a Tilton in car brake bias adjuster to adjust the rear brakes to compensate for weather and fuel load (because I will be running LOTS of fuel) and AP Racing short master cylinders (require the short cylinders due to the constraints of a very tight cabin to work in) using a 3/4" cyl for the clutch and front brakes, and a 7/8" cylinder for the rear brakes.

Needed to do the pedal box install now so the final seat position can be finalised and welded in place.

http://i459.photobucket.com/albums/qq314/mightymousetech/Rocky%20Rebuild/82ab35d7.jpg

Now was the perfect time to switch to a proper pedal set-up, as I make the switch to slightly larger front brakes, AP Racing 4 pot calipers and 13.0" rotors, which will be receiving Raybestos ST-43 compound pads (a NASCAR compound) upgrading from a stock ITR setup. I will still be using the stock ITR rear brakes with Hawk Black pads.

http://i459.photobucket.com/albums/qq314/mightymousetech/Rocky%20Rebuild/a9a67fed.jpg

Also ready to go is a complete new set of suspension arms, with new bearings and hubs. All the bushings have been replaced with spherical bearings, including PCI spherical trailing arm "bushings", and new Function 7 rear lower control arms with bearings instead of bushings. The front knuckles were also replaced with new (knuckles, hubs, bearings, ball joints) but the new part is well hidden by the new, somewhat larger front brakes. A set of Skunk2 Pro Series upper control arms are also ready to go on, with the inner bushings replaced with bearings.

http://i459.photobucket.com/albums/qq314/mightymousetech/Rocky%20Rebuild/7ec21289.jpg

[Musclecar]

This is giving me a stiffy. This is the type of thing I'd like to do with my RX-7 in a couple of years.

[PDP]

My fav buiild thread of the summer!!!

[Husband]

Wow, please keep posting updates on this. Such a nice project (not to mention the chair too <3 )

[1FSTSRT]

Love the brake setup! Should be nice to dial that in.

[MMT]

Well, the pedal box is in, the seats are mounted. This required MANY changes to the roll cage to allow a proper driving position.

This has created many other issues to actually driving the car. Because the seat and pedals are now about 4" further back (the seat is now resting against the main roll hoop) I can no longer reach the switches on the dash, the kill switch, the steering wheel or the shifter. So, many more changes will be required. A new wiring switch box has been ordered and will be located on the exhaust tunnel beside the brake bias adjuster, and hopefully all that is required for the steering wheel is a second MOMO hub adapter between the steering quick release and steering shaft will bring the wheel close enough to the driver to be comfortable. If not, a custom steering shaft will have to be made. The shifter will be easy, just have to weld a bar onto the stock Hype R shift rod that extends it further back.

Will have some pics up soon.

[MMT]

And a quick teaser shot.......

8 new Hoosier R6 225/40/17 (dry)
4 new Toyo R888 205/40/17 (wet)
not in pic 4 new BFG R1 235/40/17 (dry)

All 16 tires are mounted up now on new Enkei RPF1 17x8, ET +45

http://i459.photobucket.com/albums/qq314/mightymousetech/Rocky%20Rebuild/4fd3141a.jpg?t=1311172186

[shlammed]

And a quick teaser shot.......

8 new Hoosier R6 225/40/17 (dry)
4 new Toyo R888 205/40/17 (wet)
not in pic 4 new BFG R1 235/40/17 (dry)

All 16 tires are mounted up now on new Enkei RPF1 17x8, ET +45

[/IMG]

Either you have 4 more tires or your math doesnt add up.

cool build, tank is too big.

[empire]

Either you have 4 more tires or your math doesnt add up.

8+4+4(not in pic)=16

[JettaRacer]

cool build, tank is too big.

Actually, it may be too small for him to finish a 3hr race at Mosport without refueling, which is his goal.

[MMT]

Actually, it may be too small for him to finish a 3hr race at Mosport without refueling, which is his goal.

Fingers crossed, or short-shift the shit out of it. :)

Although, that is what caused the motor to ass-plode the first time.. :)