Hey everyone

New Member here long time lurker, Alittle back ground on myself I own a 91 dodge colt. I have been slowly picking away at over the years in between storing it and working on other projects. Browsing for a new set of wheels and tires I ran across a group called Canadian Automobile Sport Club, which led me to finding A novice group of rally racers taking part in a rally called discover ontario rally. So I have collected A group of friends teogether to enter the rally in 5 months from now.

So now we have have A bare chassis sitting on jackstands with 2 inches of dust collected from being untouched, but the chassis is super clean and straight. Over the years I have collected A number of parts for the car which are comprised of:

Suspension
Koni front strut inserts
KYB AGX rear shocks
Skunk2 400lbs 7" front springs
QA1 400lb 10" rear springs
Bilstein 7" adjustable sleeves F&R
Yoshi fab Front Camber Mounts
Workz rear pillow ball mount
Chassis also completely stitch welded

Brakes
11" drilled and slotted rotors
dual piston front caliper
hawk HPS+ front pads
10.5" drilled & slotted
ceramic rear pads
single piston rear caliper
Braided flex lines F&R
Wilwood pedal box with independant master cylinders

Turbo Setup
Evo3 16G turbo
2G manifold ported & polished
Evo3 O2 housing
Apexi downpipe
600hp Precision Intercooler

Fuel
1050cc injectors
Dual walbro 255lp HP
-6an feed and return line
Aeromotive FPR

Engine management
Megasquirt 2 v3
speed density converison

Engine
This is still a huge toss up because the engine I have is junk and I need something to replace it.

Random Part
Civic Half rad
buschur racing crank pulley
ARP crank bolt
Jay Racing alt kit

Thats A short list of things I can remember right now, So the plans are to try and get the car all put teogether and collect all the others parts I need to complete the drive train.

So far helping out I have:
Mike K
Scott M
Jim K
and a collection of other friends and family

But starting from here forward I will be keeping the build log in this thread, so keep a eye out and watch whats up with the team and the car.

Also looking for sponsers or donations You can contact either me or mike K about anything.

Thanks
Jeff

Chassis Pic


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Jeff, post some pictures so people dont think your some racer boy wannabe.

EDIT: you were reading my mind

First Update
Well with all the suspension work on the car I needed to build some tubular control arms that could handle the increased suspension angles and strong enough to handle the abuse of 400lb plus springs.

Shot at 2011-01-10

Shot at 2011-01-10

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Shot at 2011-01-10

here they are just tacked teogether because I ran out of argon on my tig. These arms will be complete and checked for this up coming weekend, I hope to also have all the brake lines finished this weekend.

If anyone has any questions feel free to ask away!

Thanks
Jeff

Next Update

Brakes
So these are Galant vr4 front brakes which is the exact same as the 93 up dual piston calipers.

Shot at 2011-01-13

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You can also notice from these pics I am using ARP extended wheel studs with this setup, because the factory rotors on a dodge colt are captive. This left the factory wheel studs much to short after the spindle was turned down for the rotor to be placed on the outside of the hub.

FRONT SUSPENSION
Upper Camber Plates

Shot at 2011-01-13

Shot at 2011-01-13
In this picture you can see the upper spring perch I made to work with the upper camber plates.

Shot at 2011-01-13
Next Two Pictures Show the stainless steel collar I made to hold the coil over sleeve.

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Rear Suspension

Shot at 2011-01-13
[img]http://img573.imageshack.us/img573/6996/new011.jpg[/img]
Shot at 2011-01-13
[img]http://img717.imageshack.us/img717/3879/new009.jpg[/img]
Shot at 2011-01-13

Next up the rear trailing axle, For this piece I made poly bushings for the mounting location to the chassis also upgraded to a 1/2" bolt and welded braces to the chassis mounting point. Then because the rear end has so much flex I welded further braces on the trailing arms to make it twice as strong.

[img]http://img831.imageshack.us/img831/9308/new043.jpg[/img]
Shot at 2011-01-13
[img]http://img152.imageshack.us/img152/6530/new042.jpg[/img]
Shot at 2011-01-13
[img]http://img593.imageshack.us/img593/1175/new045.jpg[/img]
Shot at 2011-01-13

thats all for now more updates to come.

This is a really interesting build, amazing custom work. Your fuel setup seems crazy for a 16G to me, but better to have too much than too little.

Edit: I should add that I know that 16G's are very capable, it just seemed like quite a jump from a normal turbo setup to a dual walbro, 1050cc fuel system.

Anyways, good luck with the build.

If this is for rally racing are you planning and AWD swap? I know from reading the 4G61t forums that quite a few colts have been converted and it seems you have quite a good fabrication knowledge.

Good luck with the build and looking forward to seeing more.

Quick Update!

Picked these up tonight

Shot at 2011-01-14

Shot at 2011-01-14

Shot at 2011-01-14

Thanks you kijiji

Side note it seems like no one can sell a used rim anymore, either the way they are making them now or how ruff people are on them. 3 of these rims are mint the forth has a small ding in the lip that I am going to try and fix myself, But I havent been able to buy a used set of wheel that dont need work done to them.

So people Please take care of your wheels!

Evil Kitty Approves!

Shot at 2011-01-14

Just A small Update here:

I know the fuel system maybe alittle over kill but I would like to use e85 once we get some here. As for the awd part, I have invested A bunch into FWD setup already so I am going to stick with that for now.


Control arms finished welded and sand blasted




I still need to get alot of parts, So I am really pushing to finish with what I have.

Thanks everyone for checking it out.

What sort of lower balljoint is that? I see that the OD of the body of the balljoint is threaded. Is that how the stock one is for that car? Or is that an aftermarket part?

They are no where even close to factory ball joints, The colt uses the same factory ball joint as A DSM press in junk!

These ones in question that I am using are K727 Large chrysler ball joints. With a 1.5" per foot taper which is about the same as a 1ton truck, They also have adjustable roll center because you can raise and lower the stud in the ball joint with spacers that are provided.


Also providing A link if you would like to know more
http://www.colemanracing.com/Ball-Joint-Mono-Ball-Aluminum-K727-P3689.aspx

Goes without saying using these ball joints I had to ream the spindle out to accept the larger taper, But these ball joints will outlast the car.

the balljoints are all apart of my suspension setup, because overall its so low the control arms where angled upwards.

Thanks for the info. When I saw the thread in the control arm, I thought of the old MOPAR upper ball joints.

Wow! Sweet build Jeff! I hope we get e85 soon !

We probably won't, not in this lame town of ours anyways. We don't even have 94!

More Updates

Control arms are complete




As you can see from the newer pictures I added A brace to the control arm for strength aswell.

Next I finished all the hard brake lines on the entire car aswell, Was alittle difficult because they are all now inside the car with the wilwood pedal box.

Picture of the brake setup

Brake Lines




You can also see the matching wilwood prop valve, Now just let it be known that with a pedal box you dont need a prop valve because of the balance bar thats built into the pedals. But I wanted to make it easy on myself for making lines so I just run the prop valve for that reason, Not sure if its going to cause me any problems or not but we will see.

And a few update pictures over all


[img]http://img171.imageshack.us/img171/7153/dsc00203bk.jpg[/img]

Damn man, looks great ! I'm excited to come by see this thing soon.

Hey everybody

Updates have been slow because everytime I would try and work on the car something else would come up and I would have to fight with it, Or fabricate something!

Its very frustrating when after 8 hours of work you have nothing to show for it... After a few weeks of this I started to panic alittle because I am falling off schedule, So I had to ramp it up and work on it 4 days a week to catch back up.

So I finally have some updates for everyone

Wheels and Tires Redone




Spring Perch



These are to hold the helper spring to the main spring incase the suspension goes into full drop.

Random pic
Colts stable mate


Rear Beam complete

Complete Front Suspension


[img]http://img227.imageshack.us/img227/8388/dsc00248n.jpg[/img]
[img]http://img607.imageshack.us/img607/7617/dsc00247b.jpg[/img]

Here You Can See I Started My Wire Loom
[img]http://img52.imageshack.us/img52/3866/dsc00251ss.jpg[/img]
[img]http://img51.imageshack.us/img51/641/dsc00246zw.jpg[/img]

60$ worth of metric bolts !
[img]http://img225.imageshack.us/img225/3027/dsc00245bm.jpg[/img]

And Another random, Lots Of Painted Parts
[img]http://img4.imageshack.us/img4/6587/dsc00242vh.jpg[/img]


Thats it for now stay tuned lots more updates coming soon.

nice work, can't wait to see that bay filled with something.

Jeff your doing a awesome job on this car!
Im glad that I get to help and be part of it.

Looks awesome!

Last night I finished my Brake upgrade and install, Most would'nt think that Dual piston calipers from a 93AWD and 11.5" rotors from A 91 EVO would be something special but on a Dodge Colt it is.

Factory brakes on A Colt are captive rotors which means the hub is pressed apart to remove the rotor and the rotors are bolted to the outter hub. This made it very difficult to find any sort of brake upgrades and who really wants to rip apart your hub and replace all your wheel beaings everytime you change your brakes.

Factory Brakes



So I took the outer portion of the hub and put it on the lathe and turned it down to fit inside the rotor.

This Can Be seen Here:


So now that the rotor would slide onto the hub I would need to make spacers to move the caliper out to match the new rotor location. I first started with 6mm spacer, the thickness of the rotor but the caliper was'nt centered. So last night I made new spacers 7mm and that seems to have done the trick and centered the calipers.

Complete Install :




Also Installed in these pictures but not really seen is:
Hawk HPS+ Front pads
ARP Evo Extended wheel studs
Skunk2 Extended wheel nuts
(new black edition)
Black Braided brake lines
(from Ziggy)