Rally Rolla ZRE-152

[smee]

The rally team has had the same sponsor in South Australia for a few years now, and we have had the Mazda out there presenting it well and receiving good feedback.

We got some TV coverage at the first round of the 2013 ARC. Albeit supposedly representing the Golden Years of Rallying.

On presenting our case for the 2013 season to our sponsor, instead of being offered cash, we were offered a car.

The Sponsor is also interested in setting up his office run arounds in a similar scheme to that of the rally car. It would see the car out at shopping centres etc giving that little bit of extra exposure, and really we could not say no. Could we....... :D

We asked CAMS/ARCom for approval of an engine swap to allow a 2ZZ-GE into a ZRE-152 Corolla in place of it's asthmatic relative. A recent meeting has seen approval for its use, so it is now all systems go.

With that in mind I present our donor car......

I had a phone call on Sunday 9th June from an engine builder.

The Corolla will now encase a Neil Trama built engine.

This has solved a number of issues. Sourcing a ZZ engine and then the parts and maching to bring it to fruition.

So laid into the car over the weekend for a little bit.

Noted how much weight can be taken out of the thing even without trying.

May need to make up a couple of alloy brackets to support the wipers etc.

A custom radiator and overflow tank will sort out the cooling and replace the 3 litre tank and too many hoses in the engine bay.

Need to look at getting power steering fitted. Currently has electronic and the controllers are huge.

Found the source of the weird smell in the cabin. Seems there may be a refrigerant leak from the aircon.

New motor and a few other bits picked up in a whistle stop trip to Canberra over the weekend.

Biggest pick up was the new Neil Trama ZZ engine.

OK.

Guesstimates are at around 330kg for the chassis. Alas, no access to a set of scales before it left.

And with that, some pictures.

Truck turned up to cage installers premises and has delivered it home for me.

Quaife responded to my email, so gearbox invoice being raised.

Dash has been test fitted and aligned. Will now flock it.

Have started on welding up small holes and plating around area's the cage comes through.

Paint stripping, kevlar underbody and sundry item making has also commenced.

Now to figure out the electric power steering conundrum.

How to make a toyota corolla electric power steering system operate without an ECU.

Motec M400 with loom sourced.

Hopefully no scamming this time.

Gearbox is in the building.

[sportivo2007]

Nice corolla great work keep us updated !

Edited February 13, 2014 by sportivo2007

[prodigy 07]

Thats freakin cool. Had an old corolla that was known among mates as the rallyrolla (for reasons I won't go into ;-) You have the real deal. Keen to see more, keep us posted.

[smee]

Floor mounts and false floor setup.

Amazing the use you can get from an empty slab carton.

Mock up of seating and pedal setup.

[smee]

More stuff going in.

Seat and wheel setup looks ok.

False floor done, Navs footrest and fire extinguisher mount
Footrest has the ability to move up to about 20cm's

[trentmeyer23]

Hell of a build, huge amounts of money and fabrication into a build like this, good work!

[GTL05T]

This is by far my favourite build! lol Awesome.

[smee]

So, things are progressing.

[Mystik rolla]

gonna keep a keen eye on this!!

[smee]

So, did a bit of work over this long weekend.

Seam sealing, hole plugging and topped it off with a bit of paint.

[smee]

A roll through CAD image showing the structure of the roll cage fitted to McMRallysports new Corolla Rally car. #RallyRolla

Thanks to my Navigators girlfriend for the design video and image.

Roll cage roll through - YouTube

[smee]

So, have done a little bit more work on sundry items.

Underbody protection.

Heat shield along the exhaust tunnel

Seats, firebomb, fuel tank protection.

[smee]

So, have done a little more with the fuel pump area.

Fabricated a cover and viewing port with Acrylic so at least you can see what is hiding there.

[GHOSTIVO]

Now that is a crazy build. Good job!

[Ryanj252]

Crrrraaaazzy Build! Im watching this thread closely

[smee]

Long time no post.

Took time off to run a Mazda 2 in the SA rallysprint championship and win..
 

Up to here.

 

 

[smee]

Some updates.

Lights, Door trims and electric window switches, Dash fitted up,

[smee]

A couple more things finished off.

[trentmeyer23]

Nice, really starting to take shape.

[smee]

So, took it out of the shed and drove it around the block.

Also took it to a christmas pageant in Mannum, down on the Murray.

Performed quite well.

[trentmeyer23]

Looks good!

[smee]

Ta Daaaa.

[KAA]

Wonderful job mate..loved following the progress..it looks awesome

best of luck to you both using the beast now

KAA

[smee]

Tune day 1st week of January..

Did not go as planned.
Somehow missing 45 Kw.
Only putting out 105, not 150.

Investigations into why this may be so continuing.

 

New tune date set.

[trentmeyer23]

4 hours ago, smee said:

Tune day 1st week of January..

Did not go as planned.
Somehow missing 45 Kw.
Only putting out 105, not 150.

Investigations into why this may be so continuing.

 

Drivetrain loss will be about 10-15%.

The power figure you are quoting is at the flywheel of a stock 2ZZ-GE.

Is lift engaging?