Road Race Build: 1994 EVOLUTION II RWD from Sweden

[KHRacing]

So i decided to make a build journal for you guys, to see what you can make of an old EVO II from 1994.
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Hi there. greeting from the land of the midnight sun, sweden that is !

My name is Kristian, i´m 41 yrs.. have had my EVO2 since December -06

bought it with an almost readybuilt motor, but the rest was a total mess.

This did not matter since the idea was from the beginning to build an
RWD EVO driftcar with 600bhp.


Engine:
4G63T 2L TwinCam Turbo

Wiseco pistons 8:1
Wiseco pistonrings
Eagle conrods
ARP bolt for conrods
ARP bolts for head
ARP bolts for bottom end
Clevite race crankbearings
Clevite race conrodbearings
Raceported head
Matchported channels in head to intake & exhaustmanifold
Cometic headgasket (3 layer)
1680cc Bosch injectors
E85 fuel
AEM fuel rail, modifyed
Schwitser s300 turbocharger off a Scania truck
NGK Race Iridium sparkplugs
10mm race ignitioncables
Injen oil-lid
"HKS" Oljecatchcan
K & N 4" airfilter

Fuel:
2pcs "044 Bosch fuelpumps
twin 10mm feederlines
single 8mm returnline
AEM fuelpreassureregulator

Exhaust:
homemade headers by ajden.se
3" downpipe, 3" pipe under the car to 3" race catalytic converter into rear silencer

Transmission:
BMW M3 E36 gearbox (5-speed) with one-off clutchcover made from part of my old EVO gearbox.


Quarter Masters race 7,25" twinplate
lightened flywheel
steelbraided clutchcable

Chassis:
XYZ driftspecs coilovers
XYZ camberplates
handmade strutbrace
handemade bushings all around


Rims/tires:
17"x7,5" Race
17"x7" "Flat" AFL
17"x7,5" "Oxigin" AFL
17x7,5" Mega Acera (black)


Tires:
17"s..... No need to list them, they only last about 5-7minutes

Brakes:
Front: X Y Z 330mm discs with 6-pot calipers
Rear X Y Z 303mm discs with 4-pot calipers
X Y Z hydraulic handbrake
Steelbraided braklines (Goodridge)


Interiour:
Driverseat: Corbeau Revlution FIA Kevlar/Glasfiber - Rallyshop.se
Drivers seatbelt: X Y Z 6-points
passengerseat: Corbeau Forza Sport FIA - Rallyshop.se
passengers seatbelt: X Y Z 6-point
Seats lowered 70mm, passengerseat 120mm further back
Aluminium passengers footrest /rallystyle
Sparco carbon pedals
OMP Racing steeringwheel, 320mm
Snapoff steeringhub FIA approved
0,5mm alu-doorcards
6st extra instrumetclusters
5" revcounter
HKS Turbotimer
GPS speedo

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The first 3 years i raced it with a welded centerdiff & stock gearbox & just remowed front driveshafts; just like the Tokyodrift EVO 8.
here´s how i simply made some "blockers" fo make the hubs stay in place, they worked perfectly all the time.


I also had stock steeringangles and very little camber.


During the 1,5 year built, i decided early on that right-hand-drive was not for me at all, so i aqquired an FWD Lancer Estate (swedish market version) from which i took everything needed in order to move the steering to the left-hand-side. (The EVO 1-2-3 only came from the factory with RHD)



All done: Dashboard is also Lancer fwd, mirror copy of the EVO´s stock.


Steeringwheels crashbeam (dont know the english name for it) also came from the donor car.


Made a special airbox:


The car took 1,5 years to finish,,, but finally done it was a pure beast
Vvideo from first test:
Garaget | Hysterisk EVO - utifrån

Dragpipe test:
Garaget | KHRacings EVO RWD igen :-)

dragstriptest with burnouts in third gear:
Garaget | EVO RWD på MECA Raceway

Testing at an abandoned airfield in 2008:
Garaget | KHRacings EVO RWD igen :-)
Garaget | KHRacing´s EVO RWD

Racetrack test in 2008:
Garaget | Team Sitoo Driftingträning 11/10-08 @ STURUP

100mph (160kmh) drifting at same track:
Garaget | Team Sitoo Driftingträning 11/10-08 @ STURUP

Iceracing January 2009:
Garaget | evo rwd på isen i Januari

Driftingpractice with the local motorclub April 2009:
Garaget | Driftingträning med Hässleholms MK 5/4

Show at Swedens biggest carshow which is held every Easter:
Mitsubishi Evo Drift - YouTube

Car show Elmia 2009 stuntshow DRIFTING - YouTube



First driftingcompetition with the EVO in September 2009, came in 4th: Garaget | DRIFT E V O @ BivarödsDriften


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Continuing me story:

Oktober 2009:
Driftingshow at a rallycrosstrack, a lot of mud/sand unfortunatley
Garaget | Driftinguppvisning Svampabanan

----------------------------------------------------

Then came 2010....

A year that "Murphy" visited almost every time i drove the car.

First competition the car would not start at all.. later found that the connector TO the the camsensor was broken.

Then the watertempsensor for my Engine Managment System( sound almost like in the Fast & The Furious) broke, then after that the primary ignition sensor broke twice, due to a alternatorbelt beeing slightly out of alignment.

After that, first the rear diff broke at the second competition...


So i rebuilt it:


Then after a lot of work, i managed to arrange a driftpractice at Scandinavian raceway 8there they drove F1 in the 70´s).
The car worked perfectly, except for a broken turbogasket in the end of the day:
video: Garaget | TEAM DRIFT E V O @ Anderstorp Raceway



In this picture im using 4th gear.



Crappy Conti´s. dont hold for more than 7 minutes...




2 days after this practice, I did a spontaious show at Vallakratraffen.se northern europes biggest outdoor carshow/meet
Garaget | EVO på Vallåkra 2010

a few weeks later it was time for the yearly M.O.D, Mitsubishi Owners Day.
I drove 300miles with the trailer to get there... and just managed 4 laps before the gearbox broke...




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This was the end of 2010:
at this moment i decided to make a "big" change within the car.

To really go "all in" with the Driftingmodefications for 2011.......

[arrowhead]

This is really awesome and you should have a very fun car.

Was it very hard to adapt the BMW tranny, I have been thinking of a Hewland but they are a lot of money.

Keep those videos coming. and welcome.

[EGLTAWLN]

how did he manage to use a bmw rwd m3 tranny with a transversly mounted engine?
First driftingcompetition with the EVO in September 2009, came in 4th: Garaget | DRIFT E V O @ BivarödsDriften - this video shows his engine bay. the engine is installed as is normal. how did he manage to mount the bmw m3 tranny without it sticking out the passangers wheel?
how did he mount a tranfercase to it?

[ludedude13]

I was wondering the same thing.

[KHRacing]

Hey, i´m sorry, i simply forgot a lot of stuff that was done

i have edited to first post, with pictures and text, please read it again.

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continuing on my story though:


As december 2010 came, the car was parked in the driveway under its cover, i then realized i had to take a short break from it all....

but it was not supposed to be a year and a half.... to where Iam now !

In April 2011 i remowed the engine/gearbox...


I had alreday back in February 2011 ordered the gearbox at the local breakeryard, also did I pay for it directly, but it still took them 9 months to remowe it from the crashed car. So i recived it in december 2011.

I immediatly went over to my friends garage togehter with the torn-apart broken EVO gearbox (sold the insides) so that he could cut both clutchcover and weld them together to make the M3 gearbox fit the 4G63.
Jimmy then proceeded to just this. He does this by hand with an anglegrinder, no machining of the parts at all. Then he measures for like 3-4 hours
and finally welds the parts together.




Now that the engine/gearbox transformation was done, i needed a new M3 throwout bearing (not cheap) & a set of new clutchdiscs, EBAY´s great

Then Mike my garagebuddy and I cut the front crossmember into 3pcs:
Since the gearbox will pass right through where its located:
the middle part is thrown away, the remaining parts were box-welded
reattached in order to fit the all new enginemounts + steeringrack.




We also cut the firewall open:


Since i will be using an BMW M3 gearbox, i needed the front part of an BMW propshaft. So i cut it of a E39 540V8 at the salvage yard.


BMW shaft vs: EVO shaft:


BMW shaft fits with 2mm to spare on the outside of the EVO shaft,
its gonna be easy to weld them together.


I also bought the turbo from Jimmy for 280dollars.
A Schwitzer s300: (off an Scania-bus)


I then had the compressorhousing sandblasted & powdercoated in chrome:
Here with the twin dumpvales i will start off with:


The new front crossmember was cut measured measured measured & a little more measuring, before i welded it to the sides of the remaning old crossmember:


the pedal-set has been "narrowed" 7cm in order to make the clutchcylinder on the firewall fit beside the new intakemanifold.


Mike welds the new wateroutlet at the back of the engine. A new external thermostat will also be fitted

[greengoblin]

SO far I love everything I see here. Awesome work.

[KHRacing]

Originally Posted by greengoblin

SO far I love everything I see here. Awesome work.

Thank you so much, I tend to try and make everthing myself or with a few trustworth friends help, but its not really easy, I have no education in anything, but I learn fast - the Tig-welder though, thats hard to learn

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here the new wateroutlet that sits at the back of the engine; it will pass under the intake to the radiator, the external thermostat will be on the front side attached to the waterpump.


engineblock drenched (?) in paintstripper.



Gearbox
BMW E36 328/M3 5-speed with EVO clutchcasing


welds grinded before paint.


a bit more grinding to make the starterbolts fit


remowed some parts of the gearbox that was not needed.


highpreassurewashed engineblock


a 6mm steelplate will be the start of the new enginemounts


front part of the chassies cut, wil be replaced with a remowable made from a light steel rods


engine + gearbox together:


First test:


adjusting the new front crossmember made from a 50x50x3mm,
not an easy task to measure it to the exact place without clear fixingpoints:


Made new fasteners for the steeringrack

shortened the steeringknuckles 20mm


new frontbeam, removable attached with 2pcs 10mm stainless steel bolts.


Steeringrack is now in its final place, tok about an hour or two just to make/find the exact right measurments.




one picture with the engineblock in place.

[KHRacing]

Continuing my story!

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Designatet OP: steeringangle

Stock is 32-33 degrees:


Widened front controlarms with 30mm:




Added another 5mm to make a total of 35mm, which added another 2 degrees:


Result: 5 2 degrees

sanded anf painted:


engine/gearbox in place, without the enginelift




camshaftsensor 5mm from the firewall.


Here´s the link to my thread on how i made my own intake manifold:

Homemade intakemanifold

Gearboxmount:

before:


after:


remowed welded stock enginemount:


velded all the drilled out spotwelds


My inspirationboard with pictures of different carmodefications, ,
one is an RWD EVO 6 from Greece:


Steeringknuckles version 2, the are now even more modifyed, so that Parallell-ster is almost accomplished.:


I made this "test-board" last night out of cardboard, easy way of checking
if you steeringangles will work or not.


Two new wastegates from a friends company


Propshaft testfitted to see where it is needed modefications.


Firewall viev.


BMW propshaft on top of EVO-shaft will need a lot of cutting to fit.
But no real problem. Hardy-disc (is it called that?) will be a new one
from BMW, from the model, BMW E34 M5 3,8

[RWD4G63]

Looks good man!

Your english is quite good, I'm not sure what a "hardy-disk" is though.

There aren't a lot of RWD 4G63's around, but I'll be joining the club soon with my S-chassis.

Have you ever thought about running a wider rim/tire combo in the rear? Not only will it help your tires last longer because they won't get so hot, but it'll allow you to drift with more speed.

[turboglenn]

Such an awesome and unique build.. I'm surprised by the amount of stuff you were able to get awya with in the line of welding two bell -housings together to mate the trans and such. Just goes to show even the simple "first thought" aproach can work well when properly executed. great work

BY hardy-disk do you mean the clutch friction disk or something else?? Just curiouse but that makes the most sense when i think of what it might be

[KHRacing]

Originally Posted by RWD4G63

Looks good man!

Your english is quite good, I'm not sure what a "hardy-disk" is though.

There aren't a lot of RWD 4G63's around, but I'll be joining the club soon with my S-chassis.

Have you ever thought about running a wider rim/tire combo in the rear? Not only will it help your tires last longer because they won't get so hot, but it'll allow you to drift with more speed.

Thanxs I attended an english school for 5 years when i was little ! you never forget what you learn really

Here is Sweden there are five EVO 1-3´s with RWD, but all run the simple solution of welded centerdiffs.

I will stay with the maximum width of 215/45-17 sine the wheelwells (arches?) are som very small on the car, remember its a rallycar made for 15"s´.
But i will attach some external arches like the japanese driftcars often use
and for this i will cut the fenders roughly 1,5" uppwards ang mowe the rear wheels out about 1" per side, remember the front was widened by 70mm already.


Another reason for the narrow tires is that the EVO hasa very short wheelbase
combine this with wide tires, & it will be so much easier to "loose" "drift-traction in mid-drift in any turn, I rather use narrow tires to take the strain of the gearbox/diff I have never understood why most drifters that are serious want to run 17-18-19". It will just break the drivetrain easier. i run 17" because of 330 brakediscs

Originally Posted by turboglenn

Such an awesome and unique build.. I'm surprised by the amount of stuff you were able to get awya with in the line of welding two bell -housings together to mate the trans and such. Just goes to show even the simple "first thought" aproach can work well when properly executed. great work

BY hardy-disk do you mean the clutch friction disk or something else?? Just curiouse but that makes the most sense when i think of what it might be

Thank you so much, its fun to have people like what i do !
My friend who welded the tranny has done a lot of these mostly though for Volvo´s hehe, he runs a FIAT 131 with Volvo rear axle, Fiat Croma 2L Twincam engine with an HX55 turbo & also the same gearbox i have, an M3... NO-ONE will run against him at any streetrace around here ...
Picture of my friends car...


I found a picture of an Hardydisc, its sits between outputshaft of the gearbox & the propshaft made of rubber.


---------------------------------------

Took a small timeout yesterday untill noon... They had 2 on the salesfloor... so i could not decide...



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Did some propshaftmechanics yesterday evening

had to cut a lot more of the two different propshafts.
[url=http://forumbilder.se/show.aspx?iid=6e2201294632P0cb1][/URL
together but not welded. here you can also see how much i have been forced to raise the propshafttunnel.


This part of the rollcage will be changed out to an big X + a new lower mounted pipe.

[PSI_BOOST]

This is a unique, and well executed build. Congratulations on a car well done!

[KHRacing]

Originally Posted by PSI_BOOST

This is a unique, and well executed build. Congratulations on a car well done!

Thanxs a lot, such an reply is near unique as well

But there are atleast 4 more EVO´s that have North/South engine installation...

Japanese Drift Team Orange has 2, one is an EVO 9, one is a EVO 10

The others i know of is one russian guy with an EVO3
& one greek guy with an EVO 6

.................................................. .............

My propshafttunnel is taking form.. The propshaft for the BMW gearbox is unfortunatley sitting 12cm higher in the chassies.
So all new fitting for the middle bearing is needed




Part of propshafttunnel in 2mm steel



Welded:


Stronger fittning for the bearing


-----------------------------------

Russian EVO3


Greek EVO6


Team orange EVO9


Team Orange EVO10
[URL=http://forumbilder.se/show.aspx?iid=e832012112735c169]


I got a load of stuff from a friends company called Realcar.se Scandinavias biggest stylingcompany.

I also have a recent sponsorship from MONSTER ENERGY

[KHRacing]

more stuff done....
----------------------

front top beam sanded & primed


Temporary fitted for making intercoolerfittings:


Intercooler attached


BMW fronthalf / EVO rearhalf:


The whole propshaft welded, sanded & primed:


Shifter linkage, not an easy task.



Both gearlever & handbrake need to be in the exakt right position

[RWD4G63]

Looking good man! Was there a reason you didn't go with a one-piece driveshaft?

[KHRacing]

Originally Posted by RWD4G63

Looking good man! Was there a reason you didn't go with a one-piece driveshaft?

HI, yess. the angle on the "hardy-disc would be to much.

Did we establish the correct english name for the hardy-disc ?

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Shiftermechanics....


A 2,5mm thick steel plate is welded in for the handbrake to sit on,
this thickness so that it does not flex when handbrake is pulled.

Since the EVo has a very narrow passengercompartment, it was not an easy task to place the handbrake where i anted it.




"almost done"

[KHRacing]

Photo from behind, here you see the hydraulic handbrake sitting
very close to the gearlever, But it´s also som 12cm further forward so i vill not tap it when changing gears (I HOPE)



Today i have grinded down a lot of welds hard work & not very fun...

I also modifyed the handbrake-handle, by adding some 6cm in lenght, since i had to alter the "gearing".

[KHRacing]

Today some more propshaft welding has taken place:

had to weld in a small piece of steel onto the bigger one since m missing some bigger pieces.


Will need some grinding/sandning:


I had to remake half the pedal-set, in order to make the clutchmastercylinder comoe 4cm furter back.


Also i modifyed the short lever that pushes onto the clutchmastercylinder.


The clutchmastercylinder is 4cm further back.

[KHRacing]

steeringwheelshaft fitting


lengtened 22cm


Started to cut some sheetmetal fot fit around the gearbox



Also bought 2sets of brakecoolinghoses:
just 15 dollars each:



had a meeting with a representative for Dunlop Tires, will see soon
what comes of it.

Made a hatch for easy acess to the propshaft/gearlever.



Also fitted some more sheetmetal on the gearboxtunnel


the gearboxtunnel is almost done


Here are pictures of the re-made firewall by the clutchmastercylinder, & the cam-sensor.

Enginebay wiev:


From inside the car:

[KHRacing]

Finally the gearbox/propshafttunnel was done:

Remowed engine/gearbox:


A second hatch has been done for easy acess to the gearbox/gearlever:


After one hour of using the anglegrinder on all the welds:


After two hours:


My homemade throttlepedal was re-done to fit the new firewall:


a front diffusor from a racecar,

[phizzalot]

Looks Great KHRacing!!!! Keep it up man I am still reading through some of the unique things you did but it all looks great.

Very Good Stuff.

[KHRacing]

Thanxs man !.

[Sirnixalot]

looking good!

What are you planning to do about the rear diff?

[KHRacing]

Originally Posted by Sirnixalot

looking good!

What are you planning to do about the rear diff?

Thank you so much !

Nothing except change the oil frequently
I have such a light car remember.. just som 905kgs, even lighter when all
this is done i hope, since the BMW gearbox only weights 36kgs, and the EVO
gearbox weights 68kgs

Light car = much less wear&tear on any parts.

I have used the stock LSD-diff for soon 4 years, with justone single problem after 3 years.

So i will run this one untill it explodes

then fit another my spare one with welded diff.

regards Kristian

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Now all is welded/grinded. will sandblas some parts & the put on a little fibreglas. then paint with Hammerite

[KHRacing]

Seen some pixs of an Escort Cosworth that had a small "protective cage around its intercooler, so I made my own, couldn´t hurt right ?



And primed:


Also made some adjustments to the steering, now i have 62 degree´s:

[KHRacing]

have been testing som different angles on the hydraulic handbrake today:

Old:


New:


Maximum camber tested, does not rub anywhere at full lock R/L:


Robin helped me fit the modifyed throttlepedal:



We also "budget turboed" Mikes Volvo 360GL today with Audi injectors, an Saab 9000 intercooler, Volvo S40 T4 turbocharger & some gardenhoses. will testdrive it on tuesday


Robin also testad Mike´s car..., check out the gearlever:

[KHRacing]

Grinding, sanding put on a little bondo (is that what you call it ?)

Tomorrow i will paint on some "rustpaint" to stop the metal from rusting:

[KHRacing]

Bought a lot of different sandpaper:


an hour of machinesandning per side... still not done though
left:

right:


Also welded in my reinforcementplates for the seatstays.


Finally everything has been sanded dowm b4 rustprimer & paint:
+ gearlever remowed:


started to paint on the rustprimer:


Also made som smaller "cuts" in the inner metal-arches to be 100% sure that the
tires never rub & tear.

[RWD4G63]

Looking good! Body work is a long process isn't it? Most people don't realize how much work it is till they start! Hahah.

[KHRacing]

Originally Posted by RWD4G63

Looking good! Body work is a long process isn't it? Most people don't realize how much work it is till they start! Hahah.

So very true there.
I towed the car to the new garage in January, since then i think i have worked atleast 250hour on the car :-)

But atleast this build i´m doing with N/S engingemounting, is atleast 1month ahead of scedule