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87 Galant RalliArt 2.0TURBO 4G63BT

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Amazing work!
 
Little update, trunk is completed, also an interior and the doors, every little thing was polished, galvanized bolts etc, it takes a lot of time for that (for doors I have spend 2weeks of every day work)

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Side skirts are ON :D

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Interior COMPLETE

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Front light renewd , galvanised bolts etc.

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Got some time to finish my custom made mud flaps, base design was for an EVO6

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And FRONT end finished, it looks so clean now, better than new :D

here is the pic i like the most :D

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And one with all lights ON

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so cool! i just bought a 88 dodge colt sedan. its the same body but totally different front clip, and rear bumper. its a pretty sweet old car. i might sell, or swap it. already have a swapped colt, but seeing this one makes me want to keep it
 
well Galant body doesnt have anything with the colt lancer

everything is much bigger, stronger and luxurious than Colt sedan
 
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upon closer inspection, i see they are completely different!
 
Time for new exhaust full 70mm exhaust, with electric cutout on the rear muffler ( for quieter and louder mode), and polished 80mm exit

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So here is my design

two pipes through the rear muffler (bigger one(70mm on the electric cutout side, without holes on it), and smaller one (60mm, where gasses are going when cutout is closed(with holes in it, so the muffler can absorb sounds)
remember , the angle of those two pipes is very important, the bigger angle you got, the louder car will be when the cutout is opened

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Next thing to do is to port a turbo housing, this needs to be done to prevent boost creep, here it is how it looks before and after around wastegate

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Later i had problems with a hot air when boosting. As the car still isnt mapped, and its in brake in proceduree hot air is allready a problem, so it would be big problem during the mapping

So i got almost a brand new intercooler from EVO10

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And one video how electric cutout work(sounds)
this is without middle muffler, so basically when electric cutout is opened it simulates straight pipe

[video=youtube;30WK_nj8n_c]
 

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Intercooler fits perfectlly

it is 3times bigger than the old one

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oil cooler was also relocatted

here how the intercooler looks after redoing the pipes, also a SPAL fan was added for better cooling

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Electronic boost controller is installed also

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and i got a throttle body from an evo8, much better and faster TPS and ISC sensors

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Next, i had to make adapter for ISC to the Eclipse/ early EVO installation

also i had boost leaks on throttle body, and on the outlet of a turbo, so a new flange has been made

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Rebuild kit for throtle body

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Next i got very lucky and found a brand new middle blend for redesign version complete with instructions and install hardware

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also i got a brand new right tail lamp

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to me looks much better with it :)

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another CRASH, fortunately a very light one, Opel didnt pass well haha

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All repaired now :)

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one with mine second Sapporo with ECS (Electronic controlled suspension)

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nice turnup one evening

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and meeting with a friend of mine (normal vs RalliArt)

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next thing i got is pieces for suspension upgrade

much larger holder bracket for front subframe

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and poly bushings for front end

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THAT is an awesome build. I have a question about the origins of that AMG spark plug cover though, any history or details?

congratulations on the build, I hate that it got hit twice, that must have sucked.

(short story) after I got my talon painted, I was backing out after looking all around in a local grocery store parking lot and some granny in her van whipped around the corner and into my rear passenger corner, I was far less than happy. But almost laughed when I bore witness to the damage, some scuffs and her vans white paint on my car was all it did to the Talon, her vans front passenger fender on the other hand, was caved in pretty badly. Got to love 80's-90's cars. Lighter than modern cars, and stronger too!
 
thank you

AMG cover i got from one guy from US, also i got a spare one from New Zealand :)
 
Lets post a few updates

next thing for deal with was suspension and handling


Suspension was original, but all springs are worn out and old, rear shocks were leaking, and also the car was too soft to handle that kind of power so i upgrade it to much better level

Ive bought Cusco street ZERO coilovers for Lancer EVO III

car handles much much better in corners, over the holes its almost like stock suspension, over the speed bumps you have to be little gentle , overall very good coilover

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Also got the powerflex camber bolts as the car sits little lower now

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Got new oem bumper indicator lens

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Then the next problem was grip, i had only 2 and a half years old tyres but they didnt have grip at all

So i bought new tyres Continental Contisportcontact 5 215/45/17, also as I will upgrade the brakes i need new wheels that are the same dimensions (17" , 7J , ET40) but with flatter spokes
that means more space for bigger brake calipers, luckily i found Superleggeras which are 4kg lighter than previous wheels EACH! and also they have 1,5cm more space for brake calipers

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Cleaned up the wheels, waxed them, got new central rings 67,1mm and new lug nuts

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And ready to fit on a car

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Results are awesome, lighter steering wheel (as each wheel is lighter for 4kg), and much more grip, which allows me to run full boost in second gear afer 5000rpm

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Also getting the parts for next work

new tie rods, new tie rod ends, new boots, new front bearings, new CV joints

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This thing is pimp. Keep the updates coming!
 
Next update, got the brakes, 4pot brembos with braided steel lines and 320mm discs

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redrilled discs to 4x114,3 and test fit, it fills up the 17" nicely

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got new front bearing in, and also polyurethane on arms

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Custom made heavier springs for trunk opening, as the factory didnt design it for trunk spoiler, now the trunk hood sits up alone :)

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Another gearbox from 2.4 Galant is in with lower miles on it

also installed new OEM shaft seals

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new clutch disk material

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also new braided steel line for the slave clutch cylinder, you can see how worn out is the old one

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and new slave clutch cylinder

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Disassembled front subframe

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Some new parts

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Took out the bushings front front subframe, they were in really bad condition, as you can see on the picture, new oem ones are ready to pop in

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also new stoppers

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New gasket for fuel sender unit

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New grommet for hood pin

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Then i have to install new seals in the steering rack, and also new rod ties, rod tie ends and new boots

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New boot for steering rack

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Dont have picture when shafts were finished, but painted them to OEM colour

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Painted brackets for front subframe

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Installed and painted slave clutch cylinder

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Custom made full rubber front engine mount

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Polyurethane SuperPro bush on sway bar

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Finally made an adapter for EVO ISC to DSM wire installation

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Assembled complete front subframe, car really drives fantastic now, no sounds at all, and brakes, AWESOME, it has the stopping power now

also to make it a little softer i have made custom springs, front 5,6kg/mm and rears 3,5kg/mm

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Calipers refurbed, new, bolts, paint and stickers, little before/after

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It fitted very nice :D

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New blood

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At the geometry service

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And got the fluidampr crank pulley & ARP bolts

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Few more updates

new rear steel brake feed lines

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installed fluidampr crank pulley, and also new Gates, alternator and power steering belt

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looks good underneath now :)

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Got brand new OEM front grille

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Adjustable rear dampers came in, Cusco, newer dampers, and also they are longer for 1cm, which means a little more street friendly

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Comparasion to a non adjustable CUSCO

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and one nice pic from the petrol station

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Great build. One of my favorites. The exhaust cutout with the muffler is totally sweet!
 
thanks. yeah cutout thing is pretty cool. as i use my car for holiday trips also. And i want my car for multipurpose use. Not only for street racing
 
Little update, havent been working on a car. I was driving it for a change, done over 3000km over the last 3months

In front of Pula Arena

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then i was on a oldtimer meeting, with my dad(green 4gen Galant), and a good friend of mine with his RalliArt version also in white. That was a pretty cool sight

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And some better photos of mine car :)

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Couple more updates

Crankpreassure was next thing to deal with, no more oil dip stick popping out and inlet on turbo is now dry :)

so I have made a custom valve cover, drilled a much larger hole, and weld bigger fitting, removed PCV valve and also put a bigger one, but left the thread in case i will want to return PCV :)

after that, professional coat was apllied

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difference between holes

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New oil Catch can and silicone hose

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Then few shots from the sea and driving :)

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Then got new silicone clear hose for washerfluid line, so I have replaced an old ugly one :)

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Thats all for now :)
 
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