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Thread: Kelway RallySprint Corolla

  1. #1
    Junior Member Rex_Kelway's Avatar
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    Default Kelway RallySprint Corolla


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    Welcome Knobs and Knob-ettes,

    Rex considered writing a build diary of His RallySprint car, but really couldn't be arsed. So what follows is a collection of photos of the elements that have gone into the stupid thing, with a description where necessary. As they say, a picture is worth the words of 10,000 nerds.




    For those who don't know, RallySprinting is basically short course rally. Its un-pacenoted and stages generally run from 2 to 5 minutes. Rex is a member of the WACC (Walkerville All Cars Club) and events are held out at the clubs dedicated property just outside Truro, 'Walky Park'. As you can see the number of tracks/courses that can be arranged is almost endless.



    Being basic motorsport, there is no need for huge levels of car preparation or awesomeness. Rex's Corolla was built only to flex some fabrication muscle after starting His 'Kelway' motorsport business and to show just what can be achieved on a budget***

    Anyhoo, He shall begin...



    ***Budget meaning a little money spent wisely. Not an unreliable, defected, rusty shit-box deathtrap as seems to be the meaning of 'budget' as held by some of the younger generation.
    Wait long by the river and the bodies of you enemies will float by...

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    Junior Member Rex_Kelway's Avatar
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    These few show the car as the bodywork was being done. Its only the second car that Rex has painted, He's reasonably happy with the job. He's also a sucker for the clean white look... The rear guards were split, heated, stretched and re-stitched. There is surprisingly little filler, only used for surfacing. The front guards were trimmed and flared with had formed and edge-rolled aluminium extensions riveted in place. The front section of the chassis was stitch welded both inside and out.
    Wait long by the river and the bodies of you enemies will float by...

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    Junior Member Rex_Kelway's Avatar
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    As part of the bodywork and paint the roll cage was done. Its above all else designed to be an efficient system. With only 130Hp the cars performance could be seriously blunted by having to lug around so much extra steel. For this reason He's tried to tread the line between safety and weight. Its all built to CAMS specs.
    Wait long by the river and the bodies of you enemies will float by...

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    Junior Member Rex_Kelway's Avatar
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    Suspension was upgraded with AE86 struts, KYB rally dampers, height adjustable front @ 4kg/mm and stock springs rear. Rally requires a careful blend of ride height and suspension travel and stiffness. The crossmember was modified to accept Soarer eccentric bolts to adjust camber and track. This was done because it provides adjustment while leaving the stock rubber bushed joints in place for compliance.The car runs RA40 tierod ends and adjusters. A tercel rear swaybar was added to the rear, and a stock one up the front. Bushes replaced as necessary. The wheel probe for the Monit trip-meter was installed on the front wheel to eliminate wheel spin errors. Brakes were upgraded to S13 CA18DET 250mm items, these are the largest we could get behind the 14inch wheels. Inner guards were re-made and retained, ofcourse.
    Wait long by the river and the bodies of you enemies will float by...

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    Junior Member Rex_Kelway's Avatar
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    Continued below...
    Wait long by the river and the bodies of you enemies will float by...

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    Junior Member Rex_Kelway's Avatar
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    Engine choice was the trusty 100kw 4AGE installed using AE86 crossmember and a heavily modified AE86 pedal set for the clutch conversion. The loom was stripped right back to only the necessary elements. Being FWD necessitated the usual throttle body and thermostat housing mods. Radiator was upgrated to a Cortina item with stainless radiator pipes. A fabricated airbox picks up fresh air and allows a huge selection of cheap replacable filter elements. The whole conversion was designed to be as neat and logical as possible and maintaining as many stock parts and systems as possible meaning its dead reliable and performs its best. The usual seals, pumps and belts were all replaced. The fuel system is the common lift pump, surge tank and EFI pump setup installed in the boot, but caged to prevent damage from items in the boot should the worst happen. The Lift pump to work properly must be placed at the lowest level of the tank. Its placed behind the rear axle and sheilded to prevemt damage.
    Wait long by the river and the bodies of you enemies will float by...

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    Junior Member Rex_Kelway's Avatar
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    The oil catch can as seen above proved to be a huge failure. At a Mallala track-day the continuous +6000rpm saw oil being pumped into the head faster than it could be drained away meaning that the tank was filled and overflowed quite seriously, luckily no engine fire... So an oil-air seperator system was made with a drain back to the sump while using the inlet pipe to pull a gentle vacuum in the crankcase. Below is the new system:







    MORE TO COME IN THE NEXT FEW DAYS!!!
    Wait long by the river and the bodies of you enemies will float by...

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    Senior Member doony's Avatar
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    WOW. guards are massive, this thing looks sick, wish we had some tracks like that in WA. we probably do but no one knows about them
    but it pisses me off when people assume your hooning cos your car is loud, has bald tires, a roll cage, fresh bake and dinted bumpers!!
    Or driving in a wolf pack.

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    Veteran shift_rook's Avatar
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    rally beasts are wicked! mad oil catch can setup

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    Veteran biggo's Avatar
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    Rex has done good.

    Is that the rex kelway cage that your going to be doing? Any plans for CAMS approal in the ke70?

    I also note you suspension setup, that is pretty much what Ryan smart said to go if i rally my car. Any complaints? What spring height with the kyb rally dampers?

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