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Tachyon
03-21-2011, 11:34 PM
Well, I thought I’d start a project thread of my own since, I am going stir-crazy waiting for spring and all the concomitant blessings the changing of the season brings. That being said, I thought I’d overview the development, build, and continuous process of our Rally Car, the 2003 Hyundai Tiburon GT.

http://www.technorally.com/build/shark.jpg

We have a fairly modest rally program as it’s just a few of us right now and it’s much more of a hobbyist approach rather than a hardcore lifestyle imbalance.

We’re not out to set the rally world on fire but rather just to have good dirty fun, learn a lot, and meet some interesting people along the way!
Sorry if I write a novel, it’s just how my brain works.

Please feel free to skip my textural wanderings and look at the pictures that follow :)

The number one question I get asked in regards to this project is, “why a Tiburon.” This is a fair question, and the answer is multi-part; some of which I’ll address:

Reason 1. In order to start stage rally you either have to have applicable racing experience (for turbo awd), or start in a 2WD, naturally aspirated car. Since neither me, nor the driver have "documentable" racing experience, this seemed like the way to go, plus in central there are quite a few more cars to compete with in this class.

Our first thought was to build an EG hatch with a k24 swap, and have an absurd power to weight ratio within the rules of the G2 class (2WD, N/A, under 3050cc). However the more we thought about it, it really seemed like more of a cop-out, non-creative thing to do, especially when you consider how developed that platform is. That brings me to point #2.

Reason 2. Discovery: the major reason I enjoy modifying cars is the fact that you get to create what you want – you shape a car’s performance profile to your own personality. I’ll come out of the closet at this point and say, I personally prefer naturally aspirated engines to turbo. Odd I know, being my fun car for the last 8 years has been what it is… I could write a whitepaper on why, but most of you understand the pros and cons so I’ll condense the idea to this: the challenge.

The level of knowledge, effort, and testing to extract decent levels of power without the aid of massive displacement (dynamic or static) frankly shifts my gears. Not sure how else to state it, really.

Reason 3. It’s a Tiburon... Let’s face it, this is a bitch car designed and marketed towards late 30-something year old single women, who are suddenly realizing they missed out on their optimal procreation window. It’s heavy, the engine stupidly under-cammed, and it completely lacks any modern-day technologies we now take for granted. Now, that being said, there are some advantages to this platform:

I. It’s rally proven: The Tiburon platform utterly dominated the North American rally circuit. From 1995 to 2000 it won 5 consecutive manufacturer championships racking up 34 outright wins. In 2002 it cleaned up Open class again with the Libra race team under the skilled driving of Mark Higgins (who is back in the States driving for Subaru Rally Team USA in 2011).

http://www.technorally.com/build/libra.jpg
Subawho?

II. The engine aftermarket is virtually non-existent. I know this is usually considered a drawback, but in this case the platform serves as a blank slate to put into live tangible action the engine theories and simulations some of us geek types jerk off to in the dim glow of our computers into the wee hours of the morning. If this platform was developed, and had easy 3 -step recipes to making N-power with Y-parts, I don’t think I would really be as motivated (I enjoy engines more than driving)

So all that being said, on to the build:

This specific Tiburon was purchased new in winter of 2002 by the individual who drives for our team. It has since then accrued 70k and some odd miles of complete hell, being whipped like the surrogate offspring of a rented mule. There have been zero issues.

http://www.technorally.com/build/DSC_4862.jpg
dodging cones...

Over the years, there have been a series of upgrades to various engine components. These had chiefly been what limited bolt-on’s that were available to the diminutive V6: intake, headers, exhaust, clutch, flywheel, etc... While these mods did increase the output of the engine by nearly 25% (but still less than noteworthy) the difference in throttle response was positively shocking.

Ok, enough brain dump. Off to the build!

Tachyon
03-21-2011, 11:34 PM
One of the first challenges we faced was the lack of engine management systems that would fit the bill for a race car. Besides the needing specific control over our engine, we also needed a MAP/ Alpha-N based system for our planned ITB conversion, as well as quite a few more inputs for engine and telemetry logging.

We decided to use MSII-Extra for the engine management, because it’s all about learning rather than ready-made solutions.
Prototyping the system was quite rapid:

http://www.technorally.com/build/engine.jpg

A quick peek into the engine revealed it was just a basic 60-2 crank wheel with a Hall sensor triggered on the rising edge. After that it was just a matter of matching up stock sensors to the correct inputs and of course, calibration. Spark output was done with 3x Bosch BIP 373 transistor. They are both tough and can handle the sustained high RPM output of rally.
Building the ECU was fairly straight forward:

http://www.technorally.com/build/proto.jpg

We wired this into a stock harness and plug for fast disconnect

http://www.technorally.com/build/wires.jpg

http://www.technorally.com/build/plug.jpg

We did have a few issues with the spark dwell being artificially set too low, but other than that she runs like a champ… much stronger than stock after correcting the AFR’s and dialing in better fuel and timing curve.

Tachyon
03-21-2011, 11:35 PM
Now that the car has a new brain, it was time to start preparations for the cage.
http://www.technorally.com/build//teardown.jpg

http://www.technorally.com/build//teardown3.jpg


On recommendation of fellow MN rally enthusiast, Carl Siegler (Carlvr4 on this site), we decided to use former Prodrive World Rally Team crew chief (for Richard Burns), Graham Evans for the cage. The logic being, if we are doing triple digits on gravel, scant inches from oak trees, we should probably go with a top-shelf safety cage.


The cage was assembled off and on for the next few months, lovingly fused together with grinders, welders and a steady stream of coarse language directed at the cramped interior dimensions of the vehicle...


http://www.technorally.com/build/cage1.jpg

http://www.technorally.com/build/cage2.jpg


http://www.technorally.com/build/weld.jpg


http://www.technorally.com/build/moreweld.jpg


Precision work
http://www.technorally.com/build/cagedoor.jpg


All finished
http://www.technorally.com/build/dissasembley.jpg


...and then cleanup and paint


http://www.technorally.com/build/home.jpg


http://www.technorally.com/build/inside.jpg

Tachyon
03-21-2011, 11:35 PM
From here we started further preparation.
http://www.technorally.com/build/painted.jpg

We welded a roof skin in place of the sunroof

http://www.technorally.com/build/roofskin.jpg

It was from a Chevy Caviler… turned out all right:
http://www.technorally.com/build/skin2.jpg

Then we started installing and adjusting the interior equipment:


Sparco Evo seats
Schroth6-point HANS style belts
Sparco wheel
Co-driver foot plate
Peltor Com unit
Terratrip 202+
Fabbed up switch panel

http://www.technorally.com/build/seats.jpg


http://www.technorally.com/build/into.jpg

It was starting to take shape… it would soon be time for trial by fire in her first race!

(more to come later!)

b00sted_spyder
03-21-2011, 11:41 PM
Damn that interior looks nice!

scheides
03-21-2011, 11:44 PM
Now *this* is a project thread! Nice work man, can't wait to see the progress!

Speedfreak
03-21-2011, 11:52 PM
Graham is good people. Car looks great, keep updating us through your season if you would.

Halon
03-22-2011, 12:18 AM
Badass man. Have you become pretty familiar with Megasquirt then?

s1ngletracker
03-22-2011, 12:23 AM
This is awesome. I love reading rally builds. Please keep updating! I am strongly considering rally after my Chumpcar forays are over.

I have a few questions:

How the heck did you remove the windshield without horribly messing it up? Or maybe you did mess it up...

Is there performance limitation to Group 2? I haven't spent much time reading RallyAmerica rules.

goodhart
03-22-2011, 06:59 AM
Very nice Paul. Have you guys ever considered putting an Alpine on this thing?