building a 2002: January 2008

Support out back

Finally made it to the metal place where they sell, uh, metal. This rear suspension cage(?) is going to be completely assembled out of car in order to get full welds. Still need to weld on the upper coilover mounts and one of the sideplates. It will then be welded into the car at both ends and the bottom. I was going to triangulate the hell out of it. Then I decided to keep it simple, as i think this will be plenty strong. It looks really heavy, but its actually under 15 pounds(arm scale method).

As of right now, it looks like my plans of running the coilovers inverted is going to happen.

Obviously i chopped off the old upper mount area. I also moved the upper mounting point forward a couple of inches to help maintain the original geometry as I moved the lower mount forward as well. Coolest part is that the ride height should be able to be adjusted from the trunk!

On Deck.

With the suspension coming to a close, the engine is on deck. Basically a full rebuild with stock components. Forged pistons will be added to handle the boost. Stroke will stay stock, bore will be determined once cylinders have been checked.

Give me fuel, ...

Got the basket for the fuel cell fabricated. I know it looks like a strange design, but i had to accomodate the bottom feed/return line hookups. It supported me jumping up and down on it, so unless we switch back to leaded fuel, it should be plenty strong. I still need to fabricate a strap to go over the cell to hold it down. If i dont get more steel this weeek, dont expect a progress report anytime soon. The angle iron on all four corners holds it in place nicely. I have a hard time getting it out even without an over strap.

Rear Legs

I have got to get this rear suspension done. Ive been working on this suspension for so long, and the end is so near.

After much debating, I think ive figured out how the rear lower mount is going to go:

First i welded some flat stock and wrapped it around the circumference of the control arm bearing area. This is to distribute the stress of the mount assembly. Then i welded on the mount so that the strut can go through the complete travel without the heim joint binding. I plan on mounting the coilovers inverted as long as space allows. I need some "cage" material before i can attack the upper mounts. Hopefully Ill get to that this weekend. (yes, i removed the wheel bearings before welding)

Shameless plug

If you have the chance to do business with kelleyracingcompany.com do it.

I ordered my pedal assemblies, battery box, shock mounts, rear coilover sleeves, rear shocks, and some other stuff. Theyre an excellent company to deal with.

Battery box:

I wasnt sure what i was going to need for fabricating the rear coilover mounts, so I ordered them all. Hopefully I have my design figured out before the return policy expires.

Stopping power.

Wilwood brake pedal with dual master cylinders and balance bar. Only a few components left before the brake system will be complete. Also pictured is the Wilwood floor mount clutch pedal.

ARP wheel studs for the rear. Plenty long, plenty strong. These are intended for a Lexus IS300, but fit absolutely perfectly. Im sure these are the ones Ireland engineering sells. But if you want to get them on time, right part, and without being treated like shit, order them from Jegs or Summit.

Slammed

Fully tucked. First thing to cause interference was actually the control arm hitting the floor board. I hope to never see this kind of compression, but its nice to know the room is there.

Rollin dirrrty

Well it looks like a roller. Unfortunately the rear suspension is not done and its being held up by jackstands.

When fully drooped tires are hitting the outside of the rear fender. Luckily, that can easily be trimmed.

All slow, No go

Lee's Massive kit installed(minus the front rotors for now). Everything went in perfectly, although i think i installed the parking brake assembly every way but the right way. Once i finally figured out the proper sequence(bracket>rotor>then spot caliper) it fit perfectly.