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SH Garage: Gone To The Rallye

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SH Garage: Gone To The Rallye

 

‘Not Great’ Planning Mode

 

The best part of an adventure is the planning, right? Yes, and no. The best part of the adventure to me is just saying ‘yes’ to things and doing it. Sometimes it all goes off without a hitch; other times you’re seeing the back of a recovery truck. But hey, it’s all part of it.

While many of the other Speedhunters are incredibly organised people (looking right at Paddy McGrath), I’m just a little… looser.

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Sure, to get to events, and especially a pretty strictly-scheduled rally, does take a degree of planning, but I can quite happily leave a lot of stuff to the very last minute, or even worse, to chance.

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My process is simple: I see an event; I spend about 15 minutes online checking out how feasible it is to get there; I get a hotel booked with free cancellation (and no prepayment for absolute minimum commitment); and then forget all about until it’s pretty much time to go.

Case in point: The 2021 Roger Albert Clark (RAC) Rally.

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It was the start of May when I decided that the RAC was a possibility, a full six months before the event. When did I book vital things like a ferry or even decide what car I’d drive for the week-long odyssey? I can hear Paddy wincing, but a whole three days before. Booked on Sunday afternoon, travel on Wednesday morning.

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Normally I’d have to decide which car to take, but my hand was forced this time after I sold my Hyundai i30N a few days before the event.

The Hyundai was an amazing car and I enjoyed every single one of the 21,000km we spent together, but I was paying a pretty sizeable chunk of cash every month for the privilege. While trying to simultaneously save for a house deposit, something had to give.

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Hyundai gone, attention turned to my somewhat neglected 106 Rallye.

The little Peugeot and I had been pretty distant for a few months. A busy work schedule meant it was nearly three months since I’d sat behind its wheel, but the time had not been wasted. It got a run to Rallye Omologato 2 in the hands of Maurice Malone, and then went in for some mechanical work. Owning an older performance car – with 103bhp I’m clinging to that title – requires continuous preventative maintenance, but little updates also make life easier.

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Jumping back in, it felt like we hadn’t been apart. My feet immediately reset to the incredibly offset pedal locations, the deft throw of gearshift no more than muscle memory, and the familiar urgency of the rev-happy lump upfront had turbo boost instantly expelled from my mind.

There was one issue though – the 106’s NCT (National Car Test) cert had lapsed.

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Being legal was somewhat important given I had a lot of driving ahead of me, but looking into online bookings, the wait time for this annual road worthiness test – similar to the UK’s MOT, Japan’s shaken or Germany’s TUV – was six weeks.

In an amazing twist of fate though, a cancellation appeared for Tuesday morning, a mere 14 hours before I was due to leave on a ferry. This was last minute to the extreme, but I had faith in the little Rallye. After a somewhat tense 40-minute outside the test centre, it emerged with a ‘thumbs up’ from the tester and a new cert sitting on the passenger seat. Happy days.

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Home from work and everything needed packed into the boot, the back seat and footwells of the little Peugeot, I had enough time for about four hours of rest, although that was mostly spent thinking about what I’d forgotten.

My alarm went off at 1:15am and I was on the road 15 minutes later, albeit with the 106’s engine running at a higher-than-normal idle.

From home to the ferry in Belfast took just over four hours, the only talking point being an incredibly thick blanket of fog for the first 90 minutes. Prior to crossing over into Northern Ireland was a chance to fill the Peugeot’s fuel tank and grab some pancakes for breakfast.

Dashboard dining at five in the morning isn’t all that flash, but it sure hit the spot.

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I arrived at the ferry terminal with plenty of time to spare, which isn’t something I do often. Blanket? Check. Netflix? Check. For a man who forgot to put a spare wheel in the car, I had my priorities in the right place.

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Driving onto a ferry is always a rather fun experience, and while I might not have all the ro-ro facts like Ben and Ryan did with their recent trip to Ireland for 86 Fest, I can tell you that Stena Line to Cairnryan do serve a very fine breakfast and have a very comfy lounge.

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I arrived in Scotland to weather that had turned. Rain and cold – for my first ever time in the country, it felt apt. I don’t think I’d have liked it any other way to be honest.

Thankfully, it was nicer a few days later when border-hopping again to grab that all-important ‘car in front of country sign’ photograph.

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The one thing I wasn’t expecting was the incredible filth spraying off the near constant line of HGVs as I made my two-hour trip east towards the English border and onto Carlisle. By the time I stopped for fuel outside Gretna, the poor 106 was properly blackened, but deep down I thought it just looked proper.

I’ve said it before, but the Rallye is a car that looks equally great whether it’s polished or filthy.

The real MVP on day one was my Sennheiser headphones and a stack of downloaded podcasts. Throughout the week, this pairing was called upon during long drives, although occasionally there was time for some period correct ‘dodgy’ music. Because as great as the diminutive Peugeot is, cruising alone at motorway speed (which equates to almost 5,000rpm) can get a bit wearisome, although the deceptively-comfortable seating position really helps.

I made it to the RAC scrutineering, took and few pictures and collected my media accreditation – so far, so good. After dropping my bags to the hotel, I grabbed a bit of lunch and the headed back to the rally base for some more snaps. Again, no problems.

It felt like nothing could go wrong. Until it did.

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Heading home, the Peugeot lost all battery power and ended up stranded in a dark lane. It didn’t take long to diagnose the problem – an empty space where the alternator belt should have been. Clearly it’d had enough and exited somewhere along the road.

It was the first night of my week-long adventure and my 106 was already on the back of a recovery truck. Thankfully, I’d signed up to the AA Breakdown service before leaving, so maybe I was prepared after all.

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The next morning, with a fresh battery from an absolute legend of a roadside tech named Rob – a fellow rally man – we got the 106 to a nearby parts supplier. £5.20 for a new belt, fitted right there outside the door by Rob, and I was good to go.

A little over an hour after the 106 came off the axle stand I was parked in a forest in Kielder.

Rally Mode

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Over the next few days, the routine went like this: Get back to the hotel, throw the rally map out on the bed and figure out where the entrance to any given special stage was. Once pinpointed, I’d throw it into the phone and save it, then memorise the first car due time and work from there. Adding time for travel and a need to get there early to avoid too much of a walk (I know how precious that sounds, but remember I’d be laden down with cameras and gear), I’d end up with a rough estimate of my wake-up time for the next morning. It always seemed to be 6:30am.

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Arriving earlier on a stage allowed me to take a walk around and get an idea of good shooting locations, and just enjoy the peace and quiet of a forest in the early morning sunshine ahead of a frantic day.

It was also a chance to get in and set up things like remote flashes ahead of the first competing cars.

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The Rallye also doubled as a mobile office for the week. Stage shot, I’d grab my laptop and download my images. This is handy to keep memory card space free on the cameras, but also to get a few images quickly edited for social media. Although, the second part was a rather fruitless exercise given I barely had any mobile reception out on the rally route.

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As the days past, I only grew fonder of my 106. Laden with soggy jackets and muddy boots, it climbed hill after gravelly hill through the woods to the stage-side car parks – generally openings on wider off-road tracks that were often icy. Most of the vehicles were vans and SUVs, but a few hardy souls followed the ‘not in its natural environment’ approach.

From that first night blip, the Peugeot never missed a beat. Even the high idle rectified itself quite early on, a sure sign that the 1,300cc 8V just needed driving.

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As you may know from my RAC story, weather-wise, Friday evening was downright terrifying. I tend to sit low and reasonably far from the wheel of a car, but on this occasion I was nearly bolt upright, seat slid forward with two rather white-knuckled hands gripping the steering wheel.

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Storm Arwen had struck, and having left the final stage of the day amidst a snow blizzard, I’ll never forget the drive back to Carlisle. Pitch black, the admittedly poor lights of the 106 were no match for the oncoming deluge of snow. Reduced to dipped beams and at times park lights, the road became an invisible labyrinth of standing water and was only defined by the white lines visible in places. Every few miles there was a tree or debris to swerve around, one hazard in particular appearing quite suddenly on the outside of a crested corner.

It took two gruelling hours to get back to the hotel when Google Maps had advised 53 minutes.

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Stages were cancelled the following day, providing an opportunity to do some unplanned exploring. I’d seen pictures of the Lake District and it looked like perfect 106 Rallye territory, so I grabbed a coffee and headed 90 minutes north.

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Cockermouth to Keswick via the Honister Pass is one of the most spectacular drives I’ve ever done, helped in part by a lack of traffic on this crisp winter afternoon. The fabled allure of the great British B-road was living up to its stature, and mile after mile the 106 sang to its heart’s content. Naturally though, I had to add some spice to the situation.

When I’d seen the Lake District in pictures, it was launch photos of the 2017 Ford Fiesta WRC on the Honister. What I hadn’t done was research, and didn’t know it was both extremely steep, reaching 1,167ft at a 1-in-4 gradient, and extremely prone to ice. So, yes, it was mega, except for the terrifying descent. If I had crashed, at least the scenery was nice.

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As the Roger Albert Clark rally headed south to Wales, so did I. This drive from Carlisle to Snowdonia was the second longest stint of the trip, but the 106 ate it up. Sure, it may be tiny amongst modern traffic and a wee bit unrefined, but it’s fun. There are no modern frills, but that allows a chance to think, to plan and to take in the sights of the road.

Making a quick fuel stop with 106 miles to go was most definitely not planned.

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One thing I’ve come to learn about the Rallye is that it’s a welcoming car. People pass compliment, take pictures and want to chat, in a way perhaps I wouldn’t have got with the Hyundai or something modern. During a stop to take photos on the way to Dyfnant, a group of off-roading Land Rovers pulled in, and within minutes we were all chatting and checking out each other’s vehicles.

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The last few days in Wales were flat out. There were early mornings, late evenings and plenty of miles in between, but ultimately, I knew there was a ferry leaving Fishgaurd at 1:00pm on Monday that I intended to be on. That gave me a pretty firm cut off of 10:00am leaving Walters Arena, yet here I was at 10.15am admiring my little Rallye. Welsh mud, rolling hills and a dirty Peugeot 106 isn’t everyone’s dream view, but it is mine.

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The drive to the ferry was frantic as expected, and I arrived with a whole six minutes to spare. Boarded and settled in the lounge, it felt great that the Rallye and I had made it to the end, even if another three hours lay ahead from Rosslare to home.

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When you ask what some of us are doing with our SH Garage cars, well, I’m mainly just driving mine. The Rallye is outside the window as I speak, and I now feel torn about whether to put it into winter storage or not. Over six days, across five countries and clocking up 2,450km (1,520mi), we both had an adventure of a lifetime.

Cian Donnellan
Instagram: Ciandon
Facebook: CianDonPhotography

 

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Project GC8: Taking Care Of Business With ST Suspensions

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Project GC8: Taking Care Of Business With ST Suspensions – Speedhunters



Project GC8: Taking Care Of Business With ST Suspensions

Welcome to another instalment of Fixing Broken Old Japanese Cars On My Driveway.

On today’s episode, we’ll be swapping out a set of old Cusco coilovers for a set of brand-new ST Suspensions XTA items. And because there’s a list of things to do as long as my arm, I’ll be tackling each one individually until Project GC8 – my 1999 Subaru Impreza WRX Type RA 555 Limited – is where I want it to be. Even if that means doing them in a non-traditional order.

I’ve been a Speedhunters contributor for nearly a year now, and in addition to hunting down all the raddest cars (and meeting some fantastic people along the way), it’s also exposed me to some of the coolest products, upgrades and tech available on the market. Which is dangerous when you’re embarking on your own project.

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One of those is ST Suspensions, whose parent company happens to be KW Automotive. And we’re all familiar with the incredible work KW does when it comes to making cars handle infinitely better, be that for road use or motorsport.

How does ST Suspensions fit into this? Well, ST Suspensions are like an entry-level point into KW. They still boast quality and handling improvements, but at a more affordable price for a wide selection of vehicles. Plus, when you’re ready to delve into the world of high-performance or track solutions, you can easily make the jump to KW.

You might remember from a previous update that I took the Impreza on a five-hour road trip up to Nagano recently, so the idea of a 2-way motorsport-specific kit might be slightly wasted on my daily. One thing did stand out from this trip however: the old Cusco coilovers fitted by a previous owner performed as well as they looked. Terrible.

The rebound adjusters were either seized or spinning freely, meaning there was no way to tell what setting they were on. If I had to guess, I’d say the fronts were set for time attack and the rears to try and mimic a Toyota Century. The whole car felt completely different at each corner.

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Thankfully, ST Suspensions had the perfect solution in the form of their XTA coilover kit. This is one of their top-of-the-range solutions which boasts ride height adjustment and rebound as well as camber-adjustable top mounts. But what made this kit particularly special was the customization ST currently offers on all their coilover kits.

Not only could I choose a custom spring colour, but also a neat little message which would be printed on each spring. Have a little scroll down to see what I went for; it seemed fitting given this particular car and the questions I’m usually asked about it.

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Yup, that’s cherry blossom pink – the iconic STI colour. And a little text to remind myself that this project is very much being built and not bought.

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Why choose ST over KW in this instance? Well, the ST XTA coilover uses the damper technology and components as found in KW coilover kits. They’ve even built in the same factory. But there’s two main differences – the materials being used and the price, with one of those directly affecting the other. KW units use a full stainless steel strut, whereas ST ones use galvanized zinc-coated steel to bring the price down – perfect for a project like this.

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With all my parts and tools ready, I set aside a day to remove the old Cuscos and install the new ST XTA units. I have limited experience fitting coilovers, but failure to prepare equals prepare to fail.

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Needless to say, as I unbolted the old coilovers something strange happened. All the bolts came loose… with no rounding. No threading, seizing, nothing. Each coilover emerged from its housing with no bloodied fists, and I held each up into the sun like Simba in that scene from The Lion King.

There’s a good reason for this. Firstly, it’s a clean Japanese car. Secondly, it’s never seen a salted road. The engine may be in need of love, but the rest of the car has been looked after meticulously and not subjected to a life of grime, salt or mud. The last Subaru I changed coilovers on was my Forester STI – a Japanese import that’d spent a year in the UK. You guessed it, that process was the polar opposite to this one.

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With the old units out, I gave the hubs a quick clean (as well as the top mounting points) ready to offer up the ST XTA units. The fit is perfect; no need to cut or adjust anything even to get the camber-adjustable top mounts in. I nearly fainted, although that might have also been the 30+°C weather.

The only downside was the clearance for the Cusco strut brace, but it’s a small price to pay for otherwise perfect fitment both at the top and into the hub too.

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It kept getting better, too. With the ST units firmly in place, I could connect the brake lines and ABS sensor in the provided tabs. No messing, no need for cable ties – just perfect integration with the OEM clips. You’ll have to excuse my surprise here, but that’s what a lifetime of car tuning does to you. A simple, easy fitting process shouldn’t be a surprise, but it’s a welcome change, especially when embarking on the install yourself.

The rears? Exactly the same story. The STI top hats I purchased fit perfectly too, slotting snugly around the damper piston with a satisfying click, the springs firmly held in place with a billet aluminium centering piece. Everything went together as if it were OEM.

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To get a basic height, I took measurements off the old units and set the ST XTAs to what I thought would give a similar height. Compared to the heavy, seized spring perch of the Cusco ones, the ST springs move freely meaning ride height can be adjusted in seconds.

As an added bonus, the ST XTA spring perches are made of a friction-optimised polyamide composite material with a stainless steel insert. Sounds jazzy, right? Essentially, that prevents any corrosion occurring between the spring and the strut body. Technology passed down from the halo KW range.

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Once I set the front and back heights, I took a step back to see how the car sat. The fronts were a bit low and the rear far too high. No issues however, simply jack it back up, wind the springs down and continue until happy.

It’s difficult to see in the photos, but the rear wheels have positive camber due to the ST XTA lower hub mounting tabs (which are more in line with the OEM shape) versus the old Cusco units which increased camber. It’ll need proper alignment and setting anyway, so this will get resolved later on.

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I’ll get on to that once I’ve got the rest of the mechanics and bushings up to scratch. Remember that list I was telling you about earlier on? Yup, it’s a big one. And I’ve just added a wheel alignment to it, but it’ll be absolutely worth it in the end.

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Even with my limited tools and experience, it’s been a properly rewarding process fitting my Impreza with this XTA coilover kit. What I anticipated to be a pig of a job turned out to be super easy, and it won’t be long until the fun really begins.

I say that, because on the next episode of Fixing Broken Old Japanese Cars On My Driveway I’ll be pulling out the EJ boxer engine, breaking it open and (attempting) to replace the internals. On my kitchen table.

The anxiety is already kicking in, but until then it’s time to go put some more miles on Project GC8.

Toby Thyer
Instagram _tobinsta_
tobythyer.co.uk

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SH Garage: Pushing The Limits Of Project GC8

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SH Garage: Pushing The Limits Of Project GC8 – Speedhunters



SH Garage: Pushing The Limits Of Project GC8

The Purchase

There are two ways in life: the quick way and the long way. If we use food as an analogy to unfold this deeply profound philosophy, the quick way is Uber Eats and TV dinners, while the long way is slaving over a hot stove while following a Michelin-star chef’s recipe and feeling a real sense of achievement when belts are loosened at 9:00pm.

Almost everything in life is better when we take the time to savour the moment and really put in the hard yards. It allows us time to make plans, contemplate outcomes and work out how to get there. It also helps to eliminate any chance of things going wrong, although, Sod’s law dictates that something will always go wrong. Bracing for the inevitable, the best we can do is take it slow and do it properly the first time.

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As they say, if something’s worth doing, it’s worth doing right. These profound words of wisdom also ring true when it comes to building cars. And when it comes to modifying or repairing our pride and joy, the stakes are a little higher.

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I’ve learnt my lesson in the past, rushing things with my project cars and ultimately making them worse. This one will be different, or at least that’s the plan.

As is often the case with rare old cars, my GC8 was at the other end of the country, which meant I bought it sight unseen after a late-night, Asahi-fuelled Yahoo! Auctions Japan bidding battle. Win!

To be fair, the car was very true to its photos and listing blurb. Mostly. The body is straight and paint the is excellent, but unfortunately some specifics were omitted from the mechanical description. The ad stated: “engine runs fine with no problems, but 3rd gear sometimes pops out.”

The latter part of that statement I could deal with, because a 6-speed swap from a newer GD series STI was on the cards regardless. But the first half of that statement did not really tell the full truth. While the engine did indeed run fine, boosting nicely and not leaking oil from every orifice, there’s a subtle rattling sound coming from deep within.

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I’m generally a pretty trusting guy, and even more so in Japan where I stupidly think that people are 100% trustworthy and honest. Because of this I didn’t really listen carefully to the engine when I collected the car, and with a photoshoot to get to I simply drove my auction win away into the sunset.

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After the shoot I stopped to take some pics of the new car, and in the quiet of the night it was soon obvious that the engine did in fact have a problem. By the time I emailed the seller, I was told “I didn’t hear anything, why didn’t you say something?”

Honestly, I’m actually at peace with the whole thing and looking forward to replacing the engine’s innards soon. Considering how much I won it for at auction, I’m pretty happy anyway.

The Trip

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Before I start pulling the WRX apart and replacing everything, I wanted to see what the weak points of the car are. A visual inspection would have probably been enough, but where’s the fun in that?

When I headed to Nagano Prefecture for an event recently, I had two choices: take the toll roads and get there in two hours, or take the scenic route and get there in five. Obviously, I decided to go the long way and make a kind of touring holiday out of it. It would be a good opportunity to just enjoy the car before it goes in for surgery. After all, taking things slow is my new zen, remember?

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Pushing the plucky little Impreza through the twisting mountain roads, it was easy to imagine how McRae and Burns must have felt on WRC tarmac stages. The sparse interior allows a direct connection to the outside world; the rush of the wind, growl of the motor and gentle pssshhh of the turbo blow-off valve make every corner a delight.

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And boy, there were a lot of corners.

Taking the scenic route means leaving Kanagawa Prefecture, going past Mt. Tanzawa and heading into the highlands of Yamanashi Prefecture. From there it’s a couple of hours driving through the Minami Alps past Mt. Kita (Japan’s second largest mountain after Mt. Fuji) and Mt. Aka until finally arriving in Nagano Prefecture where Nagano City has an altitude of 371.4m.

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Even though I had an evening photoshoot to get to, I could not resist stopping at what seemed like every mountain pass to take photos of either the car, the road or the view. It’s a trip that I won’t forget any time soon. A soak at one of Nagano’s local onsen was a welcome respite from the day’s drive.

The Test

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This isn’t the first road trip I’ve had in Project GC8. Some of you may remember I that I drove it home from Tokushima, a 12-hour trip, if not you can check out that story here. What I didn’t tell you was that, because of the aforementioned engine issue, I babied it, keeping revs under 4,000rpm for most of the way.

That’s why this trip was so much fun. I just stopped worrying about things and just enjoyed the drive. Knowing that I’d be replacing most of the engine, I wound down the windows and removed the exhaust silencer which drowned out the mild-but-ominous ticking from under the hood. I wanted to see how the suspension components had held up after years of track use. I was never going to really lean on it, because I didn’t want to be stuck on a mountain with a conrod lodged in my radiator, but I could at least hit boost every now and again and focus on the handling.

Admittedly, to really test the limits of an Impreza, it really needs to be driven on a track, but with very few cars on the road, I was able to attack the tight corners of these mountain roads with enough vigour to get an idea of how things are holding together. Surprisingly, the tired and worn Dunlop Direzza tires did a pretty decent job keeping grip.

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Less surprising was the lack of body roll through these corners. The Cusco half cage and strut tower braces make the chassis and body very tight indeed with little-to-no flex. Steering is direct and basically the GC8 will just go anywhere you point it. However, left-hand turns induce an irritating squeal from the steering pump and right-hand turns invokes a lovely whir from the front drive shaft, or somewhere in that vicinity.  

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Once I started pushing the car through some serious corners it became obvious that each side of the car was handling differently; the left side hard and the right side soft. When you’re driving a car renowned for its balance and low center of gravity, having mismatched coilovers is like Usain Bolt running with a trainer on his left foot and a stiletto on his right.

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The Verdict

Overall, despite the elephant in the room (or in the cylinder block), the little Impreza is in good structural and cosmetic condition and is an absolute joy to drive. It’s a very direct, visceral and sensory-tickling experience which will only improve with some attention to its worn parts.  

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As I’ve said before, these cars were never built from the factory as rally cars or track weapons. Basically, they were sold – especially in the case of the Type RA – as a base car for works teams, privateers and hobbyists to build into race cars as they deemed fit. Subaru were not, and still are not, a big company compared to the likes of Nissan and Toyota, so manufacturing costs had to be kept low in some places to make any profit. Considering that 99% of this car is stock, I think it’s held up pretty well.

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Half of the modifications it does have are inside the cabin. There’s a Sparco bucket for the driver, HKS boost meter and a Lamco triple gauge set, a Momo wheel and of course an ETC reader who reminds you to insert your card every time you turn the key.

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Being a Subaru, this one, like most, has lived a colourful life, and it’s been setup for light track work and spirited road driving. It came with some extra goodies, those I’ve mentioned already plus a Cusco rear diff brace and master cylinder stopper, as well as Endless brake lines and pads.

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The weak points are definitely all the bits made of rubber. After 22 years and 170,000km it’s safe to say all the suspension bushings need replacing with OEM STI items. The engine, gearbox and rear diff mounts could all probably do with being upgraded to poly bushings too. Further inspection found a ripped open steering rack boot.

The Next Step

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So, what’s next? Well, like a newlywed couple planning their honeymoon weekend away in Tahiti, I’m busy planning the purchase of all the new internal parts for the EJ boxer engine. It’s all very exciting, although I’ve never got as far as a honeymoon so I can’t compare.

The Cusco coilovers have to go because they have either not been looked after or have just given up the ghost of their own accord. Thankfully, one of Speedhunters’ fantastic Official Suppliers has stepped in to help in this department, and I look forward to bringing you that story in due course.

Toby Thyer
Instagram _tobinsta_
tobythyer.co.uk

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A Brake Restoration For Project Nine

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A Brake Restoration For Project Nine – Speedhunters



A Brake Restoration For Project Nine

Free Time & Fresh Plans

Time stops for no man. I’m reminded of this by the inevitable wave of guilt that crashes down around me every single time I start writing and realise just how long it’s been since the last Project Nine update.

But I guess the silver lining of zero updates means that my Mitsubishi Lancer Evolution IX has been behaving, right? This is true; since our last update the car hasn’t skipped a beat. It’s been driven daily, punctuated with a handful of spirited mountain runs to keep me sane, but sadly I’ve not had the time to get out on a track since our last story.

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Oh yeah, and I guess we shouldn’t forget that little Covid situation… So little happened in my life during 2020, that I quite frequently forget it existed at all. My memory must be stored by events and not dates, because I always refer to 2019 as ‘last year’ or a ‘few months ago.’ That’s a great excuse for about 12 months’ worth of silence.

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One positive to come from the enforced downtime was actually having enough spare time on my hands to think seriously about how I’d best like to shape my Evo moving into the future.

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It’s been my faithful accomplice for quite a few years now, so I’ve decided to spend a little more time and effort in 2021 to restore the car’s weaker and more worn components.

For a performance enthusiast, I think the Evolution IX represents the pinnacle of Mitsubishi. There’s no need to rewrite an already solid package. I’m not interested in hitting 12,000 horsepower on the dyno, making it a dedicated track car, or becoming a speedhump-fearer.

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The goal here is to chase an OEM+ look and feel. I’ll be aiming to take advantage of some of the technological advancements over the last 15 years to enhance the already brilliant package Mitsubishi released from the factory.

Brembos, Sweat & Powder

The most sensible place to start our renewed project is to restore what bugged me most about the car. After all, a chain is only as strong as the weakest link, and that link for the Evolution – at least aesthetically speaking – was faded Brembo callipers.

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The original vibrant red was roasted to a flakey brown during some ultra-high temps at Sydney Motorsport Park chasing down a friend’s NSX. For the longest time, I tried to ignore how much they detracted from the vehicle’s overall appearance.

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Scotty Barter, a mate of mine who happens to sell all the good stuff a powder-coater craves, had offered to help restore the poo-coloured Brembos a few times over the last couple of years. A kind gesture and a genuine offer for sure. ‘Yeah yeah, we’ll talk about it later,’ was my usual reply. It’s not that I wasn’t interested, I just know how busy Scotty is running Oxytech, raising a family, helping out other mates’ builds and trying to find time to work on his own project cars.

But eventually, the universe conspired against my faded callipers. I got the call to shoot Scotty’s freshly-finished and very tough ’56 Chevy work truck for Aussie magazine Street Machine. During a chilled night of photography, rum and pizza, it was agreed that I’d finally take up his generous offer and we’d give Project Nine the calliper refresh she deserved. And while the brakes were removed, my tired-looking RAYS Volk Racing CE28Ns would also cop a fresh coat of powder.

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In hindsight, I doubt I would have ever agreed if I had a full understanding of the time and effort involved beforehand. Like most automotive projects, the bulk of the work hides within the preparation – in this case a plethora of tiny tasks that take hours. In comparison, the main tasks of blasting and applying powder were by far the quickest and most fun elements of the restoration.

The Process

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It’s not a difficult task by any means, it’s actually a pretty straightforward job. Nonetheless, I appreciated having Scotty on hand to help out. The experience he brought along after having done dozens of similar restorations made the task as simple and quick as possible.

If you’re considering a similar restoration and not sure where to begin, grab a coffee and get comfortable; Scotty and I documented the entire process. While strictly speaking this isn’t a guide, it should still be detailed enough to be somewhat useful. Even if it’s just for sizing up the scale of the job before choosing to DIY or throw cash at the problem.

OK, let’s get started. Removing the wheels and brakes is straightforward, and frankly, if this is outside of your comfort zone, you should probably be paying to get the job done. Be mindful to place your brake pads in a way that’ll ensure they all go back in the same location and rotor side. Oh, and get yourself a brake line clamp kit to save a lot of mess. Brake fluid is not your friend.

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Before you get carried away splitting your callipers, give them a good inspection and check that you’ve got all the replacement seals and any other ancillary parts that may need to be replaced. Give each calliper a solid inspection for other signs of damage. Callipers are usually bullet-proof, but trust me, you’ll want to find any extra issues at this point and not further into the process.

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If you’ve decided you’ve got what you’ll need to proceed, godspeed and good luck. Loosen those nipples and use compressed air to blow out the seals and pistons through the bleed valve. Follow up by removing the nipples, lines, and seals. You can remove the squealer pads, but you’ll need a Torx bit and some patience. Lastly, and of course the least fun bit, you’ll need to crack the Allen bolts and separate the two calliper halves to prepare for a proper stripping.

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In our case, we’ve used Oxytech’s own Classique Strip AS-3. I blinked with a vacant stare when Scotty told me it’s a methylene chloride-based solution that strips quickly even at ambient temperatures. I smiled politely, but really I was thinking how fancy the word ‘classic’ looks with a slight variation in spelling.

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Each piece was hand rinsed in some fresh water, but instead of leaving them out to dry we had the luxury of baking them in the oven for 20 minutes to help remove any residual stripper.

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While the bare Brembos received a light sandblasting all the external bolts, plates, and bits were lined up for a tidy up using some general thinners and a bit of wire brush action. This was completely optional; I guess it’s up to you how far you take the restoration, but what’s the point in pulling it all apart to stop halfway?

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We took a particular interest in the bolts as we planned on giving their heads a very light colour coat, too.

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Before blasting or sanding, be sure to fill in any gallery entries and cover any factory machined surfaces. Scotty used an #80 mesh aluminium oxide blasted on low pressure.

The beads aren’t too harsh, and in his experience they leave a mint profile. Believe it or not, now we’re finally ready to lay the first coat of powder.

The nerds in here who don’t already know how a powder gun works will find it all more interesting than they’d probably presumed; I know I did. The gun actually strips away a heap of the electrons as it excites the powder before discharging. Remember as a kid rubbing a balloon through your hair to make it stand up? Well, the same principle is what ensures a nice even coat here. The negatively charged particles move and cling to the nearest earth point, which happens to be what you’re trying to coat in perfectly flat powder.

See, way more interesting than you probably thought.

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Scotty shot the first batch and explained the process: distances, motion, quantity. It looked pretty simple.

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But for some reason when it was my turn to let loose I ended up with more powder on me than the callipers. At least it gives you guys and gals a chance to appreciate my amazingly non-traditional colour choice; Dormant Purple.

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You’ll notice the two colours in the oven? The callipers enter the oven purple and exit silver after being baked at 200°C (392°F) for 35 minutes. After cooling a second coat is applied. It’s technically a clear coat, but it reacts with the base coat to create the final deep purple. There’s a time-lapse of the transition in a video I prepared at the end of this post.

Now all that’s left is to break out the new seal kit and repeat the dismantling process in reverse.

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Take your time and be extremely careful when removing the blanks you fitted to protect the machined surface; you’d hate to get this close to the finish line before you screw it up and damage your pristine brakes.

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That’s a lot of instruction for a seal kit. Just make sure you grease up the piston seals and don’t forget about the centre seal that unifies both sides.

My new Brembo heatproof decals were sourced online. I’d purchased a set for my old Evolution VII and they survived years of abuse.

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It’s amazing how a splash of colour can make such a difference. I copped a lot of ‘naysaying’ amongst mates when the bold colour choice was mentioned, not that it matters, but most of them have come around to the idea now.

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To help finalize the transformation, Scotty also sandblasted my tired-looking CE28Ns and gave their lips a quick polish too.

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Purists may scream and hunt me down for blasting away Volk Racing’s iconic anodized bronze finish, but I think Toyota 1G3 Magnetic Grey really suits these wheels.

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The wheels aren’t complete yet – there are still a few little touches to add – but hopefully everything will arrive soon and we can do the full reveal on an upcoming drive day with mates. I’m pretty keen on putting these new Yokohama Advan A052 tyres through their paces, so will report back soon.

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It’s so easy to only focus on modifying the bigger ticket items, so I hope that by seeing the impact this relatively small job has made to the car, it will motivate you to also think smaller and start attacking a few of those easy-to-ignore jobs of your own.

In the meantime, I cut a quick video of the calliper restoration process. I’m fairly new to video, so don’t expect a full-blown production, but I do hope it helps.

Matthew Everingham
Instagram: matthew_everingham
matt@mattheweveringham.com

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Team Speedhunters

Editorial Director:
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Commercial Director: Ben Chandler
Creative Director: Mark Riccioni
Contributing Editor:
Dino Dalle Carbonare
Technical Editor: Ryan Stewart
Concept Artist:
Khyzyl Saleem
Contributors: Will Beaumont, Keiron Berndt, Jordan Butters, Ron Celestine, Mario Christou, Cian Donnellan, Matthew Everingham, Blake Jones, Stefan Kotze, Vladimir Ljadov, Paddy McGrath, Rick Muda, Sara Ryan, Trevor Yale Ryan, Dave Thomas, Toby Thyer, Simon Woolley, Naveed Yousufzai


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