Delta Integrale Evo1 long term project
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Delta Integrale Evo1 long term project
By request of Guy, I am going to post progress of my long term Delta Evo1 project. Also will give some information about competition prep for the Integrale that may bee a good guide for anyone that takes on a similar project in the future. I started approximately 4 years ago now.
It took me about 8 months of looking to find an Evo 1 in good enough condition to satisfy me that it would be solid for many years.
This is what I started with 1992 K plate Integrale Evo 1
After 1 year on the road I decided to build my dream car, timescale (its done when its done), budget (unknown, whatever it takes).
1st the car was stripped to the bare shell and wear and tear cracks, slight bits of rust was assessed.
I must point out at this stage it is very important to take a close look at your bodyshell as with all integrales the stresses in the shell create cracks in time. Below is an indication of where to look for these cracks. They should be dealt with properly, with care and thought.
After the cracks were repaired I cut a set of plates as seen in the works cars used to strengthen these areas. The following picture will give you an idea of the shapes, it was best to make templates on the car then cut to suit, then shape and weld.
I proceeded to fully seam weld the bodyshell and fit the Sparco 23 point roll cage, this included making some braces to fit along the sills to make mounting the feet of the cage much stronger. Note also the seat mountings are strengthened with 3mm steel plates.
Take note again, the Sparco cage does not fit if you have a sunroof so you will have to find a solid roof to replace it with. If you are competent then fitting a roof panel is not so difficult, it is just time consuming to do the job right. Make sure you support the shell correctly before removing the roof. I fitted the cage first then put the shell on blocks made from railway sleepers to keep it level. DO NOT UNDER ANY CIRCUMSTANCES REMOVE THE ROOF PANEL IF THERE IS NO PROPER SUPPORT.
Take note on all deltas that have not had a new roof panel this rear seam is a place prone to rust. This seems to be due to this being a point where 3 panels are joined together, which may have caused a discimilar metals problem (hope my spelling is correct).
Other weak spots are the front anti roll bar mountings, one of mine had cracked so i decided to beef them up properly (over engineer) so that there would never be a problem. I used 3mm steel for the base plate then made the mounting with 3mm box section.
After all the underneath welding was finished all of the underseal and paint was removed, the bottom was treated with a chemical called Metal Ready which puts a coating of Zinc Phosphate on the metal. Then the whole underneath was painted with POR15 anti rust paint and the seams resealed.
POR 15 paint was then primed with a special primer, then painted white and covered in stone chip. The underneath now finished the shell was then prepped for paint inside and out.
Now just over 1 year from the start of the project the shell was back in paint. A PROUD MOMENT TO SAY THE LEAST
TO BE CONTINUED............................
It took me about 8 months of looking to find an Evo 1 in good enough condition to satisfy me that it would be solid for many years.
This is what I started with 1992 K plate Integrale Evo 1
After 1 year on the road I decided to build my dream car, timescale (its done when its done), budget (unknown, whatever it takes).
1st the car was stripped to the bare shell and wear and tear cracks, slight bits of rust was assessed.
I must point out at this stage it is very important to take a close look at your bodyshell as with all integrales the stresses in the shell create cracks in time. Below is an indication of where to look for these cracks. They should be dealt with properly, with care and thought.
After the cracks were repaired I cut a set of plates as seen in the works cars used to strengthen these areas. The following picture will give you an idea of the shapes, it was best to make templates on the car then cut to suit, then shape and weld.
I proceeded to fully seam weld the bodyshell and fit the Sparco 23 point roll cage, this included making some braces to fit along the sills to make mounting the feet of the cage much stronger. Note also the seat mountings are strengthened with 3mm steel plates.
Take note again, the Sparco cage does not fit if you have a sunroof so you will have to find a solid roof to replace it with. If you are competent then fitting a roof panel is not so difficult, it is just time consuming to do the job right. Make sure you support the shell correctly before removing the roof. I fitted the cage first then put the shell on blocks made from railway sleepers to keep it level. DO NOT UNDER ANY CIRCUMSTANCES REMOVE THE ROOF PANEL IF THERE IS NO PROPER SUPPORT.
Take note on all deltas that have not had a new roof panel this rear seam is a place prone to rust. This seems to be due to this being a point where 3 panels are joined together, which may have caused a discimilar metals problem (hope my spelling is correct).
Other weak spots are the front anti roll bar mountings, one of mine had cracked so i decided to beef them up properly (over engineer) so that there would never be a problem. I used 3mm steel for the base plate then made the mounting with 3mm box section.
After all the underneath welding was finished all of the underseal and paint was removed, the bottom was treated with a chemical called Metal Ready which puts a coating of Zinc Phosphate on the metal. Then the whole underneath was painted with POR15 anti rust paint and the seams resealed.
POR 15 paint was then primed with a special primer, then painted white and covered in stone chip. The underneath now finished the shell was then prepped for paint inside and out.
Now just over 1 year from the start of the project the shell was back in paint. A PROUD MOMENT TO SAY THE LEAST
TO BE CONTINUED............................
Last edited by DeltaDave on March 9th, 2009, 6:46 pm, edited 1 time in total.
GC_28
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Re: Delta Integrale Evo1 long term project
Nice, really nice.
keep them comming....
keep them comming....
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Re: Delta Integrale Evo1 long term project
Model Post!
David -thanks very much for taking time to document this very important project here.
GC
David -thanks very much for taking time to document this very important project here.
GC
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Re: Delta Integrale Evo1 long term project
You are a lucky man, David!budget (unknown, whatever it takes).
Thanks for sharing.
I always liked the agressive stance of the Integrale Evo...
Do you plan to put in a crosstube into the cage underneath the dashboard
(or in the engine compartment) to stiffen the car in lateral direction?
Thomas
GC_23
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Re: Delta Integrale Evo1 long term project
Guy Croft wrote:Model Post!
David -thanks very much for taking time to document this very important project here.
GC
My pleasure guy, many thanks in advance for the engine work and the advice and knowledge.
GC_28
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Re: Delta Integrale Evo1 long term project
Thomas, I think I will just stick with front and rear strut braces.TR-Spider wrote: Do you plan to put in a crosstube into the cage underneath the dashboard
(or in the engine compartment) to stiffen the car in lateral direction?
Thomas
GC_28
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Re: Delta Integrale Evo1 long term project
More updates...
Rear Suspension
Removing the standard fuel tank allows for the correct fitment of the underbracing supplied my OMP, additional to this I had the rear tie bars made in the states in 30mm cro-moly tubing with 3/4" rodends. The whole suspension setup is polybushed. Coilovers are by Gaz Tarmac spec with alloy tops fitted with spherical bearings.
Fuel System
The fuel system is built up with an ATL tank, 2 x Bosch 044 fuel pumps, a swirl pot and strainer filter in the rear. All enclosed in an alloy container along with a further tank that can be used for water injection if the need arises. I may actually use this water tank for the windscreen washers, not sure if water injection will be needed yet.
Interior
The dash has been trimmed to get past the rollcage and i have made myself some carbon fibre covers for the ends of the dash, the passenger side one is modeled on that of a GRP A car so controls can be reached by the passenger, for navigation equipment, lighting, secondary fuses, secondary horn etc. The dash will eventually be flocked. AIM motorsport race dash and Stack guages, Also note the GRP A gearshift tower.
Door panels stripped to bare minimum and Sparco seats fitted.
Brakes
Front are 355mm x 35mm full floating discs by Alcon with four pot AP racing calipers from a Jaguar XJ220.
Rear brakes use the standard 284mm discs off the front of the integrale using 2 pot AP racing calipers for the main braking and handbrake calipers for the mechanical handbrake. A vertical hydraullic handbrake is also connected into the rear braking circuit.
I almost forgot the pedal box.
I also bought myself a new Tig and have started making the 4" exhaust system. Note here you have to modify the diff subframe to allow a 4" pipe over the top.
Hope you are all enjoying this guys.........
All rear windows are perspex.
Further developments are that Guy has completed work on the crank and flywheel, engine underway in manable stages.
Rear Suspension
Removing the standard fuel tank allows for the correct fitment of the underbracing supplied my OMP, additional to this I had the rear tie bars made in the states in 30mm cro-moly tubing with 3/4" rodends. The whole suspension setup is polybushed. Coilovers are by Gaz Tarmac spec with alloy tops fitted with spherical bearings.
Fuel System
The fuel system is built up with an ATL tank, 2 x Bosch 044 fuel pumps, a swirl pot and strainer filter in the rear. All enclosed in an alloy container along with a further tank that can be used for water injection if the need arises. I may actually use this water tank for the windscreen washers, not sure if water injection will be needed yet.
Interior
The dash has been trimmed to get past the rollcage and i have made myself some carbon fibre covers for the ends of the dash, the passenger side one is modeled on that of a GRP A car so controls can be reached by the passenger, for navigation equipment, lighting, secondary fuses, secondary horn etc. The dash will eventually be flocked. AIM motorsport race dash and Stack guages, Also note the GRP A gearshift tower.
Door panels stripped to bare minimum and Sparco seats fitted.
Brakes
Front are 355mm x 35mm full floating discs by Alcon with four pot AP racing calipers from a Jaguar XJ220.
Rear brakes use the standard 284mm discs off the front of the integrale using 2 pot AP racing calipers for the main braking and handbrake calipers for the mechanical handbrake. A vertical hydraullic handbrake is also connected into the rear braking circuit.
I almost forgot the pedal box.
I also bought myself a new Tig and have started making the 4" exhaust system. Note here you have to modify the diff subframe to allow a 4" pipe over the top.
Hope you are all enjoying this guys.........
All rear windows are perspex.
Further developments are that Guy has completed work on the crank and flywheel, engine underway in manable stages.
Last edited by DeltaDave on March 9th, 2009, 7:00 pm, edited 1 time in total.
GC_28
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Re: Delta Integrale Evo1 long term project
Nice, looks very good!
I really like the way the rear suspension is braced.
The mechanical handbrake caliper, is that AP as well?
And how is the hydraulic handbrake integrated into the system, going to a separate piston or some trick valve?
Thomas
I really like the way the rear suspension is braced.
The mechanical handbrake caliper, is that AP as well?
And how is the hydraulic handbrake integrated into the system, going to a separate piston or some trick valve?
Thomas
GC_23
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Re: Delta Integrale Evo1 long term project
Here is my rear braking pipework, as you will see it is piped reservoir to rear master cylinder, to proportioning valve, to handbrake master cylinder then tee'd off to the rear calipers. My mechanical handbrake calipers are by Compbrake.TR-Spider wrote:Nice, looks very good!
I really like the way the rear suspension is braced.
The mechanical handbrake caliper, is that AP as well?
And how is the hydraulic handbrake integrated into the system, going to a separate piston or some trick valve?
Thomas
GC_28
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Re: Delta Integrale Evo1 long term project
Keep it up Dave, some serious money invested in this, impressed with the exhaust 4inch pipe work must take some fit up.
Rich
Rich
book 38
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Re: Delta Integrale Evo1 long term project
The project, posts and pictures are all amazing. This car is very very nice. Keep the updates going.
Regards,
Kristian
Regards,
Kristian
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Re: Delta Integrale Evo1 long term project
Further (smaller) developments, sorry Guy
Last edited by DeltaDave on May 1st, 2010, 6:03 am, edited 1 time in total.
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Re: Delta Integrale Evo1 long term project
Thanks Dave
Got the engine bay, do you have a respectable front-end view of your Int? Maybe with bonnet on, lights?
G
Got the engine bay, do you have a respectable front-end view of your Int? Maybe with bonnet on, lights?
G
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Re: Delta Integrale Evo1 long term project
I will do one of those today
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Re: Delta Integrale Evo1 long term project
Here are the new ones, I think you might find these better.
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