With all the goals and requirements in place all that was left was to start. But where do you start a project like this? With the goals set so lofty we knew the chassis/body and suspension were going to play a staring role in development. The front and rear OEM sub-frame were going to need work. To allow larger tires to be run and a larger rear differential the entire rear sub-frame was removed and replaced with a tubular sub-frame complete with stainless heim joints and over sized custom hubs. The front sub-frame was also completely re-worked. With the interior removed a custom roll cage dominates the interior. Massive strut braces and tubes intertwine the car to make it one rigid structure. Along with those upgrades, At Speed preformed a large array of other modifications.
To further build on the race car inspired chassis, Ohlins coil-overs were used to allow a large range of adjustments to the car. The custom hubs allowed for the use of wheel studs in place of the OEM wheel bolts as well as handle the added stresses.
All of these modifications are skinned beneath a custom wide body. Even the doors had to be replaced to accommodate the extra large fender flares. Total body width was pushed to almost 80 inches. The pieces are all fabricated out of carbon fiber to help keep the weight down and allow for radical body lines. With cutting edge technology major body panels such as doors were able to be kept to weights under 15 pounds. Reduced weight and added downforce were a driving force in the design. Even at this early stage of the build one thing was clear. This car would end up a far cry from what the conservative designers had originally conceived.
With the goals set and the suspension and chassis work well under way, attention was turned to the engine and related drive train parts. Upon removing the engine and disassembling it, one thing was clear. The stock block with un-supported sleeves was not up to the task at hand. To address this issue the block was prepped for Darton forged sleeves.
Down time for the block to be re-sleeved created a chance to flow the head and evaluate what needed to be done there. With all of this going on Innovative Turbo was simultaneously working on a custom ball bearing turbo for the project. What they came up with was based on their F266 ceramic ball bearing turbo, which off the shelf was almost perfect for the demands of this project.
To feed the engine, Chip Center Stockholm was contracted for a high flow fuel rail. Flow numbers in hand and with a turbo in progress, we plugged in the numbers to calculate the theoretical final horsepower for the engine. It was then we realized that even with the upgrade to the Evo VIII driveline that the stock differential would be a weak link. Fortunately, the solution was an easy one. ATS custom manufactures a carbon differential that is almost a drop in unit. To protect all of the components, Motorspot.com supplied us with Motul fluids. So what are the final projected horsepower numbers?
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