V6 Type R Project - S5 WRC Replica!

Discussion in 'Projects, modifications & how to guides' started by TYPERV6, Apr 3, 2014.

  1. TYPERV6

    TYPERV6 Owner at The Project

    Location:
    Wicklow, Ireland
    Hi All,

    I have been building a Prodrive WRC S5 Replica since 2009.

    A wee taster of the car from last summer (not much done since due to work commitments)...

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    This is a bit of a slow burn this build as my old job and a young family make finding the time to work on this near impossible. Certain financial limitations have slowed it too along the way. It's been fun to date... painful too with long spells of down-time due to other commitments... near death experience with the car tipping off its axle stand and nearly trapping me... two cases of severe arc eye... and the odd trip to the A&E. :p

    I'm going to starting posting as much of the content about the build that I have documented on another forum back home whenever I can. Please bear with me as there is a lot of it.

    It all began when I bought my V6 Type R back in 2004. I had a deposit on a 00 Type R with 18k kilometers on it when the seller disappeared with a substantial deposit and left me high & dry. The unfortunate thing was I had sold my then current UK Impreza Turbo to fund it and was car-less but hell bent on buying a Type R. Back in 04 in Ireland these were not the most common car and when one came up for sale up in Antrim I jumped at the opportunity and bought it.This may have been a slightly emotional & rushed decision, as I do pride myself for being good at spotting accident damage but the car I'd bought, began to give me trouble a few months down the road and it was then I discovered that the previous owner had crashed the car (DS front) and 'failed' to tell me.

    The damage wasn't that bad... but I was never truly happy that the car would be 100% unless I took on substantial repair work. It had been repaired... but not to a standard I would have liked. On later inpection I discovered they had pulled the DS leg back into position which had weakened it and therefore the only thing for me to do was strip the front and replace the leg. It was at about this time that financially running a Type R as a daily driver was proving quite expensive so until I could decide what to do with the accident damage that needed tidying, I choose to take it off the road.

    This is when it all went awry. I got the hair-brained idea that I should build a 22B rep. I spent nearly 2 years planning this with several trips to the UK looking at different kits. At the time a lad called Phil Chapman was doing very tasty Carbon 22B kits... but they were very pricey... but I was still keen to go that route.

    Soon after meeting Phil I saw a white S5 replica on RCM's 'Cars For Sale' section. It was a customers car that had been given to Prodrive when new and converted using genuine Prodrive steel panels. Soon after I saw it Olly & Matt made the decision to use it as the basis as the Gobstopper. I was hooked though. No matter how sexy the 22B is... a WRC arched car was just 10 times better looking. Numerous phone calls to Prodrive to get them to reproduce the steel panels were to no avail.. they had stopped supporting the early cars and me nagging them wasn't going to change that. They did kindly put me in touch with Rodney in WRC Spares though. And the rest is history. I spent another year stripping the car and selling parts not required, so as to fund the new carbon/kevlar panels.

    I was very naive when I began this... I've learned a massive amount along the way which I'll happily share... but I never thought the build would end up being to the extent it now is. The initial idea was to build a WRC replica that would be identical externally. Along the way... like a lot of good projects... it grew legs and got out of control. I planned to fit the rear quarter & sills... bolt on some front wings and two new bumpers... fit some spacers to widen the track... and hey presto... jobs a good un.

    But I've learned so much along the way and realized that each problem once solved would create another. I also made the insane decision to fully strip the shell and go the caged, bare interior route.

    11 years working in a job I absolutely hated... and a love of design and cars forced me to make the decision last year to quit my job and make this 'build' my business. I've been designing and fabricating so many bespoke parts along the way for this which gave me the confidence to go out on my own and start producing my own parts.I'm only 2 weeks into my new business but being able to combine this build and make it a sales tool for my business has been the greatest thing.

    It's made something I've been passionate about for years and turned it into my day job!

    So that's how it came about... and I'll start posting pics and info up over the next few days/weeks and try get it up to speed with were I am at currently at in the build.

    Thanks for looking.

    Jamie.
     
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  2. tekkerchrede

    tekkerchrede V-Limited Member

    What a project, when you know what is changed on a WRC! :) So you bought one and a half car due to the deposit thing or did you just want to cancel the deal?
     
  3. TYPERV6

    TYPERV6 Owner at The Project

    Location:
    Wicklow, Ireland
    Thanks lad.

    No I bought just the one. The first guy just vanished with my hard earned cash. He later sold the car but it apparently had been damaged at some point. Such a shame too as it was immaculate.
     
  4. TYPERV6

    TYPERV6 Owner at The Project

    Location:
    Wicklow, Ireland
    The first job I took on long before I had sourced my wide arch kit was to source and fit a roof vent. I had purchased a genuine S5 Carbon roof scoop from Phil Chapman which set me back a pretty penny... the start of a long road of expensive parts :)

    I then sourced a non-Prodrive roof vent as I'd heard how the real McCoy can leak as it's quite a basic piece of kit. So I found a more substantial alloy one in the US through a company called Primitive Motorsport. The key thing was that there would be no clearance issues with the scoop so after several annoying emails asking 20 questions to confirm it would work.. I purchased it. Thankfully I wasn't let down and after a full day of measuring and marking it resulted in a perfect position and fit.

    I on the other hand I ended up in the A&E after molten metal off the air cutter stuck to my eye-ball! A week with a pirates eye pad was a hard lesson considering I'd being wearing protective glasses but had removed them briefly while cutting :p

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    A few months after that I had the find of the century. I had for approx 2 years being searching for 18" Speedline 2013 alloy's... but they are rarer than hens teeth. A trader on our forum then posted up he had 18" Speedlines for sale that he thought were a rally rim. He wasn't the most familiar with what he had as he was a drift boy but I committed to buy them without a pic or price... I just had a gut feeling they were what I was so badly after. I nearly dropped dead when I went down to get them as he had 5 x 18" Magnesium Speedline 2013's on offer and only wanted the equivalent of 200 pound. These were over 500 Sterling each when new. As you can see they are in need of a refurb and two of them have minor hairline fractures in them that I can get mag welded with a guy in York... but they are perfect otherwise and are feather weight. Best thing about them is they are ET35. He said they'd been on a 22B... I don't know were they originally came from though as WRC and Grp A Mag Speedlines would all have had a different PCD and centre bore... so I assume these were a special order rim by a 22B owner at some point.

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    A few more weeks later I got delivery of my Kevlar quarters from WRC Spares. The difference in the higher cut arch can be clearly seen in the first pic.This was a very daunting stage as it was now evident how much fabrication work was involved with re-tubbing the rear arches...

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  5. type-ra

    type-ra Administrator

    Location:
    West Yorkshire
    Fantastic attention to detail Jamie:cool:

    Please keep us updated.

    Dean
     
  6. Fatharrydog

    Fatharrydog MY98 WRX Type R V-Limited 176/1000

    Location:
    Southwell, Notts
    Hi Jamie I want to fit a 22b style or WRC style front bumber on my MY98 Type R, non-wide arch. Do you sell these or can you point me in the right direction? Thanks, Steve
     
  7. Tidgy

    Tidgy Type RA Member

    scoobyclinic do the kits mate
     
  8. Iain

    Iain V-Limited Member

    Location:
    Cheshire
    Bit of a thread resurrection!
    Can see Jamie hasn't been on here for over a year.
    Does anyone know what became of his project and business?
     
  9. Iain

    Iain V-Limited Member

    Location:
    Cheshire
  10. TYPERV6

    TYPERV6 Owner at The Project

    Location:
    Wicklow, Ireland
    Thanks for the thread resurrection Iain ;)

    Sorry to all for the lack of updates... been a manic last 12 months!

    I'll try to get to get some updates up soon.
     
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  11. TYPERV6

    TYPERV6 Owner at The Project

    Location:
    Wicklow, Ireland
    Hi all... sorry for the lack of updates. I set up two businesses just over 2 years ago and I've been flat out with them. I've been meaning to update where I'm at with this for some time, but haven't been able to find much time to keep on top of the admin nor work on the car in the first place. A bit more free time recently means I've been able to get a lot done on the car. I'm so behind with updates here though, I've had to just copy/paste some that I posted on a club forum here in Ireland. Unfortunately, it's a members only section so I can 't even post up a link :(

    I have had two threads going on this ... here and my intro thread....

    http://www.type-ra.com/subaru-forum/threads/howdy-all.7906/page-2#post-108851

    So from he initial pics I posted in the first post above... I've since removed all the glass, doors, loom sound deadening etc and stripped it to a bare shell...
     
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  12. TYPERV6

    TYPERV6 Owner at The Project

    Location:
    Wicklow, Ireland
    December 2014


    They are only sitting on the floor at the minute... but I'll be creating a false floor by lifting them approx. an inch upward on a support frame, as I'll be running the loom and brake/fuel lines under them as the cage is now in the way of running these down the sills. Nice to have the though as I can start my fabrication work now.

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  13. TYPERV6

    TYPERV6 Owner at The Project

    Location:
    Wicklow, Ireland
    January 2015

    Hey all,
    Sorry for the complete lack of updates but other commitments over the last good while have meant I've had no time to work on the car. It's been a little disheartening as I've done nothing with it at all really since I bought the cage over a year ago, but over the last few months I've been getting out to do an hour here and an hour there. There's been a lot of head scratching and a general feeling of over-whelming dread due to the magnitude of work now involved with the path I've taken with the interior. I hope to have the rear fire wall I designed and got laser cut, fitted over the hols and I really hope I'll get a little further along with the cage. I did manage to get the rear half of the cage bolted in place on the rear tubs which is a starting point that I can work forward from. I've still to fabricate the mounting feet but they are spec-ed up now and just need to be cut/bent and welded into place.


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    I also managed to finish the poxy job of removing and cleaning off the last of the sound deadening... along with some of the seam sealer in the cabin.

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    I also got stuck in last night and cut out the damaged front panels... upper slam panel, DS front headlight panel, lower rad support panel etc. All that's left now is to replace them with new items.
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    I also went over the shell with a fine tooth comb and isolated only two small areas of rust.... one on the driver side foot-well and one under the PS rear window...both nothing more than minor surface rust. Not bad for a 16 year old car.

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    I also have a little more cutting to do by removing the roof brace in the centre next to main hoop of the cage as it's fouling slightly and will make fitment difficult when all freshly painted. A look at the S5 Burns car at Prodrive last year confirmed that these were removed on the works cars too.

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    At last I hope to have a new mig in the new year which should see me start to make more progress as most of the work left on the shell... if not all of it... involves welding and it's really holding me back at this point.
     
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  14. TYPERV6

    TYPERV6 Owner at The Project

    Location:
    Wicklow, Ireland
    March 2015


    Hey all...
    Another update from over the last few weeks. I've been tipping away with further shell tidying with the removal of all the window sealer from after removing all the bonded windows. Another tedious job but thankfully done.

    I did manage to get my prototype firewall fitted over the weekend though which is a good step forward!!

    It's FIA spec... CNC laser cut on 1.5 mm aluminium sheet and 1.5mm steel. The main component parts being aluminium and the smaller filler panels on 1.5mm steel. All identical to the how fitted to the Works cars.

    These steel panels were Mig welded in place as they fill a void area in the rear bulkhead so that the aluminium has a complete surface to be rivet/bonded too. Without these filler panels the firewall wouldn't seal completely around. They will also be where the loom and braided fuel lines will pass at a later stage once appropriate holes and grommets are fitted.

    Once welded in place they were etch primed and then sealed around the edges...

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    The two small raised and pressed sections were cut out to accommodate the rear shelf panel to sit flatter and seal better...

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    Then the rear shelf and larger vertical aluminium panels were dry fitted using Clecos, then I drilled all the holes for the rivets in the rear bulkhead...

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    Then the sealer was applied to both areas. This is very important if trying to meet FIA spec as the firewall must be a liquid barrier so riveting is not enough (all other holes need between cabin and boot area must be welded/sealed up too as part of this process)....

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    And then came the fun part of riveting it into place... Hey presto... job done!! :icon_grin:

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    I also managed cut out the middle roof brace.. all-in-all a productive Sunday afternoon!

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  15. TYPERV6

    TYPERV6 Owner at The Project

    Location:
    Wicklow, Ireland
    And then a very big gap in updates due to work commitments....

    Januarys 2016


    Long time since I posted anything... but you'll be possibly glad to hear I have been tipping away in the background on this and have a gotten a bit done over the last few months!

    Between a new business and family commitments, I've had very little time to get near it this year. But... I did treat myself to a new Sip 181 Mig Welder for my 40th back in September... very generous of me!! The difference this has made is unreal... It's been holding me back so much over the last year and a half not having one, as nearly all the major jobs that I have on my to-do list requires a decent welder.

    So with my new toy I've been able to get cracking on the roll cage and get it welded in. First off, I had to fabricate up support plates for the rear of the cage where it is bolted to the rear turret walls....

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    These are to stiffen up the turrets and also the return to the turret aperture spreads the load transferred by the cage...
    Bolted in place....

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    And then welded... both sides!!

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    Then the main hoop support feet were cut to shape...

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    Folded up...
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    And then the top plates with captive nuts supplied with the cage were welded on...
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    In situ in shell...
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    And then welded and etch primed...

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    Then on to the front support feet for the A-Pillar bars...

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