Delta Integrale Evo1 long term project

Non-engine, eg: aerodynamics, gearboxes, brakes, suspension
DeltaDave
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Delta Integrale Evo1 long term project

Post by DeltaDave » Sat Feb 28, 2009 7:59 pm

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
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1992 K plate Evo 1
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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.
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Start of stripdown 1
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Start of stripdown 2
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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.
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Common crack positions
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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.
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Strengthening plates
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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.
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Sill Bracing
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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.
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Roof skin removed
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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).
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New roof skin
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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.
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ARB Mounting
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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.
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Rustproofing
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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
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Interior paint
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Rear Quarter in paint
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Under wraps
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Front View (apologies for picture quality)
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TO BE CONTINUED............................
Last edited by DeltaDave on Mon Mar 09, 2009 6:46 pm, edited 1 time in total.
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Walter
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Re: Delta Integrale Evo1 long term project

Post by Walter » Sun Mar 01, 2009 2:20 am

Nice, really nice.
keep them comming....

Guy Croft
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Re: Delta Integrale Evo1 long term project

Post by Guy Croft » Mon Mar 02, 2009 9:40 am

Model Post!


David -thanks very much for taking time to document this very important project here.

GC

TR-Spider
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Re: Delta Integrale Evo1 long term project

Post by TR-Spider » Mon Mar 02, 2009 4:05 pm

budget (unknown, whatever it takes).
You are a lucky man, David!

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
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DeltaDave
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Re: Delta Integrale Evo1 long term project

Post by DeltaDave » Mon Mar 02, 2009 8:46 pm

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.
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DeltaDave
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Re: Delta Integrale Evo1 long term project

Post by DeltaDave » Mon Mar 02, 2009 8:48 pm

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
Thomas, I think I will just stick with front and rear strut braces.
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DeltaDave
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Re: Delta Integrale Evo1 long term project

Post by DeltaDave » Sat Mar 07, 2009 8:39 pm

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.
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Rear subframe and tiebars
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Under car view
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Underbracing
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Spherical bearing top mounting
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Front coilover
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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.
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Fuel tank
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Rear view
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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.
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Dash
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Door panels stripped to bare minimum and Sparco seats fitted.
deltadave_23.jpg
Interior
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Brakes

Front are 355mm x 35mm full floating discs by Alcon with four pot AP racing calipers from a Jaguar XJ220.
deltadave_24.jpg
Front brakes
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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.
deltadave_25.jpg
Rear brakes
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I almost forgot the pedal box.
deltadave_26.jpg
Pedalbox
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deltadave_27.jpg
Bulkhead modification for pedalbox
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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.
deltadave_28.jpg
Rear silencer
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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 Mon Mar 09, 2009 7:00 pm, edited 1 time in total.
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TR-Spider
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Re: Delta Integrale Evo1 long term project

Post by TR-Spider » Sat Mar 07, 2009 9:35 pm

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
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DeltaDave
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Re: Delta Integrale Evo1 long term project

Post by DeltaDave » Sun Mar 08, 2009 8:26 am

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
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.
deltadave_29.jpg
Hydraullic handbrake pipework
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Rich Ellingham
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Re: Delta Integrale Evo1 long term project

Post by Rich Ellingham » Fri Apr 03, 2009 9:46 pm

Keep it up Dave, some serious money invested in this, impressed with the exhaust 4inch pipe work must take some fit up.

Rich
book 38

kritip
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Re: Delta Integrale Evo1 long term project

Post by kritip » Mon Apr 06, 2009 1:50 am

The project, posts and pictures are all amazing. This car is very very nice. Keep the updates going.

Regards,

Kristian

DeltaDave
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Re: Delta Integrale Evo1 long term project

Post by DeltaDave » Thu Apr 29, 2010 10:05 pm

Further (smaller) developments, sorry Guy
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Last edited by DeltaDave on Sat May 01, 2010 6:03 am, edited 1 time in total.

Guy Croft
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Re: Delta Integrale Evo1 long term project

Post by Guy Croft » Sat May 01, 2010 1:25 pm

Thanks Dave

Got the engine bay, do you have a respectable front-end view of your Int? Maybe with bonnet on, lights?

G

DeltaDave
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Re: Delta Integrale Evo1 long term project

Post by DeltaDave » Sun May 02, 2010 6:49 am

I will do one of those today

DeltaDave
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Re: Delta Integrale Evo1 long term project

Post by DeltaDave » Mon May 03, 2010 3:47 pm

Here are the new ones, I think you might find these better.
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