Auto Technica Garage's Rally raid project!

[kuroi]

I have decided to take this poor beat up Pajero and turn it into a rally raid truck!


So, 2.4 liter 4g64T twin cam engine looking to make between 300-350hp and around the same amount of torque when done.
The trucks curb weight is 3260lbs so it should scoot along pretty well, looking for a 0 to 60 time in the 4.5 second range roughly.
The drivetrain is going to stay 2WD/4WD selectable as the KM145/32 trans has proven itself reliable up to 400hp or so I've heard, maybe in the future I will upgrade the trans to a SS2 out of a newer 5speed montero to give me the option of 2WD/AWD/4WD or maybe not....


The laboratory


Doing a complete overhaul of everything to get it abuse worthy. There's something like 10+ yrs of deferred maintenance lurking under this thing and a tired trans that howels like a WRC gearbox. haha, poor little truck's had the **** beat out of it off road for many years.



Found a factory mechanical LSD at pick n pull!

LSD trip FTW! haha


packages with car stuff yea!!


Poppin in the bouncy bits!


aaand this is why you don't get in a hurry.... bent oil control ring FTL haha.


Getting it ready 4 paint


Oh boy, mail santa brought me a box!


It's baaack...


and better than ever!


Next comes this


It's been slow going lately, were in the middle of moving the shop to a bigger building so .....
Artsy piston shot!!!


Cleaned the head, no more dirty thoughts....


Test fit

[kuroi]

Getting the factory thermostat location cleaned up for a block off plate


Measuring to drill for 2nd coolant hole at the rear of the head.


Treasure located, time to dig


Start with a little bit, there's not a ton of room for error. EGR passage on one side and valve dome wall on the other
and its gotta line up with the passage on the block


First small hole drilled


drilling second larger hole after confirming correct location


Done, yay!


Lines up nicely


Notice front of RWD head gasket has no coolant passage holes


The maddness behind this is, because I'm moving the thermostat housing to the front of the head I need to improve coolant flow through the rear so coolant doesnt sit there stagnant and steam. I accomplish this by closing off the ports in the front and opening them up in the rear of the head therby forcing the coolant to flow up through the back of the head from the block and to the front exiting via the newly located thermostat housing.

Moving into the thermostat cave with the boroscope, scary!!



Shavings from drilling are on the floor of the coolant passage which is actually the celing as the head is upsidedown right now,
the big circular structure ahead with the casting line in it is the outer jacket of cylinder #4's valve dome, no monsters yet.



Were on the inside of the coolant passage in the head looking through the hole I just drilled,
yes that is my eye ball pressed against the outside bottom of the head looking back inside, haha found the monster


Helping the epoxy paint on the moddified headlight bezels to dry


Stir in some moddified BMW 5 series projector buckets


With a nice press in fit.


Add some clean epoxy adhesive action


compared to old sealed beam


It has projectors!! and retains factory aiming ability. I might give 'em halos, depends on how rice I feel later.


rarrr!


New injectors yaay!


Mitsubishi loves california so much that they included a model of it with every twin cam 4G head!

[kuroi]

It looks like it's trying to crawl back up in there...

So it was obliged...


decided to stud it just because


as it sits now


Progress on the rally truck today!
Now it's on to the 10% of the stuff that takes 90% of the time....










The engine assembly sits behind the front axle. :good: This is a good thing.

[kuroi]

Craft time! gotta modify the pan to clear the front diff






pieces mocked up gotta weld...




All kinds of projects goin on here!




too late, will finish pan tomorrow.

[kuroi]

So moved to the rear suspension to give this thing some better manners.
The factory setup is pretty basic, were gonna add some drag links, sway bar to keep the rear under control.


Throw in some fire!


line up some mount points on the axle and frame rail do a little welding.


and viola! drag links


The sway bar will come later...

There's also this little problem to get on.




peak-a-boo!

[HARABAS]

...

[HARABAS]

That was me being speechless.

[Christian P.]

And there I thought I knew a few things about engine...

I love the project in the background too. A Celica 1977 is somewhere in my future.

[off-roader]

[haven]

Thanks for sharing. I always liked the 2 door Pajero/Montero/Dodge Raider.

If people call ahead, can we stop by to see the vehicle? Is this the address for the Auto Technica shop?
2000 9th Street
Sacramento, CA 95818
(916) 491-4100