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My DP MR2

The slow building of a D-Prepared class SCCA Solo Toyota MR2:
College Debt, Hurricanes, and Cancer really interfere with building an autocross car


(It should go without saying that I'm the sole copyright's holder to any/all of these images unless otherwise noted. Any use in commerce is forbidden unless my explicit permission has been given.)
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To win the 2008 SPOKES of Austin Golden Stromberg Award for
To win the 2008 SPOKES of Austin "Golden Stromberg" Award for
Almost had a Darwin Award.
Almost had a Darwin Award.
No Tarantula, but she's a terror in the shop
No Tarantula, but she's a terror in the shop
A little foreshadowing...
A little foreshadowing...
Gutted 87 T-top MR2
Gutted 87 T-top MR2
DP Car v1.0: THE starting point 87 MR2 w/ Sherwood Toning
DP Car v1.0: THE starting point 87 MR2 w/ Sherwood Toning
Hey, I might make money on this project!!!
Hey, I might make money on this project!!!
Proof it ran...
Proof it ran...
Camber plates... ooohh pretty
Camber plates... ooohh pretty
If you know Eibach part #s you know my spring rates
If you know Eibach part #s you know my spring rates
Koni OTS Yellows
Koni OTS Yellows
Race inserts for rear.
Race inserts for rear.
Parts supplied with Race inserts: excludes only gland nut.
Parts supplied with Race inserts: excludes only gland nut.
Assembly - Parts laid out on box
Assembly - Parts laid out on box
Race inserts come with this black shim, and eliminates the need for a spacer.
Race inserts come with this black shim, and eliminates the need for a spacer.
Shim is just positioned right at bottom of internal threads
Shim is just positioned right at bottom of internal threads
Fully Assembled:  actually, this was shockingly easy.
Fully Assembled: actually, this was shockingly easy.
Sport inserts.  Comes with shim as part of housing cap (not pictured)
Sport inserts. Comes with "shim" as part of housing cap (not pictured)
The gap between the top of the insert and the bottom of the threads
The gap between the top of the insert and the bottom of the threads
Measuring 1 -  5/16
Measuring 1 - 5/16"
Measuring 2 - 5/16
Measuring 2 - 5/16"
Front Strut assembled.
Front Strut assembled.
Front housing left, rear housing right
Front housing left, rear housing right
Front left, rear right... identical.
Front left, rear right... identical.
Bolt hole spacing front
Bolt hole spacing front
Bolt hole spacing rear.
Bolt hole spacing rear.
Here is where the problem starts...
Here is where the problem starts...
The rear strut housing from base to top is ~13 7/8
The rear strut housing from base to top is ~13 7/8"
Close up measurement rear
Close up measurement rear
The rear strut housing from the same point would be 11 3/4
The rear strut housing from the same point would be 11 3/4"
Close up measurement front
Close up measurement front
Comparison sake both up right (Front left, Rear right)
Comparison sake both up right (Front left, Rear right)
Close up of the difference... remember though this does not take into account the difference in the pick up location
Close up of the difference... remember though this does not take into account the difference in the pick up location
measurement to pick up location...
measurement to pick up location...
The ACTUAL comparison as they sit.
The ACTUAL comparison as they sit.
Verifying not feasible. 1072 SPORT top, 8610 RACE bottom
Verifying not feasible. 1072 SPORT top, 8610 RACE bottom
Farther back picture:  shaft on 1072SPORT is 1 longer, body is ~2.5 longer.
Farther back picture: shaft on 1072SPORT is 1" longer, body is ~2.5" longer.
Close up of race shaft, can see that maximum shock travel is 5.5 (very faint) losing 3 of travel would be bad.
Close up of race shaft, can see that maximum shock travel is 5.5" (very faint) losing 3" of travel would be bad.
The parts
"The parts"
Spacer to fit Koni Sport into front housing with out cutting housing
Spacer to fit Koni Sport into front housing with out cutting housing
Gland Nut + Spacer
Gland Nut + Spacer
Front shims stacked...
Front shims stacked...
Assembled rear coilover sleeve
Assembled rear coilover sleeve
Rear Shim Top,
Rear Shim Top,
Bevelled shim-top
Bevelled shim-top
Tight fit = more prep
Tight fit = more prep
Rear Housings
Rear Housings
Polished and welded on
Polished and welded on
All prepped, ready for install
All prepped, ready for install
Front strut prepping for install
Front strut prepping for install
Front strut...
Front strut...
Front camber plates from Ground Control
Front camber plates from Ground Control
Current ride height set...
Current ride height set...
Rear strut/coilover.
Rear strut/coilover.
And they nicely rigged the radiator to the car
And they nicely rigged the radiator to the car
DP v1.0  in progress
DP v1.0 in progress
New steering wheel...and quick release
New steering wheel...and quick release
MR2 Trophy-truck?!
MR2 Trophy-truck?!
Control arm angle: coilover bottomed out....
Control arm angle: coilover bottomed out....
On the scales.
On the scales.
Debut Delayed....  (see caption)
Debut Delayed.... (see caption)
Twos-R-Us toe link: no more constantly variable toe.
Twos-R-Us toe link: no more constantly variable toe.
Already for the test run...
Already for the test run...
SPURT!! SSQQQQuuueeaaallll!!!  2007 campaign: OVER
SPURT!! SSQQQQuuueeaaallll!!! 2007 campaign: OVER
Fast Forward 3 months: do-over
Fast Forward 3 months: do-over
Parts Swapping
Parts Swapping
Swapped Front Suspension
Swapped Front Suspension
Getting there
Getting there
That header looks shiny and new
That header looks shiny and new
B-pipe interference problem
B-pipe interference problem
Up top: things look color coordinated now...
Up top: things look color coordinated now...
A race seat!
A race seat!
Everything looking good on this one
Everything looking good on this one
Paint is all dry now...
Paint is all dry now...
It's the little things
It's the little things
Progress?
Progress?
New brake set up finalized
New brake set up finalized
Rear Brakes with Stainless lines
Rear Brakes with Stainless lines
The new car still moving around the shop...
The new car still moving around the shop...
Master Cylinder Brace
Master Cylinder Brace
Bleeding the brakes
Bleeding the brakes
All the way down, on the ground
All the way down, on the ground
As installed.
As installed.
The new Kirkey seat
The new Kirkey seat
Progress.
Progress.
This above all else thrills me...
This above all else thrills me...
More progress
More progress
Woohoo more progress
Woohoo more progress
HVAC Unit removed...
HVAC Unit removed...
The interior
The interior
Another shot of the 'office'
Another shot of the 'office'
As she sits...
As she sits...
And from the front...
And from the front...
The Repaired Front end...
The Repaired Front end...
Zip-tie Stitching  the Front Lip Together
Zip-tie Stitching the Front Lip Together
Trash Pile Growing Larger
Trash Pile Growing Larger
OEM window seal
OEM window seal
Installed
Installed
Carbon Fiber Sample!!
Carbon Fiber Sample!!
Problem Grounds...
Problem Grounds...
Headlight covers
Headlight covers
Updated picture from the front.
Updated picture from the front.
Almost Ready to go
Almost Ready to go
SUCCESS!  DP  V 2.0 is ready to go
SUCCESS! DP V 2.0 is ready to go
We have lift off!!
We have lift off!!
Houston Tour - 4th place!
Houston Tour - 4th place!
PHASE II:  Improvement.
PHASE II: Improvement.
Insulation removal
Insulation removal
Bare metal on the firewall
Bare metal on the firewall
Door bars
Door bars
Prepping for paint.
Prepping for paint.
Trim removal...
Trim removal...
Rear quarter repair.
Rear quarter repair.
Bad welds, where?
Bad welds, where?
Just making everything look good.
Just making everything look good.
Paint preparation
Paint preparation
Reworking the front end
Reworking the front end
New bumper fitting,
New bumper fitting,
Stripping continued
Stripping continued
Cockpit painted
Cockpit painted
In progress
In progress
Paint Prep.
Paint Prep.
Preparation continued
Preparation continued
PAINT? Finally?
PAINT? Finally?
Trim prep!
Trim prep!
Finished!!
Finished!!
Trim is done... car is not...
Trim is done... car is not...
Tape removed...
Tape removed...
I hate paint prep.
I hate paint prep.
Hate. Prep.
Hate. Prep.
Painting base coats
Painting base coats
First clear coat
First clear coat
Without clear coat
Without clear coat
Tape removed
Tape removed
Roof shine
Roof shine
You can read BMW in the reflection of the flag
You can read BMW in the reflection of the flag
Outside, with trim installed
Outside, with trim installed
From the front
From the front
Over cast skies
Over cast skies
Sunny skies
Sunny skies
Carbon Fiber Quarter Panel
Carbon Fiber Quarter Panel
KD Garage Trunk Lid
KD Garage Trunk Lid
Trunk Lid Reflections
Trunk Lid Reflections
Race Seat Re-Install
Race Seat Re-Install
Interior Shot
Interior Shot
Fender Flares....hrrmmmm
Fender Flares....hrrmmmm
DP V2.1 rolls out with new spats...
DP V2.1 rolls out with new spats...
Time to race again.
Time to race again.
High angle...
High angle...
Finally!
Finally!
Keizer wheels.
Keizer wheels.
Thanks to Apex Vinyl and SOULSPEED!!
Thanks to Apex Vinyl and SOULSPEED!!
Nats East Course
Nats East Course
Nats East Course Start Chute
Nats East Course Start Chute
Nats East Course 1st sweeper
Nats East Course 1st sweeper
Nats East Course 1st Sweeper
Nats East Course 1st Sweeper
Nats East Course, 1st Right turn
Nats East Course, 1st Right turn
Nats East Course
Nats East Course
Nats East Coast
Nats East Coast
Post Nationals...
Post Nationals...
Thinning out the harness.
Thinning out the harness.
Quaife Rack.jpg
Quaife Rack.jpg
Back on jackstands.
Back on jackstands.
9lb AL radiator to replace leaking ~14 OEM radiator.
9lb AL radiator to replace leaking ~14 OEM radiator.
Alternator not from Hell.
Alternator not from Hell.
First coat of (re)paint down, Viper Red.  Now two layers of Chevy Victory Red followed by a clear coat.
First coat of (re)paint down, Viper Red. Now two layers of Chevy Victory Red followed by a clear coat.
New exhaust floor mock-up.
New exhaust floor mock-up.
TRD header flange removal
TRD header flange removal
Mock up under the car
Mock up under the car
From the other direction
From the other direction
Hrrrrrrm we have some space to add longer tubes
Hrrrrrrm we have some space to add longer tubes
Hrrrrmm we're going to have to check ground clearance...
Hrrrrmm we're going to have to check ground clearance...
Long wheel studs mounted to hubs...
Long wheel studs mounted to hubs...
Repainting Steelies
Repainting Steelies
New lug nuts.
New lug nuts.
Little test fit
Little test fit
Other direction
Other direction
Nationals tires headed for the steelies.
Nationals tires headed for the steelies.
Polydyn Gold HS 1300 Coated header
Polydyn Gold HS 1300 Coated header
Header coating will turn gold/yellow in time.
Header coating will turn gold/yellow in time.
Mocking up a hanger
Mocking up a hanger
New Exhaust
New Exhaust
Completed Exhaust
Completed Exhaust
Smurf Car - Texas Tour '10
Smurf Car - Texas Tour '10
First picture of the car lifting a wheel
First picture of the car lifting a wheel
New lower front brace
New lower front brace
Modify!
Modify!
TC Sportline Caster Rods
TC Sportline Caster Rods
Class 10.9 hardware
Class 10.9 hardware
Assembled/refreshed front suspension
Assembled/refreshed front suspension
Brace installed
Brace installed
Custom Trailer!
Custom Trailer!
From the other side
From the other side
Adjustable hitch!
Adjustable hitch!
Fits in a garage!!!
Fits in a garage!!!
New Intake
New Intake
Filter in the trunk... again
Filter in the trunk... again
Stainless Clutchline
Stainless Clutchline
Long hours
Long hours
Measurements for rear tie rod heims
Measurements for rear tie rod heims
Tubular tie-rods and bumpsteer pins installed
Tubular tie-rods and bumpsteer pins installed
fromByanH
fromByanH
FromBryanHtoo.jpg
FromBryanHtoo.jpg
Back to work...
Back to work...
Surgery underway.
Surgery underway.
Trunk accessible exhaust
Trunk accessible exhaust
Trunk Floor (-8 lbs)
Trunk Floor (-8 lbs)
Old bumper mounts  (-10 lbs)
Old bumper mounts (-10 lbs)
CF rear spoiler
CF rear spoiler
Projected spoiler support locations
Projected spoiler support locations
ARP wheel stud
ARP wheel stud
Verifying engagment
Verifying engagment
New wheel studs installed
New wheel studs installed
13 Keizer / cantilever backspace
13" Keizer / cantilever backspace
15x10 wheel / FA slick
15x10 wheel / FA slick
Side by side comparo
Side by side comparo
Contact patch comparo
Contact patch comparo
Test fit #1
Test fit #1
Test fit at current ride height
Test fit at current ride height
Clearance for wheel/strut
Clearance for wheel/strut
Clearance for bumpsteer pins
Clearance for bumpsteer pins
Plenty o' room for RCAs
Plenty o' room for RCAs
Front measurements
Front measurements
Rear Measurements
Rear Measurements
Teardown...
Teardown...
Inspection
Inspection
Lifters
Lifters
Foreign object -WAIT WHAT!
Foreign object -WAIT WHAT!
Guide damage
Guide damage
Block inspection
Block inspection
Headgasket inspection.
Headgasket inspection.
Hurst Street Zombie Co.
Hurst Street Zombie Co.
HSZC MR2 area
HSZC MR2 area
SpinWerks
SpinWerks
Hotwheels
Hotwheels
Radiator replacement
Radiator replacement
Radiator replacement
Radiator replacement
New radiator
New radiator
Radiator location testing
Radiator location testing
Comparing venting location feasibility
Comparing venting location feasibility
Front lip/splitter test fitting
Front lip/splitter test fitting
Toysport front lip
Toysport front lip
Valve guide
Valve guide
Disassembled head
Disassembled head
Empty head
Empty head
Bumper holes plugged
Bumper holes plugged
Weighing rear strut  (Not sharing data from other struts that were weighed, but Thanks to Jay and Kevin for stopping by this w
Weighing rear strut (Not sharing data from "other" struts that were weighed, but Thanks to Jay and Kevin for stopping by this w
Weighing front strut
Weighing front strut
Front Bump Steer Pins - Hinson Super cars kit.
Front Bump Steer Pins - Hinson Super cars kit.
Fender contact 1
Fender contact 1
Fender contact near the top of the tire
Fender contact near the top of the tire
Venting hood
Venting hood
Aluminum screening
Aluminum screening
Spoiler side view
Spoiler side view
Bottom end pulleys and new water pump reassembled...
Bottom end pulleys and new water pump reassembled...
Redone rear taillights
Redone rear taillights
Installed
Installed
A test
A test
Bumper Trimming
Bumper Trimming
Installed - 3 shorter bumper
Installed - 3" shorter bumper
Back to ground zero for the struts
Back to ground zero for the struts
More long hours in the shop...
More long hours in the shop...
Struts re-welded
Struts re-welded
Reassembled strut
Reassembled strut
Diamond w/ Hoosier vs Spinwerks w/ Avons
Diamond w/ Hoosier vs Spinwerks w/ Avons
Width comparo Hoosier top, Avon bottom.
Width comparo Hoosier top, Avon bottom.
Ride height test front
Ride height test front
Ride height test rear
Ride height test rear
On the ground
On the "ground"
Longer view
Longer view
Front control arm
Front control arm
Rear control arm
Rear control arm
New radiator actually installed
New radiator actually installed
New fan and aluminum angle bracket
New fan and aluminum angle bracket
Shortened/relocate radiator brackets
Shortened/relocate radiator brackets
Gap
Gap
Weight reduction
Weight reduction
Ride height
Ride height
BECAUSE RACECAR
BECAUSE RACECAR
Minimal wheel gap
Minimal wheel gap
lip.jpg
lip.jpg
shims.jpg
shims.jpg
trim.jpg
trim.jpg
front RCA.jpg
front RCA.jpg
rear rca.jpg
rear rca.jpg
RR corner.jpg
RR corner.jpg
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Nats 2011
Nats 2011
zbarnes2.jpg
zbarnes2.jpg
zbarnes3.jpg
zbarnes3.jpg
Hurst St. Zombie Co.
Hurst St. Zombie Co.
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SCCA Solo Nationals 2012-108.jpg
SCCA Solo Nationals 2012-108.jpg
SCCA Solo Nationals 2012-109.jpg
SCCA Solo Nationals 2012-109.jpg
SCCA Solo Nationals 2012-111.jpg
SCCA Solo Nationals 2012-111.jpg
SCCA Solo Nationals 2012-112.jpg
SCCA Solo Nationals 2012-112.jpg
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