HF integrale rebuild

Oh. My. Word.

I'm in for the ride, following with interest.

I bet you can't believe your luck with the values of these now!

I probably should have added that it's a 1992 evo 1. The last of the homologated models so that means big turbo and no cat.

The later evo 2 had a touch more power made with a smaller turbo and a cat but better ecu. I like the 1 as it's the real deal in my mind. Being build for Group A there are loads of nice touches like how the complete front of the car is an air intake, it has a cooler for the power steering fluid and the front suspension towers were higher than the previous version for increased travel.

Its easier to use the front and rear bumper mounts as points to attach it to a spit - although I can't imagine it needs much with only 34,000 on the clock? Having it upside down does make fitting things to the underside easier though.

Stitch welding won't necessarily help much - but it will put more stress into the areas that are known weak points - top and bottoms of the A-pillar, center tunnel where the inner mounts for the front seats and the handbrake are, and the "chassis legs" in the engine bay. I found anywhere where three layers or metal (outer sill, inner sill, edge of floor for example) joined two, it cracked.

It needs bracing - reinforcing plates - I made mine, but you can buy them from several specialists.

Just for a laugh, if you've not done it, with your road car, with the wheels on the ground, put you hand over the area where the rear corner of the bonnet sits into the corner between the top of the front wing and the scuttle - then move the steering wheel side to side . . .everything moves in all directions, even on good ones.

If you've not found it yet, evocorner forum has a lot of info in the FAQ on the front page - forums.delphiforums.com/evoforum

I bought my 16V in around 2005, put 100,000 miles on it in all weathers, stored outside, commuted to work in Germany every two weeks for a while. Bought an evo1, sold the 16V a year later having fixed all the stress cracks, small rusty bits, oil leaks on the evo, and then put another 100,000 on the evo1 in ten years in all weathers again, including with a trailer on the back - which is when you find out how good your engine is, as you can be on boost for a long time if you aren't careful - mine was good:) Now owned it for 18yrs, its on close to 200,000, but for obvious reasons, its not gone far in the last year. I've turned down some good offers, but driving it puts a big smile on my face, even standing still it does.

If you need an as new-head with new guides, new valves, mildly ported . . I have one sat in the front bedroom I'm never going to fit it as my plans changed.

Thanks Bricol. I’ve been on evocorner since 2003, you probably know me as fiche2 on there.

The stitch welding of the cabin, especially across the floor pan has been recommended by some well-respected grale specialists. Not necessarily to reduce cracking but to give the shell more torsional strength. I’ll be making up reinforcement plates for the lower and upper A pillar sections, both outer chassis rails forward of the windscreen and the inside of the offside front bulkhead where the rail meets it. I’ll also be welding around the B pillars and round the rear strut turrets.

I’ll be using the bumper pickups for the spit, it’s simply mounted on dolleys at the moment hence the use of suspension and diff points.

Awesome cars these would love one in yellow..

Fantastic read... intergrale was the only car I had been in that had such violent acceleration/ boost/ both that it hurt my belly muscles.... fond memories!

+ 1 regarding timeframe I bought my E30 318is in 2013 as it was dirt cheap.... 2021 and I’m only half way round... young family delayed it but never wanted to give up so locked it up, used to drink more than the weekly garage rent do swapped it round! .

Have to say, those are both stunning cars,
Always had a dream to own one when my mate had a UR Quattro but, with 2 rug rats and a mortgage, couldn't afford one even then,
(Now they've gone and I can afford one I can't afford one lol,)
Really looking forward to seeing future updates on this thread,
Nigel

Nice car and thorough work on the welding. I also seam welded most seams of my MGB before converting it to V8 to make the body more stiff.
I did not have the stress cracks. If you look at the theory, You should be carefull with welding stress cracks. Welding changes the material structure and it will be hardened and therefore less flexible and more prone to cracks. This is all theory. Things would improve if you could weld another plate in that area but doing this in the area as pictured is not easy. It may not be needed as the car might be pampered after the resto is done.
Keep up the good work as i like these cars and the work you are doing.
Peter