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EVO Project RSR 575 #1097672
07/09/2010 11:08
07/09/2010 11:08


Hi there,

During the coming weeks I will be posting updates on my project EVO RSR 575 and your comments are welcome.

I have been working on this car literally for years on an on/ off basis, finance permitting, but finally the day has arrived to put it all back together for one final time. I have paid a lot of school fees in the process and you are welcome to ask me anything about the project, no secrets here. Your recommendations are also welcome.

To be honest I don’t even know how much of the modifications done on the car would be applicable to a standard 20VT since standard parts were modified to accommodate customs parts etc, but I will be as detailed as possible in all my discussions.

This one is not for the purists, you don’t have to agree with me on the esthetics or technical route I took, but maybe you can appreciate the effort that went into the project.

I chose the name RSR 575 because I am trying to extract 575BHP from the 2.0 20VT motor and drop the weight down to as close as possible to 999kg’s.

The Project EVO RSR 575 includes the following upgrades;

• Custom front spoiler.
• Custom rear spoiler.
• GRP bonnet.
• GRP boot lid.
• Removed all plastic protection covers.
• Complete flat bottom under tray.
• Remote opening of boot.

• All colour coded door and dashboard trim custom coated.
• Centre switch panel custom coated.
• Leather covered front bucket seats on custom adjustable rails.
• Remote Start button.
• Gated gear lever housing.
• Instrument panel replaced with Stewart and Warner Maximum Performance range of gauges
o Speedo (3.38”) 0 – 200mph
o Rev counter (3.38”) 0 – 10 000rpm vertical scale
o Fuel pressure (52mm) on dash.
o Oil pressure on dash.
o Boost where the clock used to be.
o Exhaust temp in the place of the ashtray
o Water Temp in the pace of the ashtray
o Fuel level in the place of the ash tray

• HID Driving lights.
• HID Main beams.
• LED Rear lights.
• LED Indicator lights

• Six point harnesses for both driver and passenger.
• Master cut off switch both interior and exterior.
• Battery moved to the boot.

Brake system (No more ABS)
• Wilwood SL6 radial mounted six pot calipers front.
• Wilwood GT 328mm rotors front.
• Wilwood Dynalite four pot calipers rear.
• Wilwood Ultra-lite 309mm vented rotors rear.
• Wilwood brake cylinders.
• Wilwood balance bar adjuster.
• Dry break quick release fittings on brake calipers.
• Aeromotive braided stainless steel hose with rotator fittings.
• Wilwood Polymatrix brake pads.
• Solenoid activated hand brake.
• Modified Fiat brake pedal assembly.

Suspension system
• H&R lowering springs.
• AVO Custom made gas strut inserts.
• Front and rear anti roll bar kit upgrade.
• Custom made strut brace.
• Custom made adjustable pillar top mounts.
• Poly urethane bushings.
• Dimag Magnesium alloy wheels – 18”
• Spacers on all the wheels.

Fuel system
• Modified fuel tank to accept Stewart and Warner fuel level sensor.
• Twin Walbro 255lph fuel pumps
• Custom fuel pump assembly to house the two in tank Walbro fuel pumps.
• Aeromotive push lock fittings and fuel line from the fuel tank to the engine bay.
• Aeromotive braided stainless steel hose and reusable fittings in the engine bay.
• Custom inline fuel filter (100 micron) between the fuel tank and the fuel pressure regulator (FPR) and a second 10 micron fuel filter between the FPR and the injector rail.
• Jiffy-Tite dry break quick release fittings on the fuel rail and FPR.
• Aeromotive adjustable fuel pressure regulator.
• 2 x Custom built Marren Fuel Injector Rail made form billet aluminum. One rail for fuel injection and another rail for direct water injection per inlet port.
• 5 X 1000cc Marren Fuel injectors.
• 5 X Aquamist Water injectors.
• Aeromotive push lock fuel return line and fittings.

Engine management system
• Splitfire or KMS engine management.
• Wide band Lambda control.
• Fiat Coupe coil packs

Induction system
• Garrett T61 turbo with Smart Racing 360 degree bearing.
• Smart racing blow off valve.
• Smart racing external waste gate.
• Smart racing exhaust manifold.
• Modified throttle body.
• Front mount intercooler.
• Aliminium boost pipes.
• Silicon hose fittings.
• Norma stainless steel hose clamps.
• Front mount intercooler spray system.
• Custom made intake manifold (Pending performance results).
• BMC air filter
• 76mm exhaust system.

Cooling system (thermostat and mechanical water pump removed)
• Custom build triple core cross flow radiator.
• EWP electrical water pump with electronic controller.
• Custom made coolant tank.
• Remote mount oil filter.
• Performance oil cooler with 21 rows.
• Stainless steel oil cooler hoses.
• Stainless steel coolant hoses.
• Norma stainless steel hose clamps.
• Up rated twin cooling fans

Engine (all balanced and blue printed)
• Wiseco pistons.
• Eagle/ K1 connecting rods.
• Standard Fiat 20VT head with matched exhaust and outlet manifold ports.
• Modified hydraulic valve lifters.
• Modified Auxiliary pulley.
• KG Gun-Kote

• Modified 6 paddle Fiat Coupe clutch assembly.
• Lightened Fiat Coupe flywheel.
• KG Gun-Kote

• Head unit – ????
• Speakers - ????
• Amp - ????

• Custom made window washer fluid tank.
• Anti smash and grab film on the windows.
• All air hoses are PU and Festo push lock fitting based.

Last edited by I8AV8; 07/09/2010 11:09.
Re: EVO Project RSR 575 Discussion [Re: ] #1102017
15/09/2010 16:02
15/09/2010 16:02


I did some work on the car during the past couple of days.

Installed soundproofing on the interior surfaces, it is a foam product with a thin reflective material on both sides.

click to enlarge click to enlarge click to enlarge

Installed the 6x9 rear speakers and new front speakers, ICE is not a priority and I went with some Phillips components and piggybacked on the existing wiring. I am in the process of modifying the tweeter enclosures and I will be installing a Kenwood unit with MP3 and Bluetooth capabilities.
click to enlarge

Installed the door trim and I must say that the new finish gives a far more sedate feel to the cabin, not so in your face.

Installed the main feed from the battery that was moved to the boot. The power cable was placed in a protective shroud.
click to enlarge click to enlarge
Installed an auxillary Poly U tube that could be used for the water injection. (see above pic)

Installed all the vacuum and other tubes associated with the manual boost control, boost gauge and auxillaries.
click to enlarge

Last edited by I8AV8; 15/09/2010 16:40.

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