2002 Hyundai Elantra - Champ Car Build/Story

[kevinatfms]

Ive always wanted to try some wheel to wheel racing. While I wont have the time to dedicate myself to a class I thought maybe some occasional racing in Lemons or Chump Car would be an easy/cheap way to get into racing.

A few friends agreed with my idiotic plan to build a $2019 Challenge/Chump Car style race car. They are me, V and J. Ill withhold names until they give me the OK to post some photos of the lunatics.

We set out to find a car for $500 and then build it to compete in crap can racing, autocross, HPDE events and the like. Since most of us have a build already going with other cars, this would be built to be as budget as possible. The budget would follow the Grassroots Motorsports $2019 challenge build.

The search lasted a few months before we found a good candidate. A 1995 Saturn SL with a 5 speed manual and a SOHC engine. Turned out it was in great shape but the motor was on its last leg and had excessive blow by. We didnt want to start with a total engine swap so we passed. A few hours wasted but it was for the better.

A few Sentra SE-R's were candidates, mostly for the 6 speed manual transmission, the optional LSD in the Spec-V models and the fact they were stupid cheap. Checked a few out but most were totally destroyed or the owner wouldnt budge on the price.

About a week ago, a 2002 Elantra popped up on my Craigslist search. Guy wanted $700 for it and said it had 117k miles, working a/c, heat and new exhaust. The photos showed it had some front end damage. Not a biggy as long as it wasnt rusted to buts underneath.

So i contacted the owner, said id offer $350 for it and that i was turning it into a Chump Car. He agreed to the $350 as long as i came and got it ASAP. If anyone knows me and Hyundai's, they know my last 2002 Elantra was a great little autocross/daily driving car with 300ish thousand miles of trouble free operation. So, knowing these Hyundai's, i wanted to jump immediately.

LOOKED CLEAN ENOUGH FOR ME.

Headed down to see it and found that it ran a little rough but was in overall great shape, very little rust and had a bunch of new parts on it. Guy got into a DUI with it and mangled the front end. He wanted it gone.

So, loaded it up on the trailer, exchanged the dough/title/BOS and we headed off back to the shop.

More updates to come!

 

[kevinatfms]

We got it back to my buddy's shop. Unloaded it off the trailer and took it for a short drive. Clutch slips, runs rough like it has an ignition problem, rattle from the driver side axle and it had a rear wheel bearing making a little bit of noise.

Started to tear it apart. Hood, fenders and what was left of the bumper came off to see what the front end looked like underneath.

To our surprise it was fairly intact. Nothing bent or broken on the unibody itself and only minor sheetmetal supports needed to be bent back into shape. We could even reuse the passenger side headlight!

Now it was time to dig into the engine. Scanned the CEL and found it had misfires on 2 cylinders and an EVAP code.

Pulled the plugs and......

GOOD

BAD

GOOD

BAD


So, found that it really only needed a tune up, clutch, axle and rear bearing to be running and driving 100%. So set off to order some parts from Rock Auto and to start scouring the eBay listings/junkyards for body parts.

Ordered:
clutch Kit w/ flywheel + TOB
slave cylinder
spark plugs
wires
2x fenders
grille
2x headlights(just in case)

Total with car: $696.94

We still need a bumper, hood, axle and wheel bearings to complete the drivetrain.

Other plans for performance parts will be ordered soon too including a $40 short shifter with bushings, motor mount inserts/poly fill mounts, H&R springs, Tiburon struts, Tiburon 19mm rear sway bar, 15x7 aluminum wheels w/ 195/55R15 R-comps, tow hooks, a roll cage(V will be welding it in), a fat guy race seat and whatever little odds and ends i have left over from my old Elantra. Mr V. will be welding up the tow hooks, cage and filling in the antenna hole, cutting out the rear floor area for 18g sheet metal(remove some weight). Dash will be gutted and cut apart.We will be doing some Home Depot body mods like duct hood vents, a lexan rear spoiler and maybe a rubber garage door lip. Spraying the car with rattle can silver or green, maybe a two tone paint job? We will see. Lots of discussions on color.

More updates to come when parts come in. Friday headed to the local u-pull-it to see if we can get a bumper and hood.

 

[Deceptive]

Awesome!


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[Kartracer]

Keep us posted, looks like fun.

 

[xblitzkriegx]

Make some ducts for the front brakes.

 

[kevinatfms]

Parts on order as of today:

Headlights
Fenders
Tiburon struts
H&R springs
Tiburon 19mm rear sway bar
tow hooks
plugs
wires
clutch kit
flywheel
slave cylinder
rear motor mount insert
front and rear sway bar poly bushings
shifter and shifter base poly bushings
front strut tower brace
left front axle shaft
high performance drop in air filter

Total: $1,409.46 including the car

Most parts coming this week and early next week. Only thing missing from the list is a front bumper, hood and a set of alloy wheels(trying to find OEM GT wheels for cheap).

Once we get the car up and running with suspension completed we will try out an autocross with it to see how it drives. From there, we will go and add the cage, race seat, fire suppression and strip the not-needed windows, A/C components, wiring, dash components and sound deadening.

We are hoping for sub 2500lbs once everything is removed.

The setup above is what I basically had on my last Elantra and it was a reliable, fun and competent autocross car. The brakes will more than likely be the biggest issue as they are only 10ish inch front rotors with single piston calipers. Once we figure out which wheels we are going with we can plan brake upgrades with DSM calipers and 12" rotors or a set of Tiburon GT front calipers and Optima 11" rotors. Both can be stuffed under a 16" wheel but not a 15" wheel. The 15" tire size of 205/50R15 is the cheapest with the most options for track tires so we might just try to keep the brakes cool with ducting and good pads.

More updates to come this week...

 

[kevinatfms]

Some work today. Start to gut the interior. Removed the rear seats, carpet and insulation.

Installed new spark plugs and wires. Car now runs like a top. Had a misfire before and the plugs as shown in my first post were just toast.

Also installed the two new front fenders. Need to make some brackets for the front tie point but other than that they fit great.

We also installed a Spectre Performance drop in filter. No intake just yet. The stock box is more than enough for what we need.

A few things showed up when I got home. Got a sick deal on the H&R springs for only $60. Amazon was blowing them out and I got the last set. New headlights too!

I also ordered the seat we will be using. A Corbeau Forza Wide with a Corbeau direct fit bracket.

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[kevinatfms]

Some work today. Start to gut the interior. Removed the rear seats, carpet and insulation.

Installed new spark plugs and wires. Car now runs like a top. Had a misfire before and the plugs as shown in my first post were just toast.

Also installed the two new front fenders. Need to make some brackets for the front tie point but other than that they fit great.

We also installed a Spectre Performance drop in filter. No intake just yet. The stock box is more than enough for what we need.

A few things showed up when I got home. Got a sick deal on the H&R springs for only $60. Amazon was blowing them out and I got the last set. New headlights too!

I also ordered the seat we will be using. A Corbeau Forza Wide with a Corbeau direct fit bracket.

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[kevinatfms]

More done!

Front end is back together. Tow hook welded to front bumper beam. New headlights, bumper and pinned the hood down.

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[kevinatfms]

New shifter installed. Shift bushings also went in. The OE ones were shot.

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[Sonic605hp]

Coming along nicely.

 

[kevinatfms]

Coming along nicely.

Yeah, spent the better part of the day pulling all non essentials out. Still have more to go. This week I’m going to focus on the suspension, clutch and driveline.

Needs struts and springs installed. New clutch and flywheel. Driver side axle and passenger rear wheel bearing.

Wheels we went with Drag DR33. Like these in 15x7 4x114.3 +40 offset. Tires will be 205/50R15 Federal 595 RS-RR.

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[kevinatfms]

Total to date is: $1,618.06.

Should be complete at that dollar amount. Now the hard part of doing all the install work on it. More pics and updates to come in the next two weeks.

 

[RedRocketMike]

I think this is more interesting than reading about someone tracking a Ferrari or whatever.

I'm surprised you're replacing sheet metal and headlights though?

 

[kevinatfms]

I think this is more interesting than reading about someone tracking a Ferrari or whatever.

I'm surprised you're replacing sheet metal and headlights though?

Sheet metal was needed. The front fenders were basically hitting the tires while the front bumper was cracked and missing 1/3 of the cover.

Headlights for anything during dawn/dusk and to keep a profile of a vehicle. Dont want a derby looking car.

We will have incar video of all events along with pictures and thoughts from each person driving(we have 4 so far). First event will be an autocross in March which we should have the car completed by then.

 

[kevinatfms]

Delivery!

Rear sway bar came in. I ordered a 2006 Tiburon GT GS rear 19.2mm rear sway bar but since Hyundai's QA/QC control during the mid 2000's was total garbage, I actually got an 18mm bar off a regular GT V6. Not a big deal as i have poly bushings for both.


Original bar is a 12mm. Basically a pool noodle. This will be a significant upgrade to reduce roll in the corners along with the H&R lowering springs.

 

[Swine]

great thread, chump racer here as well. love the build

 

[kevinatfms]

great thread, chump racer here as well. love the build

Any tips? This is our first build and so far we are under budget by around $450. The car will be more reliable than fast and we just want to finish our first race versus even thinking of placing. We have 4 people signed up with a 5th as a possibility.


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[kevinatfms]

Welp, ordered our steering wheel and hub. NRG Innovations short hub(no QL at this time since the seat moves) and a suede covered 3 spoke wheel with yellow centering stripe. NRG was very helpful in identifying the hub requirements for the Elantra.

Ill post up when they get here and mounted inside.

 

[Swine]

Any tips? This is our first build and so far we are under budget by around $450. The car will be more reliable than fast and we just want to finish our first race versus even thinking of placing. We have 4 people signed up with a 5th as a possibility.

Our poison of choice was a 91 Volvo 740 Wagon, it was a free car. Automatic and NA initially. Our goal was the same as yours starting out, get on track, stay and track, and complete a race. We finished Charlotte and besides being blown off the banks by the nascar pit crews in their thundering monte carlos (we topped out at 93MPH heh) we had a blast. Then we turbo charged it and manual swapped it and havent finished a race since haha. Did manage to complete 11hrs at daytona though.

My suggestion is find a way to get full life out of your tires. This means proper roll control so you arent eating the outside shoulders and proper camber. Find ways to make these things happen. Chump is supposed to be affordable racing but uneven wear will kill perfectly good tires. We are still searching for chump "legal" solutions to gaining the camber we need without incurring to many points.