Hi, thought I would share my manxster build here on AVD. The project started in August last year when I picked up the new Manxster body with the aim to build a modern dune buggy using most of the latest mod cons found in new cars. I purchased a salvaged current model WRX that was just 9months old that had the new FA20T motor, which is the latest generation subaru engine that has taken over from the older EJ series. The FA20 features variable cam timing on intake and exhaust and is direct injection. It puts out 198kw in standard form. The aim was to try and re-use as much as practically possible from the WRX to save on purchasing aftermarket parts and to give it the OEM look.

The manxster was ordered with the manx hardtop roof and cage, side and front bars, however a custom rear bar was made to suit the FA20 engine. The only manxster modifications was to integrate a pair of BRZ led tail lights instead of the standard manx lights.

Parts used from the wrx include:

Engine (air-air intercooler replaced by PWR water to air cooler with radiator in side vent)
6speed gearbox (modified by Subarugears)
Front seats
Rear seat (cut down to suit)
Steering column and wheel
Brakes (for disc brake conversion)
Instrument cluster
Multifunction display (boost gauge, mpg display, reverse camera)
Stereo with handsfree
Pedal box, master cylinder and brake booster
Heater box (cut down to remove condensor) and controls (no air con, but has heated demister for ADR compliance)
Side mirrors
Fuse box's and wiring (modified by AGT Engineering)

Other features include a Holden Camira steering rack

The aim was to have this at the Nationals next month, but still waiting on a few components, so new target is for Valla.

The barwork is currently out getting powdercoated and the body prepared for painting.

Anyway, some photos.

I also have a video of the engine running

http://youtu.be/9IQ5-vw4GnI

Damn, that's a lot of work.

Well done.

Very impressive build - will be a weapon.

Just one question: where are you locating the fuel tank?

Amazing, all credit to you.

Cant wait to see the finished product

Kev

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Originally posted by wombatventures No Words left!

Thanks guys. The fuel tank is in the front keeping the brake booster company, its an L shaped tank that goes to the side and in front. Lucky the buggy has a 2" body lift, so I have 2" of extra tank depth to make up for the lost area taken up by the booster and master cyl.

This is very cool, good work !

Hi Andrew

Have you done any measurements on the new FA20 motor in comparison to your old EJ20 motor? The area around the quad cams looks by eye to be much more compact. Also how low does the new turbo location sit in comparison to the depth of the sump?

thanks
Jak

PS your old gearbox is still in my bug! Amazingly

It's definitely smaller in the heads Jak. I've been over and had a good look but that intake, turbo and cat are not only the lowest parts of the engine, they are also the furthest back. It's not affecting Andrew much in this raised car but it's the reason we just decided against putting one in a mates Ghia and are sticking to the EJ.

Imagine dragging that lot along the ground! They are lower than the sump and headers.

Andrews has done a kick ass job of making it all work though. Smart bloke that one.

wow that's gong to be one tough buggy

Hi Jak, actually I havnt really taken any notice on the FA to EJ quad cam differences. I still got my old buggy with the EJ20 DOHC, i'll have a compare tomorrow.
Yeah turbo sits about the same depth as the sump (same as the EJ), however its further back away from the axle. You would need to raise the motor somewhat I would imagine in a beetle.

Ohh and forgot to mention, it is now on the road! Made it to Valla (just).
Have a done a small video with some finished stills and a running video.

https://www.youtube.com/watch?v=W8ltIlhm5ko

I have to say the low down torque of the FA20T is out of this world. It doesnt really feel like a turbo car, more like a V8. It builds boost very quick and hits full boost (20psi) at around 3500-4000rpm. For anyone wanting to do a turbo converion I would highly recommend the FA motor. Even the non turbo FA would be a good engine, they have about 150kW standard, which is pretty good for a 2L N/A engine.

Hey Toddy. It looks awesome can't wait to see it in real life!

Unbelievable- and awesome.