Conversion of a Lada 2106 car into a rally racing car

Abstract

The subject of this publication is a rally car designed as a diploma thesis and later produced. G-Sport Ltd. designs and manufactures racing car bodies, chassis components and all other motorsport related components for both the domestic and international markets. The aim was to design the Lada 2106 race car to accept a Ford Mk2 suspension, a Toyota 4A-GE engine and other parts that would enable it to compete in official FIA rally events. The work was done using a 3D scanner. The first phase involved creating 3D models of the body, engine, gearbox and other components, while checking their dimensional accuracy. Then, the custom parts of the car, including the roll cage, had to be designed to meet FIA specifications. This article describes the steps of the 3D scanning method, how the scans are processed, oriented, assembled correctly, and how the deformations of the body frame were detected. In addition, the typical problems encountered during 3D scanning of large objects and their generally applicable solutions are shown. The components of the drivetrain and components of own custom design are also described.