Omari Gates
Building a rally car in Australia can be an expensive and time-consuming endeavour, but with the right knowledge, preparation, and equipment, it is achievable. Before beginning the build, it is important to familiarise yourself with the Motorsport Australia regulations and the Road Traffic Act and Australian Design Rules, as deviations from these standards may require an exemption for the vehicle to be granted conditional registration. It is also crucial to set a budget and obtain quotes for the necessary parts, such as a roll cage, race seats, wheels, tyres, and brake upgrades. Joining a car club and obtaining the appropriate licences, such as the Motorsport Australia or AASA licence, is essential for competing in rallies. With dedication and a clear understanding of the requirements, building a rally car in Australia can be a rewarding experience.
| Characteristics | Values |
|---|---|
| Licence | A 2NS (non-speed) licence costs less than $100. A Clubman Rally Licence costs less than $2000 for the year. |
| Safety equipment | A bolt-in roll cage costs around $4,400. Race seats cost around $750 each. |
| Wheels | A set of five 15-inch factory wheels cost around $850. |
| Tyres | Rally tyres are required to meet mudflap to ground clearance rules. |
| Lights | Additional lights are required, along with a map-reading light for the co-driver. |
| Underbody protection | Required in Western Australia due to abrasive gravel. |
| Brakes | ABS should be removed from the brake circuit. |
| Suspension | The suspension should be reliable. |
| Car model | A common car like a Lancer or Hyundai Excel is recommended. |
| Regulations | The Motorsport Australia Manual provides detailed information on regulations. |
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What You'll Learn
Budgeting for a build
Building a rally car can be expensive, but it need not be prohibitively so. A good first step is to join a car club, which will allow you to purchase a Motorsport Australia or AASA licence that enables you to compete and provides insurance. A basic entry-level licence costs less than $100, while a Clubman Rally Licence, required for bigger events, will cost less than $2000 for the year. On top of this, you will need to pay an entry fee for each rally.
When it comes to the car itself, it is recommended that you spend as much as you can on safety and handling. A bolt-in roll cage that meets safety standards is likely to cost around $4400, while a pair of race seats will cost around $1500. A set of five 15-inch wheels will cost around $850, and you will also need to factor in the cost of tyres. Additional safety equipment includes a set of six-point harnesses, which cost around $730, and an adapter frame to bolt in your seats, which is another $680. You should also budget for incidentals such as harness plates, electrical wiring, and cable ties, which will cost around $500.
Other recommended equipment includes an intercom, a rally computer, and additional lights, including a map-reading light for the co-driver. Depending on where you live, you may also need extra underbody protection.
In total, a basic rally car build is likely to cost around $15,500, not including the cost of the car itself or any major mechanicals. It is possible to build a rally car on a budget, but it will still be a significant expense.
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Safety equipment
When building a rally car in Australia, safety should be the top priority. Motor vehicle modifications are regulated to ensure vehicles are safe and comply with the Road Traffic Act and Australian Design Rules. Here are some essential safety equipment considerations for your rally car:
Roll Cage
The roll cage is the most important piece of safety equipment in your rally car. It provides crucial protection in the event of a rollover or collision. A bolt-in roll cage that meets the required standards typically costs around AUD 4,400, excluding freight. Ensure that the roll cage complies with the relevant regulations to avoid issues during vehicle inspections.
Race Seats
Invest in a pair of race seats that provide support and safety during high-speed rallies. Standard-width, non-winged seats typically cost around AUD 750 each, while wider or winged seats come at a higher price. Ensure the seats are securely fastened and compatible with any required safety harnesses.
Suspension
A reliable suspension system is crucial for handling and safety. It helps absorb shocks, providing a smoother ride and reducing the risk of losing control. Choose a high-quality suspension setup that can withstand the demands of rally driving.
Helmets and Head & Neck Safety
Ensure that you and your co-driver have appropriate helmets that meet the required safety standards. Consider investing in a Head and Neck Support (HANS) device for additional protection during high-impact collisions. Check that the helmets fit securely and comfortably with the necessary visors and accessories.
Fire Safety
Consider fire safety equipment, such as fire-retardant solutions like Oil Eater, which can handle spills of oil, paint, and other chemicals. Ensure easy access to fire extinguishers and that they are regularly serviced and maintained.
First Aid Kit
Invest in a comprehensive first aid kit that meets the requirements for rally events. The CAMS spec First Aid Kit is specifically designed to cover most in-rally medical emergencies. Ensure it is easily accessible within the vehicle and regularly restocked.
Remember, this list is not exhaustive, and you should always refer to the Motorsport Australia Manual for the most up-to-date and comprehensive safety regulations and requirements when building your rally car in Australia.
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Car modifications
Motor vehicle modifications in Australia are regulated to ensure vehicles are safe and comply with the Road Traffic Act and Australian Design Rules. Before modifying a car, it is important to check the relevant regulations and consult with professionals to ensure that any modifications are legal and safe.
When building a rally car, safety should be the top priority. The roll cage is the most important safety feature and can cost around $4,400. Race seats are another crucial safety component, costing approximately $750 each. It is also important to consider the suspension and handling of the car. While building a rally car can be expensive, there are ways to save money. For example, buying a used rally car or a common car like a Lancer or Hyundai Excel can provide access to cheaper panels and parts.
Upgrading the brakes is an essential modification for a rally car. This may involve fitting rear discs, removing the ABS from the brake circuit, and re-plumbing the brakes with stainless steel braided brake hoses. It is also important to upgrade the brake pads to handle the demands of rallying. The Hawk HP+ brake pads offer a good cold bite but may reach their limit on heavier cars or events requiring heavy braking. For faster events, a more aggressive compound like the DTC-60 may be preferred.
Other modifications to consider include adding a roof vent, sump guard, and mud flaps. A helmet hammock, first aid kit, and reflective triangles are also important safety additions. Additional lights may be needed, especially if auxiliary lights are fitted to the front of the car, as this will require a map-reading light for the co-driver. Depending on the location, extra underbody protection may be necessary to protect against abrasive gravel.
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Registration and regulations
Before building a rally car in Australia, it is important to familiarise yourself with the rules and regulations that govern rallies and rally car building. The Motorsport Australia Manual is considered the "bible" of Motorsport Australia regulations and is issued annually, detailing almost everything you need to know about rally car regulations. The Motorsport Australia website also provides a full list of downloadable rules and regulations for various vehicles and event structures.
When building a rally car, it is important to consider safety and handling first. The roll cage is the single most important piece of safety equipment, and standards must be met regardless of whether you are building to state or national-level requirements. A bolt-in roll cage that meets these standards typically costs around $4,400, excluding freight. In addition, race seats are required, with a pair of standard-width, non-winged seats costing approximately $1,500.
To compete in rallies, you will need to purchase a Motorsport Australia or AASA licence, which allows you to compete and provides the necessary insurance. An entry-level 2NS (non-speed) licence costs less than $100 and enables you to participate in closed-to-club events in Australia. However, for larger events, a Clubman Rally Licence is required, costing less than $2,000 per year, in addition to the entry fee for the specific rally.
Motor vehicle modifications are regulated in Australia to ensure compliance with the Road Traffic Act and Australian Design Rules. Rally cars that deviate from the appropriate standards must obtain an exemption before being granted conditional registration for use in rally car events. This process can take up to 15 business days, and if the proposal is acceptable, Vehicle Standards will issue a Statement of Requirements (SOR). If the proposal is unacceptable or additional information is required, Vehicle Standards will request further details. Once the SOR is received, evidence of compliance must be prepared by a light vehicle engineering signatory and lodged at least five working days before the vehicle inspection. If the vehicle fails the inspection, any faults must be rectified, and a re-inspection will be necessary.
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Joining a car club
You can find your local club by visiting the Motorsport Australia Club Finder. Membership of a typical Australian car club can cost from $60 to $150 per year, depending on the particular club you choose. Being a member of a Motorsport Australia-affiliated car club is a great way to meet like-minded enthusiasts and get involved in events, either as a volunteer or competitor. There are over 580 affiliated car clubs, so you are sure to find one that suits your needs and interests.
The Rally Car Club is one example of a club dedicated to rally sport. It is affiliated with Motorsport Australia and offers a platform for rally enthusiasts to connect, learn, and participate in the world of rallying and motorsport.
Additionally, car clubs provide a great opportunity to network and seek advice from fellow members. Whether you are building your own car or buying a used rally car, it is important to do your research and understand the specific requirements and challenges of rallying. Don't be afraid to ask questions and seek guidance from those with more experience.
Finally, being a member of a car club will allow you to obtain the necessary licences for competing in rallies. An entry-level non-speed licence costs less than $100 and allows you to compete in closed-to-club events. However, if you want to participate in bigger events, you will need a Clubman Rally Licence, which costs less than $2000 per year.
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Frequently asked questions
First, you'll need to decide whether you want to build a car from scratch or buy a used rally car. Building a car from scratch can be expensive, so buying a used car can save you time and money. Once you have your car, you'll need to modify it to meet the relevant safety standards and regulations. This includes installing a roll cage, race seats, and upgrading the brakes and suspension. You can find the full list of regulations in the Motorsport Australia Manual.
In Australia, motor vehicle modifications must comply with the Road Traffic Act and Australian Design Rules. You can find the specific regulations for rally cars in the Motorsport Australia Manual, which is issued annually. Some key safety features include a roll cage, race seats, and a fire extinguisher.
The cost of building a rally car in Australia can vary depending on the car and the components used. A basic rally car can cost around $15,500 in parts, including wheels, tires, an intercom, a rally computer, and additional lights. A roll cage, one of the most important safety features, can cost around $4,400, while race seats can cost around $750 each. On top of the build costs, you'll also need to budget for a licence to compete in rallies, which can cost up to $2,000 per year, as well as entry fees for individual rallies.
