Toyota 86 Rally Car Build
Introducing one of our most exciting projects to date, transforming a 2018 road-registered Toyota 86 into a full-blown rally car, purpose-built to meet Australian Rally Regulations.
From day one, this build was a complete ground-up transformation. We stripped the car to a bare shell, removing every non-essential component and prepping the chassis for its new life in the forest.
A custom roll cage was installed to Motorsport Australia specs, and we began test-fitting key components. After seam welding, closing unnecessary holes, preparing for safety and strength, and dry-fitting key components we gave the shell a fresh coat of paint and began the next stage of the rebuild.
Underneath, we fabricated extensive underbody protection, including a Kevlar fuel tank guard, bash plate, and high-clearance stainless steel exhaust system.
Performance-wise, the Toyota 86 was upgraded with:
- Headers by Sydney Motorsport Engineering
- Custom stainless exhaust
- Exedy lightweight flywheel
- Toyota limited slip diff
- MCA Gold suspension
- Alcon brake kit
Every detail has a purpose — when you’re building a rally car, function, reliability and performance always takes priority
Inside, the cockpit was stripped and rebuilt to rally spec. A Tilton pedal box, Monit rally computer, Stilo intercom, and a full MoTeC computer system including a C125 dash, M1 ECU and Motec 15 button keypad were installed, along with a custom loom, PDM, and onboard fire suppression. We also 3D-printed and custom-fabricated mounts and fittings throughout the interior to maximise durability and serviceability.
Every inch of the car was designed with competition in mind — from the reinforced sill stands and fabricated seat mounts to the relocated fuel system and carefully routed brake lines.
After months of hard work, late nights, and precision fabrication, we’re proud to say this car is now stage-ready. It’s a perfect example of what we do at MortSport — turning road cars into rally weapons.
