Building a Corsa C C20XE 1600cc Rally Car

[fearless]

I'm just in the progress of building a Corsa C Tarmac Rally Car with a mate - At the moment he runs an Astra GSI with a Bowyer Developments 260 ish engine and Quaife Dog box/ Proflex etc

The engine has since being rebuilt to a higher kitcar spec - with barrel throttle bodies !!!!


However - A six speed sequential dog box is on order from Holland (about 12 grand !!!!!)

This, with the engine out of the Astra will end up in the Corsa - Running Super1600 bodykit, but with fibreglass wings/bonnet/tailgate/doors

All in all is should be a lightweight flier !!!!


I've already been on the http://www.corsasuper1600.com/ website - and managed to gain access to the build details via a password :D


Right then - here's the update so far !!!


Bought a Corsa C shell with the intention of having a complete weld-in roll cage fitted and all the modified inner arches and suspension pickup points fitted - booked in with Harry Hockley to have that lot done at a cost of over 3 grand !!!!!


But then this ex-works bare shell came up for sale

Last used on the JWRC Rally Turkey 2003

http://img.photobucket.com/albums/v516/fearlessmotorsport/mikeshell_turkey.jpg


Managed to get Carbon Fibre Doors Tailgate and Bonnet with the deal as well !!!! - Should be a real light weight flyer !!!!


http://img.photobucket.com/albums/v516/fearlessmotorsport/Ex_Works_Shell032.jpg

http://img.photobucket.com/albums/v516/fearlessmotorsport/Ex_Works_Shell002.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/Ex_Works_Shell003.jpg

http://img.photobucket.com/albums/v516/fearlessmotorsport/Ex_Works_Shell010.jpg

http://img.photobucket.com/albums/v516/fearlessmotorsport/Ex_Works_Shell015.jpg




The challenge now is to make it a rolling shell - ready for the engine transplant


Has anyone any info/contact details/pictures of any corsa C rally cars to help us on our way

We've already been in contact with Ray Mallock Ltd - who built the works cars - but has anyone any more contact


Contacts so far include Rob Palmer (Ran Kriss Meeke for Colin Mcrae) and Chris Birckbeck who also ran a works team - Harry Hockley and Walden Engineering - but as you can guess they want big money !!!


Help !!!!

What I'm after is as much information/pictures on any Corsa C rallycars/Rallycross etc to assist in the build and possible problems/solutions we may come across



Cheers Dave

[Marc]

looks good mate, the roll cage in that is made with it all over but will be a beast when its done :D

[ANDYRACER]

That will be one hell of a car when it is finished. That cage looks quality. And the plans sound spot on.

[RJM25R]

Dave, have u tried Dave at Magnum Motorsport in St Helens? I know he was making some parts......

Rick

[fearless]

Dave, have u tried Dave at Magnum Motorsport in St Helens? I know he was making some parts......

Rick

Yeh - We supplied him with the original kit that we got !! - for him to make some moulds

[benji]

i think you should cut the cage out and stick it in the escort van....


sorry, that probably didn't help :roll:

[nova---chris]

be ok with some subs and moniters in there :)

[martweaver]

:o Gulp, looks like a fair project you have on your hands there! I'm sure with your skills Dave - it will be awesome!!

Couldn't you look at some old rally entrant lists & try contacting some of the privateer teams, I bet they would be more helpful than the works boys. I'm sure there were loads of these run privately & still are.

Just an idea! Good luck!

Mart

[starkmotorsport]

Corsa C's are now starting to be used in UK motorsport, Walden are producing a fair amount and Ive helped on a privately built car.

Got two words for you though : Driveshaft Breakers! :lol:

Nice wee cars though, keep us up to date with progress pics :wink:

[srs1]

if i get time to have a look at the new brighton prom rally this week end and there are a few or even one there. i'll get as many pics as pos for you.

my mate is also going over to ireland for a rally he has arranged. i'll ask him to keep an eye out for you too.

[srs1]

you could even pm bigruss.

he might know of some when he rallies.

[fearless]

if i get time to have a look at the new brighton prom rally this week end and there are a few or even one there. i'll get as many pics as pos for you.



I'm servicing for my mates orange astra (the one in the first link !)at the prom on Saturday - Come over and say Hi !!

It may be it's last outing before some of the bits are taken off for the corsa

Dave

[fearless]

Got two words for you though : Driveshaft Breakers! :lol:



**** Breaks out into a sweat ****

????? Why? What engine's have they ran, spec of shafts etc - We've not had any breakages in the astra YET (reaches out and touches wood !!! ) - which is donating its running gear - whats the reason for breakages in the corsa ??


Have you any picture/info on the one you have helped build ?

Cheers


Dave

[fearless]

:o

Couldn't you look at some old rally entrant lists & try contacting some of the privateer teams, I bet they would be more helpful than the works boys. I'm sure there were loads of these run privately & still are.

Mart

Hi Martin

Unfortunatley - Not many of these Ex works Corsa's have made it to Clubman Rallying yet !!! - Just too expensive !!! (Cost over 70K new!!)


Due to the shell being modified to works spec - a lot of the mods only allow works stuff to be fitted ?????? -

Take for example the rear suspension/beam

Standard Corsa C's run a similar setup to a nova - solid rear beam

However the works Corsa's ran independant rear suspension

So our shell has a mountings for the rear beam like this - 3 bolts either side

http://img.photobucket.com/albums/v516/fearlessmotorsport/Ex_Works_Shell025.jpg

And needs to mount this works spec rear beam

http://img.photobucket.com/albums/v516/fearlessmotorsport/rearbeam.jpg


http://img.photobucket.com/albums/v516/fearlessmotorsport/Billing_2005092.jpg


So without modifiying the shell back to original spec (A step backwards in terms of handling) things start getting expensive

eg

B23-E1029 SWING ARM LH ASSY ?1682.06 (complete left hand swing arm assembly including bearings/fixings etc.)

23-E1037\5 SWING ARM LH ?1360.98 (swing arm only)

B23-E1030 SWING ARM RH ASSY ?1682.06

23-E1038\5 SWING ARM RH ?1360.98

B23-E1031 SUBFRAME BEAM INDEP MTG ?674.07 (complete assembly including rollcentre spacers/bolts etc.)


All Plus VAT

!!!
And thats just for the rear beam and 2 swinging arms - doesn't include suspension or brakes !!!!!

Your looking at about 12 grand for the rear suspension/brakes !!!!!



I've managed to contact 2 teams that ran them in the Junior WRC - just a matter of negotiating a deal for some of their spares packages ??????




Cheers for the comments so far - I'll keep you all informed


Dave

[starkmotorsport]

Dave

One "C" Ive seen out competing has broken a short shaft everytime its been out on tarmac. Engine is a redtop with TB's, exact spec is unknown.

As for the one Ive helped with, its sitting in a workshop as the driver has been given a drive in a Escort Cossie, so this "C" is 90% built and just sitting idle. The owner has a library of photos, can ask about getting some, but hes a bit secretive.

Another friend has just recieved one from Walden and promptly blew the engine up on the Jim Clark a few weekends ago. Should be rebuilt for the Manx at the end of the month though.

[MARTIN KELSON]

So this is whot your upto then is it mate.
Thought you were concentrateing on your own little project now?
Might look nice with some little stumpy mirrors!!!!!!!!!!!!!!

Cheers

[njc11]

So this is whot your upto then is it mate.
Thought you were concentrateing on your own little project now?
Might look nice with some little stumpy mirrors!!!!!!!!!!!!!!

Cheers

:lol: :roll:

eerrrmm.... and not forgetting my service Dave!! :roll:

Cheers

Nick

[MARTIN KELSON]

You get some stick dont ya Dave!!

[fearless]

eerrrmm.... and not forgetting my service Dave!! :roll:

Cheers

Nick

Errr - yes I had forgot that one - Saturdays looking a good possibility - speak to you before then !!


Dave

[njc11]

eerrrmm.... and not forgetting my service Dave!! :roll:

Cheers

Nick

Errr - yes I had forgot that one - Saturdays looking a good possibility - speak to you before then !!


Dave

Dave,

No probs mate, just keep me posted!!

Cheers

Nick

[fearless]

**** UPDATE **** (at last :thumb: )

Years have pasted and some progress has been made

The spec of the car has changed somewhat since the original plan of transfering most of the running gear from the Astra Gsi he was running. The original plan of a cheap reshell using the C20XE engine and Dog box and Proflex suspension/AP brakes from the Astra has now turned into a money pit - using new proflex, sequential box, new brakes and a Destroked C20XE into an all steel 1600 screamer :d

The shell is now a rolling shell with a Hockly Motorsport independant rear beam - with the shell modified to allow even more suspension travel front and rear - running on proflex dampers all round
Brakes are Works OPC AP Calipers and 355mm front discs and Alcon rear calipers/disc
A new 6 speed sequential Sadev gearbox and gearlever have been purchased
A dummy engine has been fitted to the box and all mounts and driveshafts fabricated by HHMS
Martin Bowyer (Bowyer Developments) is in the progress of building the destroked C20XE into a 1600cc (steel crank/rods, new pistons, new throttle bodies etc) which expects 220+ bhp on his dyno

So most of the fabrication etc has been done

Just completing the final mods to the shell (RHD conversion) and then it can be painted and assembled :nod:

These are some of the pics I took the other night when we were tinkering
http://img.photobucket.com/albums/v516/fearlessmotorsport/Mike_S1600001.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/Mike_S1600002.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/Mike_S1600003.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/Mike_S1600005.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/Mike_S1600007.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/Mike_S1600008.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/Mike_S1600009.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/Mike_S1600010.jpg



Mods might want to move this thread to the Project section and I will try to keep it updated :)

Dave

[fearless]

http://img.photobucket.com/albums/v516/fearlessmotorsport/Mike_S1600011.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/Mike_S1600013.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/Mike_S1600014.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/Mike_S1600016.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/Mike_S1600018.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/Mike_S1600020.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/Mike_S1600021.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/Mike_S1600024.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/Mike_S1600030.jpg


Dave

[let_nova]

stunning mate.

go to

thread tools>move thread.

[Ben]

Looks excellent- sounds expensive!

[fearless]

Cheers let nova - you learn something new everyday

+rep

[Plug]

that rear suspension set up looks the bollacks :thumb:

looking good progress aswell

[The Simps]

Mmmm tasty! That rear suspension setup is cool.

Just hope it hasn't destracted you from your own project!

[Connor]

mmm those arches :P

[garethcolley]

Very nice.

[liam944nova]

that will be cracking car when done :thumb:

[Pistol Pete]

Looks like this will be an awesome build. I look forward to more updates.

[Count Vaux Alot]

that rear suspension set up looks the bollacks :thumb:

looking good progress aswell

well said and i agree

[fearless]

We lost the bonnet vents that we had for the Corsa S1600 Rally car



Does anyone know where to get a pair from





Look like these


http://www.xwmatinos.gr/xwma/images/07/gaz01.jpg



Cheers


Dave

[The Simps]

And I thought it was gonna be an update! :(

Sorry I can't help.

[fearless]

Will try and update with pics soon - I'll take my camera next time I'm in his garage

He wants it finished this year - so just prepping the shell for paint - then its just a matter of throwing all the parts back on it

Spoke to Martin Bowyer last week - just a nudge to remind him we need the engine soon

He's got our dash display unit - so a trip down in a few weeks to pick it up


Dave

[The Simps]

Need some more pics of your project too.....

[fearless]

***** UPDATE *****
Making a little progress on the Corsa.
Finally got round to throwing some paint on the underside, wheel arches and inside - nothing too fancy - just stonechip and white paint where neccesary

http://img.photobucket.com/albums/v516/fearlessmotorsport/SP_A0109-1.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/SP_A0110.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/SP_A0112.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/SP_A0126.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/SP_A0128.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/SP_A0129.jpg
The plan is to make it into a rolling shell and then take to the body shop for the outside to be painted

[Cle]

5 year project and its just gettin painted lol Looks sweet thought :thumb:

[fearless]

5 year project and its just gettin painted lol Looks sweet thought :thumb:


Anyone who knows me will know that quick progress for me lol

[fearless]

Since we had finished some aspects of shell prep - We couldn't resist bolting on some shiny bits !!!!
http://img.photobucket.com/albums/v516/fearlessmotorsport/SP_A0116.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/SP_A0117.jpg
Proflex rear coilovers

http://img.photobucket.com/albums/v516/fearlessmotorsport/SP_A0121.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/SP_A0124.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/SP_A0125.jpg
Premier bag tank with carbon covers

[fearless]

http://img.photobucket.com/albums/v516/fearlessmotorsport/SP_A0131.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/SP_A0134.jpg

Proflex front struts with works OPC AP Calipers/355mm Discs

http://img.photobucket.com/albums/v516/fearlessmotorsport/SP_A0138.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/SP_A0146.jpg
http://img.photobucket.com/albums/v516/fearlessmotorsport/SP_A0142.jpg

IRS beam with Alcon rear calipers/discs

Oh - forgot about this little purchase
http://qedmotorsport.co.uk/qed-shop/vauxhall-xe-c20xe/specials/aluminium-engine-block
Now back with Martin Bowyer for the final build after a trip to Millington for the rebore for the special pistons :)

Dave

[Mazz]

nom nom nom

Alloy block too, shweet

Very very nice!