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Thread: Pauls Astra Mk2 rallying adventures...

  1. #91
    Senior User Iain's Avatar
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    Turrets are good. I like this.

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    Bit more progress..

    Rear beam mounts fully welded and painted



    Front coilover bodies spruced up



    Exhaust refitted and rear hubs, brake lines and handbrake cables



    Rear coilovers assembled and fitted- ride height to be sorted when car is on the ground



    Front hubs fitted with new wheel bearings and drive flanges pressed in



    Coilovers assembled with springs



    and then fitted to the car, brakes refitted etc



    Next step is to get spare gearbox casing stripped and fitted with the gear kit and to get the brake bias box stripped back and new AP master cylinders fitted and set up along with a new balance bar,

    Paul..

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    Some further progress at the weekend....

    Brake bias box completely stripped, new balance bar, short AP master cylinders and remote reservoirs and pipework fitted.



    Rear opening thermoformed polycarb windows fitted and seals bonded in



    Gearbox and clutch removed...



    ready for this to be fitted later in the week once the diff/CWP etc is swapped over



    Paul..

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    looks good

    assembling the dogbox, is that an straight forward job?

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    Very nice. I keep putting it off but need to buy one of those myself.

  6. #96
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    Quote Originally Posted by prs View Post
    looks good

    assembling the dogbox, is that an straight forward job?
    To be fair, Ive bought a good used cluster and we have inspected it but not fully stripped it. I think the gear kit assembly is similar to any other one but I have a mate who does it for me as I know its right then.

    Quote Originally Posted by 8valve-craig View Post
    Very nice. I keep putting it off but need to buy one of those myself.
    Which bit - the dogbox? Im only upgrading as Im very hard on the synchros of the SCCR box Ive got at the moment, especially down into 1st so going to try it out. Id love a Sadev but just cant justify it without selling one of the cars.

    This one has a 5.1 CWP so low top-end speed but will see how it goes.

    Paul..

  7. #97
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    A couple of Quaife sequentials have come up recently, old models though and I can't use one anyway.

    Same here with the SCCR, it takes its time to change sometimes, when there is no time.

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    Upshifts are really quick with the cable shift system Ive got now although I am beating the synchros a bit, downshifts are fine 5th>4th, 4th>3rd but under heavy braking (into chicanes etc) then 3rd > 2nd can be a little snatchy and 2nd>1st is a waiting game to snick it in as Im often going too quick for the syncros to be able to equalise the speeds and Im sometimes treating it like a dogbox...

    I dont know what your allowed to do, but this setup is really good now Ive ironed out the weak spots.

    Paul..

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    The next step was to prep the box for the car.. Diff stripped and checked



    Then crownwheel swapped and diff fitted to F18 casing



    and cluster fitted with a diff pan spacer as the 5.18 crownwheel is huge and hits the diff pan otherwise..



    Then we took the car to a trackday at Blyton so I could get used to a dog-box and dial the car in. Use the settings from the other car as a starting point albeit different springs and was pretty good. Tried to get the brakes right but the pedal feel isnt as good so needs more work. Also found a few niggles..



    One niggle was the spring droop on these Proflex meaning the trackrod arms hitting the inner chassis leg and the driveshaft hitting the exhaust manifold so I ended up making some drop-stops to limit droop.



    Then took the car to be remapped. We had an issue with the fuelling last year and once we resolved that the fuel pressure was higher meaning the car was running richer, Got it all sorted now.



    and got some good numbers / fantastic power curve and nice flat torque line for a 1600 16v..



    Then we did the Jack Neal stages at Blyton last weekend. Was very very wet with lots of standing water so couldnt really get power down. Made the guys work hard when I got it stuck in 2nd gear on 2 different stages losing us 40 odd seconds..



    But after going from 4th in class to 3rd in class to 1st in class in the 1st 3 stages then back to 4th in class after stuck gear, I then managed to claw back time and finish 1st in class and 13th overall. Very happy with the result on a difficult day driving wise..




    Now we focus on the 2000cc engine build and install for our next event in March.

    Paul..

  10. #100
    Senior User Iain's Avatar
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    Great result especially with the 2nd gear issues. Any light as to what caused it?

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