985cc Turbocharged Nova Sprint Car

[MK999]

Hinged window and jump in dukes of hazard stylee lol

[novarally]

And for the ongoing weight saving efforts, ditching the 4mm thick perspex windows, along with their rubber seals;
http://i285.photobucket.com/albums/ll66/hillclimbescort/009-17.jpg

and replacing them with bonded in 2mm polycarbonate;
http://i285.photobucket.com/albums/ll66/hillclimbescort/008-18.jpg

Saves me 5kg.

I also did some research on starter motors, and found that the lightest one available is 2.7kg (I had a couple of them);

http://i285.photobucket.com/albums/ll66/hillclimbescort/010-18.jpg

I'm pretty certain that the starter motor on my Nova is a bigger one than this, so as soon as I get the car back from BTEC Racing I will whip out the starter and do a comparison.

It's currently at BTEC for turbocharger work, the old one was showing signs of old age and will be replaced by a new one from Owen Developments (more details to follow).

[burgo]

would riviting not be lighting than bonding for the windows?

good find on the starter as well

[novarally]

I also picked up a new seat, which will save me 3kg. I have never seen another seat like this, and have no idea of the history of it;

http://i285.photobucket.com/albums/ll66/hillclimbescort/006-25.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/007-19.jpg

It's a carbon kevlar Recaro. One of the stickers on the base of it suggests that it may have been made for an AMG car...........

[Edd]

I think 16xechris is working on some fibreglass doors

[ryansnova]

is the kit from a hot rod/stock car ?

[Mike]

Carbon Kevlar good ness :)

Really liking the mini youve got for sale ATM aswell Colin, that proper awesome!

[novarally]

would riviting not be lighting than bonding for the windows?

It probably would be a little, but I think bonding looks better, and obviously gives a better weather seal. I will consider further.

[MK999]

Saves me 5kg.
:eek:

Although you've yet to weight whatever is bonding them in I assume :p

Re starter motors I did see in a mag this month, cambridge automotive do a range of lightweight aluminium starters for race use... Get your wallet to sit down though as they're for the jap market mainly so the standards ones are around £200... expect more for the race versions I assume :p

[novarally]

I think 16xechris is working on some fibreglass doors

He is, I'm supposed to be testing them for him when they're done, but I've asked for a progress report several times and not heard anything back.

[burgo]

It probably would be a little, but I think bonding looks better, and obviously gives a better weather seal. I will consider further.its a sprint car, does the weather seal really matter lol imo riviting looks much more hard core lol

[novarally]

Really liking the mini youve got for sale ATM aswell Colin, that proper awesome!

It's a piece of history that Mini, but it's got to go, I've got way too many toys, and no money in the Bank!

[novarally]

:eek:

Although you've yet to weight whatever is bonding them in I assume :p

Re starter motors I did see in a mag this month, cambridge automotive do a range of lightweight aluminium starters for race use... Get your wallet to sit down though as they're for the jap market mainly so the standards ones are around £200... expect more for the race versions I assume :p

I have been talking to Jon at Cambridge Motorsport (a couple of weeks back), and he confirmed that the OE starter at 2.7kg was the lightest available. It was him who put me onto the lithium battery I got hold of that saved 4kg, he's a great source of knowledge.

[Danb1987]

Just read through nearly all of this thread Colin!

Top work mate this car is awsome be good to see it finished!

p.s you must have some serious money ;) lol

[MK999]

I have been talking to Jon at Cambridge Motorsport (a couple of weeks back), and he confirmed that the OE starter at 2.7kg was the lightest available. It was him who put me onto the lithium battery I got hold of that saved 4kg, he's a great source of knowledge.

Ah fair enough, the starters do seem to be for fairly hefty engines.

[peester]

cant help but like the aladins cave of retro motorsport bits and cars lying about at your place col

[LEWI007]

That widearch kit is mental, you should of used that with those compotive split rims you had.

Any news on posting that widearch kit AlanH payed for yet ? its still on the black car in those photos :(

[BRoadGhost]

That seat's gonna retail at around the four figure sum alone under that brand...

VERY interested in your findings about that battery, I'm going through lead batteries at an alarming rate atm because I can't full isolate them for 9-10hrs per day like they should be when not being run. I dunno if you'll be able to give a suitable evaluation though as this will only be used in the hill climber every so often?

[novarally]

That seat's gonna retail at around the four figure sum alone under that brand...

VERY interested in your findings about that battery, I'm going through lead batteries at an alarming rate atm because I can't full isolate them for 9-10hrs per day like they should be when not being run. I dunno if you'll be able to give a suitable evaluation though as this will only be used in the hill climber every so often?

I doubt I'll be able to give you any useful feedback. Mine gets used for a day of very short races, then goes back in the workshop with the battery on charge.

Did a very quick mock up of the new fibreglass door skin on the passenger side;

http://i285.photobucket.com/albums/ll66/hillclimbescort/002-32.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/003-35.jpg

It fits pretty well, I shall put it on quick release pins so it can be completely removed when necessary. If I need to get out of the car in a hurry on that side, it will get kicked off!

[mowgli]

colin, if you needed to get out that quick, i doubt if the door will still be there anyway.....any rules on drivers door as in stock hinges/catches etc??? or metal skin?

[novarally]

colin, if you needed to get out that quick, i doubt if the door will still be there anyway.....any rules on drivers door as in stock hinges/catches etc??? or metal skin?

Door material is free, and there are no specific rules laid down for hinges/catches. But on the drivers side it's going to have to be conventionally hinged I think.

[mowgli]

slap both doors on quick then.....
soon you'll run out of stuff to strip.....
did you hear the story of the skoda rally cars, where they did all they could to lighten them, then kept sticking the shells thru the factory acid bath to thin all the metal down..? they had lots of time & ideas, but no money to do it with.

[bmw156]

its a sprint car, does the weather seal really matter lol imo riviting looks much more hard core lol

until colin thrashes the car so much that the rivets come loose.

normally people rivet and bond so the rivets dont rattle.

[scott.parker]

Loving the updates Colin, and how many dam cars you got at your place? lol Ive counted two xr2i's in with all your novas now..

As for the wide kit if you don't use it it may be of use to Steve on his 4x4 nova?

Scott

[mowgli]

until colin thrashes the car so much that the rivets come loose.

normally people rivet and bond so the rivets dont rattle.

decent bonding agents don't need rivets.. the rivets will induce cracks & cause things to fail.

[novarally]

Loving the updates Colin, and how many dam cars you got at your place? lol Ive counted two xr2i's in with all your novas now..

As for the wide kit if you don't use it it may be of use to Steve on his 4x4 nova?

Scott

I've got a very nice spec. XR2i circuit race car which I bought and plan to do a few track days with. I also have a spare XR2i race car rolling shell, an XR2i Zetec 16v and an RS Turbo Fiesta. So it's actually 4 of them, not 2!

Don't ask me why.......they were cheap and I couldn't say 'no'.

Steve did say the wide arch kit might be of interest to him.

[Southie]

Is the wide arch kit a one off then? You should be getting moulds made Colin.

Very nice btw, will it be getting sprayed a new colour then?

[peester]

I've got a very nice spec. XR2i circuit race car which I bought and plan to do a few track days with. I also have a spare XR2i race car rolling shell, an XR2i Zetec 16v and an RS Turbo Fiesta. So it's actually 4 of them, not 2!

Don't ask me why.......they were cheap and I couldn't say 'no'.

Steve did say the wide arch kit might be of interest to him.

ha true petrol head car addition lol

[novarally]

No updates (yet), but a plea for some parts I need...........cash is waiting if anyone can sell me;

Mk.1 front bumper with snowplough front spoiler

Pair of Mk.1 headlamp protectors

Thanks!

[Cle]

Is the wide arch kit a one off then? You should be getting moulds made Colin.

Very nice btw, will it be getting sprayed a new colour then?

Wide arch kit is a one off, iirc colin got molds with it :) The kit came off my boss's brothers old stock nova. Nova acually got cut up and made into a trailor when he started his fencing company lol

[therealnovaboy]

Colin, you said a few pages back you will use 2mm perspex. I thought there was a requirement that perspex windows must be no less than 6mm.

I may be wrong or working to differant regs which is hy i ask.

I know people who use 4mm and its pretty bendy, specialy on the boot. 2mm is hell of a thin.

Edit: I noticed polycarbonate, is that much stronger than perspex, thus, why you can use 2mm?

[Dayle_]

Didn't think you were aloud to use perspex, we aren't in rallying as it shatters into big sharp shards. Its plexiglass that they use a flexable plastic.

[novarally]

Colin, you said a few pages back you will use 2mm perspex. I thought there was a requirement that perspex windows must be no less than 6mm.

I may be wrong or working to differant regs which is hy i ask.

I know people who use 4mm and its pretty bendy, specialy on the boot. 2mm is hell of a thin.

Edit: I noticed polycarbonate, is that much stronger than perspex, thus, why you can use 2mm?

Perspex is a generic term, and not really relevant these days. My windows are Lexan (polycarbonate).

For rallying I believe you need to use 4mm polycarbonate as a minimum, but for hillclimbs and sprints there are no such stipulations, so I can use as thin a material as I want.

[mowgli]

cling film???lol

[novarally]

Small update only, as I'm still waiting for the new turbo to be fitted over at BTEC Racing.

I've found nearly a 2kg weight saving from the starter motor which will be replaced when I get the car back.

Old starter motor;
http://i285.photobucket.com/albums/ll66/hillclimbescort/002-33.jpg

'New' starter motor;
http://i285.photobucket.com/albums/ll66/hillclimbescort/003-36.jpg

I now have another wide arch kit, which is more suited to my plans than the hugely wide Hot Rod kit that I acquired recently;
http://i285.photobucket.com/albums/ll66/hillclimbescort/004-30.jpg

And I also have a CO2 intercooler spray kit which I plan to experiment with to reduce intake temperatures;
http://i285.photobucket.com/albums/ll66/hillclimbescort/006-26.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/007-20.jpg

If it works, the tank will have to be replaced with something small and lightweight, as this is a huge 10lb tank, which is totally wrong for this car!

The straight cut gearbox I got hold of has finally been inspected by my gearbox man, who tells me that the baulk rings are knackered, and the CWP isn't too clever either. It's running a ZF plate LSD.

So I am now raiding the clusters out of some spare F10's I have,from which we will salvage the best baulk rings (mo longer available new apparently). And I will just change the complete cluster over, so I end up with a set of straight cut gears in there, and will retain my existing 4.5 CWP and the Quaife ATB LSD.

[peester]

wow, quite crazy with the raiding old f10 'boxes lol

[comptoncj]

Looks good Colin. I didnt think there was much difference in weight in the starters lol

[fearless]

Would you not be better running the ZF plate LSD ?

[novarally]

Would you not be better running the ZF plate LSD ?

I'm familiar with the ATB one, and it works well for what I'm doing. It would be nice to do some back to back testing at some stage though.

[MK999]

intercooler kit looks heavy :eek: lol can you not just wind the boost up a tad for that bit more power? :p

[t45_ste]

Is there any more weight you could shave off the starter with a grinder?

[fearless]

I'm familiar with the ATB one, and it works well for what I'm doing. It would be nice to do some back to back testing at some stage though.

Go for the Plate !! - Better traction out of the corners :thumb:

[fearless]

Is there any more weight you could chave off the starter with a grinder?


I was thinking the same - a few large holes in the 'nose' part of the starter wouldn't do any harm

[novarally]

intercooler kit looks heavy :eek: lol can you not just wind the boost up a tad for that bit more power? :p

It's actually really light - but only if you ignore the bottle! I'm sure there will be a lightweight bottle option available, bearing in mind CO2 is used in paintball applications.

[novarally]

Is there any more weight you could shave off the starter with a grinder?

Certainly worth trying, free weight saving very welcome.

[t45_ste]

http://cgi.ebay.com/Smart-Parts-Max-Flo-4500-psi-carbon-fiber-tank-/220727523961?pt=LH_DefaultDomain_0&hash=item336462ba79

Forever finding them when searching for carbon bits lol

[MK999]

Bloody hell, 310 bar in that little thing! :eek:

[t45_ste]

Colin, have you thought about cutting some of the bits out that you arnt really supposed to, ie bit being the dash and the floor bars then thinning them with a grinder then spotting them back in?

[novarally]

http://cgi.ebay.com/Smart-Parts-Max-Flo-4500-psi-carbon-fiber-tank-/220727523961?pt=LH_DefaultDomain_0&hash=item336462ba79

Forever finding them when searching for carbon bits lol

Very interesting, thanks for that.

I've just been browsing paintball tanks, and there are all sorts of them around.

Need to work out how much CO2 it will consume in a typical hillclimb or sprint run, and then decide if I want a tank which will need changing after every run, or one which will last the whole day.

This assumes that it works as I hope of course.......

[ste porter]

http://www.max-boost.co.uk/max-boost/intake/intercooler_C20LET.htm

bit of interesting reading for you mate about half way down the page.

i ran nitrous and co2 through a spray bar on both my nova and the cav and to be honest mate save the weight and dont bother as co2 is near useless in comparison to nos and nos is silly dangerous to use as s cooler spray
You have got to remember your turbo is sucking in all that nitrous after it hits your cooler with no added fuel and dumping it in your engine!
and take it from someone that knows it will cause lean running when used and melted pistons

my cryo bar was rigged to my purge valve for the gas and when you spray the cooler with nos you get instant ice on the cooler which is great but for a few seconds after the engine would pic up a few rpm and the wide band would go nuts as it sucked in the nitrous thats in the area causeing lean conditions that the ecu couldnt enrichen enough to sort it

best thing i ever did was fan jets small washer bottle volswagen washer jet pump and a little methonol mixed with water
i had mine atached to my turbo smart boost controller so it sprayed the cooler when set presures were reached and it worked better and safer than what any gas style spray i have ever used or tryed

problem was pod got funny about me using it but that wont bother you

imho you will be better of safer and lighter using water spray

or better still and the best option available aqua mist water injection

when your over sat i will show you the washer jets ect i used to create a mist and the whole set up cost less than 10 quid and is miles better than the 130 quid cryo spray bar 1k worth of zex nitrous setup and spare bottle for co2 option was

[Mitchell Motorsports]

Great project you got here Colin!

Is that a Magnum Motorsport Wide Arch Kit you are going to use? I'm looking to put a Wide Arch Kit on my GSi.

You are right about Paintballing CO2 bottles there are small refillable bottles that aren't too heavy and then there are even smaller and lighter disposable ones, If I remember right there were tiny disposable ones about 3 inches long.

[novarally]

Great project you got here Colin!

Is that a Magnum Motorsport Wide Arch Kit you are going to use? I'm looking to put a Wide Arch Kit on my GSi.

You are right about Paintballing CO2 bottles there are small refillable bottles that aren't too heavy and then there are even smaller and lighter disposable ones, If I remember right there were tiny disposable ones about 3 inches long.

Thanks, I'm thoroughly enjoying being back in a Nova, and the ongoing development of it is what keeps my enthusiasm fresh.

I honestly don't know who made the kit, it's possibly Magnum, but over the years there have been plenty of companies turning out 'rallycross' style wide arch kits. I also have the wider front and rear bumpers to go with it (not shown in the photo).

I had originally planned to get my friend Phil Baines (PB Fibreglass, Darlington) to produce me an ultra-lightweight carbon wide-arch kit, and I may still take that route.

But at least having this kit in my hands, I can do some proper measurements and work out what size wheels to go for.

Of course that would mean this wide-arch kit might be coming up for sale in due course!

I did see some of those disposable CO2 cannisters for sale, and they might be an option, it just depends how much gas it will use. I haven't a clue until I get it installed and tested.

[mowgli]

colin, you need a vacform engineer to join the forum... i still reckon 2mm polycarb would vac form onto a wing really well. and imagine what one would weigh....

[MK999]

polycarb is quite flexible when it's that thin though, especially after vac forming as the material thins, it would need strengthening or thicker sheets imo, by which time it's getting heavier... which is why people go for FRP materials.

[mowgli]

bending it into the shape of a nova wing would give it more than enough strength. and a couple of foam inserts would soon sort out any bendy bits...
the bonnet would be more fun though..

[MK999]

bending it into the shape of a nova wing would give it more than enough strength. and a couple of foam inserts would soon sort out any bendy bits...
the bonnet would be more fun though..

Might be worth exploring but I'm not convinced it would hold it's shape well enough tbh, polycarbonate is very flexible, people love thinking it's hard as a coffin nail cos it's bulletproof and riot shields are made of it, when it's the flexibility that makes it suitable for that, and riot shields are like 4-5mm thick from what I can tell lol

FRP is going to be roughly the same stiffness wise, with the addition of whatever fibre is used... that's how/why/what of FRP materials!

[novarally]

colin, you need a vacform engineer to join the forum... i still reckon 2mm polycarb would vac form onto a wing really well. and imagine what one would weigh....

I love the idea, and even more so if the panels were left in clear polycarbonate......

If I remember rightly Lotus did a few cars using vacuum formed polycarbonate panels some years ago, but for the life of me I can't remember the model number now (looked a bit Ariel Atom-like). It was the predecessor to the 2-Eleven they are doing now. I can remember seeing one turn up at a hillclimb event when they'd just come out, and it looked incredible with a see-through bodyshell.

Goes off to Google for more timewasting research........

Anyone involved in polycarbonate moulding, feel free to volunteer your services please.

[novarally]

If I remember rightly Lotus did a few cars using vacuum formed polycarbonate panels some years ago, but for the life of me I can't remember the model number now (looked a bit Ariel Atom-like). It was the predecessor to the 2-Eleven they are doing now. I can remember seeing one turn up at a hillclimb event when they'd just come out, and it looked incredible with a see-through bodyshell.

Goes off to Google for more timewasting research........



I am of course thinking of the Lotus 340R.

Need to find some photos of it, just like a giant RC car.

[novarally]

Here we go, it's the Lotus 340R Expose;

http://i285.photobucket.com/albums/ll66/hillclimbescort/images2.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/2531054799_cec02deb7b.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/images.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/intake.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/fsusp.jpg

[Count Vaux Alot]

/\ i want one!

[MK999]

I find myself going "oooh" and inspecting the pickup points etc on the chassis/geometry. Think I need help lol

[Mitchell Motorsports]

Wow! Love the 340R! Never seen them with the see through panels before the were usually just silver and black shame they were limited production not seen one for ages.

I did ask Magnum about making a Carbon Widearch Kit they never got back to me :S

[novarally]

Wow! Love the 340R! Never seen them with the see through panels before the were usually just silver and black shame they were limited production not seen one for ages.

I did ask Magnum about making a Carbon Widearch Kit they never got back to me :S

Doesn't surprise me greatly, I've not heard a lot of great reports about Magnum.

Phil Baines will make a kit in carbon, and his work is superb (he supplied all the panels on my last 2 Escort Cosworths). It will NOT have the carbon weave exposed on it though, all his stuff is finished in gel coat. And inevitably, they're not cheap, he was talking about £1k for a full kit.

[Mitchell Motorsports]

Doesn't surprise me greatly, I've not heard a lot of great reports about Magnum.

Phil Baines will make a kit in carbon, and his work is superb (he supplied all the panels on my last 2 Escort Cosworths). It will NOT have the carbon weave exposed on it though, all his stuff is finished in gel coat. And inevitably, they're not cheap, he was talking about £1k for a full kit.

Yes I have brought stuff from them before took over 6 months for my fibreglass roof skin to turn up.:mad: Will have to give Phil Baines a go, is he one of the guys that has some fibreglass Nova panels on eBay along with escort cosworth ones too?

[novarally]

Yes I have brought stuff from them before took over 6 months for my fibreglass roof skin to turn up.:mad: Will have to give Phil Baines a go, is he one of the guys that has some fibreglass Nova panels on eBay along with escort cosworth ones too?

Yes, that will be Phil, he does list on EBAY from time to time. He's a one man band, and supplies most of the rallycross guys. If you're contacting him, tell him that I sent you his way please.

[Bubba]

Certainly worth trying, free weight saving very welcome.

any bolt on the car...shave the head to and remove any excess thread

[MK999]

any bolt on the car...shave the head to and remove any excess thread

He's already done that lol

[Mitchell Motorsports]

Yes, that will be Phil, he does list on EBAY from time to time. He's a one man band, and supplies most of the rallycross guys. If you're contacting him, tell him that I sent you his way please.

Thanks Colin Will make sure I mention your name.:)

[novarally]

Picked up the bumpers to go with that wide arch kit at the weekend;

http://i285.photobucket.com/albums/ll66/hillclimbescort/011-15.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/010-19.jpg

And as you can see acquired a snowplough splitter as well.

I still haven't decided whether to go with the Mk.2 bumpers, or stick with my current Mk.1 style.

There is also a carbon fibre splitter/undertray sat beneath the fibreglass Mk.2 front bumper, I got it off a Touring Car long ago and plan to modify it to fit whatever bumper I end up using.

[bmw156]

keep it mk1 IMO. keeps it in character. it will look to new with a mk2 bumper.

[novarally]

Photo update to follow soon.........I've been to visit the Nova at BTEC Racing today.

The new turbo is on, and they are in the process of fabricating a complete new exhaust system.

And my STACK dash has been fitted too.

All being well it will be up and running next week and on the rolling road, before returning to me for lots of little jobs before it's ready to race for the season.

[chrisnovaturbo]

my old wide arch kit i think lol

[Nova_Tek]

I say stick to MK1. That wide arch kit should look good :)

[scott.parker]

I say go mk2 and sell me the plow font valance?

[novarally]

I say go mk2 and sell me the plow font valance?

Scott.

The snowplough is now for sale, I've decided against using it.

Drop me an e-mail please.

[scott.parker]

E-mailed..

[novarally]

The new turbo and downpipe in place;

http://i285.photobucket.com/albums/ll66/hillclimbescort/untitled-1.jpg

The boot floor and inner skin of the rear panel removed (as explaind previously, I am not permitted to remove any more than this);

http://i285.photobucket.com/albums/ll66/hillclimbescort/untitled2-1.jpg

And my favourite bit, the STACK dash display;

http://i285.photobucket.com/albums/ll66/hillclimbescort/untitled3-1.jpg

After literally years of searching, I managed to find one which incorporated the boost pressure display on it.

[novarally]

Apologies for the poor quality photos, these were taken on my Blackberry, great phone, rubbish camera.

Once I get the car back from BTEC I will get some proper photos together.

[mk1nova_rich]

Coming along nicely Colin, one more vote for keeping it Mk1 though...

[Cle]

Would it not be better to run a tubular manifold rather than a cast one ?

[burgo]

so what turbo is it now colin?

[novarally]

Would it not be better to run a tubular manifold rather than a cast one ?

We did discuss it, but there's so a fair bit of weight in the turbo, and tubular manifolds are prone to cracking, so it would probably need an extra support on it as well.

It's something I may look into at a later date, but Andrew Bradley (Mr. BTEC) is of the opinion that tubular ones are a complete pain and need re-welding frequently.

[craig green]

intercooler kit looks heavy :eek: lol can you not just wind the boost up a tad for that bit more power? :p

Stick to chassis design FFS. :p

This has changed a fair bit since I last looked in colin.

[novarally]

so what turbo is it now colin?

It's a Garrett GT2052, supplied and modified to suit by Owen Developments.

Looking at the state of the turbo which came off it, I'm hoping for big improvements. The turbine wheel was showing significant signs of damage.

[craig green]

Has the Garrett gone back onto the old manifold?

[calibra-keith]

looking good Colin, shame i didn't get to see this today maybe next time.

[novarally]

Has the Garrett gone back onto the old manifold?

It's the old manifold, but the flange has had to be modified.

[novarally]

The Nova is still away, but should (fingers crossed) be back with me next week.

In the meantime, I acquired a set of 7" x 13" split rim Compomotive Turbos, with Yokohama hillclimb slicks;

http://i285.photobucket.com/albums/ll66/hillclimbescort/002-36.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/003-39.jpg

They are from a Mini, so the PCD is the correct 101.6mm (4") to suit my Mini rear hubs. My plan is to re-drill the front drive flanges to change the front PCD to match so I can use Mini wheels all round.

The rear ones do protrude beyond the arch lip, so I'm going to have to provide some sort of 'flare' in the bodywork to accommodate them;

http://i285.photobucket.com/albums/ll66/hillclimbescort/012-18.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/013-14.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/011-18.jpg

My plans to wide arch the Nova have been put on the back burner, mostly because I have got hold of a new 'mobile home' for it, which to say the least of it is a very tight fit!;

http://i285.photobucket.com/albums/ll66/hillclimbescort/untitled-2.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/untitled2-2.jpg

[novarally]

The trailer has a bed size of 11' x 5'5", so in theory a Nova is too long to go in it.

http://i285.photobucket.com/albums/ll66/hillclimbescort/009-20.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/007-23.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/008-21.jpg

But after removing the tyre rack, and the wheel chocks, and both the bumpers, I can just squeeze a Nova in there!;

http://i285.photobucket.com/albums/ll66/hillclimbescort/016-18.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/022-10.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/014-15.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/015-16.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/021-14.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/018-20.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/019-18.jpg

But as you can see, there's no way a wide-arch bodykit is going to fit in there......

[db_1.2]

That is a tight fit! I like the flap at the front. Is that so the Nova can go RARRRR through it?

Comps are nice, what does a single one weight?

[novarally]

That is a tight fit! I like the flap at the front. Is that so the Nova can go RARRRR through it?

Comps are nice, what does a single one weight?

The flap at the front is vital, as there's no other way to get down the sides of the car to strap it down at that end!

I haven't weighed the wheels yet, and it wouldn't be a great comparison as I know the carcass of the Yokohamas fitted to them is fairly heavy.

I need to get a tyre off to do a proper test, but they do feel very light.

[MK1_Ben]

This car and project is awesome, was reading it before I even joined PNG aha :)

Really can't wait for it to be finished, will be a proper animal.

[mowgli]

it will never be finished..

[MK1_Ben]

*Really can't wait to see it on a track/hillclimb, will be a proper animal.

[novarally]

Got my Quaife SCCR gear cluster back, so that can get fitted as soon as the Nova returns to me (next week I hope!!);

http://i285.photobucket.com/albums/ll66/hillclimbescort/008-22.jpg

Also picked up a wide arched Nova shell which will allow me to test out whether it will actually go into my new trailer;

http://i285.photobucket.com/albums/ll66/hillclimbescort/012-19.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/013-15.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/014-16.jpg

I'll be surprised if it goes in!

[novarally]

Big sheet of carbon fibre which will soon cover the gaping hole in the boot;

http://i285.photobucket.com/albums/ll66/hillclimbescort/046-2.jpg

If anyone has made something similar previously, which is a perfect fit into all the nooks and crannies of the boot floor area, I'd be very interested in hearing from them as I'd like to get a template off them (saves me the time and horror of trying to get all the profiles correct!). Thanks.

Recently picked up this rather nice Nova rally car;

http://i285.photobucket.com/albums/ll66/hillclimbescort/041-3.jpg

Originally this was Dave Marshall's track/show car shell with full Safety Devices welded in roll cage, now has 1600cc 16v engine, Quaife ATB, bias pedal box, Konis, choice of wheels and tyres etc. It will be up for sale soon.

[Jonlem]

Dave Marshalls old motor, nice car that was !

Just got back in Colin and may of sourced those parts locally, I'll drop you a email shortly once I get a reply from the other chap.

[Edd]

could you not trace round a boot carpet for a template for the carbon ?

or are you looking for it be smaller ?

[scott.parker]

IIRC Dave's old car had a Custom built fabricage, not that it matters lol

Shame to see the poor car left like that, i loved that car when Dave had it, was one of the cars that got me into the idea of tracking one, nice lad to Dave is.

As for boot floor its not hard to get some card cut it out bigger then a boot carpet and then just keep trimming it till its right then use that for your template no??

Scott

[Ben]

are you selling it as it is Colin or removing the trick bits and then selling?

[novarally]

are you selling it as it is Colin or removing the trick bits and then selling?

I'd prefer to sell it as is, but that obviously depends on whether I can get the pirce I need for it.

[novarally]

IIRC Dave's old car had a Custom built fabricage, not that it matters lol

Shame to see the poor car left like that, i loved that car when Dave had it, was one of the cars that got me into the idea of tracking one, nice lad to Dave is.

As for boot floor its not hard to get some card cut it out bigger then a boot carpet and then just keep trimming it till its right then use that for your template no??

Scott

It's 100% definitely a Safety Devices cage - it has the plates with their name welded onto it!

Yes, I could cut some cardboard up bigger, I'm just trying to save myself some time, which is in short supply at the moment. I've driven 2,000 miles so far this week!!

[novarally]

Good news is that a wide-arched Nova does fit in the enclosed trailer I have.

There's about 10mm of clearance either side at the tightest point - photos to follow tomorrow as it was almost dark when I'd got the shell rolling and loaded up.

I'll be bonding some foam to the insides of it to give some protection from scratching.

[bmw156]

good times!
makes the trailer a good buy then lol.

theres a guy who list opposite me, who has one similar for motorbike racing.

[Mike]

Good news is that a wide-arched Nova does fit in the enclosed trailer I have.

Have you got yourself a race shuttle now then Colin??

[mk1nova_rich]

go back a couple of pages Mike... lol

[MK999]

Have you got yourself a race shuttle now then Colin??

Read the thread! :p lol

[bmw156]

The trailer has a bed size of 11' x 5'5", so in theory a Nova is too long to go in it.

http://i285.photobucket.com/albums/ll66/hillclimbescort/009-20.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/007-23.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/008-21.jpg

But after removing the tyre rack, and the wheel chocks, and both the bumpers, I can just squeeze a Nova in there!;

http://i285.photobucket.com/albums/ll66/hillclimbescort/016-18.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/022-10.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/014-15.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/015-16.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/021-14.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/018-20.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/019-18.jpg

But as you can see, there's no way a wide-arch bodykit is going to fit in there......

for mike! lol

[Mike]

Mobile internet tends not to show pictures on the most part Im afraid.

[novarally]

Have you got yourself a race shuttle now then Colin??

I certainly have Mike, I'd been thinking about getting one for ages as I was fed up with arriving at events with the Nova covered in muck, and worried about leaving it on an open trailer if I parked up anywhere.

I'm going to need to remove the rear bumper to shorten it enough to get it in, but that's no great issue.

[chris gsi]

as you said it is a safty devices cage as he had the roof changed at the same time to get rid of the sun roof as it a genuine gte and was white when he first had it

[MK999]

Is there a reason there's a rear bumper on it anyway? lol

[Mike]

I certainly have Mike, I'd been thinking about getting one for ages as I was fed up with arriving at events with the Nova covered in muck, and worried about leaving it on an open trailer if I parked up anywhere.

I'm going to need to remove the rear bumper to shorten it enough to get it in, but that's no great issue.

Wise move then (can see pics now on home PC) Ive never seen a shuttle with a 50/50 opening like that before, proper smart IMO. I bet that was a damn sight cheaper then a Brian James RS5 aswell :eek:

[novarally]

Is there a reason there's a rear bumper on it anyway? lol

Because I've never seen a bumperless Nova that looks right. Anyone who can prove that opinion wrong please feel free to post up photos.

[MK999]

Because I've never seen a bumperless Nova that looks right. Anyone who can prove that opinion wrong please feel free to post up photos.

Bumperless saloon smoothed out properly would look spot on imo, been wanting to do that for ages! However go before show Colin :p lol

[novarally]

Wise move then (can see pics now on home PC) Ive never seen a shuttle with a 50/50 opening like that before, proper smart IMO. I bet that was a damn sight cheaper then a Brian James RS5 aswell :eek:

It's a Minno Shuttle, which has just been deleted from the Brian James range. It's really intended for Caterhams.

Cheap it wasn't, but it's definitely less than an RS5!

[Mike]

It's a Minno Shuttle, which has just been deleted from the Brian James range. It's really intended for Caterhams.

Cheap it wasn't, but it's definitely less than an RS5!

Ah ok, never seen one like that before tbh :confused: but I can fully appreciate it wasnt cheap. Even old RS5's still sell for £6kish.

A friend of mine bought 2, brand new & has never told me how much they cost lol but can imagine full well they werent cheap at all lol

[scott.parker]

Sorry Colin, i was sure it was a Fab one, maybe thats in his mk1 let, Sorry for any confusion.

[mk1nova_rich]

Bumperless saloon smoothed out properly would look spot on imo, been wanting to do that for ages! However go before show Colin :p lol

Saloon also wouldn't fit in the trailer, bumper or not... :p

[novarally]

Saloon also wouldn't fit in the trailer, bumper or not... :p

After further investigation, I reckon there's a slim possibility that the Nova wiill tuck iinto the trailer with just the bonnet taken off, and with both bumpers still fitted.

It's the leading edge of the bonnet which is touching against the 'lid' of the trailer, and without the bonnet the whole car should be able to come forward an inch or two more, which might allow the rear lid to shut. Something to try when it stops raining.

[fearless]

It's the leading edge of the bonnet which is touching against the 'lid' of the trailer, and without the bonnet the whole car should be able to come forward an inch or two more, which might allow the rear lid to shut. Something to try when it stops raining.


Time to lower the nova a little more - bonnet will clear then ????

[novarally]

Time to lower the nova a little more - bonnet will clear then ????

It would need to be lowered about 12 inches to be of any help!

[Danny s-p]

is there any vids any were of this before you owned it

[novarally]

is there any vids any were of this before you owned it

Not as far as I am aware, I've searched a lot for some.

[novarally]

Not much to report at this time, although I really must put together a 'To Do' list for the car, as time is pressing on, and when it comes back to me from BTEC Racing there's going to be an awful lot of work required before the first test session/race.

Following a visit from Steve Porter today, I've decided I need to lose metalwork out of the front inner wing area, just like Steve has done on his car (photos copyright and thanks to Mr. Porter);

http://i285.photobucket.com/albums/ll66/hillclimbescort/IMAG0820.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/IMAG0821.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/IMAG0822.jpg

I've also bought some 6-pot KAD brakes (from a Mini), complete with discs, which I'm hoping to adapt to fit, in much the same way as we adapted KAD rear discs to fit;

http://i285.photobucket.com/albums/ll66/hillclimbescort/DSCN0616.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/DSCN0619.jpg

As you can see, they are solid, not vented, and they are smaller in diameter, so less weight too. The Nova weighs much the same as a Mini now, so they should be adequate for the job.

Continuing with my weight saving theme, I'm looking into the possibility of getting some titanium suspension springs. They've been used on Formula 1 cars, but I need to do some research on whether they've ever made it on to saloon cars.

I've found some for sale from an Arrows F1 car, but the spring rates are way too high, and they are too short as well.

Anyone know of any other possibilities? - mountain bikes and some motorcycles use titanium springs, but again I suspect they will all be too short for my application.

[lee303]

coilsprings 89 will supply Ti springs colin, not sure on cost obviously and their website appears to be down for me at the moment, but they definitely do them, some of the supertouring cars may well have used them, don’t think the regs specified steel

[fearless]

On initial viewing of the front Alloy Bells, it looks to me as the offset is way too high - ie. the disc will sit too far in !!!

I looked at fitting some Astra Grp A front discs my mate had to my project but the brake bell had a deep offset and ment the disc touched the nova front knuckle :( - Back to the drawing board !!

[novarally]

coilsprings 89 will supply Ti springs colin, not sure on cost obviously and their website appears to be down for me at the moment, but they definitely do them, some of the supertouring cars may well have used them, don’t think the regs specified steel

That's brilliant, thanks for that. I've found their website and will give them a ring for a chat on Monday.

[novarally]

On initial viewing of the front Alloy Bells, it looks to me as the offset is way too high - ie. the disc will sit too far in !!!

I looked at fitting some Astra Grp A front discs my mate had to my project but the brake bell had a deep offset and ment the disc touched the nova front knuckle :( - Back to the drawing board !!

Agreed.

The brakes will be with me on Monday so I can start doing some test fitting, but I am 99% certain I'm going to end up having alternative bells made up.

[clubberlang23]

Agreed.

The brakes will be with me on Monday so I can start doing some test fitting, but I am 99% certain I'm going to end up having alternative bells made up.

I could possibly make you some new bells if needed as i'm a precision engineer my trade.

[Jonlem]

Looking good Colin, nice brakes.

[ste porter]

couple more pics that may help and be of interest colin
also if you want to pop over when your next this way on for a peek your more than welcome mate you know where i am.

http://img.photobucket.com/albums/v65/porter/IMAG0163.jpg?t=1287535589

http://img.photobucket.com/albums/v65/porter/IMAG0178.jpg?t=1287535671


http://img.photobucket.com/albums/v65/porter/IMAG0179.jpg?t=1287535892


http://img.photobucket.com/albums/v65/porter/IMAG0194.jpg?t=1287602585


http://img.photobucket.com/albums/v65/porter/IMAG0196.jpg?t=1287602585

http://img.photobucket.com/albums/v65/porter/IMAG0199.jpg?t=1287602681



Also mate will give you a call mid week so i can arange with you when your about to collect that shell and and doors ect if thats ok mate

[novarally]

couple more pics that may help and be of interest colin
also if you want to pop over when your next this way on for a peek your more than welcome mate you know where i am.

Also mate will give you a call mid week so i can arange with you when your about to collect that shell and and doors ect if thats ok mate

Thanks Steve, very useful.

Wednesday, Friday, Saturday and Sunday are looking like good days for collecting the shell.

Tuesday and Thursday are not good at all!

I eventually remembered where that place which does all the composite moulding is that we were talking about - it's at Binbrook (Market Rasen/Grimsby direction).

[novarally]

coilsprings 89 will supply Ti springs colin, not sure on cost obviously and their website appears to be down for me at the moment, but they definitely do them, some of the supertouring cars may well have used them, don’t think the regs specified steel

I've spoken with Neil at Coilsprings 89, and he reckons around £300 per pair to make titanium springs to my specifications.

I'll have to weight my springs, and see if a 40% weight reduction on them would justify those sort of costs.

[MK999]

I've spoken with Neil at Coilsprings 89, and he reckons around £300 per pair to make titanium springs to my specifications.

I'll have to weight my springs, and see if a 40% weight reduction on them would justify those sort of costs.

Considering a spring must weigh around 2kg+ £300 to lose 4*0.4=1.6kg is a bargain when you get to the kind of level your car is at colin!

[lee303]

I've spoken with Neil at Coilsprings 89, and he reckons around £300 per pair to make titanium springs to my specifications.

I'll have to weight my springs, and see if a 40% weight reduction on them would justify those sort of costs.

seems pretty reasonable to me tbh! and imagine the spec list kudos!:thumb: glad they were of use though, great company to deal with in my experience

[t45_ste]

Your getting some nice bits together now colin. What dampers are you running on the front? Just wondered if you spoke to gaz about getting some short bodied dampers made with less travel would save you a bit more weight?

[novarally]

Your getting some nice bits together now colin. What dampers are you running on the front? Just wondered if you spoke to gaz about getting some short bodied dampers made with less travel would save you a bit more weight?

The fronts are off the shelf Leda ones (2.5" springs I believe).

They are an area I plan to look at, I can't see why it wouldn't be possible to use 1.9" ID sturuts/springs to save weight.

[novarally]

Considering a spring must weigh around 2kg+ £300 to lose 4*0.4=1.6kg is a bargain when you get to the kind of level your car is at colin!

Agreed, except it's £600 to save 2kg!

I weighed one of my 1.9" ID rear springs, and it's about 2.2kg, so there would be a bit more to be saved than 2kg in total, especially as if I remember rightly the Ledas use 2.5" ID springs on the front end.

[t45_ste]

There is definatley quite a bit of weight to be saved then. Next time im down at the unit i will measure the body of mine and the amount of travel and let you know how much they weigh. They are certainly a lot lighter than a standard coilover.

[novarally]

There is definatley quite a bit of weight to be saved then. Next time im down at the unit i will measure the body of mine and the amount of travel and let you know how much they weigh. They are certainly a lot lighter than a standard coilover.

Thanks, that would be really useful information.

I'm sure a custom built front damper could save 2 or 3kg per side, and would be well worth doing.

[16xe_chris]

Agreed, except it's £600 to save 2kg!

I weighed one of my 1.9" ID rear springs, and it's about 2.2kg, so there would be a bit more to be saved than 2kg in total, especially as if I remember rightly the Ledas use 2.5" ID springs on the front end.

You can save 2.5kg's per side roughly using fiberglass wings, much cheaper option lol


I have some old wrc siera or cossy rear shockers in the garage and they are made from titanium, they are seriously light :thumb:

[novarally]

You can save 2.5kg's per side roughly using fiberglass wings, much cheaper option lol


I have some old wrc siera or cossy rear shockers in the garage and they are made from titanium, they are seriously light :thumb:

I'll be going full fibreglass front wings when I fit the wide arch kit, and I have yet to do a weight comparison between steel and fibreglass.

2.5kgs per side seems a lot though, I wouldn't have thought a steel wing weighs much more than that in total. Must check tomorrow!

[lee303]

my steel front wings were 5kg each and the standard width fiberglass ones i have now are 2.4 each side:thumb:

[ste porter]

it may sound a daft surgestion but had you thought about blow moulded or injection moulded abs front wings?

i dont know what your regs allow or how strong you would want them but a sheet of 1.5mm abs the size of the car would only weigh about 2 kg at the most so if you found someone that could vac form a wing for you cut a steel wing down to about 10mm all the way around the outer lip bond the abs wing wing to that and whola a wing that would weigh about a kilo at most

only issue is how strong it would be but abs is fairly impact resistant but how long they would last with cconstant gravel pebal dashing i dont know

as i say proberly not feasable but just a thought

also if you find some one to do it door skins boot lids ect would all be possable but again how flexable and stong they would be i dont know but the weight saving would be un beliveable

anybody know about the possabilitys of this?

[bmw156]

it may sound a daft surgestion but had you thought about blow moulded or injection moulded abs front wings?

i dont know what your regs allow or how strong you would want them but a sheet of 1.5mm abs the size of the car would only weigh about 2 kg at the most so if you found someone that could vac form a wing for you cut a steel wing down to about 10mm all the way around the outer lip bond the abs wing wing to that and whola a wing that would weigh about a kilo at most

only issue is how strong it would be but abs is fairly impact resistant but how long they would last with cconstant gravel pebal dashing i dont know

as i say proberly not feasable but just a thought

also if you find some one to do it door skins boot lids ect would all be possable but again how flexable and stong they would be i dont know but the weight saving would be un beliveable

anybody know about the possabilitys of this?

it was suggested a few pages back, and a lotus was shown with a completely see through body :)

[lee303]

only thing with vac moulding is the part would have to be in its installed position when moulded, as the abs wont want to flex like fiberglass or even steel does, and as you know when you fit a nova wing you tend to flex it into shape when you fit the lower bolts, interesting concept though, personally i think you could make a really light fiberglass or kevlar front wing by making it just a single skin, but then you probably add back any weight saved making a frame to support it so it fits the car right, swings and roundabouts...

[mowgli]

vac formed nova wings would be a max 200g per side at a guess though... but would be real fun to make..

[t45_ste]

Hi colin

What flywheel/clutch are you running? Could you drop down to a 5.5" clutch to save a bit more weight?

Also noticed there is some excess wiring coiled up............ getting desperate i know.

[novarally]

Hi colin

What flywheel/clutch are you running? Could you drop down to a 5.5" clutch to save a bit more weight?

Also noticed there is some excess wiring coiled up............ getting desperate i know.

I'm not 100% certain what spec. the flywheel and clutch is, but I believe it may be a standard flywheel, lightened and a Helix plate and cover.

So yes, there is room for improvement there, I'd like to go for a titanium flywheel and a 5.5" clutch eventually, as always it's a question of cash though!

The extra wiring is there in readiness for a traction control system which was originally planned, and may still happen one day.

The great news for today is that I've had a phone call from Andrew Bradley at BTEC Racing, and he's been running my Nova up on the rolling road.

With the new exhaust system (no silencer) we are seeing 219 bhp and 140 lbs/ft of torque at 7,500 rpm.

The power was still climbing as well, but it's not safe to rev it any higher than this with the standard bottom end which is in it.

We need to test the noise levels next to see if we are going to need to incorporate a silencer, which may steal a few horsepower of course.

I'm absolutely delighted!

[Edd]

That's very impressive !

Is that the level of power you were expecting ?

[mowgli]

that is fantastic... i hope you whallop those pesky minis this year...

[bmw156]

219BHP

OMG, who needs a let

[novarally]

That's very impressive !

Is that the level of power you were expecting ?

It's way more than I had expected. I'd have been more than happy if we'd found 190 bhp.

If my estimate of 570kg is correct, that's going to give me 384 bhp/tonne.

[General Baxter]

that the wheels or fly?

[Connor]

that's going to give me 384 bhp/tonne.
:eek: :eek: :eek: :eek: :eek: :eek: :eek: :eek: :eek:
Thats awesome news colin, well done

[t45_ste]

That power figure is bloody impressive. You are taking this car to the next level and im seriously impressed (and a bit jealous lol)

Just think what weight you could get this down if it wasnt for the pesky regs, a few more bits of metal could be removed.

Well done

[BRoadGhost]

She's a honey!

[novarally]

You can save 2.5kg's per side roughly using fiberglass wings, much cheaper option lol


I have some old wrc siera or cossy rear shockers in the garage and they are made from titanium, they are seriously light :thumb:

I weighed a Mk.1 Nova standard steel wing this morning;

http://i285.photobucket.com/albums/ll66/hillclimbescort/024-7.jpg

It's a shade over 3kg.

Chris, are your fibreglass Mk.1 wings weighing as little as 0.5kg?

[lee303]

hmm, seems you have more accurate measuring equipment than my bathroom scaleslol my metal wings appeared to be nearly 5kg, with the fiberglass coming in at 2.5...

[mowgli]

well, apart from putting helium in the tyres, there isn't much else you can do to it......lol

[novarally]

hmm, seems you have more accurate measuring equipment than my bathroom scaleslol my metal wings appeared to be nearly 5kg, with the fiberglass coming in at 2.5...

Yes, I have some pretty accurate kit. Longacre corner weight scales for the big stuff, and for the small things, the sort of scales used to weigh drugs.

[novarally]

well, apart from putting helium in the tyres, there isn't much else you can do to it......lol

Helium in the roll cage......

[mowgli]

isn't that what porsche did on the 917, so they could wire up a warning light/sender to let them know when the chassis cracked during a race????

[novarally]

well, apart from putting helium in the tyres, there isn't much else you can do to it......lol

It looks like there may be something else.

Thanks to Gary C on here who gave me the idea...........

Some grasstrack cars are apparently running air shocks at the back end, Fox is one of the suppliers involved.

I fired off an e-mail this morning to a Fox agent, and they tell me that there are actually a few tarmac Nova rally cars using Fox air shocks on them (on the rear).

Anyone on here know anything about these Novas, or indeed any other tarmac cars using this sort of system?

Doing away with the coil spring has got to be a good move in weight saving terms.

But my only (tiny) knowledge of air shocks is on mountain bikes.

[16xe_chris]

hmm, seems you have more accurate measuring equipment than my bathroom scaleslol my metal wings appeared to be nearly 5kg, with the fiberglass coming in at 2.5...

Same here lol

Its was the mk2 wings i weighed which have a tiny bit more metal on them lol , but my scales are no where near as acurate as your matey :thumb:


P.s. i could try making you a set at 0.5kg if your interested ;) i could make them without the gelcoat so it was pure resin and 2 layers of 450gauge glass.

Did you weigh your wide arch wings?

[novarally]

i could try making you a set at 0.5kg if your interested ;) i could make them without the gelcoat so it was pure resin and 2 layers of 450gauge glass.

Did you weigh your wide arch wings?

I haven't weighed the wide arch wings yet, but they do feel fairly heavy (at least as much as a steel wing I suspect).

I'm pretty sure I'm going with the wide arch kit now, but if I don't, I would definitely be interested in ultra-lightweight Mk.1 standard wings. Thanks.

[novarally]

Nothing to do with the Nova directly, but it will make working on it easier.........I picked up this on Tuesday;

http://i285.photobucket.com/albums/ll66/hillclimbescort/006-29.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/007-24.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/009-21.jpg

And this is where it was to be fitted on Wednesday;

http://i285.photobucket.com/albums/ll66/hillclimbescort/008-23.jpg

Playing before the hard work started;

http://i285.photobucket.com/albums/ll66/hillclimbescort/010-23.jpg

Unloading it on my own was fun, it weighs a huge amount;

http://i285.photobucket.com/albums/ll66/hillclimbescort/011-19.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/012-20.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/015-18.jpg

When the fitter arrived eventually, we were able to get the baseplate down;

http://i285.photobucket.com/albums/ll66/hillclimbescort/016-20.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/017-23.jpg

[novarally]

I've got limited height in the workshop, and this beam was right in the way;

http://i285.photobucket.com/albums/ll66/hillclimbescort/020-16.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/018-22.jpg

But easily solved with the aid of the trusty Stihl chainsaw;

http://i285.photobucket.com/albums/ll66/hillclimbescort/019-19.jpg

Also had to make some adaptations to other woodwork;

http://i285.photobucket.com/albums/ll66/hillclimbescort/022-11.jpg

And it was up by lunchtime, with the aid of an engine crane, a few ratchet straps and a very large neighbour farmer!;

http://i285.photobucket.com/albums/ll66/hillclimbescort/021-15.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/023-8.jpg

Just waiting for the electrician to come and wire it up now, as it's on a 30 amp supply. Can't wait to try it out.

[Mike]

Colin, dont mean to be a kill joy but be very wary cutting out horizontal joists :S they stop sideways movement in roof structures...

Other then that, top work :)

[scott.parker]

Awesome Colin, love the Chase HQ arcade too!

[scott.parker]

Colin, dont mean to be a kill joy but be very wary cutting out horizontal joists :S they stop sideways movement in roof structures...

Other then that, top work :)

Be fine Mike hes only removed one from what i see...;)

[novarally]

Colin, dont mean to be a kill joy but be very wary cutting out horizontal joists :S they stop sideways movement in roof structures...

Other then that, top work :)

Don't worry, I've since braced them up with steel, so they are stronger than before. I'm also going to brace down onto the posts of the lift itself, just to be 100% sure.

[novarally]

Awesome Colin, love the Chase HQ arcade too!

One of the great arcade games, but sadly it stopped working recently. I believe it's the monitor which has gone, so if anyone knows where I can get a 20" Hantarex MTC-9000 (circa 1988!), let me know.

[MK999]

Don't worry, I've since braced them up with steel, so they are stronger than before. I'm also going to brace down onto the posts of the lift itself, just to be 100% sure.

Actually a lot of woods have a higher youngs modulus/density than steels, so if you've replaced it weight for weight it may not be stiffer.

It will be fine braced with steel, obviously, but there's a little fact for you to surprise people with lol

[Mitchell Motorsports]

Wow just catching up on this thread that is some power your getting now from that tiny engine.

[novarally]

Picked up the Nova yesterday from BTEC Racing, so the hard work for me begins now to get it ready for testing, and then the first race weekend 16/17th April.

There's an awful lot of stuff to do, so panic time.

[stupot89]

what no pics :(

[novarally]

what no pics :(

Sorry, here you go, not much to see though really, as there's lots of re-fitting and things to be done;

http://i285.photobucket.com/albums/ll66/hillclimbescort/003-40.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/004-34.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/005-28.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/006-31.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/007-26.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/008-25.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/009-23.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/010-25.jpg

Also got myself a rather flash Dymo label printer, which will allow me to do some fancy labelling for switches, fuses etc.;

http://i285.photobucket.com/albums/ll66/hillclimbescort/002-37.jpg

[novarally]

The new exhaust system now exits on the passenger side;

http://i285.photobucket.com/albums/ll66/hillclimbescort/011-21.jpg

It's currently unsilenced, and may well be too loud to get away with at race meetings. The old exhaust system has been modified so it can be re-fitted in case of emergencies........

The new STACK dash is lovely, but the boost pressure sensor that came with it seems to be faulty, and at £250 +VAT for a new one, I'll make do with a temporarily rigged up separate boost gauge for the moment;

http://i285.photobucket.com/albums/ll66/hillclimbescort/019-20.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/016-21.jpg

The boot floor will be covered with carbon fibre, I will make up a cardboard template first, based on the Vauxhall-supplied carpet template;

http://i285.photobucket.com/albums/ll66/hillclimbescort/025-7.jpg

Ian Bennett has kindly made me up some rear light stickers to go along with the headlamp stickers he did for me earlier;

http://i285.photobucket.com/albums/ll66/hillclimbescort/012-21.jpg

[novarally]

Did a trial fit on the new Compomotive Turbo split rims on the back;

http://i285.photobucket.com/albums/ll66/hillclimbescort/014-18.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/015-19.jpg

Without major surgery to the mechanicals, it's certainly going to need to be wide arched.

Also trial fitted the new 2mm plastic windows, which fit perfectly (thanks to ACW Motorsport Plastics);

http://i285.photobucket.com/albums/ll66/hillclimbescort/020-17.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/021-16.jpg

I'm tempted to fit a tailgate with a GTE/SR spoiler moulded into it, which I have already, but it's laid up in pretty thick fibreglass and is going to end up adding weight;

http://i285.photobucket.com/albums/ll66/hillclimbescort/022-12.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/023-9.jpg

The rear piece of the bodykit which incorporates the rear light blanks is ridculously heavy for fibreglass!!;

http://i285.photobucket.com/albums/ll66/hillclimbescort/024-8.jpg

And I think I'll do away with the rear towing eye, saves a small amount of weight, but more importantly it reduces the overall length which it needs to fit into my enclosed trailer;

http://i285.photobucket.com/albums/ll66/hillclimbescort/026-9.jpg

The rear anti-roll bar can be used as a towing point without a problem.

The ARB has another useful purpose, I can stand in the hole cut-out in the boot floor and lift the whole rear end off the floor with ease.

[Bubba]

And I think I'll do away with the rear towing eye, saves a small amount of weight, but more importantly it reduces the overall length which it needs to fit into my enclosed trailer

now THATS a tight fit lol

loving the comp turbos :d

[MK1_Ben]

Amazing build :)

+rep :)

[bmw156]

Looks great Colin. Just thought of a few more possible areas for weight removal.

The door handles. What people normally do and remove the plastic leaving the metal frame.
The part of the shell where the rear bumper mounts on the sides of the car. Surly it can be chopped similar to the front wings.

[novarally]

Looks great Colin. Just thought of a few more possible areas for weight removal.

The door handles. What people normally do and remove the plastic leaving the metal frame.
The part of the shell where the rear bumper mounts on the sides of the car. Surly it can be chopped similar to the front wings.

I plan to do away with the door handles completely at some point. The passenger door will be quick release, and I intend to use an alternative fixing method on the drivers side.

The rear wings could be cut away as you suggest, although that will allow water and mud into the car.....I could replace the steel with something else to seal it up though.

[BRoadGhost]

Colin I respect the car & yourself, but if were mine i'ud go all out for the stock look rather than easier option. Make the push & reengineer that beam so those monster slicks live behind standard looking arches.

[MK1_Ben]

Colin I respect the car & yourself, but if were mine i'ud go all out for the stock look rather than easier option. Make the push & reengineer that beam so those monster slicks live behind standard looking arches.

Very good point, Colin certainly appears to have the skills to do so.

Would it still be within Hillclimb/sprint regs?

[fearless]

http://i285.photobucket.com/albums/ll66/hillclimbescort/009-23.jpg





What's that little yellow toy we see in the garage

Wide arch C20XE rally car ??

More pictures/info please :thumb:



Dave

[LEWI007]

Thats the Mattig wide arch kitted nova ;)

here you go dave:

http://www.pngclub.com/forum/showthread.php?t=165506&page=4

[Rick Draper]

Looks possibly like a mattig kitted vauxhall nova dave?

[fearless]

I really must keep upto date with Colins projects :)

Cheers boys

[nova ian]

Glad you received the stickers, hope there ok for you.

The cars looking like a seriously light weight weapon now. It'll be interesting to see if you can notice any major differences from the last time you drove it.

Ian

[dan23]

more weight saving?

remove the bulkhead/ firewall panel
take the hole saw to the metal panel inside ( that the dash normaly covers)

cut off the lower part of the rear bumper
remove the front towing eye an replace with ne of those fabric loops found on touring cars

[novarally]

more weight saving?

remove the bulkhead/ firewall panel
take the hole saw to the metal panel inside ( that the dash normaly covers)

cut off the lower part of the rear bumper
remove the front towing eye an replace with ne of those fabric loops found on touring cars

This has been covered dozens of times previously........I cannot lighten the bodyshell anywhere between the wheel centres.

The alloy tow eye is without question lighter in weight than a tow strap.

And I guess that the bumper could be cut down, but would look daft I suspect.

[lee303]

looking great colin, loving the light stickers! only thing i can see that would save decent weight is to make the passenger door bar a single rather than a x, yes it makes it slightly less safe but you are sat a long way from there...and of course the regs may say you have to have a x bar

but really, its so skinny now finding big losses will be hard, probably more performance gains to be made elsewhere on the car, love it!:thumb:

[novarally]

Dragged it out into the sunshine this morning to get a bit of work done on it;

http://i285.photobucket.com/albums/ll66/hillclimbescort/027-7.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/028-7.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/029-9.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/030-8.jpg

More detailed photos later, depending on progress!

[mowgli]

colin, i can't remember.... are you swapping the bonnet or not?? the cooling scoop does look a touch odd, is there a tidier way of doing it?

[novarally]

colin, i can't remember.... are you swapping the bonnet or not?? the cooling scoop does look a touch odd, is there a tidier way of doing it?

I'm not planning to swap the bonnet.

The cooling scoop is a hangover from an earlier intercooler installation from quite a few years back. It's redundant now.

I have a carbon fibre scoop that could be fitted, or I could just glassfibre over the hole. It's not on the 'high priority' list with all the other jobs that need doing though!

[novarally]

Bit of playing with the kevlar door skin I have for the passenger side. It's going to need some imagination with quick release clips to get it fitting nicely;

http://i285.photobucket.com/albums/ll66/hillclimbescort/017-24.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/018-23.jpg

Made up some rear light 'blanks' using the stickers which Ian did for me. They save just over 100g each compared with the cut-down rear lights I was using;

http://i285.photobucket.com/albums/ll66/hillclimbescort/019-21.jpg

And I made up some quick-release door hinge pins for the drivers side. Naturally they are aluminium to save on weight;

http://i285.photobucket.com/albums/ll66/hillclimbescort/022-13.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/023-10.jpg

This afternoon I will be experimenting with (yet another) wide arch kit which I've got hold of.......

If anyone wants to wide arch their Nova, get in touch with me as I have lots of bits.

I have one complete rallycross-style kit (all in fibreglass, including bumpers, wings, rear quarters and sideskirts). I also have a pair of steel wings with the wide arches fitted to them, and a complete pair of Mk.1 fibreglass wide arch front wings.

[boffer8]

Whats the blue and yellow wide arch nova colin? looks an interesting bit if kit

[LEWI007]

read the last couple pages, i put a link to pics.

[nova ian]

Looks like you have your work cut out on the car as you said! Its coming on though, and you can tell from looking at the pics that its been on a massive diet! lol

Stickers look like they have gone on well, nice and flat. Good Stuff.

[novarally]

Whats the blue and yellow wide arch nova colin? looks an interesting bit if kit

Mattig-kitted with 8" x 15" Compomotive split rims, Redtop 2.0 16v, unused for 10 years (when it was built). Very much a stripped out track/sprint car, but it is road legal.

Just got a new MoT on it, and it is up for sale....

Usual e-mail address for those with cash burning a hole in their pockets

[novarally]

A quick question for anybody who is expert on Vauxhall colours.......

What shade of red do you think this Nova of mine is?

I'm thinking Carmine Red, but could it be Flame Red? Or something else?

I spoke to Andy Bradley who built the car in 1999, and he had a vague recollection it was Carmine Red, but wasn't 100% sure. It's definitely a Vauxhall red though he says.

[mowgli]

my money is on carmine. mine is flame red & i reckon the carmine is a deeper shade.

[novarally]

my money is on carmine. mine is flame red & i reckon the carmine is a deeper shade.

Thanks, I did just find an old can of Flame Red in the shed, and it does seem to be a little bit lighter than the car, so it looks like Carmine is correct.

[Harvey]

It looks to be Carmine red, paint code is 76L. It's a tad more orange in colour than Flame red.

[bmw156]

carmine is mk1.
flame is mk2.
AFAIK

[mowgli]

martin..... mine is both mk1 & flame

[bmw156]

martin..... mine is both mk1 & flame

****.

[Ben]

Does it matter? I really hope it changes colour lol

[novarally]

Does it matter? I really hope it changes colour lol

It will change colour completely one day, but I haven't got time to get it done before this season starts.

[stupot89]

strip it dip it one coat of primer and i 2pak paint keep the weight down

[Southie]

Bare metal and just lacquer only is even lighter, would look quite good with maybe white graphics on.

[novarally]

strip it dip it one coat of primer and i 2pak paint keep the weight down

Yes, that will be the way it goes, I shall have it dipped at SPL or similar.

Only question is what colour it will be........at the moment I'm favouring plain white, but I do have days where I fancy an extreme colour e.g. Renault Clio Alien Green, or a vivid orange.

[MK999]

Im sure you can guess my suggestion lol

[Cle]

instead of panit just get every panel made in carbon fibre and leave it raw, Would look the bee's knee's lol

[Plug]

/\ and also cost a small fortune

[Welsh Dan]

Yes, that will be the way it goes, I shall have it dipped at SPL or similar.

Only question is what colour it will be........at the moment I'm favouring plain white, but I do have days where I fancy an extreme colour e.g. Renault Clio Alien Green, or a vivid orange.

3M hi-vis-jacket yellow :D

[Lewis.]

3M hi-vis-jacket yellow :D

but in summer it will just be black because of all the little bugs lol

if you want white, Colin, then what about Ford Diamond White? (the new shade, from the Focus RS, not the old one from the transit) It's a pearlescent, and a really bright white, with a slight hint of blue about it.

[Ben]

i think white with graphics is the way to go, problem with bright flashy colours is they look ace when straight out the gun but after a season of racing it will look awful.

[novarally]

but in summer it will just be black because of all the little bugs lol

if you want white, Colin, then what about Ford Diamond White? (the new shade, from the Focus RS, not the old one from the transit) It's a pearlescent, and a really bright white, with a slight hint of blue about it.

I think they call it Frozen White, and I do really like it. It's a strong contender.

[Paul]

Check my WIP out, mines been painted in frozen white

[SR-Rally]

I like it red. White nova's look great but it's the most common colour nova track/rally car now. Although I've heard White is lightest colour so will save waight lol :)

[c20tbo]

Grey is the new white, some lovely greys out there ie, stornaway grey ect

[Mike]

Frozen white is a lovely colour. Im also quite liking that Range Rover Sport off white too.

[novarally]

Im also quite liking that Range Rover Sport off white too.

Must have a closer look at that one, as Paul has beaten me to it on the Frozen White.

[Lewis.]

I think they call it Frozen White, and I do really like it. It's a strong contender.

ah yeah thats the one. Its just so expensive being perlescent :(
And remember, white paint covers better than any other colour, so less coats means less weight lol

[scott.parker]

New BMW's and Audi's have a nice white with hint of blue.

[novarally]

Bit of an update coming tonight, with less than 2 weeks to go to the first race of the season there's still a lot to be done.

If anyone has rose-jointed track rod ends on their Nova, please see my post in 'Mechanical'. Thanks.

[novarally]

The new lift is proving invaluable;

http://i285.photobucket.com/albums/ll66/hillclimbescort/075.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/078.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/100.jpg

I've fitted the quick rack and rose-jointed track rod ends today, and changed the starter motor for a lighter weight one. Both these would have been miserable jobs on axle stands.

http://i285.photobucket.com/albums/ll66/hillclimbescort/090-1.jpg

The new turbo unit;

http://i285.photobucket.com/albums/ll66/hillclimbescort/076.jpg

Big hole in the boot, that is about to be filled with a carbon fibre sheet. My other half has been making herself useful making the template for it;

http://i285.photobucket.com/albums/ll66/hillclimbescort/097.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/089.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/088.jpg

The carbon sheet has now been cut out and I will post up some photos of that tomorrow.

Also fitted a different oil catch tank, which is a bit lighter and neater than the previous one;

http://i285.photobucket.com/albums/ll66/hillclimbescort/087.jpg

And the new tiny lithium battery is now installed too;

http://i285.photobucket.com/albums/ll66/hillclimbescort/098.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/099.jpg

[novarally]

And a few general shots of where it's got to so far............it now has a carbon fibre Recaro seat, which is 2.5kg less than the fibreglass one I had previously;

http://i285.photobucket.com/albums/ll66/hillclimbescort/096.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/091-1.jpg


Note the gold heat reflective sheet on the sill to protect from the new exhaust location. I've also used this heat mat on the battery.

http://i285.photobucket.com/albums/ll66/hillclimbescort/095-1.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/094-1.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/093-1.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/092-2.jpg

[mowgli]

colin, where is the 1st event at?

[Spudly]

Colin i hate you lol



Me and Rob wouldve given anything for the use of a two poster this weekend doing the xe swap out of my cav, which barring wiring is done (i hope lol) as Mike asked though when and where is the first event?

[novarally]

colin, where is the 1st event at?

In Wiltshire (near to Salisbury), at Gurston Down. It's a 2-day meeting, Saturday/Sunday 16th and 17th April.

I'll see how it goes there, as that's going to be something of a test weekend for the revised car, and then I plan to book in some more local events, e.g. Harewood, Mallory, Cadwell.

Tomorrow's main job is to replace the gear cluster with the Quaife straight cut one, but I also need to fit the new polycarbonate windows, and the rear quarters of the wide arch kit.

[General Baxter]

Me and Rob wouldve given anything for the use of a two poster this weekend doing the xe swap out of my cav, which barring wiring is done (i hope lol) as Mike asked though when and where is the first event?

looking at it, you would of lifted the cav up and it would have broken in half

HA HA HA HA lol

[mowgli]

sod & bugger colin... i'm booked for an almighty pissup/reunion in oxford on the 16th... i doubt the missus would allow me to pop down & support you...

[Spudly]

looking at it, you would of lifted the cav up and it would have broken in half

HA HA HA HA lol




Stop spamming Colin's thread, Pug boy:p

[Harvey]

Keep at it Colin your nearly there.

[peester]

this is the business now, great work

[M Sutton]

Looks like that will be fun to drive! Keep the updates comming.

[novarally]

Keep at it Colin your nearly there.

Thanks Harvey, it is getting nearer to ready, after a lot of hours on it this week.

I fitted the Quaife straight cut gear cluster last night, and also documented all the gear ratios compared to what I had previously.

I've changed the brake reservoirs over from being remotely mounted (under the bonnet), to feeding directly into the master cylinders. This has saved the weight of the pipework and some unions, plus they hold less fluid, so there has been roughly a 350g saving. Not much but it all helps.

The 2mm polycarbonate windows are now installed in the doors, but I still have to do the rear side and tailgate window. They're on the dining room table now awaiting the painting of a black border around the edge of them (to hide where they will be bonded to the shell).

All the traditional alloy sliding bonnet pins have been removed and replaced with a revised design with 'R' clips (photos soon), and that's saved another 200g.

The wide arch front wings and kevlar door skin for the passenger side have been painted and fitted. The painting was done by me so it's rather amateur, but the long term plan as mentioned is to get the whole car stripped and painted anyway, so my dodgy rattle can painting has had to suffice for now.

I still have to fit the wide rear arches........I'm not looking forward to cutting out the metalwork and rivetting those on, it's got the potential to look rubbish as there will be no time for professional finishing of the job!

[MK999]

Just make sure the riveting is neat and evenly spaced colin and it will look a nice rough and ready track weapon style

http://img361.imageshack.us/img361/3782/porsche993p73xy9.jpg

Be just like that I'm sure! :d

[burgo]

i assume you will be weighing it again once your done?

[novarally]

Be just like that I'm sure! :d

I wish..........

I haven't got a lot of influence over the rivet spacing, as the rear arches I'm using have been fitted on a car already, and are therefore pre-drilled.

[mowgli]

can i suggest self tappers instead? or even plastic trim clips... so the wings will be removeable for repair/replacement in the event of a prang

[novarally]

i assume you will be weighing it again once your done?

I certainly will, my corner weight scales have just come back from being repaired, so it will be very interesting to see what the weight comes out at.

It will be slightly heavier than the ultimate incarnation, as I'm not yet ready to fit the 13" split rims on the front (drive flanges need to be re-drilled to suit the 4" PCD of the Mini wheels), and the 6-pot caliper and solid disc brake conversion for the front end is not quite completed.

[novarally]

Just a handful of photos;

The new carbon fibre floor;

http://i285.photobucket.com/albums/ll66/hillclimbescort/070411072.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/070411073.jpg

The direct mounted brake reservoirs;

http://i285.photobucket.com/albums/ll66/hillclimbescort/070411074.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/070411091.jpg

I need to get hold of a matching AP master cylinder and reservoir to do the clutch circuit to match.

My efforts at painting the front wings. I will not be seeking a career in this field;

http://i285.photobucket.com/albums/ll66/hillclimbescort/070411076.jpg

And the carbon fibre Recaro now fully mounted;

http://i285.photobucket.com/albums/ll66/hillclimbescort/070411075.jpg

[burgo]

floor looks awesome

[mk1nova_rich]

Looking good Colin, I'd be happy if I could paint as well as that lol