985cc Turbocharged Nova Sprint Car

[novarally]

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

The front wings are the best of a bad bunch. You will note I haven't posted any photos of the passenger door..........

I'm going to have to have another go at that tomorrow.

[novarally]

The old bonnet pins;

http://i285.photobucket.com/albums/ll66/hillclimbescort/076-1.jpg

And my new lightweight version;

http://i285.photobucket.com/albums/ll66/hillclimbescort/077-1.jpg

[lee303]

looking great colin!
did you have any issues bleeding the brakes with the master cylinders being level if not below the height of the callipers?
i nearly went that way on mine but heard of bleeding issues and also long pedal caused by the fluid draining back to the master cylinder more easily, probably be fine but thought it worth mentioning in case you come across a brake issue

[lee303]

oh and if you do find you get a long pedal with the new setup, you can fit these in line to stop it happening
http://www.rallydesign.co.uk/product_info.php?cPath=562_596&products_id=4081

[novarally]

looking great colin!
did you have any issues bleeding the brakes with the master cylinders being level if not below the height of the callipers?
i nearly went that way on mine but heard of bleeding issues and also long pedal caused by the fluid draining back to the master cylinder more easily, probably be fine but thought it worth mentioning in case you come across a brake issue

I can't comment on that as I haven't bled the brakes yet.

I must admit I hadn't considered the height, but plenty of race cars use floor mounted pedal boxes with direct reservoirs. Thanks for drawing my attention to it, if I get any problems it's certainly something to think about.

[novarally]

oh and if you do find you get a long pedal with the new setup, you can fit these in line to stop it happening
http://www.rallydesign.co.uk/product_info.php?cPath=562_596&products_id=4081

Thanks for that, I hope I don't have a problem as I have enough to get done to the car without having to order more bits, wait for them to arrive and then get them plumbed in and tested!

[lee303]

yeah like i say it may well be fine, but i know that quite a few of the prototypes run the residual pressure valves to get rid of the need to double pump the pedal, at least you wont be scratching your head if you do find a problem:wtf: but can appreciate the hassle it may entail isn’t what you need right now!

[BRoadGhost]

Colin ~ depending on ride height you might want to put the RJ rod ends under rather than over on the knuckles.

[novarally]

Colin ~ depending on ride height you might want to put the RJ rod ends under rather than over on the knuckles.

Thanks.

We did all the geometry and corner weights yesterday, and the steering arms are perfectly flat with the TRE above the knuckle, and just a thin washer under the rose joint to prevent any binding up on metal to metal contact.

Straight out of the box the corner weights were within 2kg on the diagonals.

It was weighed without the exhaust system, doors, rear bumper or the rear side/tailgate windows.

And the total weight was..............drum roll............540kg.

I reckon those bits that need to be bolted back on will weigh 25-30kg, so my target weight of 570kg certainly seems to have been achieved.

I'll weigh it again once everything is back on the car just to be sure.

Once the split rims go on the front, and I get the lighter weight front brakes fitted, there should be another 10 to 15kg to come off the total. Happy.

[Ben]

That is a good result, all your pinching and stealing 100-200grams here and there have certainly added up without taking anything away from the overall car.

[fearless]

Good result so far Colin

Without going back through 101 pages - what was the weight when you first started ?

[novarally]

Good result so far Colin

Without going back through 101 pages - what was the weight when you first started ?

Off the top of my head it was 614kg.

[Prey]

Was great to see this in the flesh, great bit of kit - and cheers for the tour colin - i'd love your place!

[novarally]

Got the brakes bled yesterday, and the wide rear arches pop rivetted into place.

It's not going to be looking terribly pretty for the racing this weekend, as I won't have time to get the arches blended in and professionally painted.

A few aerosols of red paint will have to suffice.

It's a shame as there might be a TV opportunity, as 'Fifth Gear' are there (at Gurston Down) to film Tiff Needell driving the Ariel Atom V8.

I took the Nova for the first test run since doing all this work, and it's much quicker than before.

Unfortunately I have issues with the brakes.......the new KAD discs on the back are locking up too early, and no amount of fiddling with the bias valve seems to help.

Further experimenting will continue today on the brake rollers at the local MoT station.

I'm not sure if the bias valve is to blame (it was OK last season), or whether these discs are just too efficient, especially when coupled with the weight loss that's happened at the back end.

I've got another bias valve I can try, but failing that I think the only cure (short-term), is to somehow reduce the efficiency of the rear brakes, possibly by removing part of the rear brake pad area.

[Stuart]

you could get some lairy as feck pads that need a LOT of heat in them to start working.... That way the fronts will do the bulk of the work until the rears get a little heat in and they start to do their job.

[mowgli]

if you are really struggling, you could grind some grooves in the pads or remove some pad material

[MK999]

edit: read something wrong.

[Ben]

or a well placed air bubble!

[Stuart]

Does he REALLY need rear brakes at all though.... So vaugely working ones will be more than adequate imho





or a well placed air bubble!


CP's old trick after he fitted Wilwood two pots on the rear lol

[Ben]

i agree for years very inadequate drums served novas well, rear discs are purely a vanity modification on nova's (obviously in this instance its for weight saving).

[Paul]

Not sure if this will work, but Put that second bias in, after the first?

[Stuart]

Most bias valves work on a stupid setup where no matter what you set the valve to they let past (for example) 100Psi and then reduce the line pressure after that depending on the valve setting.

IF you have lock up problems at 85Psi (for example) then no amount of bias valves will help.

[Paul]

On my wilwood one i tested it braking on bends turning it by half a rotation per time til it didnt lock the rears.

I dont know how they work, but if you max out the first one, then reduce it again to let less through the second one, but it may already be maxed out so to speak?

[Ben]

if they limit the pressure then 2 valves limiting ot 80psi will be the same as 1

[Stuart]

If they both only START limiting from 100psi (example) then having 10000000000000 of them wont help if you lock at 80psi.

[Harvey]

This could help click me (http://www.merlinmotorsport.co.uk/p15285/HYDRAULIC-BRAKE-LINE-LOCK/product_info.html) as it actually locks the line. It might be as efficient the other way round and limit the rear pressure more than an adjustable bias valve can.

Colin, I'm assuming you're also running a fixed in-line bias valve for the rear like on the stock Nova? if not fitting one might help.

[Paul]

Ok, if they limited a % through it would have worked, but they dont. As i said i didnt know how they worked.

[jonn]

could you fit a valve that can stop fluid going to the back brakes?
on my mid engined autocross nova i have a bias valve that allows me to adjust or turn off the front brakes so i can use the brake pedal as a hand brake

[mowgli]

like i have already said, if it is over braking on the rear, you could physically remove brake material from the pad. or get a different sized master cyl for the rear

[Stuart]

Removing pad material wont 'lose' much braking imho... The pads are small and assuming the contact is in the middle of the pad he will wind up taking the top 75% off the pad, it will sit wonky and really go wrong when braking, so the upper 25% would need leaving on too, which will result in more force on the outer edge.

tbh just adding a layer of grease might reduce things enough

[novarally]

tbh just adding a layer of grease might reduce things enough

I did consider that......

But fortunately it looks like the problem is now solved.

I ran it on the brake rollers at my friendly local MoT station, and the back brakes were locking up with almost no pressure on the pedal.

And it didn't seem to make a blind bit of difference on where the pressure valve was adjusted to either. Also, rather worryingly there was no physical 'stop' on the valve, so you could actually unwind the knob completely out of the valve (and then spray fluid over the whole interior!).

So I pinched the AP Racing pressure valve off my Fiesta circuit race car, and installed that in the Nova.

With the brakes bled and back on the rollers, there was an immediate improvement, as I needed to properly stand on the pedal to lock the backs up.

On the (private, naturally) road it pulls up nice and square, and all seems well, steering nice and straight and pulling right up to the rev limiter in 5th (about 115mph, although I really must work it out properly).

[mowgli]

Removing pad material wont 'lose' much braking imho... The pads are small and assuming the contact is in the middle of the pad he will wind up taking the top 75% off the pad, it will sit wonky and really go wrong when braking, so the upper 25% would need leaving on too, which will result in more force on the outer edge.

tbh just adding a layer of grease might reduce things enough

the grease idea will make a mess of the pad.

i'm serious about cutting the area down, it was a method used lots when everyone had drum brakes & there weren't off the shelf bias valves.., i'm not on about simply hacking it, more like a spot of cnc machining..

[Stuart]

simply reducing the pad area wont necessarily change the actual braking effort... just increases pad wear. Like I said, if you only had the smallest diameter part exposed then yeah reduced braking effect (marginally as its not going to be far from the pressure centre), but you may get a wonky pad when trying to stop.

Seems like using a proper inline limiter has worked, what was the one you had before? a tilton etc?

[novarally]

Seems like using a proper inline limiter has worked, what was the one you had before? a tilton etc?

I have no idea who made the previous one, it was absolutely tiny, with no markings on it to indicate a manufacturer. I will post up a few photos shortly, I would be curious to find out.

We carried out some rudimentary testing of the 2 valves by blowing through them, and the one which was on the car originally offered no restriction to the amount of air flowing through it.

The AP one which is now on the car is much more substantial, and heavier, but it works!

[novarally]

This was the valve which came off the car (the one that was faulty). Anyone recognise what make/origin it has?;

http://i285.photobucket.com/albums/ll66/hillclimbescort/016-22.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/017-25.jpg

And this is what's been fitted now (being bigger the brake pipe is now too long so it isn't fitting quite straight);

http://i285.photobucket.com/albums/ll66/hillclimbescort/018-24.jpg

[Stuart]

Looks like a tilton style one.

The blow test also implies its the type that has a 'free flow' rating then the adjust simple changes how much it limits after a given pressure.

[novarally]

Looks like a tilton style one.

The blow test also implies its the type that has a 'free flow' rating then the adjust simple changes how much it limits after a given pressure.

The design certainly looks similar to Tilton (here's a photo of the latest version);

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

It seems brake pressure valves are very much prone to faults/failures, I spoke to 2 of my racing friends this morning, and both of them have knackered valves sat in drawers......

[gary_808]

old valve looks identical to pneumatic restricters we use at work.

[Ben]

old valve looks identical to pneumatic restricters we use at work.

thats all they are.

[calibra-keith]

Hi Colin how did you get on at Gurston Down ?

[novarally]

Hi Colin how did you get on at Gurston Down ?

Hi Keith,

It was an excellent weekend thanks, 3rd place on Saturday (with a new personal best time for this car), and then a 2nd place on Sunday, with another improvement on my PB.

There's a bit of a report at this link, and you can also access a PDF file with all the times on it if you are really bored!;

http://gurstondown.org/latest.htm

The Mini of Neal Masters that was always beating me last season was the one quicker than me again, he has a brand new KAD works engine for this season, with all steel bottom end and 9,200 rpm capability.

It's a monster, he's pulling out between 4 mph and 7mph on me at the 2 speed traps at Gurston.

I have a few more developments to implement before the next race, which I think will just about put me on equal terms with him.

I'm going to fit ARP rod bolts and whack the rev limiter up from the current 7,500 to 8,000.

That should allow me to hold onto 4th gear for long enough to avoid the 2 changes to 5th I was needing to make with the new Quaife gear cluster fitted.

I may also try and find a longer 4th gear ratio, but that could prove tricky as Quaife no longer make parts for the F10 'box.

Apart from that I was suffering a leaky brake bias valve (leaking from the unions), so I need to sort that out, and the new lightweight lithium race battery only held charge long enough for 2 race runs before it gave up!

[lee303]

sounds like you had a great day, excellent result too!:thumb:

[Paul]

Are you allowed to use a steel bottom end? Lairier cam and rev it harder? Nitrous etc?

[novarally]

Are you allowed to use a steel bottom end? Lairier cam and rev it harder? Nitrous etc?

Nitrous is not permitted.

An all steel bottom end is totally ok, it's just I don't have the money for one.

[mowgli]

http://www.tsl-timing.com/sprint/2011/111584.pdf

page 58/59 gives times for the meeting. colin needs to find about 0.4sec to head the class, but just check out the other stuff that the little nova whalloped on the hill.

[Connor]

Good results Colin, you can only get quicker

[rallypvc]

Any fresh pics or vids from the event Colin?

[novarally]

Any fresh pics or vids from the event Colin?

I've put out a plea on the main hillclimb website for videos (I'm keen to see it myself!).

If I get anything I will post them up on here.

[mowgli]

i guessed you were pretty busy trying to go up the hill quickly and not trying to get piccys.... any tyre warmers allowed in your class?? cos your motor must be pushing out at least what the mini has..

[novarally]

i guessed you were pretty busy trying to go up the hill quickly and not trying to get piccys.... any tyre warmers allowed in your class?? cos your motor must be pushing out at least what the mini has..

No tyre warmers allowed in hillclimbs or sprints.

According to the rolling road at BTEC Racing I have 220bhp at 8,188rpm.

But I have it rev-limited to 7,500, where it is showing 195bhp - precisely the same as I am told the KAD Mini is producing.

So getting the revs up is a definite priority so I can see some more power, and benefit from holding on to gears for longer.

[rallypvc]

Hi Keith,

It was an excellent weekend thanks, 3rd place on Saturday (with a new personal best time for this car), and then a 2nd place on Sunday, with another improvement on my PB.

There's a bit of a report at this link, and you can also access a PDF file with all the times on it if you are really bored!;

http://gurstondown.org/latest.htm

The Mini of Neal Masters that was always beating me last season was the one quicker than me again, he has a brand new KAD works engine for this season, with all steel bottom end and 9,200 rpm capability.

It's a monster, he's pulling out between 4 mph and 7mph on me at the 2 speed traps at Gurston.

I have a few more developments to implement before the next race, which I think will just about put me on equal terms with him.

I'm going to fit ARP rod bolts and whack the rev limiter up from the current 7,500 to 8,000.

That should allow me to hold onto 4th gear for long enough to avoid the 2 changes to 5th I was needing to make with the new Quaife gear cluster fitted.

I may also try and find a longer 4th gear ratio, but that could prove tricky as Quaife no longer make parts for the F10 'box.

Apart from that I was suffering a leaky brake bias valve (leaking from the unions), so I need to sort that out, and the new lightweight lithium race battery only held charge long enough for 2 race runs before it gave up!

Don't know the full spec of your engine Colin but if you haven't already have you thought of having the crank lightened balanced and knife edged? I had this done and was quite supprised by the result it allowed me to push my rev limit up 250rpm and made power more accessible by making the engine rev quicker it reached optimum power range quicker and with the extra 250rpm allowed me to use it for longer. I'm sure with a knife edge crank and arp bolts you should be able to use 8250rpm the only drawback was a slight loss in torque on my n/a engine was 2ft lbs but I'm sure with a turbo engine it would prob be less.
And the best part was it only cost £285 which I thought was not bad

[novarally]

Don't know the full spec of your engine Colin but if you haven't already have you thought of having the crank lightened balanced and knife edged? I had this done and was quite supprised by the result it allowed me to push my rev limit up 250rpm and made power more accessible by making the engine rev quicker it reached optimum power range quicker and with the extra 250rpm allowed me to use it for longer. I'm sure with a knife edge crank and arp bolts you should be able to use 8250rpm the only drawback was a slight loss in torque on my n/a engine was 2ft lbs but I'm sure with a turbo engine it would prob be less.
And the best part was it only cost £285 which I thought was not bad

The bottom end of my engine is all standard components - 1200 block, sleeved down to reduce the capacity. Austin Metro van pistons, 1200 crank, 1200 rods, ordinary rod bolts, standard flywheel.

So there would be loads more to come if I bit the bullet and modified the bottom end properly.

But the whole point of getting this Nova was to reduce the costs of going racing, at least compared to the 500bhp Escort Cosworth I used for 4 years, and which cost me an arm and 2 legs.

I could very easily blow £5k+ on a new bottom end for the Nova, which would allow me to rev it up to 9k and probably see 250bhp, but I can't justify spending the money on it.

So I shall spend £60 on some ARP rod bolts and raise the rev limit, and hope that gets me even closer to the front.

To be honest it's just a question of when the engine cries enough, it's inevitable it's not going to stand the abuse it gets forever (and it's already old!).

[rallypvc]

Fair play I know what you mean I think I lose a grand each time I lift my bonnet! Lol

Just thought it was an idea while you had the bottom end opened up to do the bolts

[tony k]

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!

Hello Colin how's things,my mate txted me a picture today of his mates nova,he just bought,thought I had seen it before that yellow wide arched one in the backround

[calibra-keith]

I've put out a plea on the main hillclimb website for videos (I'm keen to see it myself!).

If I get anything I will post them up on here.
i have looked a few times and this is the closest i got (i think its you in background ?)

http://www.youtube.com/watch?v=MBX625yp3m8

hope someone finds a video

[hotrod192]

looking cool

[novarally]

Time for a small update.

I've removed the wide arches from the back (these were only ever temporary);

http://i285.photobucket.com/albums/ll66/hillclimbescort/001-6.jpg

And this morning these rather lovely carbon fibre wide rear arches landed with me;

http://i285.photobucket.com/albums/ll66/hillclimbescort/002-39.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/003-42.jpg

The new carbon ones are well under half the weight of the fibreglass ones I've removed, at just over 1kg each.

I've got the braking system in pieces at the moment, waiting for my new solid discs to be made along with revised caliper mounting brackets.

The injectors are away to be tested and cleaned (just a precaution).

And I need to get some more gearbox oil, as I'm going to swap the final drive from the current 4.5 to a 4.18, which should help to save me a couple of gearchanges when I go back to Gurston Down hillclimb at the end of the month, for the British Hillclimb Championship meeting.

[toymex]

I like the rear arches Colin can i ask where you got them and how much ,can you get the fronts in carbon too

[novarally]

I like the rear arches Colin can i ask where you got them and how much ,can you get the fronts in carbon too

They're from PB Fibreglass in Darlington (Phil Baines).

Phil has done all my composite panels over the past 8 years, and supplies many of the rallycross guys.

Yes, he can do the front wings as well, and I intend to get him to do me some ultra lightweight ones of those when funds allow.

He did the pair of rear arches for me for £280. I can't promise he will do the same for someone else though.

[thedjse]

Those arches look reallyyyyyyyyyyyy nice love this project Colin

[MK1_Ben]

To be honest it's just a question of when the engine cries enough, it's inevitable it's not going to stand the abuse it gets forever (and it's already old!).

It is, Hasn't the car been doing the rounds on Ebay for years? I'm pretty sure I remember seeing it on there a few years back.

[novarally]

I like the rear arches Colin can i ask where you got them and how much ,can you get the fronts in carbon too

I spoke to Phil Baines just now, and he has quoted me £500 for the pair of carbon front wings together with the GSi-style front bumper with grille.

The wings and bumper/grille are all designed to be fitted as one piece.

I'm a bit reluctant to leave the Mk.1 styling behind me, but it may be necessary as this would save me another few precious kg.

[novarally]

It is, Hasn't the car been doing the rounds on Ebay for years? I'm pretty sure I remember seeing it on there a few years back.

Soon after I bought this Nova (back in 2009) I did advertise it on EBAY a few times. I got distracted by a Westfield or two which I thought would be more fun to race.

But I had nothing but cretins bidding on it who thought they were going to buy it for £2k.

Thank God I decided to keep it, and sold the Westfields instead.........

[toymex]

I spoke to Phil Baines just now, and he has quoted me £500 for the pair of carbon front wings together with the GSi-style front bumper with grille.

The wings and bumper/grille are all designed to be fitted as one piece.

I'm a bit reluctant to leave the Mk.1 styling behind me, but it may be necessary as this would save me another few precious kg.

Colin when you decide to have the fronts made can you let me know as depending on funds i would be interested ,would he be able to put a lip of about 2 inches around the wheel aperture as the normal wide arches are not wide enough to cover my wheels
Many thanks:thumb:

[ryansnova]

i LOVE they back gold wheels lol

[novarally]

Colin when you decide to have the fronts made can you let me know as depending on funds i would be interested ,would he be able to put a lip of about 2 inches around the wheel aperture as the normal wide arches are not wide enough to cover my wheels
Many thanks:thumb:

Sounds like you need the EXTRA WIDE wheel arches like the set I sold to Steve Porter recently.

If you're not familiar with it, check out his Project thread (four wheel drive Nova).

Steve has the moulds for the front wings, and I know he was considering getting a set made up in carbon, so it would be worth having a word with him.

[novarally]

A trial fit of the new rear arches;

http://i285.photobucket.com/albums/ll66/hillclimbescort/035-4.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/036-4.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/037-5.jpg

The way they fit is a bit different to the previous ones, and as you can see it overlaps the rear light area in a rather odd fashion. I'm not quite sure how I'm going to deal with this yet.........I could cut the arches down to meet the rear light aperture, or I could extend the tailgate to meet up with the rear light 'covers' on these arches.

[Ben]

those wings look very high quality!

[MK1_Ben]

"Trial Fit" See; Tape on. :)

They look bloody awesome, I'd personally say cut the arches to meet the aperture, as that's surely lighter than extending the boot?

[toymex]

I cut mine around the rear light aperture but found the arch doesnt quite meet the existing rear quater near the light, if that makes sense ,you could probably persuade it to meet but as its a race car i wasnt too fussed

[calibra-keith]

its a shame the light area didn't carry a little then you could of just put some light decals on

jealous of you colin lol i need to earn more money

also are they the same size as the F/G ones and what size wheels you using think i missed that part.

[novarally]

its a shame the light area didn't carry a little then you could of just put some light decals on

jealous of you colin lol i need to earn more money

also are they the same size as the F/G ones and what size wheels you using think i missed that part.

Hi Keith,

Agreed, it would have been nice if the mould had been just a little bigger so it could have blanked out the whole of the rear light aperture.

The flare of the arch is identical to the normal 'rallycross' style kit (i.e. the same as the ones on your Nova).

My rear wheels are 7" x 13", I can't tell you what the offset is offhand, but they fill the arches absolutely perfectly (by luck, rather than judgement).

[CoolTiger]

extend boot out imo cut out back end of each quarters aswell,

what's regs say replacement of corried metal if your not allowed to cut anything between hubs?

[novarally]

No updates for the moment, but just a note to mention that I will be taking this Nova to the PNG Nationals weekend in Derbyshire.

I suspect it will be in an unfinished state though, unless a miracle happens and I get it all put back together and painted in time.

And don't forget to watch 'FIFTH GEAR' on Channel 5 tomorrow......they were filming at Gurston Down hillclimb when I was there recently, so you never know, you might spot the Nova in the background.

[ryansnova]

do you know wit time mate lol

[Graeme]

19.30 just Sky+'d it myself

[ryansnova]

thanks..... i will be watching that lol lol

[rallypvc]

No updates for the moment, but just a note to mention that I will be taking this Nova to the PNG Nationals weekend in Derbyshire.


When and where is this event in Derbyshire can anyone tell me???

[mowgli]

When and where is this event in Derbyshire can anyone tell me???

may2012... its fully booked for this year........oh, and pay the membership subs, and its all there in the club section.

[calibra-keith]

did you see the post i made with youtube link Colin a page or two back? im sure its you in background, only one i found.

[novarally]

did you see the post i made with youtube link Colin a page or two back? im sure its you in background, only one i found.

Yes, it is me, I still haven't manage to find any footage of my car in action.

[rallypvc]

Yes, it is me, I still haven't manage to find any footage of my car in action.

Shopping list-:

In car camera

Maybe Colin?

[mowgli]

/\ weight.....

colin has lightened the whole car, sometimes by grams..

[rallypvc]

/\ weight.....

colin has lightened the whole car, sometimes by grams..


Found this

http://www.spytechs.com/spy_cameras/fly-cam.htm

Ultra light weight 30grams! Used on rc helicopters

[mowgli]

too heavy.... he even has to go for a slash before each run just to make sure....

[rallypvc]

too heavy.... he even has to go for a slash before each run just to make sure....
:thumb: lol

[novarally]

Small update, as there are lots of ongoing jobs on the car at the moment, and not a lot of them are finished.

Over the last few days I got around to sorting out the rocker cover. Ever since I got this Nova, the rocker cover gasket has leaked, and has been replaced several times.

It's the old cork type gasket as used with the metal smallblock rocker covers, which are clearly just terrible at sealing. I have to tighten the bolts down after every race (less than 40 seconds sometimes), as they just come loose.

So I've now changed to the later style plastic rocker cover which has the rubber 'O' ring style gasket;

http://i285.photobucket.com/albums/ll66/hillclimbescort/001-7.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/003-43.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/002-40.jpg

You can see where I've modified it to fit the breather unions in to the top, and where some bits of plastic have been welded onto the inside of the cover to act as splashguards to stop oil going directly out of the breathers.

The eagle eyed may spot that the splash guards have been cut out of an Ecotec engine cover..........

With a splash of paint and a bit of carbon fibre cut for it, it looks quite presentable;

http://i285.photobucket.com/albums/ll66/hillclimbescort/004-36.jpg

Hopefully this will solve my leakage problem..........and the plastic rocker cover is over 200g lighter than the aluminium one, so it's all good.

And I've also fitted one of those 'Aero' wipers, which was all of 40g lighter than the previous wiper blade;

http://i285.photobucket.com/albums/ll66/hillclimbescort/005-30.jpg

[Mazz]

Every little helps I suppose!

[novarally]

I'm currently relocating the battery to the passenger footwell, and upgrading the battery cables at the same time as they were a bit weedy in my view (and the view of others too).

I'm also taking the opportunity to wire in an Anderson plug so I can start the car each time off a slave battery, and save discharging my ultra lightweight and very small race battery.

I am not happy about the weight being added, but it has to be done to aid reliability.

The revised front brakes should be with me next week, the other major job which is in progress is (again!) fitting the wide rear arches.

I'm also waiting on some different 15" wheels for the front, as I sold the Compomotive MO's which I was using. The plan long term is to have a set of 15" split rims made to my requirements, assuming that I am happy with the gearing after the change to a 4.18 final drive.

[lee303]

looking great colin, are you allowed to ditch the wiper all together and just run rain-x or at least remove the arm for dry runs?

[scott.parker]

How does that windscreen look from inside, as i can see a few slight scratches on it, my plexi rear window has some scratching and it gives a haze glare etc..

Looks like your really starting to get things together now mate, just a quick question, what was the start weight of the car when you bought it, and what has it decreased to now?

Scott

[Mike]

Good shout on an Anderson setup :thumb:

[mowgli]

colin, i can't remember if you run an alternator or not?

[novarally]

looking great colin, are you allowed to ditch the wiper all together and just run rain-x or at least remove the arm for dry runs?

No, the wiper arm has to be there at all times.

[novarally]

How does that windscreen look from inside, as i can see a few slight scratches on it, my plexi rear window has some scratching and it gives a haze glare etc..

Looks like your really starting to get things together now mate, just a quick question, what was the start weight of the car when you bought it, and what has it decreased to now?

Scott

The windscreen has been polished to try and get some of the scratches out, and it's not too bad, but now looks worse after it got sprayed with brake fluid when the pressure valve failed!

The screen is on the 'to be replaced' list, but I can't justify the expense right now. It's £250+ for a new one.

I'm going to hold fire until I strip the whole car for re-painting, and then I will bond in a new screen and do away with the heavy rubber.

When I got the car it was 614kg (if memory serves correctly), and now it is roughly 565kg, subject to a final weighing when it all goes back together again, and my scales come back from being loaned out yet again!

[novarally]

colin, i can't remember if you run an alternator or not?

Nope, no alternator.

[scott.parker]

Yeah a scrutiner at SCRW told me you can buy a polish for perspex/plex/ploy windows to help stop/reduce it etc, cant remember the name of it though, and I'm contemplating replacing my rubber with bounded and a few screws etc, and maybe same for the rear 1/4's as i weighed the car today, needs a diet i think 800kg with halth tank fuel no driver.

Scott

[novarally]

Yeah a scrutiner at SCRW told me you can buy a polish for perspex/plex/ploy windows to help stop/reduce it etc, cant remember the name of it though, and I'm contemplating replacing my rubber with bounded and a few screws etc, and maybe same for the rear 1/4's as i weighed the car today, needs a diet i think 800kg with halth tank fuel no driver.

Scott

This is the stuff a lot of people use;

http://cgi.ebay.co.uk/Plastic-Polish-Perspex-Aircraft-Visor-Windscreen-Window-/160335254689?pt=UK_CPV_Aviation_SM&hash=item2554b9d4a1

I did have some of this polish, but the bodyshop who I used for the polishing job managed to lose it (!).

In the end they did it with a very fine cutting/polishing compound on an electric mop. It came up really well, obviously you've got to be very careful not to burn/scratch the surface.

[scott.parker]

Thats the stuff..

Cheers Colin.

Scott

[MK999]

Brasso works really well too.

[Welsh Dan]

Would a magneto based ignition setup save weight over the battery/dizzy/coil? Would one be suitable for your motor Colin?

[mowgli]

it only needs enough power for about 5 mins running then it can be recharged.

[novarally]

Last week's photos, getting ready to go off to the National Championships meeting at Gurston Down;

http://i285.photobucket.com/albums/ll66/hillclimbescort/020-18.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/021-17.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/022-14.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/023-11.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/024-9.jpg

Lack of time prevented any painting of the rear arches, and as you can see there's still some work to do to sort out the finishing off of the rear arches.

I've got some carbon fibre front wings and bumpers coming, so long term the plan is to strip and repaint the whole car (over the Winter).

[novarally]

Thursday night last week was spent fitting some ARP rod bolts, and on the way to Gurston I called in to see BTEC Racing who raised my rev limit to 8,000.

Along with the change to a 4.1 final drive, I was confident that this would allow me to get away with 2 or 3 less gear changes over the course.

Saturday morning practice seemed to bear this out, seeing some new quickest times and higher speed readings, so very happy.

Unfortunately as I approached the finish line in the early afternoon, there was a sudden drop in power..........

I was sure the head gasket had failed. We ran a compression check in the paddock (85, 110, 100, 125psi), so there was a fair bit of variation between cylinders.

We whipped the head off, to find there was no sign of head gasket failure, and nothing obvious amiss with the valves or pistons.

So now it has to be investigated further.

It would appear that the sudden loss of power is something else unconnected with the compression readings.

Very disappointing, as weather conditions on Sunday were perfect, and I know I could have taken a battle to the leading Minis.........those 2 went on to re-set the hill record 4 times yesterday afternoon!

[scott.parker]

A mate who races in quarter mile said to me anything close to 4.0 fd is about perfect for very fast acceleration and no more then around 100mph top end.

But i don't think i would want that on my xe really...

Colin thats a massive shame to here after getting it going well that something unexplained has gone and stopped you from finding it's potential, i guess these things happen as really your still testing it after getting changes made.

Hope its nothing to drastic though.

Scott

[mowgli]

check the piston heights.. you might have bent the rods..

[novarally]

Some other bits I did last week........

Re-sited the race battery and made a quick release bracket for it;

http://i285.photobucket.com/albums/ll66/hillclimbescort/003-44.jpg

And fitted an Anderson plug so that I can start the car from a slave battery and save draining the tiny race battery;

http://i285.photobucket.com/albums/ll66/hillclimbescort/005-31.jpg

Acquired a carbon fibre bonnet (trial fit in these photos);

http://i285.photobucket.com/albums/ll66/hillclimbescort/001-8.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/002-41.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/004-37.jpg

The internals of the bonnet will be cut out to leave me with just the carbon outer skin.

[scott.parker]

lol how much for the bonnet as it is now??

[novarally]

The insides of the bonnet now cut out, and roughly fitted to the car;

http://i285.photobucket.com/albums/ll66/hillclimbescort/004-38.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/001-9.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/002-42.jpg

The start of the Intercooler Spray System (awaiting delivery of a missing nozzle!);

http://i285.photobucket.com/albums/ll66/hillclimbescort/003-45.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/007-28.jpg

[novarally]

lol how much for the bonnet as it is now??

Too late Scott, I've got it on the car as you can see!

I'm delighted, it's saved me 1.5kg compared to the fibreglass bonnet.

[scott.parker]

Yes i was quick to ask there..lol

No worries, i was just being cheeky.

Scott

[novarally]

The internals of my engine..........first time I've ever seen inside it as well;

http://i285.photobucket.com/albums/ll66/hillclimbescort/005-32.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/006-33.jpg

Note the liners inside the bores and rather small pistons.

The only consolation of this disaster is that it makes getting at the starter motor and block oil breather so much easier.

So I've taken the chance to replace the starter motor with a Z18XE one (same weight, but geared to make starting easier), and I'm revising the crankcase breather to the later GSi style one.

I've also taken the opportunity to replace some of the old water hoses buried under the inlet plenum with some silicone ones.

Whilst the head is off I will also be doing some measurements on the pistons to see if there's any chance of getting a 16v head on there one day.

Thanks to Mowgli for his research on small GM 16v engines around the World!

[calibra-keith]

are the carbon front wings and bumper your getting going to be one full piece and will you be cutting out the holes on the carbon bonnet ?

dont suppose you know if any ones found or taken video of it yet ?

[novarally]

are the carbon front wings and bumper your getting going to be one full piece and will you be cutting out the holes on the carbon bonnet ?

dont suppose you know if any ones found or taken video of it yet ?

The carbon front wings and bumper are dsigned to be fitted as one piece and removed all as one. I'm going to be getting them next week so I will post up some photos.

I'm probably going to leave the bonnet as it is, I don't need the extra cooling vents, and less holes in it will mean more strength, as it's pretty flimsy as a single skin!

My friend got a video of me on the startline on his mobile phone, so I'll get him to load it up and post a link on here soon.

[mowgli]

colin, as the cutouts prove, the 1600 head is 'too big', so getting 4 little cutouts would be doable...

[novarally]

Just got off the phone to Andrew Bradley (BTEC Racing) who built my Nova and the engine in it.

He's wondering whether the problem could be down to the hydraulic lifters pumping up as a result of the new revs (8k).

I'm out of my experience here, so who knows FACTS about the rev capability of standard lifters, and whether this could explain my sudden loss of power (and the fact that it subsequently ran ok again at idle and revving it up in the paddock).......

There doesn't seem to any leakage on any of the boost hoses, which was one of my possibilities.

I still have to check the fuel pressure in case there is any problem there.

PS - my bore size measures 70.5mm

[24sevenslacker]

i believe thats my old bonnet, was waiting for an update to see what it looks like

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc4/37972_452375663707_502823707_6300329_2230604_n.jpg

[Jonlem]

I'd imagine the lifters are struggling at that rpm, possibly best to get some solids in their Colin.

Will catch up on the thread when I get home as looks like you have had one or two problems !

[mowgli]

maybe in the short term, they could do with a good clean & the oil replaced in them, cos it doesn't drain out with the rest of the engine oil when you change it..
but i'd imagine you are at the limit on hyd. lifters

[Ben]

i have always been led to believe the rule of thumb for limit of hydrulics was 7750 and anything around 8k was a job for solids!

[dhdev (Oli)]

A couple of potential weight savings I've just spotted...

You appear to have stainless overbraided rubber fuel hoses, these can be swapped with PTFE lined stainless hose or kevlar hose http://www.earls.co.uk/earls/hose/ultraflex.html

Also the brake lines are stainless overbraid throughout, solid bundy where possible is lighter and can provide better feel.

I'm also a bit dissapointed that you painted AND put a piece of carbon fibre on the rocker cover :(

Also is the intercooler spray really necessary? Surely a blast onto the cooler with a hand-held fire-extinguisher would drop the charge temps for the startline, plus you could always take a coolbox with some icepacks to cool all the piping/intercooler prior to runs and when you are moving the airflow should be sufficient :confused:

Nice to see your progressing and 565kg is a job well done! :cool:

[scott.parker]

Oli hes got it WAY below that now mate..

But im sure there is more simple savings as you say..

[dhdev (Oli)]

Oli hes got it WAY below that now mate..


What is it now then?!?

[scott.parker]

I'm not sure, but i don't think that weight is with the single skin passengers door, or the carbon skin bonnet etc..

Ask Colin, as he might know the exact weight, but I'm sure i heard it was "possibly" 25kg lighter??

[novarally]

i have always been led to believe the rule of thumb for limit of hydrulics was 7750 and anything around 8k was a job for solids!

Interesting, thanks for that Ben.

Anyone else with any information on this?

[novarally]

A couple of potential weight savings I've just spotted...

You appear to have stainless overbraided rubber fuel hoses, these can be swapped with PTFE lined stainless hose or kevlar hose http://www.earls.co.uk/earls/hose/ultraflex.html

Also the brake lines are stainless overbraid throughout, solid bundy where possible is lighter and can provide better feel.

I'm also a bit dissapointed that you painted AND put a piece of carbon fibre on the rocker cover :(

Also is the intercooler spray really necessary? Surely a blast onto the cooler with a hand-held fire-extinguisher would drop the charge temps for the startline, plus you could always take a coolbox with some icepacks to cool all the piping/intercooler prior to runs and when you are moving the airflow should be sufficient :confused:

Nice to see your progressing and 565kg is a job well done! :cool:

Fair points Oli, and the fuel lines are certainly an area I plan to look at one day.

For the moment though I can't afford to spend any more money on it, so unless it can be done for free it's not happening!

I did consider the fire extinguisher way of cooling, but I think it would be frowned upon by the organisers......

The intercooler spray hasn't been tried yet, if it doesn't prove effective in testing I will remove it, but for less than £20 it was worth trying.

As for the rocker cover, the carbon fibre and paint was a trade off of looks vs. weight. That cover still needs work as it was leaking a bit of oil from the breathers at the weekend, so I need to re-think the design of that.

By my calculations current weight is 560kg, although I can't confirm that yet as my corner weight scales STILL haven't been returned to me from their loan out to a 'friend'.

There's roughly 10kg still to come off with the new solid front disc brakes and the 15" split rim wheels I'm having made for it.

So in the end I hope to have 550kg, and there's no real scope for going anything beyond that without spending serious money.

[Ben]

just out of intrest how much time has the 15-20kg's saved you?

[novarally]

just out of intrest how much time has the 15-20kg's saved you?

Impossible to quantify, as the weight reduction has been in conjunction with better tyres, more power etc.

[MK999]

Oli hes got it WAY below that now mate..

But im sure there is more simple savings as you say..

That was when you said it was 620ish at nats, I didn't realise he'd gone below 600 now, and well below it too lol

[boffer8]

Hi Colin,

When i built my 1.2 engine in its first guise, it was running hydraulic lifters. I was recommended to go to solid lifters with the revs that i was wanting to use (8250rpm) and with the camshaft, but with only a student budget to be used, a new set of hydraulic lifters was found and fitted. The engine in combination with a kent race cam made just over 100hp at the flywheel which at the time i was vey happy with. This proved that yes, solid lifters could be used at this rev range as the power was still increasing when the 8250 was reached.

It is possible that the lifters could quite easily be allowing the valves to remain open, however what timing are you running as this in combination with some worn hydraulic lifters could cause issues.

Try removing the lifters and either cleaning them or even better replacing them with some new ones as this could help allow the oil to drain quicker and reduce the possibilities of the valves remaining open.

Another worthwhile test is as this has only just started to occur (i believe? and i am not sure what camshaft you are running) try running a milder cam or even a standard road one as with the shorter duration the effects of the hydraulic lifters are vastly reduced.

another thing is, have you checked your valves are straight as i had one that was bent that could not be seen that well and meant that it was not seating correctly reducing the compression on the cylinder

could these help you?

sorry for the spelling mistakes as i have cut me fingers and its hard to type :(

[daz_9124]

I have been following this with interest, what a special little car

I hope you resolve the current issue's with little hassle as im dying to see videos of this thing in action

good luck with the fault finding Colin

[burgo]

definitely sounds like the lifters pumping up. i over revved mine going down a hill and barely got up the other side, sat with it on tickover for a minute or two and it was back to normal. i say pikey solids being as your on a tight budget to get you back up and running

[novarally]

definitely sounds like the lifters pumping up. i over revved mine going down a hill and barely got up the other side, sat with it on tickover for a minute or two and it was back to normal. i say pikey solids being as your on a tight budget to get you back up and running

When you say 'pikey solids', do you mean something like these?;

http://cgi.ebay.co.uk/Vauxhall-8-Valve-Solid-Lifter-Rally-Car-Track-Engine-/200614559205?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item2eb58f3de5

Incidentally, I am running a standard 1600cc camshaft in this engine.

[jonn]

if you really wanted to save more weight could you replace the back window and rear side windows with carbon fibre pannels? like a nova van

[TeddyThom]

I'm not going to re-read all of these pages again lol

Got a vid of it in action Colin??

[novarally]

if you really wanted to save more weight could you replace the back window and rear side windows with carbon fibre pannels? like a nova van

Not permitted under our regulations, windows have to remain as windows, and no commercial vehicles allowed.

[mowgli]

/\ and the polycarb is plenty light enough

[JordyzNova]

is there any videos of this car doing any events i would like to see it go and be driven :thumb:

[mowgli]

When you say 'pikey solids', do you mean something like these?;

http://cgi.ebay.co.uk/Vauxhall-8-Valve-Solid-Lifter-Rally-Car-Track-Engine-/200614559205?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item2eb58f3de5

Incidentally, I am running a standard 1600cc camshaft in this engine.

they look like a lot of hard work to sort out... any bigger springs gen?

[burgo]

no pikey solid are standards welded and then shimmed lol.

that ebay set is a rip off, they have simply been drilled and tapped so how they warrant £200 asking is beyond me

i would be tempted to have a custom cam made for it as well if it was me

[novarally]

There's a set of Kent Cams solid lifters on their way to me now - thanks to Gary C for those.

I'm praying that solid lifters will solve my problems, certainly after discussing it with a lot of people, most reckon that stock hydraulic lifters are beyond their limits at 7,500rpm+.

A couple of photos of how the front end looks now with the carbon bonnet, I'm really pleased with how tough it looks;

http://i285.photobucket.com/albums/ll66/hillclimbescort/001-10.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/002-43.jpg

And another small contribution to the weight reduction.....I've re-made the Gurney flap on the tailgate in carbon fibre instead of the previous aluminium angle;

http://i285.photobucket.com/albums/ll66/hillclimbescort/004-39.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/003-46.jpg

[Ben]

Is that a different trailor again Colin?

[24sevenslacker]

did you sort the cracks out in the bonnet or have you just left them, it flipped on me last year, thats why rid of it

EDIT: whats the gurney flap for? never seen one before?

[mowgli]

google it. its a serious downforce generating flap

[24sevenslacker]

thats awesome

[db_1.2]

Is that a different trailor again Colin?

I did wonder if Colin would be able to fit it in his previous one myself.

How's the weight loss going? You any idea what it's down to now?

[Connor]

Looks so aggressive. Love this car!!

[novarally]

Is that a different trailor again Colin?

Yes, I got that one a few weeks ago.

The little Minno Shuttle enclosed trailer was a touch too small to get a Nova in safely, so I sold it on again.

The new one is a Minno Max and it's superb. It has the centre deck on it so at least it stops all the rubbish getting thrown up at the underside. And it has colour matched mudguards!

[novarally]

did you sort the cracks out in the bonnet or have you just left them, it flipped on me last year, thats why rid of it

I've filled the holes where the old catches were, but I haven't done anything with the cracks.

They will be covered up with the new graphics when I get them sorted.

[novarally]

A friend of mine just sent me a link to a few photos he took at recent Gurston Down events.

Why he took so many before the startline I have no idea;

http://s301.photobucket.com/albums/nn75/corozin/2011/Nova/

[novarally]

And for anyone curious to see what Gurston Down hillclimb looks like from inside a car, this video is my arch-rival Neal Masters driving his works KAD-engined Mini to a new Class Record last Sunday;

http://www.youtube.com/watch?v=DYNUQ7kpwZw

[scott.parker]

Holy ****, is your nova almost as quick over the stage as that? thats just silly, and the tracks so narrow!

[novarally]

Holy ****, is your nova almost as quick over the stage as that? thats just silly, and the tracks so narrow!

Yes, the Nova is only a little bit shy of that pace, and I fully expect it to be faster once I've finished development and problem solving.

[Southie]

:eek::eek: That's going some, love the stance of yours now Colin :cool:

[scott.parker]

Yes, the Nova is only a little bit shy of that pace, and I fully expect it to be faster once I've finished development and problem solving.

lol fair play to you Colin, you have bigger balls then i realised, as that video from the mini looks stupidly fast, only just enough time to react surely?

Scott

[jonn]

what sort of speed would you get upto? i think you should invest in a camera for the nova! would love to see it in action

[zeifer33]

Fantastic car, it feels like to drive?

[calibra-keith]

seen a few of his videos and the recent ones at gurston, gives a good idea of what your nova goes like Colin, i can only dream of a nova at that level


what sort of speed would you get upto? i think you should invest in a camera for the nova! would love to see it in action
if i remember correctly 80-90 mph ?

[novarally]

what sort of speed would you get upto? i think you should invest in a camera for the nova! would love to see it in action

96mph over the finish line, possibly a little more than that into and through the first sweeping left hander.

[novarally]

lol fair play to you Colin, you have bigger balls then i realised, as that video from the mini looks stupidly fast, only just enough time to react surely?

Scott

For several years I held the course record with my 450bhp Escort Cosworth, which was obviously considerably faster than the Nova!

http://i285.photobucket.com/albums/ll66/hillclimbescort/349.jpg

[novarally]

lol fair play to you Colin, you have bigger balls then i realised, as that video from the mini looks stupidly fast, only just enough time to react surely?

Scott

For several years I held the course record with my 450bhp Escort Cosworth, which was obviously considerably faster than the Nova!

[MK1_Ben]

As always, awesome progress Colin!.

Plus, the Nova looks like a proper weapon now it's carbon fibre clad on the front end :)

[RossRog]

impressive....

[ryansnova]

do you ever do eny hill climbs up in scotland colin ??;)

[scott.parker]

For several years I held the course record with my 450bhp Escort Cosworth, which was obviously considerably faster than the Nova!


I bet it was, but also i would have thought considerably more expensive to fix/work on?

[novarally]

I bet it was, but also i would have thought considerably more expensive to fix/work on?

Yes. That's why I went back to a Nova, although that isn't proving to be an awful lot cheaper!

[MK999]

That looks awesome, must build a car already lol Can you enter just for fun with a car that doesn't fit the tight regulations?

[novarally]

That looks awesome, must build a car already lol Can you enter just for fun with a car that doesn't fit the tight regulations?

Yes, there are classes for roadgoing cars, and they run a 'Hillclimb School' where you can take your road car along and see if you enjoy it.

[scott.parker]

Really any websites?

[Mike]

That is one fast mini.

Re: Escort, definetly something Id like to build one day soon.

[Mike]

Really any websites?

Loton hillclimb, Shrewsbury. Im hoping to enter Got Bored in the road cars next spring if I get the engine & car finished in time.

http://www.hdlcc.com/

[MK999]

Yes, there are classes for roadgoing cars, and they run a 'Hillclimb School' where you can take your road car along and see if you enjoy it.

I meant more track cars than my derv lol

[scott.parker]

Sweet Mike we can do png/pcg hillclimb days lol

[Mike]

Sweet Mike we can do png/pcg hillclimb days lol

Ill be more then up for it Scott if you want :)

[scott.parker]

As long as it cheeper then track days its worth doing just to use the car some...

[Mike]

As long as it cheeper then track days its worth doing just to use the car some...

£105 per event + fuel + general expenses.

Not cheap cheap, but not exactly ludicrously expensive either (unless you get a tank slapper on)

Ironically part of Loton is actually downhill anyway lol

http://www.youtube.com/watch?v=Ieysno2iuHA&feature=related

[scott.parker]

Wernt expecting the off lol

[Mike]

Un-turning S2000 is un-turning lol

[daz_9124]

Now you see why Im so keen to see this thing on video

Ive been to Lydden hill these Hill climb guys are nuts :thumb:

[Ben]

Maybe one of the keyfob spycamera's would work well for you Colin, they weigh a couple of grams!

[novarally]

http://www.youtube.com/watch?v=Ieysno2iuHA&feature=related

Loton Park is one of the events I'm keen to do once the car is completely sorted.

I like the data display on the video, I must do some research into that!

[lee303]

do you have an android based phone colin? you can get an excellent ap for them called alapHD that allows you to overlay all sorts of data and does a gps map for you to log lap, or in your case run, times and you can blue screen it and add it to any video too, think its available for the iPhone too

[zeifer33]

I have a question, what is the best position that you've gotten with this car?

[daz_9124]

Im going to Barbon for the nation B on the 18th - looking forward to seeing this Hill Climb Malraky

[novarally]

do you have an android based phone colin? you can get an excellent ap for them called alapHD that allows you to overlay all sorts of data and does a gps map for you to log lap, or in your case run, times and you can blue screen it and add it to any video too, think its available for the iPhone too

No, I've got a Blackberry (Bold 9780).

[lee303]

ah shame, as i reckon a decent smart phone is about the lightest way to get an overlay data vid from a car nowadays, i’m sure there will be other overlay software available though

[novarally]

Managed an hour on the car today, so here's a progress report;

Intercooler Spray System now piped up, filled with water and methanol, and all tested. It just remains for me to wire in a switch to activate it;

http://i285.photobucket.com/albums/ll66/hillclimbescort/010-26.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/009-24.jpg

Solid lifters (Kent Cams top adjustable) ready and waiting to be fitted to the engine;

http://i285.photobucket.com/albums/ll66/hillclimbescort/014-19.jpg

[novarally]

http://i285.photobucket.com/albums/ll66/hillclimbescort/015-20.jpg

Work in progress on the rocker cover (last time attempt was not a 100% success);

http://i285.photobucket.com/albums/ll66/hillclimbescort/016-23.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/017-26.jpg

I will plastic weld in some more oil splashguards when I'm happy that this one isn't going to leak from around the breather pipe unions.

And for a long time I've been meaning to get some lower rear springs. The originals were 11 inches long, and I had to wind the coilover platforms right to the bottom of their adjustment to get them to fit.

So I ordered some 8" ones which are much more suited, and have the added bonus of being HALF the weight of the 11" ones!!;

http://i285.photobucket.com/albums/ll66/hillclimbescort/011-22.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/012-22.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/013-16.jpg

[Royston]

Colin,

I am intrigued to know how you adjust the solid followers when fitted?

Are there any lock nuts?

Do the followers have holes in for the allen key?


See your making more progress:thumb:

[Mazz]

Rally Design springs?

[toymex]

Colin i had those Kent solid lifters in my old sport engine and had loads of grief with them keep winding themselves in ,so we but a tack of weld on them when they were set right,i am not sure how old they were so it might be an age thing but something to keep an eye on

[novarally]

Colin i had those Kent solid lifters in my old sport engine and had loads of grief with them keep winding themselves in ,so we but a tack of weld on them when they were set right,i am not sure how old they were so it might be an age thing but something to keep an eye on

Thanks, I will discuss that with the man who's fitting them for me.

Another small update, I went up to Darlington yesterday and collected these;

http://i285.photobucket.com/albums/ll66/hillclimbescort/001-11.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/002-44.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/003-47.jpg

They are incredibly lightweight, the front wings are just 1kg each.

Whilst I was in the Darlington vicinity I also had a chance to visit the Royston tractor and Nova collection, which was most interesting. Thanks to him for his hospitality.

Started by fitting the rear bumper, the rest of the kit will probably wait until I strip and paint the car at a later date;

http://i285.photobucket.com/albums/ll66/hillclimbescort/007-29.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/008-26.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/009-25.jpg

Not much else to report, the intercooler spray is all now wired in and functional, and next week it's off to BTEC Racing for the solid lifters to be fitted.

[peester]

christ. royalty status now eh lol

[burgo]

noooo mk2 fail :(

[calibra-keith]

cant wait to see them all fitted Colin, is the boot next on the carbon fiber list ?

[Royston]

Great catching up Colin;) , those panels are Uber light:eek:

Your welcome to call any time, as long as I can pop down for a rummage through your spareslol

[Edd]

Noooo mk2 stuff :(

Couldn't you of just got a early mk1 bumper/grill and snowplough moulded the same as the mk2 stuff ??

I know this nova is more for competition than looks but putting mk2 stuff on kinda takes something away from it IMO

[novarally]

Noooo mk2 stuff :(

Couldn't you of just got a early mk1 bumper/grill and snowplough moulded the same as the mk2 stuff ??

I know this nova is more for competition than looks but putting mk2 stuff on kinda takes something away from it IMO

I really didn't want to go away from the Mk.1 look myself, but there are only moulds for the Mk.2 out there, and the cost of having new moulds made for a one-off set of Mk.1 panels would have been astranomical.

[novarally]

Great catching up Colin;) , those panels are Uber light:eek:

Your welcome to call any time, as long as I can pop down for a rummage through your spareslol

Not a problem Royston, give me a shout if you're near anytime.

[novarally]

cant wait to see them all fitted Colin, is the boot next on the carbon fiber list ?

Yes, it is planned, although the weight saving will be small as the current boot is single skin fibreglass.

[Connor]

Amazing!

[novarally]

Following the fitting of the solid lifters, I was out again for a weekend of racing.

Unfortunately, all was still not well with the engine, power was way down on what it should be, so this week it has once again been delivered to, and now stripped down at BTEC Racing.

The news is not good.........

Cylinders 1 to 3 have between 70 and 75% leakage, and the best one, Number 4 has 35% leakage.

I'm told the acceptable figures would be about 25%.

One of the pistons shows signs of damage. Two of the spark plugs have been clipped by the pistons, suggesting that the strain of 8,000 rpm is too much for the bottom end (maybe a bit of whip from the crankshaft?).

So I am looking at a minimum of the bores being honed, and 4 new pistons.

But of course whilst it's in pieces anyway, it would make sense to fit some forged pistons, and if you're going to do that, then better con rods would be nice, plus a steel crank and maybe a different cam.

And I could pursue one of my other plans, which is to use a 16v head.

Of course it all depends on money, and as I have a miniscule budget left for it this season, all my ideas are largely irrelevant.

None of this is a great surprise really, the engine was getting old (over 10 years of competition work), and forcing a lot of boost through standard components was only ever going to go one way.

So the bottom line is it really needs a new engine building, if it goes back together with standard components I can't see it surviving long. The problem of course is funding it! And justifying the funding is even harder.

[novarally]

Following the fitting of the solid lifters, I was out again for a weekend of racing.

Unfortunately, all was still not well with the engine, power was way down on what it should be, so this week it has once again been delivered to, and now stripped down at BTEC Racing.

The news is not good.........

Cylinders 1 to 3 have between 70 and 75% leakage, and the best one, Number 4 has 35% leakage.

I'm told the acceptable figures would be about 25%.

One of the pistons shows signs of damage. Two of the spark plugs have been clipped by the pistons, suggesting that the strain of 8,000 rpm is too much for the bottom end (maybe a bit of whip from the crankshaft?).

So I am looking at a minimum of the bores being honed, and 4 new pistons.

But of course whilst it's in pieces anyway, it would make sense to fit some forged pistons, and if you're going to do that, then better con rods would be nice, plus a steel crank and maybe a different cam.

And I could pursue one of my other plans, which is to use a 16v head.

Of course it all depends on money, and as I have a miniscule budget left for it this season, all my ideas are largely irrelevant.

None of this is a great surprise really, the engine was getting old (over 10 years of competition work), and forcing a lot of boost through standard components was only ever going to go one way.

So the bottom line is it really needs a new engine building, if it goes back together with standard components I can't see it surviving long. The problem of course is funding it! And justifying the funding is even harder.

[mowgli]

it sounds like that upgrade was a step too far on the old bottom end.

the trouble with the 12st bottom end is that there isn't much available from later models to use, as in newer cranks/rods etc...

maybe its time to brush up on your portugese & go on brazilian eBay for a 1.0 ohc 4pot....

[Edd]

A 1.0 ohc ? What were they fitted in ?

[mowgli]

brazilian spec corsa b & c, 8v. it runs 12:1 cr on corn alcohol.....70 odd hp & revs like hell......

[db_1.2]

brazilian spec corsa b & c, 8v. it runs 12:1 cr on corn alcohol.....70 odd hp & revs like hell......

Sounds awesome. So in standard form its spi? Same head as 12st?

[novarally]

maybe its time to brush up on your portugese & go on brazilian eBay for a 1.0 ohc 4pot....

That is certainly an option Mike, and you beat me to it as I was going to contact you about it.

Where was it you found out about this engine/car combination? A specific website/magazine? Or was it just General Knowledge for you?

I need to do some more research on it.

BTEC Racing were keen to build me a 3 cylinder Corsa motor, but I don't thing there's a way I can get away with that under our Regulations;

12.6.1. The engine block must be externally identifiable as that fitted to the original model or specified option.......

Thinking out loud, the other option is to abandon the turbocharger, and stick a N/A 1400cc 16v engine in there.

But that doesn't really appeal to me, a lot of the fun of this car is it being a tiny capacity turbo.

Plus a high spec. baby XE will cost an arm and a leg, and even the best of the best is maybe 210bhp tops.

[mowgli]

see below

[mowgli]

That is certainly an option Mike, and you beat me to it as I was going to contact you about it.

Where was it you found out about this engine/car combination? A specific website/magazine? Or was it just General Knowledge for you?

I need to do some more research on it.



i was looking at corsa variants on the web one night & then found a youtube link (http://www.youtube.com/watch?v=T3Bg06hnyHk&feature=related) to a turbo 1.0 4cyl corsa in brazil, then sort of went to look for that, as i didn't think they still did a 4cyl 1.0...

and i found this (http://translate.google.co.uk/translate?hl=en&sl=pt&u=http://www.vrum.com.br/Autos%3Ftp%3DVRUM%26name%3Ddb:FichaTecnica%26fabri cante%3DChevrolet%26modelobase%3DCORSA%26anomodelo %3D2006%26codigo%3D004285-4&ei=UOMBTqOdDoTLhAfc5djgCQ&sa=X&oi=translate&ct=result&resnum=9&ved=0CFgQ7gEwCA&prev=/search%3Fq%3DX10YFH%26hl%3Den%26rlz%3D1R2ACAW_enGB 330%26biw%3D1280%26bih%3D888%26site%3Dwebhp%26prmd %3Divns)

[mowgli]

Sounds awesome. So in standard form its spi? Same head as 12st?

mpi, basically a mini c16se i think..... but if you ran it on european grade super u/l it would be crazy...

[mowgli]

here is some more tantalising info from our friends at wiki...link (http://en.wikipedia.org/wiki/GM_Family_1_engine) for full page

GM do Brasil
GM do Brasil (http://en.wikipedia.org/wiki/GM_do_Brasil) specializes on SOHC (http://en.wikipedia.org/wiki/SOHC), petrol (http://en.wikipedia.org/wiki/Petrol)-powered and FlexPower (powered with ethanol (http://en.wikipedia.org/wiki/Ethanol) and/or petrol (http://en.wikipedia.org/wiki/Petrol), mixed in any percentage) engines.

X10YFH - 1.0 L SOHC (http://en.wikipedia.org/wiki/SOHC) FlexPower - Chevrolet Celta (http://en.wikipedia.org/wiki/Chevrolet_Celta), Chevrolet Corsa (http://en.wikipedia.org/wiki/Chevrolet_Corsa) C and Chevrolet Classic (http://en.wikipedia.org/wiki/Chevrolet_Classic) (Corsa B sedan 4 doors).
X14YFH - 1.4 L SOHC (http://en.wikipedia.org/wiki/SOHC) FlexPower - Chevrolet Prisma (http://en.wikipedia.org/wiki/Chevrolet_Prisma), Chevrolet Corsa (http://en.wikipedia.org/wiki/Chevrolet_Corsa) C and Chevrolet Meriva (http://en.wikipedia.org/wiki/Chevrolet_Meriva).
X18XE - 1.8 L SOHC (http://en.wikipedia.org/wiki/SOHC) FlexPower - Chevrolet Corsa (http://en.wikipedia.org/wiki/Chevrolet_Corsa), Chevrolet Montana (http://en.wikipedia.org/wiki/Chevrolet_Montana), and Chevrolet Meriva (http://en.wikipedia.org/wiki/Chevrolet_Meriva); Fiat Palio (http://en.wikipedia.org/wiki/Fiat_Palio), Fiat Siena (http://en.wikipedia.org/wiki/Fiat_Siena), Fiat Palio Weekend (http://en.wikipedia.org/wiki/Fiat_Palio_Weekend), Fiat Strada (http://en.wikipedia.org/wiki/Fiat_Strada), Fiat Idea (http://en.wikipedia.org/wiki/Fiat_Idea), Fiat Punto (http://en.wikipedia.org/wiki/Fiat_Punto) and Fiat Stilo (http://en.wikipedia.org/wiki/Fiat_Stilo).GM Brasil also made 16-valve versions of the 1.0, 1.6 and 1.8-liter engines.

[calibra-keith]

Thats gutting Colin, but the idea of it been 1L turbo at that level is half the appeal and excitement about the car.

[Edd]

Any pics of those engines mowgli ?

Interesting stuff tbh

[mowgli]

look at the youtube linky, there's plenty of other portugese vids about these turbo corsas

http://images.ookaboo.com/photo/m/Brazilian_Chevrolet_Celta_FlexPower_four_views_10_ 2008_m.jpg

http://images.ookaboo.com/photo/m/Tanquinho_Celta_GM_FlexPower_02_SAO_10_2008_m.jpg

[novarally]

i was looking at corsa variants on the web one night & then found a youtube link (http://www.youtube.com/watch?v=T3Bg06hnyHk&feature=related) to a turbo 1.0 4cyl corsa in brazil, then sort of went to look for that, as i didn't think they still did a 4cyl 1.0...

and i found this (http://translate.google.co.uk/translate?hl=en&sl=pt&u=http://www.vrum.com.br/Autos%3Ftp%3DVRUM%26name%3Ddb:FichaTecnica%26fabri cante%3DChevrolet%26modelobase%3DCORSA%26anomodelo %3D2006%26codigo%3D004285-4&ei=UOMBTqOdDoTLhAfc5djgCQ&sa=X&oi=translate&ct=result&resnum=9&ved=0CFgQ7gEwCA&prev=/search%3Fq%3DX10YFH%26hl%3Den%26rlz%3D1R2ACAW_enGB 330%26biw%3D1280%26bih%3D888%26site%3Dwebhp%26prmd %3Divns)

Thanks Mike.

Looks like I may have to register on AllCorsa.co.uk and do some checking. I did just find a post from someone on there who's in Brazil and has one of these Corsas.

The main issue is going to be whether the block is externally identical to a 1200/1300/1600

[mowgli]

http://produto.mercadolivre.com.br/MLB-189335632-10-kit-pisto-anel-biela-bronzina-motor-vhc-e-gm-original-_JM looks interesting off brazils version of ebay

[zeifer33]

And I could pursue one of my other plans, which is to use a 16v head.

That this is possible in 1.0?:eek:

[mowgli]

That this is possible in 1.0?:eek:

it is possible with machined valve cutouts in the block

[db_1.2]

Great work on the info Mowgli, I tried to rep you, but couldn't.

[Ben]

From the photos it certainly is a close look a like for the late astra g 1.6 8v,s which in turn were nigh on the c/e16 se.

[AlexW]

They are similar bore as the 1.4 16v X14XE's, Slightly smaller as a brazilian asked for some so he could reborn his 1.0 8v.

Youtube search for 1.0 corsa turbo will bring up a good few videos.

[novarally]

OK, a plea for help.

Has anyone got English-speaking friends or relatives in Brazil?

I need to get hold of more information about these X10YFH series 1.0 OHC engines, in particular whether the engine block is of the same external design as a Nova.

Assuming I can get hold of that information, and it is the same, then I want to buy an engine and get it shipped here.

I've drawn a blank on trying to find a breaker or an EBAY seller in Brazil, so someone living there seems to be my best chance of success.

Any help welcome, and any results can be rewarded in Nova parts............thanks.

[mowgli]

as i am guilty of sending you on this course.. i feel duty bound to try & help you. i know a bloke who is married to a portugese woman, and he is pretty much fluent too, i'll go & investigate any connections they might have.

i'd imagine there are few portugese speakers in your part of the world, wherever there is vegetable picking, there are portugese people

[novarally]

as i am guilty of sending you on this course.. i feel duty bound to try & help you. i know a bloke who is married to a portugese woman, and he is pretty much fluent too, i'll go & investigate any connections they might have.

i'd imagine there are few portugese speakers in your part of the world, wherever there is vegetable picking, there are portugese people

Thanks Mike, any help much appreciated.

Round here the fields seem to be mostly filled by the Polish, and their cans of lager. I'll do some enquiring though, and see if there are any Portugese around. Someone actually in Brazil would be a bonus though!

[MK999]

Admin Lee's dad lives over in Brazil, not sure if he's fluent or there's large English speaking areas but might be worth a PM?

[mowgli]

good memory.... paint the engine grey & make out its a suitcase.... then lee can bring it home for nowt

[MK999]

good memory.... paint the engine grey & make out its a suitcase.... then lee can bring it home for nowt

We actually have a job in at work atm which is on a deadline as the guy is taking 2 Manta CIH blocks back with him to the states, I can try and ask how exactly he's doing it.

[novarally]

Admin Lee's dad lives over in Brazil, not sure if he's fluent or there's large English speaking areas but might be worth a PM?

Do we mean Lee with the blue Vito?

[MK999]

Do we mean Lee with the blue Vito?

That be him!

[Edd]

Might be worth a ask in a vauxhall dealer to see the price/avalibilty and to compare to when you get a total price for one shipped over ???

[Edd]

Or someone that has a worldwide copy of EPC will be able to see if the blocks are the same :)

My copy only does vauxhall and Opel I think, but will check later

[novarally]

Might be worth a ask in a vauxhall dealer to see the price/avalibilty and to compare to when you get a total price for one shipped over ???

It's a good point Edd, thanks. I'm on friendly terms with the local main dealer Parts people, so I will nip in there and make the enquiry.

I suppose there's also a chance that they might have access to a database with detailed photos of the block (EDIT ; which is precisely what you then went on to say in your second post!!).

[BRoadGhost]

Exciting times :)

[novarally]

Exciting times :)

Expensive times

[OllieKing]

Cracking Car! Have you considered a carbon fibre gear shift similar to the WRC focus's carbon fibre handbrake. May save half a kilo at a guess although price/weight savings probably not worth it.
http://i298.photobucket.com/albums/mm268/Olliekingnova/Screenshot2011-06-24at164443.png

[Ben]

Bit of a long shot but this engine was not used in any of the "other marques" carrying gm engines eg daewoo, fiat etc? Might be a way of finding one in europe then.

[mowgli]

nope it is brazil only.. they use corn ethanol. thats why its 12:1 cr.

[MK999]

nope it is brazil only.. they use corn ethanol. thats why its 12:1 cr.

12:1 turbo sounds tasty, chuck some petrol in it anyway lol

[novarally]

Cracking Car! Have you considered a carbon fibre gear shift similar to the WRC focus's carbon fibre handbrake. May save half a kilo at a guess although price/weight savings probably not worth it.

It's a good suggestion, I'd buy one if someone can make it at a sensible price. The aluminium one is actually quite heavy.

[MK999]

Carbon fibre tube is available off the shelf colin, sure you can cut the ally down a fair bit and bond the carbon on yourself, you'd need that ally end piece on the shifter anyway for wear.

Also added to a list of ideas for mine lol

[novarally]

Carbon fibre tube is available off the shelf colin, sure you can cut the ally down a fair bit and bond the carbon on yourself, you'd need that ally end piece on the shifter anyway for wear.

Also added to a list of ideas for mine lol

Yes, I see the place where I got my carbon fibre angle from also does the tube;

http://www.easycomposites.co.uk/Category/Carbon-Fibre-Products/Carbon-Fibre-Tube/Roll-Wrapped-Carbon-Tube.aspx

Not too badly priced either if it can save 0.5kg or thereabouts.

[MK999]

Try this:

http://www.carbonology.com/carbon-fibre-tubes-woven-surface-finish-tubes-c-64_146.html

Will be slightly tougher than the roll wrapped version, quite essential if you like banging through the gears, and well, everyone does :d lol

[novarally]

Try this:

http://www.carbonology.com/carbon-fibre-tubes-woven-surface-finish-tubes-c-64_146.html

Will be slightly tougher than the roll wrapped version, quite essential if you like banging through the gears, and well, everyone does :d lol

Thanks Mark, next time I see my car I will measure up and get some of that ordered.

Almost irrelevant that the engine is dead if you've got a carbon fibre gear lever.....

[Novasport]

As per my PM, there was the possibly of destroking a later 1.2 from a mk2 Nova with the 12ST crank and rods.
I have checked the sizes and the 12ST has a stroke of 62.9 and the later 1.2 8v has a bore of 72mm which combined makes 1024cc.
Whether a decked blocked and skimmed head will lose you that 24cc I am not sure but may be the cheapest way of doing it as there is still plentiful supply of these engines over here. The only issue I can see is the different size of little end bearings between the two engines.

Or...

I am sure the 1.2 16v will be similar again so you could use the 12ST bits on that which wouls give you your 16v engine but not sure of the efficiency of the head and the reliability of the timing chain.

[novarally]

As per my PM, there was the possibly of destroking a later 1.2 from a mk2 Nova with the 12ST crank and rods.
I have checked the sizes and the 12ST has a stroke of 62.9 and the later 1.2 8v has a bore of 72mm which combined makes 1024cc.
Whether a decked blocked and skimmed head will lose you that 24cc I am not sure but may be the cheapest way of doing it as there is still plentiful supply of these engines over here. The only issue I can see is the different size of little end bearings between the two engines.

Sounds a feasible one Rich, but beyond my technical expertise I'm afraid.

I will certainly run it past my engine man. Decked blocks and skimmed heads sound like higher compression ratios to me though, which may not be appropriate.

The 1.2 16v is an interesting suggestion, I have absolutely no experience of that one.

Anyone got one or know anything useful about it?

[Novasport]

Would make a cracking revvy little engine imo

[Novasport]

What are the rules governing what engine you can use? Can you go for a different manufacturers engine? Say like a Diahatsu 1.0 GTtti engine?!?

[stt]

As per my PM, there was the possibly of destroking a later 1.2 from a mk2 Nova with the 12ST crank and rods.
I have checked the sizes and the 12ST has a stroke of 62.9 and the later 1.2 8v has a bore of 72mm which combined makes 1024cc.
Whether a decked blocked and skimmed head will lose you that 24cc I am not sure but may be the cheapest way of doing it as there is still plentiful supply of these engines over here. The only issue I can see is the different size of little end bearings between the two engines.
.

decking the block / skimming the head wont alter the swept volume,only the CR

[novarally]

What are the rules governing what engine you can use? Can you go for a different manufacturers engine? Say like a Diahatsu 1.0 GTtti engine?!?

The one overriding rule on the engine we have to adhere to is (in my words);

The engine block must be externally identical to that which was factory fitted to a Nova

So for example a destroked 20XE is not allowed in a Nova (but would be OK in an Astra).

Use of other manufacturer engines (e.g. an XE in a Mk.2 Escort) automatically pushes people into the anything goes 'Sports Libre' race classes, where as you can imagine there are some ludicrous machines, and not a hope of winning.