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autoworksnovasport
30-03-12, 09:36 PM
this one??
http://www.djm-motorsport.co.uk/images/products/images/alloy%20pedal%20box%20chassis%20pr~.JPG

novarally
30-03-12, 09:46 PM
Yes, that's the one, although I'd prefer the carbon fibre version they do;

http://www.djm-motorsport.co.uk/Carbon_Fibre_Pedal_Set.html

Sadly the carbon pedals are well over £2k, so they won't be finding their way to me. I haven't asked the price for the aluminium set-up yet, but I'll bet it's horrendously expensive.

Life would be a lot easier if I was allowed to modify the bulkhead for more clearance.....

autoworksnovasport
30-03-12, 09:48 PM
could you not make a set of them?? they dont look very complicated

novarally
30-03-12, 09:50 PM
could you not make a set of them?? they dont look very complicated

Someone talented could, but that excludes me.

autoworksnovasport
30-03-12, 09:53 PM
:)

i could make some out of steel but alloy is also beyond me

BRoadGhost
30-03-12, 11:50 PM
You could create some sort of large bolt in ally / carbon plate that effectively raises the entire drivers footwell and mount the box on it, that way you could get things further back and the angle of your legs would increase the distance too.

Alright you'd need to suss the throttle setup again, but without bulkhead mods / new pedal box the options are limited.

Those carbon arches are sexy time!

Heh those carbon pedals would scare the bejebus outta me :eek:

novarally
01-04-12, 08:39 AM
This arrived in the post yesterday;

http://i285.photobucket.com/albums/ll66/hillclimbescort/001-44.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/002-80.jpg

It was cheap as whoever removed it from the car had simply cut through the cable going into the back of the module (!). I've had a word with Farringdon Instruments who make these, and they're going to repair it at a very sensible price.

Not sure whether I will replace my STACK display with this one eventually or not - obviously I won't be using the steering wheel which came with it!! It's a tiny 250mm one out of a single seater.

BRoadGhost
01-04-12, 07:56 PM
I'd keep the stack & have something to shroud it in either carbon or ally. Gogo on the floor & pedals!

novarally
06-04-12, 09:12 PM
Scarcely an update, but I did fit my titanium sump plug today (it's a racing motorcycle item!). Looks lovely, and saves a tiny fraction. Another one that can't be seen normally though;

http://i285.photobucket.com/albums/ll66/hillclimbescort/031-10.jpg

In the backround you can see a honeycomb carbon fibre plate I made for the gearbox (the bit that covers the flywheel).

I tested the wiring today, and everything seems to be working as it should, so tomorrow I will put some fuel in and give it a try.

Danb1987
06-04-12, 09:58 PM
What's this weighing in at now Colin? That steering wheel can't have been that cheap even if the loom was cut ;) lol

Anychance if having a browse when we pop over tomorrow?

Lewis.
06-04-12, 10:59 PM
at least it's better than some of my previous updates, which have simply been to announce that I've done nothing lol

I can't work out the relative positions of your sump/manifold/gearbox though. has the sump been modified, or am I up too late?

novarally
07-04-12, 07:50 AM
at least it's better than some of my previous updates, which have simply been to announce that I've done nothing lol

I can't work out the relative positions of your sump/manifold/gearbox though. has the sump been modified, or am I up too late?

Yes, the sump has been extensively modified.

novarally
12-04-12, 10:15 PM
Thanks goodness the engine has today been fired up for the first time since the paintwork and other rebuilding.

It needed a bit of detective work by someone cleverer than me, as I couldn't get it to spark........turns out one of the pins in the connector for the crank sensor was not pushed fully home, so I only have myself to blame.

There's now an arm-long list of jobs to be ticked off before the first race on 21st April.

Jonlem
12-04-12, 11:02 PM
Good to hear its running again

As a precaution I'd check all the connectors if you have had a pin drop out, you certainly wouldn't want it to drop a injector on full boost

novarally
13-04-12, 07:03 AM
Good to hear its running again

As a precaution I'd check all the connectors if you have had a pin drop out, you certainly wouldn't want it to drop a injector on full boost

I will check them all, but the crank sensor connector was the only one which had to be dismantled - as it passes through a tiny hole in the bulkhead, the plug had to be removed.

So at least I know it was not put back together properly (by me).

novarally
16-04-12, 07:51 PM
The Nova took a test run on Saturday afternoon, with no doors, no wings, no bonnet, no tailgate and no windscreen. Quite breezy.

The clutch has been giving us major headaches, and still isn't quite right, it looks like long term the master and/or slave cylinder will need to be changed. But hopefully it will be OK for the racing this weekend.

A few photos of it sat in my friends' workshop;

http://i285.photobucket.com/albums/ll66/hillclimbescort/001-48.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/002-82.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/003-85.jpg

I would never have got it to this stage without his help, that's for sure. We've now spent 4 days pretty much non-stop on it.

Suspension geometry is now all set-up, the doors have now been primed, and will be top coated tomorrow. So I now have to bolt on all the bodywork (not a big job on this!).

I'll fit this rather natty new 'catch tank' tomorrow;

http://i285.photobucket.com/albums/ll66/hillclimbescort/004-72.jpg

And then I need to make some panels to fill the rather gaping hole in the boot;

http://i285.photobucket.com/albums/ll66/hillclimbescort/006-65.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/005-61.jpg

Other jobs to be ticked off are;

Getting the tyres filled with nitrogen (now available at our local tyre depot)
A bit of tidying for the wiring
Sealing up various holes in the bulkhead/floorpan
Bleeding the cooling system
Fitting the battery properly (I had to send the race battery back due to charging problems, and it's coming back to me tomorrow)
Machine polishing the paintwork
And a bunch of other little jobs, so more late nights.....

mowgli
16-04-12, 07:59 PM
colin, if there is no rule on what you need to make it out of, could i suggest using that corrugated plastic stuff they use on cheap coldframes & sell at b&q, correx it think its called... it weighs about a 1/4 of feck all...

Nova_Tek
16-04-12, 08:10 PM
Mental Nova!

novarally
16-04-12, 08:12 PM
colin, if there is no rule on what you need to make it out of, could i suggest using that corrugated plastic stuff they use on cheap coldframes & sell at b&q, correx it think its called... it weighs about a 1/4 of feck all...

I'm not familiar with that material, I was going to make it out of carbon fibre, but as I'm in a rush and don't really have time to make a lot of templates, your cheap and cheerful suggestion might be the one for me (no rules on what the infill panels are made of, so far as I am aware).

Mike
16-04-12, 08:21 PM
Crack on, looking the part now Colin!

Giving me some real good ideas/inspiration of something Im planning on building at some point.

mowgli
16-04-12, 08:30 PM
colin, try any local sign shops too, this stuff is used on cheap signs, as backing, it is twin wall corrugated plastic, you can bend it one way really easily.. also packaging companies do it.

Mike
16-04-12, 08:35 PM
colin, try any local sign shops too, this stuff is used on cheap signs, as backing, it is twin wall corrugated plastic, you can bend it one way really easily.. also packaging companies do it.

Ah I know the stuff you mean, what estate agents use to make for sale signs etc.

mowgli
16-04-12, 08:35 PM
thats the badger...

novarally
16-04-12, 08:45 PM
thats the badger...

Of course, the moment you mentioned signs being made out of it, it dawned on me as to what material we are talking about.

I remember the drunken procurement of various 'For Sale' signs that we used to make into shields for a New Years Eve fancy dress outing as the 'Knights of the Round Table'........

burgo
16-04-12, 10:36 PM
saw this is the flesh on sunday, just wow!! i think i could spend all day looking at it and still not see all the neat little touches

MARTIN KELSON
16-04-12, 10:49 PM
You at Loton park this year Colin?
Not far from me so if your there this year i may pop along for a look.

novarally
17-04-12, 08:09 AM
You at Loton park this year Colin?
Not far from me so if your there this year i may pop along for a look.

Yes, I certainly hope to be at Loton. Never been before, but it looks a fantastic venue. Everyone I've spoken to who's driven there loves it.

novarally
18-04-12, 10:17 PM
I'll try and do a photo update tomorrow.

The doors are now painted and fitted to the car, along with the polycarbonate windows.

The slicks have today been filled with Nitrogen, supposedly it gets up to temperature faster than air, so that's got to be good for hillclimbing/sprints where you have to start with virtually cold tyres.

Having said that, looking at the weather forecast for the weekend I need to sort out some wet weather tyres! I have a set of wheels and wets that go on the rear, but the 13" wheels I normally use on the front of the car in the wet won't go over the Yamaha R1 calipers I now have fitted........annoyingly it is just the bleed nipple that they're fouling on, so it's very close.

Might have to use some 15" wheels and road tyres on the front if it rains lots.

I shall get it weighed tomorrow as well.

Only a few jobs outstanding now;

Fuel tank breather
Infill panels in the boot floor area
Battery straps need fitting
Tidying of wiring
Sealing up any remaining holes in bulkhead/floorpan
Testing the front brakes (needs to stop raining ideally!)

autoworksnovasport
18-04-12, 10:24 PM
very good fingers crossed for the weekend then :)


have you had the caliper brackets remade yet??

burgo
18-04-12, 10:25 PM
very interested to see the weight result

calibra-keith
18-04-12, 10:32 PM
any plans for video's/pictures of it in action Colin ?

novarally
18-04-12, 10:34 PM
any plans for video's/pictures of it in action Colin ?

Yes, I have a friend attending the event at the weekend who will be videoing, so I really hope to have some proper footage soon.

Lewis.
19-04-12, 06:59 PM
ah forgot you said the first race was this weekend, i really wanted to go and watch, but already agreed to go to p*ssing hunstanton :( lol maybe next time

mowgli
19-04-12, 07:08 PM
ah forgot you said the first race was this weekend, i really wanted to go and watch, but already agreed to go to p*ssing hunstanton :( lol maybe next time

thats what they should name that place....... who did you agree it with, a magistrate????

fearless
19-04-12, 08:20 PM
Would be nice to see some incar footage - but I know your weight saving obsession would never allow a heavy onboard camera to be fitted :)

novarally
19-04-12, 08:58 PM
Would be nice to see some incar footage - but I know your weight saving obsession would never allow a heavy onboard camera to be fitted :)

I'm distraught, I've just weighed it tonight and got 541kg. About 10kg more than I was expecting.........I'll have to adjust it tomorrow with my lardy-ass in the seat to set the spring heights;

http://i285.photobucket.com/albums/ll66/hillclimbescort/008-48.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/007-53.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/001-49.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/002-83.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/003-86.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/004-73.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/006-66.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/005-62.jpg

novarally
19-04-12, 09:04 PM
As you can see in the pictures, it got a little bit muddy today, it barely stopped raining, so it went for a test run on some 14" RFX's with gravel tyres, and my wets on the back.

The gear linkage could do with a little adjustment, and the bonnet decided to part company from the rest of the car.......I've had to revert to running pins at the back of the bonnet, as the thin carbon skin is flexing enough to detach the tubes I fitted from their locating holes.

Just the 15 hours spent on it today, I started soon after 7am and have not long finished for today.

Still more to do tomorrow before I set off for the race venue though.

Jonlem
19-04-12, 09:12 PM
Good to see it coming along so well Colin.

Sorry if it's been mentioned but I guess your using the iscv for ALS ?

Lewis.
19-04-12, 09:15 PM
looking good, where's the extra weight come from then? just in paint?


thats what they should name that place....... who did you agree it with, a magistrate????

nah just the gf. may as well be though, there will be no getting out of it lol

Royston
19-04-12, 09:17 PM
Looking good Colin, is the driver now on a crash diet to save weight:d?

I know I'm on a crash diet for NATS................lol

Can't wait to see the transformation inn the flesh next month hopefully at NATS

Keep up the good work:thumb:

novarally
19-04-12, 09:23 PM
Good to see it coming along so well Colin.

Sorry if it's been mentioned but I guess your using the iscv for ALS ?

It hasn't been mentioned as far as I can recall......during the time it was owned/developed by BTEC Racing there had been plans to run ALS, but he never got any further than installing all the gubbins to get it operational.

At the moment that part of the mapping is de-activated as it needs some tinkering to get it spot on.

novarally
19-04-12, 09:25 PM
Looking good Colin, is the driver now on a crash diet to save weight:d?

I know I'm on a crash diet for NATS................lol

Can't wait to see the transformation inn the flesh next month hopefully at NATS

Keep up the good work:thumb:

I've sustained myself so far today on just 6 x McVities chocolate digestives, so I'm making an effort on that front.........but I fear now I shall almost certainly relapse and eat properly.

novarally
19-04-12, 09:31 PM
looking good, where's the extra weight come from then? just in paint?

Certainly extra layers of paint/lacquer are a factor. It did end up getting lavished with more of both than I intended.

But I've also had to go back to the original doors, rather than the composite items, which has resulted in a small increase.

My calculations for a lower weight also included losing the windscreen rubber, as I intended to replace the 'screen with a bonded in item, which hasn't happened yet due to the costs.

There are still a few places where I can shave some weight for no money, but I am now refusing to spend any more cash......

Jonlem
19-04-12, 10:43 PM
It hasn't been mentioned as far as I can recall......during the time it was owned/developed by BTEC Racing there had been plans to run ALS, but he never got any further than installing all the gubbins to get it operational.

At the moment that part of the mapping is de-activated as it needs some tinkering to get it spot on.

Good stuff, probably best not to hurt the engine much but a little ALS would probably help the response, saying that I have no idea what it goes like so I must come along to a sprint day and see for myself.

All the best for the weekend, hope it goes well !

novarally
20-04-12, 12:25 PM
All loaded up and (I hope!) ready to race...........

http://i285.photobucket.com/albums/ll66/hillclimbescort/007-54.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/006-67.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/005-63.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/004-74.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/003-87.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/002-84.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/001-50.jpg

I'm still not sure about the clutch and the new front brakes, but I haven't had time to take it anywhere to properly test them, so the first practice tomorrow morning will have to do.

I'm taking the old Wilwood brakes with me, just in case I have to do a swap in the paddock.

peester
20-04-12, 12:29 PM
wow, nice quick turnaround that has been. Looking great. People will wonder where this has come from and maybe where the BTEC red n yellow famous 1.0T has gone lol.

scott.parker
20-04-12, 01:11 PM
Looks really nice now mate, i wish you the best for tomo and hope it goes well mate, and the weather is good for you at the event.

Scott

istf
20-04-12, 01:43 PM
Very nice! Waiting for the first hillclimb videos! :)

M Sutton
20-04-12, 04:14 PM
Looks great!good luck tomorrow mate ;)

SimonTW
20-04-12, 06:25 PM
Good stuff Colin. It's looking amazing. All the best for the weekend. Looking forward to seeing some pictures and footage after the event!

Lewis.
20-04-12, 06:57 PM
Certainly extra layers of paint/lacquer are a factor. It did end up getting lavished with more of both than I intended.

But I've also had to go back to the original doors, rather than the composite items, which has resulted in a small increase.

My calculations for a lower weight also included losing the windscreen rubber, as I intended to replace the 'screen with a bonded in item, which hasn't happened yet due to the costs.

There are still a few places where I can shave some weight for no money, but I am now refusing to spend any more cash......


Ah I'd forgotten about the doors, are you going back to composite doors in the future?

and good luck for the weekend! I hope the weather holds out for you :thumb:

SGA33
20-04-12, 08:07 PM
Awesome Good luck for the weekend.:)

calibra-keith
20-04-12, 08:17 PM
was it just the alloy hinges that we had trouble with ?

and good luck, bring home the win you deserve it

kenny_afh
20-04-12, 08:26 PM
all the best for its "debut" after the rebuild. looks stunning in the grey and the split rims set it off nicely.

id be very interested in your 14inch RFX wheels for my rally car, would you sell them? not worried if you only have an odd number or that. let me know if so and i'll email you.

MK999
20-04-12, 09:30 PM
Looking very good Colin, you've done an awesome job on this car :)

BRoadGhost
20-04-12, 10:46 PM
I'm not sure how you'd change the 70-30 front to back weight balance without adding weight or moving parts.

Maybe the battery could go the near side rear behind the axel. Ride heights will help if you go to extremes and dialing in the top mounts to sit fully back for more castor should be worthwhile. Those arches & wheels could put you in some really desirable values if you got some adjustable / modified parts.

Can the bumper side tags not be attached on the inside of the wings, rather than the outside?

Have fun with the event and here's to a good time :)

burgo
23-04-12, 10:15 PM
wheres the weekends report?

novarally
24-04-12, 10:33 AM
was it just the alloy hinges that we had trouble with ?

and good luck, bring home the win you deserve it

It was just the hinges which were giving problems. Two people have promised to make me sets, but have failed to deliver.

See forthcoming post for event details.......


all the best for its "debut" after the rebuild. looks stunning in the grey and the split rims set it off nicely.

id be very interested in your 14inch RFX wheels for my rally car, would you sell them? not worried if you only have an odd number or that. let me know if so and i'll email you.

Thanks. The wheels might be available, drop me an e-mail and let me know what you're offering. Thanks.


I'm not sure how you'd change the 70-30 front to back weight balance without adding weight or moving parts.

Maybe the battery could go the near side rear behind the axel. Ride heights will help if you go to extremes and dialing in the top mounts to sit fully back for more castor should be worthwhile. Those arches & wheels could put you in some really desirable values if you got some adjustable / modified parts.

Can the bumper side tags not be attached on the inside of the wings, rather than the outside?

Have fun with the event and here's to a good time :)

I'm still considering moving the radiator to the boot to give me some improvement. The left rear corner is really light, and is picking itself up far too readily.

novarally
24-04-12, 10:57 AM
wheres the weekends report?

Apologies, it's been a very busy time since returning from racing.

Sadly it was not the glorious debut I had planned.........

I had electrical problems through both days of racing, which weren't solved by swapping batteries numerous times.

Basically I've had a top end misfire, only evident under load, anything much above 5k rpm and it starts missing, and popping. You'd think to listen to it I had a very aggressive anti-lag system on it, but I don't.

First thoughts were that the voltage was dropping enough for the ECU to stop talking to the fuel pump, but I don't have the OMEX software/laptop lead to get into the ECU so I can see what's going on in there.

We re-wired the fuel pump as that seemed to be one problem (it was only seeing 10v after the relay), but that didn't cure it.

We've removed the crank sensor and re-set the gap to the pulley with no improvement, gone through every wire on the car, every earth etc.

In the end the weather was so bad I didn't race on Sunday afternoon, and the misfire was enough that it could cause damage, so it wasn't worth the risk. An awful lot of cars went off the track that afternoon!

Bearing in mind the engine was re-fitted without any changes from last year (when it was running perfectly), logically the suspicion has got to be the wiring/earths.

I've not had chance to investigate any more yet, but the other things I need to check are;

1. Fuel pressure
2. Compression
3. Coil pack
4. HT leads
5. Replace the plugs (always start with the basics!)

Apart from the engine running woes, the new clutch/flywheel and front brakes all performed fine.

I had 2 spins, one on Saturday and one on Sunday, both at exactly the same corner, and I've never had so much as a twitch there before, so that's a bit worrying. It's a left hand turn, and it could be that the left rear corner of the car is now so light it's upsetting the balance. But I've also now got the Tran-X plate LSD in it, which has very different characteristics to the old ATB diff I used, so it may be that I need to adapt my driving style to the diff.

There's an oil leak from between the engine block and bellhousing, it looks to be gear oil, so the 'box is going to have to come out to replace the input shaft seal.

Basically I suffered from not having time to do some proper testing before racing it in anger!!

There are some videos and photos from the event, I will post up the links when I've got them.

istf
24-04-12, 11:17 AM
Still awesome! Unfortune of the built cars, but don't give up!

novarally
24-04-12, 11:41 AM
A few photos that a friend of mine took at the Saturday meeting, when the weather was just very cold;

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

http://i285.photobucket.com/albums/ll66/hillclimbescort/Nova2.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/Nova3.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/Nova4.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/Nova5.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/Nova6.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/Nova7.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/Nova8.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/Nova9.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/Nova10.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/Nova11.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/Nova12.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/Nova13.jpg

scott.parker
24-04-12, 05:56 PM
Shame to hear about the teething issues, sound like a naff coil pack to me, as i had similar on my TB set up when my coil pack started to go, it was hitting a stuttering fluctuation at 5krpm at combe, new coil pack and it was fine...

Like the off pics too!

Scott

Mazz
24-04-12, 06:38 PM
vroom vrooom :)

http://gickr.com/results3/anim_a7321be7-de21-15b4-e15a-b2933b76d885.gif

novarally
24-04-12, 08:37 PM
Shame to hear about the teething issues, sound like a naff coil pack to me, as i had similar on my TB set up when my coil pack started to go, it was hitting a stuttering fluctuation at 5krpm at combe, new coil pack and it was fine...

Like the off pics too!

Scott

Thanks Scott, that's definitely interesting, the coil pack is on my list for replacement in an effort to get to the bottom of the problem.

Mine is a Ford coil pack, part number 988F-12029-AD. It seems to originate from a Ford Focus, and a bit of Googling suggests they are prone to failure, although I'd have thought they would show up faults at lower revs than this.

MK999
24-04-12, 08:45 PM
Will be a ford EDIS type I imagine, they are indeed prone to failing, and for some reason most aftermarket management systems use them!!

lee303
24-04-12, 09:44 PM
high rev mis fires are usually crank sensor related ime, just because it was ok when it was removed it may not be now, but a laptop will help you find that i’m sure
car looks great though, and it sounds like you had some fun at least:thumb:

Jeff16v
24-04-12, 10:13 PM
Shame it didn't run right Colin, top marks for turnout though,

Dayle_
24-04-12, 10:25 PM
I believe have to drive them trans-x diffs with aggression same as the gripper ones throw it in plant the throttle and let the diff do the work and drag you out the Sh*t so to speak!!! Totally different to the ATB Quaife ones. Shame about the misfire Colin hope you get it sorted.

BRoadGhost
24-04-12, 10:33 PM
Looks a bit close to a roll for my liking; could it be time to dump it on it's ar5e? I can recommend it as not only will it help CoG / corner weights, but also reduce turn in, which is what caused the oversteer to begin with?

IMO running a total loss is a bad idea, especially on a small dry cell. You can get all manner of gremlins when voltage drops; just imagine the drain on it when you're at 5,000rpm. Put the alternator on it before doing anything else & drive it.

burgo
24-04-12, 10:40 PM
how annoying for it to be things you haven't changed that cause you the problems. good to hear the clutch and very experimental brakes are all good though

Jonlem
25-04-12, 07:40 AM
Car looks superb Colin. I'm sure you will get the bottom of the miss fire

novarally
27-04-12, 01:19 PM
In the post today I got a new set of spark plugs, a new crank sensor and a new coil pack.

The plan is to replace one part at a time to (hopefully) get this misfire resolved.

I've found that the problem does show up with the car sat still, if I rev it anywhere much past 6,000 it starts missing, popping and generally misbehaving.

This morning I replaced the fuel pressure regulator, which hasn't made any difference at all. I did dismantle the old FPR just to check, and all is in perfect condition, so it's no surprise to find this isn't at fault.

The new FPR has a convenient take-off union on it which I have plumbed my fuel pressure sensor into, and I'm seeing around 3 bar, so there doesn't look to be anything amiss there either.

Coil pack and plugs are easy changes, but unfortunately the crank sensor has been hard-wired, so that will be the last thing I try.

I've also got some new HT leads on order from Magnecor.

If none of these cure it, I guess it will have to go on a little holiday to BTEC Racing for them to run it up on the rolling road and plug in the OMEX laptop.

nova ian
27-04-12, 04:46 PM
Not posted in here for while, but always check up on the progress. Got to say this has changed alot since I last saw it! Looks top notch though Colin, really like the new wide arches and colour. Are you planning on having any graphics put on it, or are you keeping it subtle looking?

Shame about the teething problems, pitty you didn't get to iron them out before race day, but it's always the way I suppose... Not enough time in the days and the unluckiness of having these things happen when you least want them too! Hope the new parts cure the problems, and keep us up to date with racing progress :thumb:

Andy
27-04-12, 05:07 PM
That looks brilliant.

novarally
27-04-12, 05:52 PM
That looks brilliant.

Thanks, I'm really pleased with the way it's turned out.

If anyone wants an up-close and personal meeting with my Nova, they need to get themselves along to the PNG National Weekend! Booking closes soon, so don't miss out.....

novarally
28-04-12, 11:30 PM
Just got a CD through with a bunch of photos from last weekend's racing. There's a lot, and they are big files so taking a long while to upload, but here is the first batch;

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA1072.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA1073.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA1074.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA1075.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA1076.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA1077.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA1078.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA1079.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10710.jpg

Andy
28-04-12, 11:35 PM
So much like a savage little RC car!!
Guess thats a good thing really!? Looking very light and nimble even just in the great action pics,cant imagine what it must be like!

Spudly
28-04-12, 11:37 PM
That looks awesome Colin, good work, hope the misfire issue doesnt take too long to sort, sods law says it will be the coilpack, annoyingly as thats the bit thats not so easy to change:cry:

novarally
28-04-12, 11:41 PM
That looks awesome Colin, good work, hope the misfire issue doesnt take too long to sort, sods law says it will be the coilpack, annoyingly as thats the bit thats not so easy to change:cry:

I hope it is the coilpack, that's really easy. It's the crank sensor which is more difficult. To be honest I'll be delighted if it's any of the ancillaries I can easily replace, and not something more dramatic (i.e. inside the engine!).

Connor
28-04-12, 11:47 PM
Looks awesome in action colin, really looks the part.

novarally
28-04-12, 11:49 PM
http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10711.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10712.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10713.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10714.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10715.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10716.jpg

Spudly
28-04-12, 11:52 PM
I hope it is the coilpack, that's really easy. It's the crank sensor which is more difficult. To be honest I'll be delighted if it's any of the ancillaries I can easily replace, and not something more dramatic (i.e. inside the engine!).




It sounds to be electrical though i wouldve thought, so fingers crossed its not going to be an internal issue as that would throw up a misfire all the way through the rev range wouldnt it?

novarally
28-04-12, 11:56 PM
It sounds to be electrical though i wouldve thought, so fingers crossed its not going to be an internal issue as that would throw up a misfire all the way through the rev range wouldnt it?

That's certainly the logic I'm working with, so I hope we're right.

Spudly
28-04-12, 11:57 PM
That's certainly the logic I'm working with, so I hope we're right.




Ill keep my fingers crossed for you then bud :thumb:

novarally
29-04-12, 12:10 AM
The photos have been really useful, as they explain the first of my 2 spins..........clearly I was completely out of control before I even got to the corner I spun on...........

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10717.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10718.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10719.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10720.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10721.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10722.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10723.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10724.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10725.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10726.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10727.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10728.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10729.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10730.jpg

I'm putting this spin down to the new Tran-X LSD. It's a wild ride with a diff like this, and it does make the car weave, you really have to hold on. With the previous Quaife ATB it was very easy to drive, but lacked the ultimate edge that a plated LSD gives you.

Andy
29-04-12, 12:14 AM
Also driving a glorified kite must be a skilled occupation? lol

16xe_chris
29-04-12, 12:37 AM
Looking good on the track Colin

Plated tran x diffs are really something else, wait till its a damp day and you really do go where the grip is ha ha, makes you feel like your weaving all over the place.

What heat rating are the plugs your using, I've known them be an issue when the revs go high also known turbo engines to blow out the spark!!

16xe_chris
29-04-12, 12:45 AM
Just noticed with the very top picture whilst you were turning in your car was already on 3 wheels, this won't help much with under steer and the potential to spin if the other remaining tyre brakes traction?

Higher poundage front springs maybe?

burgo
29-04-12, 12:59 AM
tripodding doesn't cause under steer at all, the opposite in fact and is usually very desirable to give you more turn in hence stiffening the shells so much to get it lifting the wheel

Bubba
29-04-12, 01:19 AM
http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10724.jpg

i LOVE that photo...i see shiny stuff...looks awesome

16xe_chris
29-04-12, 01:20 AM
From the photos provided I would put money on that being caused by understeer, due to the forward weight distribution.

Tripodding as you say is good to a certain extent

novarally
29-04-12, 09:33 AM
Just a few more photos (I won't publish all of them!), but these do show the tendency to lift a wheel;

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10731.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10732.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10733.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10734.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSU1077.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/GSA10735.jpg

16xe_chris
29-04-12, 10:17 AM
Did it feel understeery??

This was when I realised my front springs were well far too soft, but I didn't have the option to change anything this particular day, so I just got mad and kept my right foot planted lol

http://i1160.photobucket.com/albums/q496/16xe_chris/5b18d7ee.jpg

mowgli
29-04-12, 10:24 AM
are you allowed any lower front aero?

novarally
29-04-12, 10:48 AM
Did it feel understeery??

No, it didn't feel bad at all on that front. But I was also so distracted by the misfire that I wasn't concentrating too much on the handling.

novarally
29-04-12, 10:49 AM
are you allowed any lower front aero?

Yes, and I really do need a proper carbon fibre splitter/undertray at the front. But finding someone to make it at a realistic cost is proving difficult.

burgo
29-04-12, 11:32 AM
would it not be worth making a plyboard one just to see if you feel any benefit before shelling out for a carbon one? you can experiment with different designs much easier as well

novarally
29-04-12, 01:55 PM
would it not be worth making a plyboard one just to see if you feel any benefit before shelling out for a carbon one? you can experiment with different designs much easier as well

Possibly it would, the biggest problem is going to be finding something solid at the front end of the car to mount a splitter onto! An aerodynamicist friend of mine once told me that if you can't stand on a splitter and it supports your body weight, you may as well not bother..........

novarally
29-04-12, 02:01 PM
Right, who's an expert on OMEX ECU's?

I've just changed the spark plugs and the coilpack, with absolutely no difference to the misfire.

It starts missing at a shade over 6k rpm, and I'm starting to wonder if the internal rev-limit in the ECU has somehow reset itself? Is this possible? Maybe there's a default setting for Omex units at 6,000 rpm? I've done a fair bit of Googling with no useful info so far.

The rev-limit has always been set at 8k rpm, but I must admit I never revved it up to 8k at a standstill to see what it did. So I may be wrong, but it seems to me that at 6k rpm it's behaving just like the rallycross Supercars, where they just bury the throttle pedal and the electronics hold it on the rev-limit, with all the popping/banging which goes with it.

BTW - I don't have a PC lead or software for the Omex, so I can't check it, before anyone asks........I will get myself a data lead and software tomorrow and plug my laptop in.

lee303
29-04-12, 03:52 PM
changing the rev limiter is simple, pretty sure its just a drop down box, in general engine settings or similar, doubtful it reset itself though tbh
you should also be able to see in the data logging if the crank sensor is giving a fault

novarally
29-04-12, 04:23 PM
changing the rev limiter is simple, pretty sure its just a drop down box, in general engine settings or similar, doubtful it reset itself though tbh
you should also be able to see in the data logging if the crank sensor is giving a fault

Thanks.

I'm also doubtful that it could have reset on its own, but you never know with computers.

I haven't replaced the crank sensor yet, but I have a new one ready to be soldered into place.

nova23
29-04-12, 06:08 PM
Have you got full throttle gear shift setup on your omex, my R5 turbo had a similar fault at 5k after we had done some welding and refitted the dash, turned out I had forgotten to connect the clutch pedal switch so the ecu was cutting the revs ready to flat shift, also sounded like a rally car and firing flames out the exhaust!

novarally
29-04-12, 07:40 PM
Have you got full throttle gear shift setup on your omex, my R5 turbo had a similar fault at 5k after we had done some welding and refitted the dash, turned out I had forgotten to connect the clutch pedal switch so the ecu was cutting the revs ready to flat shift, also sounded like a rally car and firing flames out the exhaust!

That's interesting, but no, I don't have that set-up on my ECU (not yet, anyway).

novarally
30-04-12, 08:10 PM
I can't remember seeing this photo before (from last year), and there are some good photos of other Novas in competition here;

http://www.zipp.co.uk/search/gallery/nova

peester
30-04-12, 08:18 PM
ah cool link - didnt know mr turpin was still running his nova, in hillclimb.. need to find a vid..

novarally
07-05-12, 06:48 PM
The misfire has now been cured, by the simple fitment of a new crank sensor. We've fitted a new plug onto the wiring loom so that I can carry a spare at all times, as they seem to be rather unreliable.

It's like a new car now, the way it revs up to the 8k rev-limit is incredible, with only 5kg of flywheel and clutch to spin!

Can't wait to take it testing now, there's still some other small niggles to be ironed out.

At least as a result of this I've now got the OMEX software on my laptop, and a Comms lead so I can plug in and interrogate the ECU if I need to.

Royston
07-05-12, 06:55 PM
Please you have bottomed it out, always nice to be able to check the ecu.

Looking forward to seeing your car in a couple of weeks (and yourself of courselol)

mowgli
07-05-12, 06:58 PM
having had nothing to do with crank sensors, i assume they work the same as abs sensors, with an exciter ring.. i swap a lot of abs sensors on wagons, and have even had new ones that are faulty.

glad you have the power back, now its time to play with your suspension again..

novarally
13-05-12, 08:43 PM
Overdue for an update on this, which will follow soon in words and pictures.

I have trimmed back the rear arches, which in combination with machining 5mm off the rear hubs was going to allow me to lower the rear end much more. But unfortunately the hubs are too big to fit in my friends lathe, so I need to find someone else to do that job.

Today I've bought a new trailer for my Nova.......I hope it's happy now, it's going to have better accommodation than me.

Mike
13-05-12, 08:50 PM
Race shuttle?

novarally
13-05-12, 08:56 PM
Race shuttle?

Sprint Shuttle (a little easier for the towing as I don't want to be using a juicy 4x4).

Mike
13-05-12, 09:30 PM
Sprint Shuttle (a little easier for the towing as I don't want to be using a juicy 4x4).

Oooh nice one.

Harvey
14-05-12, 11:48 AM
unfortunately the hubs are too big to fit in my friends lathe, so I need to find someone else to do that job.

http://www.derbyracingservices.co.uk

Myself and mates have used them a few times now and they are very good. They did the hub machining for Iain, drop him a note and see what he says about them.

novarally
14-05-12, 02:03 PM
http://www.derbyracingservices.co.uk

Myself and mates have used them a few times now and they are very good. They did the hub machining for Iain, drop him a note and see what he says about them.

Thanks, but I need to find someone local as we always seem to be coming up with machining jobs that need doing on mine, and various friends race cars.

Hopefully I have found the place today, I'd never heard about it before, but just a couple of miles from me there's a farm, and one of their buildings is packed full of ultra-serious machinery. The boss wasn't there when I dropped in, so I'm going back later to meet up.

novarally
17-05-12, 08:47 PM
Just got the rear hubs back this morning after having 5mm machined off them;

http://i285.photobucket.com/albums/ll66/hillclimbescort/004-77.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/007-58.jpg

I'll get them re-anodised at a later date, I want to get the front alloy bells done in gold anyway, so I'll get everything done together.

In combination with trimming back the arch lip, it's allowed me to drop the back end right down, it looks miles better and should improve the corner weights/handling;

http://i285.photobucket.com/albums/ll66/hillclimbescort/006-69.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/005-65.jpg

calibra-keith
17-05-12, 09:25 PM
How are the bike brakes colin, did you get the idea from autograss/spaceframed cars ?

novarally
17-05-12, 10:04 PM
How are the bike brakes colin, did you get the idea from autograss/spaceframed cars ?

I'm not 100% sure yet......the engine was running so badly at the first race meeting the brakes didn't really get stretched. The feel is OK, but I'll reserve judgement on overall performance until I get chance to do more testing.

Put it this way, I haven't sold the old Wilwoods yet. They will only go up for sale if/when I am completely happy!

istf
18-05-12, 09:16 AM
No Centering on rear hub?

mowgli
18-05-12, 06:17 PM
conical nuts... proper old school

novarally
23-05-12, 09:46 PM
Inspired by conversations at the National Weekend, and seeing an Autotest Nova at the PPC Show at Mallory Park, I decided there's still more weight to come out of the doors, so tonight I attacked the passenger one;

http://i285.photobucket.com/albums/ll66/hillclimbescort/003-90.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/004-78.jpg

Including lightening the locking mechanism there's nearly half a kilo out of that door, and the same to follow from the drivers door.

Mike
23-05-12, 09:48 PM
there's nearly half a kilo out of that door, and the same to follow from the drivers door.

Blimey.

I totally forgot how light your panels are when shutting the drivers door at National Day lol lol

SimonTW
23-05-12, 10:09 PM
Thats insane! There isn't a lot of door left though. Why do they allow metal removal like that but dont allow removal or modification of metal around the seal areas on the rear windows or modifications to the bulkhead / battery area firewall?

novarally
23-05-12, 10:11 PM
Thats insane! There isn't a lot of door left though. Why do they allow metal removal like that but dont allow removal or modification of metal around the seal areas on the rear windows or modifications to the bulkhead / battery area firewall?

It's all to do with what is classified as the 'monocoque'......i.e. the main structure of the car which is made in one piece.

Because the doors and front wings are not permanently attached to that main structure, you are free to do as you wish with them.

The overriding rule is that you are not allowed to lighten the monocoque between the centres of the wheels. Hence my bulkhead remains completely standard, and part of the spare wheel well is still there at the back.

C612DNM
02-06-12, 04:47 PM
Colin,
I've looked at the pics of your "spin", and I'm thinking that it's probably due to your wheel on the grass - and your new fierce plate diff. It probably "snatched" and that led to what happened. When I put new plates/springs in my diff, it always got snatchy, and the only answer is to be brave and keep your foot in!! If you lift, it bites you in the bum!

I also note that your ride height is tail low. I always found that that made any of my cars tail happy, far from balanced/neutral. After having mine set up professionally back in 1991 (eek!), it was always tail up, only a bit, numbers in my little black book (and my head).

Back to the weight of the car - what's it down to now?

novarally
03-06-12, 04:29 PM
Colin,
I've looked at the pics of your "spin", and I'm thinking that it's probably due to your wheel on the grass - and your new fierce plate diff. It probably "snatched" and that led to what happened. When I put new plates/springs in my diff, it always got snatchy, and the only answer is to be brave and keep your foot in!! If you lift, it bites you in the bum!

I also note that your ride height is tail low. I always found that that made any of my cars tail happy, far from balanced/neutral. After having mine set up professionally back in 1991 (eek!), it was always tail up, only a bit, numbers in my little black book (and my head).

Back to the weight of the car - what's it down to now?

Yes, it wasn't until I got the photographs through that the reason for the spins became clear! The new diff is so twitchy it was pulling me way over to the right hand side of the track, and onto the grass. I'm sure it's just a question of me learning to drive the diff, and I'm equally sure that ultimately it will be faster, but having been used to the Quaife ATB it's a bit of a shock! But everyone says the same that plated LSD's are evil to drive with, so I certainly expected it.

The ramp angles are 55/90, and I may look at changing those later on, although I am far from an expert here, so will be taking advice from others.

As for weight, it's currently 541kg, but is set to gain a couple of kg soon, as I'm going to fit an alternator as I am fed up with the battery issues.

Balley
03-06-12, 04:33 PM
Is the door Steel Colin?

novarally
03-06-12, 05:00 PM
Is the door Steel Colin?

What's left of the frame is steel, the skin itself is aluminium;

http://i285.photobucket.com/albums/ll66/hillclimbescort/011-44.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/012-43.jpg

novarally
03-06-12, 06:38 PM
Time for a bit of an update.

The exhaust system is now off the car, and is with a local exhaust fabricators who are going to make it in aluminium for me, which will hopefully save a Kg or two, and it'll be slightly larger to hopefully allow it to breathe a little better. It's a bit of an experiment, as aluminium exhausts aren't commonly used, but my research suggests it should be ok.

As mentioned, I have decided to fit an alternator, after successive problems with lightweight batteries. So I've acquired this alternator;

http://i285.photobucket.com/albums/ll66/hillclimbescort/006-70.jpg

And this lower pulley, which looks like it should be a direct replacement for my current one (I hope!);

http://i285.photobucket.com/albums/ll66/hillclimbescort/007-59.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/008-51.jpg

I've had a bit of a leak from the gearbox, which seems to be from the diff cover, so I've removed the cover to check it's all true, and got a new gasket set to go on. I'm taking the opportunity to swap the old diff cover for one which has a drain plug in it, to make future maintenance easier. Note the Straight Cut crownwheel in the gearbox;

http://i285.photobucket.com/albums/ll66/hillclimbescort/010-50.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/009-51.jpg

Just as a precaution I got Magnecor to make me up a new set of HT leads, which look rather nice;

http://i285.photobucket.com/albums/ll66/hillclimbescort/014-32.jpg

And I've picked up a few sheets of 3mm carbon fibre, which I reckon can be fashioned into rather lovely front and rear towing eyes;

http://i285.photobucket.com/albums/ll66/hillclimbescort/013-31.jpg

And finally I found a Corsa VXR engine with exhaust manifold and turbo, so I can work out what's feasible in terms of future engine developments. Might be a long while before I can afford to do that though;

http://i285.photobucket.com/albums/ll66/hillclimbescort/004-79.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/003-91.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/002-87.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/001-53.jpg

mowgli
03-06-12, 07:39 PM
will you get that past the scrutineers, isn't the rule that the block must be from the original model?

if yes, then it will be a truly awesome device.

novarally
03-06-12, 08:31 PM
will you get that past the scrutineers, isn't the rule that the block must be from the original model?

if yes, then it will be a truly awesome device.

The scrutineers would only notice if it's protested by another competitor.......and that's bound to happen, so wouldn't be worth the risk/expense.

The exact wording of the regulations is;

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

So, if I am going to progress this plan it would be dependent on being able to use the VXR head on a 1600cc 8v Nova block.

I was hoping that the VXR block would look the same as a Nova one, but it's totally different.

MK999
03-06-12, 08:52 PM
Tap an E16 engine number into it... that would make it externally identifiable as an E16 lol

I had heard they use the Z18XE head, but that's actually entirely different, looks more like a late X16XEL evolution.

Why the VXR head specifically btw, an x16xe head would fulfill the requirements?

mowgli
03-06-12, 08:52 PM
those extra chunks sort of mess it up..

didn't tom reid fit all the mucky bits into a 1600 ecotec?? you could get round it that way, as the 8v block fits the 1600 head.

lee303
04-06-12, 10:00 AM
the 1800 heads are streets ahead (‘scuse the pun) of the 1600xe variants, 5mm valve train as stock, better port design and angles, and the breathers are cast internally to the block so fitting one to an earlier block is not so simple as the head gasket faces are quite different as i’m sure you can see colin
you can fit all the 1800 crank/pistons etc into a 1600 block but you will need to machine the crank case to clear the crank webs/rods at half stroke

novarally
11-06-12, 10:35 AM
Nothing much to report on my car, so I thought I'd post up these photos a friend took when he visited a Berg Cup hillcimb recently;

http://i285.photobucket.com/albums/ll66/hillclimbescort/fahrerlager-167.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/fahrerlager-081.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/fahrerlager-085.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/fahrerlager-084.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/fahrerlager-083.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/fahrerlager-082.jpg

Edd
11-06-12, 10:39 AM
That looks epic

Is that a custom bodykit? Looks awesome !

pie
11-06-12, 10:42 AM
that looks epic :)

Mike B GTE
11-06-12, 11:04 AM
these berg cup things look amazing, ive got a few dvds in the house. Quite a few Novas (corsa a's) run in. The Risse motorsport Kadett is amazing!!!

Mazz
11-06-12, 11:29 AM
Hasn't there been a video posted of that recently?

calibra-keith
11-06-12, 11:51 AM
Hillclimb fans on you tube, some great videos/cars on there

SimonTW
11-06-12, 01:54 PM
Some links to vids of the car in the thread below. Its one of the only Corsa A's competing in the Berg Cup.

http://www.pngclub.com/forum/showthread.php?186209-This-looks-alright&highlight=

calibra-keith
11-06-12, 03:31 PM
you got any ideas/plans to take from this car Colin for your own ?

novarally
11-06-12, 04:31 PM
you got any ideas/plans to take from this car Colin for your own ?

Not really, I do want to get a front splitter, but that will be all.

peester
11-06-12, 05:44 PM
yeah seen lots of that one in action on the youtube vids too. Best thing about the car is the driver lol.

Mike
11-06-12, 06:52 PM
http://i285.photobucket.com/albums/ll66/hillclimbescort/fahrerlager-167.jpg

Reminds me of SVA's 2012 time attack Evo lol lol

toymex
11-06-12, 07:09 PM
Does anybody know any contact details as i could do with that bodykit ,it looks to be wide enough for my wheels and the height looks just about right for the 40mm min ground clearance allowed

Connor
11-06-12, 07:25 PM
My mate was there also, and also felt the need to take some photos of it and send it to me. Unfortunately this was crashed early on :(
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-prn1/551010_463850183630836_45957445_n.jpg
http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash3/536269_463853570297164_1358360549_n.jpg
http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash3/562473_463853636963824_781139109_n.jpg

Mike
11-06-12, 07:26 PM
^Aaaaaaaw, it looks like a frowny face :(

Edd
11-06-12, 07:36 PM
Sad times :(

Anyone got anymore info on the car ? Build thread ?!

SimonTW
11-06-12, 09:02 PM
Noooooo absolutly gutting to see it trashed!

BRoadGhost
11-06-12, 11:44 PM
Oh nohes! I'm sure he'll have that fixed before the summer's out though. At last a proper airbox on a humble nova; no wonder it sounds so good :)

Wonder why / how he crashed?

Gazza808
12-06-12, 01:11 PM
Oh nohes! I'm sure he'll have that fixed before the summer's out though. At last a proper airbox on a humble nova; no wonder it sounds so good :)

Wonder why / how he crashed?

who knows, but most of them fall off the track due to slicks and damp/wet tracks added in they give it 110percent effort lol!

i went to watch the berg cup in homberg (sp?) 2 years ago, was epic every one was really friendly, had convo's about the cars in broken english lol!

novarally
13-06-12, 09:47 AM
Still messing about with fitting an alternator, I'm going to have to get a new crank pulley machined up (using the standard GM pulley would have meant moving the crank sensor, which I didn't fancy).

So I took the opportunity to change the alternator pulley from a 'V' belt to a multi-groove type, which are less prone to getting thrown off at high revs;

http://i285.photobucket.com/albums/ll66/hillclimbescort/001-55.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/002-91.jpg

The new pulley is aluminium, and the retaining nut is titanium, so a useful weight saving as well.

MK999
23-06-12, 08:19 PM
Just been to see this in action, really impressive car on track. Colin narrowly missed taking a first in class spinning on the last corner on what looked to be a very quick run. Definitely has the potential to beat the quickest of the mini's now!

calibra-keith
23-06-12, 08:22 PM
Just been to see this in action, really impressive car on track. Colin narrowly missed taking a first in class spinning on the last corner on what looked to be a very quick run. Definitely has the potential to beat the quickest of the mini's now!

i hope there are pictures or maybe a video coming shortly ?

burgo
23-06-12, 11:02 PM
best be or mark is getting negged lol

MK999
24-06-12, 05:08 PM
Pff, when has anyone ever seen me at a show with a camera lol

Wanna see it run I highly recommend getting off your lazy arses and getting to an event as it was pretty damn good, huuuuge variety of cars running :) Back next month! :d

Lewis.
24-06-12, 05:23 PM
But you never bring anything to a show Mark lol your Nova lives in lots of boxes lol

novarally
26-06-12, 09:07 PM
i hope there are pictures or maybe a video coming shortly ?

No idea who took it, but I just found the video!;

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

nova_stee
26-06-12, 09:11 PM
The back wheels were on the grass in that video wont of helped

MK999
26-06-12, 09:13 PM
But you never bring anything to a show Mark lol your Nova lives in lots of boxes lol

Last few shows I've been to were in a TD Nova? lol

novarally
26-06-12, 09:29 PM
The back wheels were on the grass in that video wont of helped

Indeed........still getting used to the new LSD, which seems to have a mind of its own.

calibra-keith
26-06-12, 10:19 PM
looks like it goes well Colin, im dieing to see it in action its a shame you dont do any closer to me

novarally
27-06-12, 07:56 AM
looks like it goes well Colin, im dieing to see it in action its a shame you dont do any closer to me

I won't be doing any events at all after July, sadly. It will probably have the rest of the year off, and then I shall re-evaluate once I know where I'm living pemanently, whether I have an income etc.

Yesterday I moved the Nova to its new home, it's tucked up nice and safe thanks to a friend of mine.

John
22-07-12, 09:25 PM
Just seen on mig you've had an off. :(

http://www.migweb.co.uk/forums/car-talk/504402-nova-gurston-hillclimb.html

BRoadGhost
22-07-12, 09:48 PM
Oh Colin no!

...You got the thing air borne?

Was it running better with the alternator on?

Hazzz
23-07-12, 02:56 AM
Just read this from start to finish, and from what i can see.. its better than eating custard creams and having sex.

Tomasson
23-07-12, 06:38 AM
Does anybody know any contact details as i could do with that bodykit ,it looks to be wide enough for my wheels and the height looks just about right for the 40mm min ground clearance allowed

hello! this car is built and driven by tobias auchter. http://www.honda-auchter.de/motorsport/index.html
a friend of mine bought this bodykit from him!

novarally
23-07-12, 09:40 AM
Oh Colin no!

...You got the thing air borne?

Was it running better with the alternator on?

The new crank pulley TTV are meant to be making for me still hasn't been done, so I was still on total loss electrics.

I had loads of problems over the weekend, dodgy gear linkage, overheating and then a fairly big crash.

The event photographer captured most of the accident on camera (stills, not video), he's sending those to me so I will post them up soon.

There's a fair bit of damage to the car, but considering the violence of it, and the distance it covered (I left the track at around 100mph), it looks to have withstood it pretty well. Although I reserve the right to amend that view when it gets stripped down.

As it sits on the trailer now it looks like it will need;

Front bumper
Drivers door
Drivers front wing
Radiator
Air filter
Gearbox casing
Front crossmember
Tie bars
Front anti-roll bar
Turbo wastegate
Steering arms

SimonTW
23-07-12, 10:06 AM
Sad news Colin. Glad you are all right and hope the car isn't too badly damaged! :cry:

Mazz
23-07-12, 11:48 AM
:cry:

BRoadGhost
23-07-12, 02:27 PM
Fcuking BAD TIMES. Is it the diff again you think that's making it a bit unwieldy or is it because it doesn't feel as stable as you'd like?

novarally
23-07-12, 03:56 PM
Fcuking BAD TIMES. Is it the diff again you think that's making it a bit unwieldy or is it because it doesn't feel as stable as you'd like?

I'm blaming the gearbox/gear linkage.........I've been completely unhappy with the gearing since I fitted the new gearbox, which means at Hollow Bend and over the Finish line at Gurston Down I'm needing to use 5th gear (even though I've upped the rev-limit to 8,250 rpm, I'm still hitting the limiter in 4th gear).

As I approached Hollow Bend on this occasion, it refused to go into 5th, so I stuck it back in 4th, and either that unbalanced the car, or disturbed my concentration sufficiently that I strayed off the tarmac, and once on the loose stuff at 100-odd mph I was just a passenger. At some point whilst off the road, the throttle stuck wide open, so the car just kept on going. It would appear I hit a tree stump or similar in the undergrowth which launched the car upwards, and did a lot of the damage.

We've started stripping the car down now, and there are more things to add to the list of broken bits;

Track Control Arms
Offside front wheel and tyre
Turbocharger
Intercooler

It's getting seriously expensive.

paul james
23-07-12, 04:02 PM
Its such a shame to see that happen after all the effort you've put in.

Mike
23-07-12, 05:24 PM
Gutted for you mate. The first list alone looks expensive, let alone a new turbo pack & cooler aswell as other things!

martstdvan
23-07-12, 08:31 PM
Dont worry too much Colin the the nova is in good hands.
im sure you will be happier tomorrow when you see whats been happening over the last few hours
:)

novarally
23-07-12, 10:00 PM
Dont worry too much Colin the the nova is in good hands.
im sure you will be happier tomorrow when you see whats been happening over the last few hours
:)

Interesting.

Thank goodness I have staff........shame for them they don't get paid.

burgo
23-07-12, 10:14 PM
Interesting.

Thank goodness I have staff........shame for them they don't get paid.

I think you would be surprised at the amount of people who would jump at the chance to help you out, your a good honest bloke that just needs a break but isn't getting it, just seems to be one thing after the other so if there is anything people could do I'm sure they will.

It's at times like this it would help if it wasn't such a high spec one off car as people could help you out with parts but I doubt we have got anything of any use.

Lewis.
23-07-12, 10:18 PM
Ah that must be gutting, Colin, given your plans to store it, will you be returning it to its former glory?

novarally
23-07-12, 10:23 PM
Ah that must be gutting, Colin, given your plans to store it, will you be returning it to its former glory?

It will come back again, lighter and faster than before.

The only question mark is when that will be. Right now I simply haven't got any spare cash to undertake the rebuild, so for the moment it's been stripped down to fully assess the damage, and we're at the planning stage with how to best repair/replace, whilst at the same time incorporating some improvements.

The engine and gearbox were removed this afternoon, so I will post up some photos soon to show where we are.

stupot89
23-07-12, 10:26 PM
proper gutted for you colin hope you get it sorted soon and glad your ok

John
23-07-12, 10:28 PM
that sucks :(

Lewis.
23-07-12, 10:29 PM
good to hear it's not going to disappear, still a shame it's been bent. Glad you're okay though

martstdvan
23-07-12, 10:36 PM
Interesting.

Thank goodness I have staff........shame for them they don't get paid.

down to your last 4 million??
:)
ive spoken to the doctor of motorsport and he has laid down some plans for the tie bars.
i will have to speak to you about the engine bits but i wont be around tomorrow until late afternoon so i'll try and catch you later in the week.

Benn
23-07-12, 11:07 PM
Just seen the pics, gutted dude.

pie
23-07-12, 11:25 PM
bad time's dude :(

novarally
26-07-12, 08:53 AM
A video has turned up;

http://www.youtube.com/watch?v=K2BFUpEUoOQ

Southie
26-07-12, 08:56 AM
:eek: You were flying, luckily you didn't roll it Colin.

Truly gutted for you though... but a man of your talent will get this back on track ;)

scott.parker
26-07-12, 09:39 AM
Sorry to here about this mate, and you did get away lucky not to go over onto your side.

vauxluva
26-07-12, 03:21 PM
Wow you lucky so and so!!!! bet your bum was the size of a pea.!! any pix of the said poor nova.Again lucky you did not flip.

toymex
26-07-12, 04:25 PM
Looks like you were lucky to get away without rolling it Colin ,did it just not turn in? i know my plate diff is set really tight and a slight back off of throttle as you go to turn in really does unsettle the car ,i have to be brave and keep my foot in when all senses are telling to back off.On a plus side it looks like the carbon panels have held up quite well considering .Good luck with the repairs ,im sure you will get her back looking better than ever and no doubt a little lighter

novarally
26-07-12, 04:53 PM
Looks like you were lucky to get away without rolling it Colin ,did it just not turn in? i know my plate diff is set really tight and a slight back off of throttle as you go to turn in really does unsettle the car ,i have to be brave and keep my foot in when all senses are telling to back off.On a plus side it looks like the carbon panels have held up quite well considering .Good luck with the repairs ,im sure you will get her back looking better than ever and no doubt a little lighter

I definitely didn't back off the throttle as I take that corner absolutely flat....but I did miss 5th gear just before the apex, and I think that's possibly what unsettled the car, although I may also have caught the kerb on the inside a bit hard, which is to be avoided in small cars.

I've just received a CD full of photos from the event, and some of the images the photographer got of the accident are excellent. I will post up soon!

Hobbit
26-07-12, 04:55 PM
As said that really looked like it was going onto its roof :eek:

novarally
26-07-12, 05:26 PM
The photographer didn't quite catch the beginning of my 'moment' (he was a little bit round the corner from there), but here's the sequence of shots he got;

http://i285.photobucket.com/albums/ll66/hillclimbescort/G2Y4631.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/G2Y4632.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/G2Y4633.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/G2Y4634.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/G2Y4635.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/G2Y4636.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/G2Y4637.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/G2Y4638.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/G2Y4639.jpg

novarally
26-07-12, 05:28 PM
Clearly I was a little dazed and confused as it would seem I then tried to proceed along the track and to the finish.........

http://i285.photobucket.com/albums/ll66/hillclimbescort/G2Y4640.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/G2Y4641.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/G2Y4642.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/G2Y4643.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/G2Y4644.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/G2Y4645.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/G2Y4646.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/G2Y4647.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/G2Y4648.jpg

Benn
26-07-12, 05:30 PM
Funking hell! That was a hell of an endo...

Glad your ok after seeing that.

novarally
26-07-12, 05:30 PM
And then ground to a halt with the engine screaming;

http://i285.photobucket.com/albums/ll66/hillclimbescort/G2Y4649.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/G2Y4650.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/G2Y4651.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/G2Y4652.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/G2Y4630.jpg

Iain
26-07-12, 05:38 PM
Woah that looks real bad in the pics! Amazing that he caught that sequence of pics

Glad you're OK and assessing it with a few to fixing it!

pie
26-07-12, 05:48 PM
:eek::eek:

paul james
26-07-12, 06:02 PM
Proper scary stuff! it really looks like it should have tipped over from this angle:

http://i285.photobucket.com/albums/ll66/hillclimbescort/G2Y4636.jpg

scott.parker
26-07-12, 06:17 PM
****theBed! lol lol You were even more lucky then it first looked in the vids, from them pics you can see how close it was to going over, cray good pics thought, shame the cars damaged from it all though, one of them needs to be your new AVATAR.

Edit: Colin do you do stunt events in your other spare time?? http://www.youtube.com/watch?v=xlzWg0U-rAc

Scott

Dervy
26-07-12, 08:01 PM
omg colin you are so luck that it didn`t go on its roof, it was so close, was there much damage?

SimonTW
26-07-12, 08:16 PM
Those pictures look brutal. I can't believe the angle of the car during the crash!

mowgli
26-07-12, 09:01 PM
well, there's no doubting your commitment there colin....

considering the speed you were doing, the damage is quite light

if they ever do another png awards, you get my vote for bravest.

burgo
26-07-12, 10:12 PM
Good god you are the luckiest bloke I know. How that didn't flip, roll, spin is beyond me.

The noise and speed is unbelievable as well, I want one lol

Harvey
27-07-12, 10:46 PM
Oh no Colin, all the effort you have put into the car and your unfortunate personal issues and now this has happened. Just hope you get it sorted over the coming months/year and get it back out there better than ever.

Mieran
27-07-12, 10:49 PM
Regardless of the crash I still think you're a class driver for avoiding rolling that!

Novasport
27-07-12, 10:49 PM
Awaits photoshopped photos.....

Nasty one that, glad you got out OK. The Nova stood up to it well. Hope you get it sorted soon.

16xe_chris
27-07-12, 11:31 PM
Very lucky the front end didn't dig in!!

A real life Brown underpants moment.

istf
30-07-12, 11:36 AM
Lucky the steering wheel is on the right side! :)

novarally
06-08-12, 10:15 PM
Nothing in the way of photos (sorry), but behind the scenes there has been work going on to get it repaired.

The front panel and both front inner wings were mangled, so the entire front end has been cut off just in front of the suspension turrets.

I've got a length of 32mm T45 tubing which will be bent up and made into a 'spaceframe' to take the front tie bars and the new engine mounts. We reckon this is going to trim another 5kg or so off the car.

Some new lightweight tie bars, track control arms and steering arms are being fabricated, which should get at least 2.5kg off. I may also try it without the front anti-roll bar.

And there's been some modifications to the rear axle, saving another 1.5kg.

I've ditched the floor mounted pedal box, and a Lotus Elise alloy pedal box is being modified to fit (2kg lighter as well). An electric water pump is going on in place of the old mechanical system, no weight saving there but it should be more efficient and it can be left to circulate coolant after the engine has been switched off.

The gearbox has been stripped, and I'm going to have my gearbox man alter the ramp angles on the LSD, and hopefully I will be acquiring a different Final Drive (CWP) to solve the problem of the short gearing. I have to pay a visit to Quaife in Kent for that though, and then pay for it somehow.

This morning I took the turbo unit to CR Turbos (New Milton, Hampshire), and they reckon it just needs a new compressor wheel, following the intake of dirt/gravel during the crash.

The engine is being stripped tonight to see if there's any damage to that - fingers are firmly crossed that it will live again.

Other than these things it needs repairs to the front wheel inner rim sections, the exhaust downpipe, plus a new radiator and intercooler. Oh, and body panels of course.

Finally I'm having an aerodyamicist friend of mine, Simon McBeath, review the whole car and see what he suggests for improvements there. Expect to see it next season featuring a front splitter and a rear spoiler.

Massive thanks to Martin Haresign (MARTSTDVAN off here), and to Mark Windley (Mark One Garage) at Tattershall, Lincs, for all their work so far. It's much appreciated at a stressful time for me as I'm moving house!

gte-87
06-08-12, 10:26 PM
You don't hang around good work

Jonlem
06-08-12, 11:18 PM
Glad to hear the car is coming back together, sounds like quite a shunt although any shunt in a nova tends to finish it off so glad to hear it is atleast repairable.

BRoadGhost
07-08-12, 01:42 PM
Holy sh1t Colin well done for not ramping the thing over, if it was a LHD you might have had a lot more to repair.

It's always a funny situation when driving & all you can see out of the windscreen is the ground below ;O

novarally
09-08-12, 06:50 PM
Got the T45 tube bent up today to form the front spaceframe, so that can be welded into place now.

All the rose joints and fittings have been ordered for making the new TCA's, tie bars and steering arms.

The revised, lightweight rear beam is now back from the blasters, and freshly painted in a nice shade of pink primer.

I'm after an Irmscher rear spoiler, or a fibreglass/carbon fibre GTE Mk.1 spoiler if anyone knows of anything. I had arranged to buy an Irmscher one, but I appear to have been let down by the seller.

We started dismantling the engine, and are thinking about a different camshaft for it. But before deciding on that, I want to find out what camshaft is in there at the moment - see my post in 'Mechanical' in case there are any 8v Vauxhall camshaft specialists on here..........

CT Turbos have rung me to say my repaired turbo unit is ready to be collected, and they also informed me that the wastegate has never shut, because the actuator rod was wrongly adjusted (presumably by the people I bought the turbo from). So for 2 years I've been racing it with a lot of lag that shouldn't be there.

BRoadGhost
09-08-12, 07:36 PM
It's gonna be a totally different animal once all back together.

Would you not want to run some sort of bespoke carbon wing on top of the tailgate rather than a larger MK1 GTE item?

novarally
09-08-12, 07:41 PM
Would you not want to run some sort of bespoke carbon wing on top of the tailgate rather than a larger MK1 GTE item?

Not allowed in our rules, only standard fit stuff is accepted.

martstdvan
09-08-12, 09:26 PM
another update for you colin,
the new bottom arm's have been mocked up along with the tie bars
and the new space framed front is ready to be cut and fitted.
also the new rear ARB design is finished, looks like i'm in for a long weekend ;)

Mazz
10-08-12, 11:47 AM
pics pics pics!

BRoadGhost
10-08-12, 12:55 PM
Ahh thought that might be the case. From what i'm aware of the GTE spoiler is fairly efficient for what it is.

Iain
10-08-12, 02:34 PM
Does standard fitment stuff not rule out carbon/fibreglass copies as you could make them slightly different?

MK999
10-08-12, 03:24 PM
Does standard fitment stuff not rule out carbon/fibreglass copies as you could make them slightly different?

Silhouette side on has to remain standard/recognisable as a nova, so only standard 'shape' stuff is allowed

novarally
17-08-12, 09:34 AM
Look out for a small photo update later today......

novarally
18-08-12, 08:05 AM
My apologies for the lack of updates recently, but I moved out of my house and workshops last week, and as you can imagine there was a lot of sorting out to be done.

I still have a lot of Nova and Corsa parts if anyone needs anything............

Anyway, a few photos of progress with the resurrection of my Nova, firstly some mocking up of the new front end, following removal of the mangled front inner wings and crossmember;

http://i285.photobucket.com/albums/ll66/hillclimbescort/002-93.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/003-96.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/004-84.jpg

The turbo, fresh from being rebuilt at CR Turbos (great service and sensible prices);

http://i285.photobucket.com/albums/ll66/hillclimbescort/008-55.jpg

The Lotus Elise pedal box awaiting more modification and installation;

http://i285.photobucket.com/albums/ll66/hillclimbescort/009-54.jpg

Irmscher 3-piece rear spoiler (many thanks to Vessey for the loan of this). It's going to my aerodynamics man next week for him to assess it's suitability, if it is right for the job I'll get it made out of carbon fibre;

http://i285.photobucket.com/albums/ll66/hillclimbescort/015-37.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/006-76.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/007-64.jpg

And finally for now, the new rear beam, which has been lightened by 1.5kg compared to my old one;

http://i285.photobucket.com/albums/ll66/hillclimbescort/010-53.jpg

http://i285.photobucket.com/albums/ll66/hillclimbescort/011-47.jpg

Royston
18-08-12, 09:37 AM
Please to see you are making progress Colin

SimonTW
18-08-12, 10:25 AM
How did you shed so much weight off the beam? I see the pink one doesn't have the parts for the rear anti roll bar. Have you redesigned the roll bar attachments or are they still to be added?

mowgli
18-08-12, 10:36 AM
i was curious too, as the new beam has no bushes.

novarally
18-08-12, 02:07 PM
How did you shed so much weight off the beam? I see the pink one doesn't have the parts for the rear anti roll bar. Have you redesigned the roll bar attachments or are they still to be added?

The pink beam still needs bushes in it, we haven't decided yet if we're going to use a rose joint or just the poly bushes that were on the old axle.

The weight has been taken away with a lot of hours of cutting and grinding to smooth down, along with removal of the spring platforms, drilling of holes etc.

I plan to test the car with no rear anti-roll bar, I'd like to think it can run without one to save even more weight. But if it's decided it does need one, we will probably fabricate something in T45 tube as the old one was quite heavy.

lee303
18-08-12, 04:51 PM
liking the new tube front end colin, are you planning to keep the rad angled? thats my plan for this winter but with the rad angle forwards with sealed in airflow entry and exiting out the bonnet via some vents like most current GT cars
i think the plan for no ARB will yield interesting results, personally i think you'll need one, or to stiffen the beam in a different way may be a lighter solution

Mike
18-08-12, 05:16 PM
liking the new tube front end colin, are you planning to keep the rad angled? thats my plan for this winter but with the rad angle forwards with sealed in airflow entry and exiting out the bonnet via some vents like most current GT cars

If you can, take a peek at a C2 R2 or DS3 R, as the current Citroen off the shelf rally pack contains all the bits to re-angle the rad & also includes an airflow entry system for it. VERY effective simple engineering. Also found on Swift JWRC cars now too.

fearless
18-08-12, 05:30 PM
Any picks or links mike - sounds interesting

Mike
18-08-12, 05:37 PM
Any picks or links mike - sounds interesting

I have loads on a memory card somewhere from my friends JWRC Swift, Maxi C2 R2 & a DS3 R he/his business currently building. Hes also done a few "conversions" on 106's & normal C2's to repositioned tilted rads. Works really well IMO.

EDIT: Found memory card but not got a reader for Mini SD cards anymore :/

EDIT2: All is not lost, I have a DS3R build manual somewhere...

lee303
18-08-12, 07:17 PM
does sound interesting, i have a good idea what i want to do though and some alloy sheet and a bit of imagination may suffice, but pics/links would be ace either way:thumb:

fearless
18-08-12, 07:48 PM
Details of Citroens rally build manuals show basic pictures here - page 14 onwards

http://boutique.citroenracing.com/cms/web/upload/documentation/17/4e9ec9a5603f9.pdf

But we still need your pictures :)


Edit : Loads of bedtime reading here on the works C2'R2D2's and DS3's etc

http://boutique.citroenracing.com/documentation.php?id_nav=4&id_lang=1

lee303
18-08-12, 07:59 PM
nice links there dave, looks exactly like what i want to do!!

Mike
18-08-12, 08:02 PM
Pages 14 ~ 17 in the first link are what you want :thumb: The OEM rad shroud is fleixble plastic type stuff, the lower dummy bar is steel obviously, as are the replacement rad mounting brackets.

Its a dead simple design TBH, shocked that no ones though of using it sooner on a track car TBH lol although with a standard manifold implacation with downpipe interference will definetly happen. The works cars overcome this by using a titanium over gearbox type manifold & heat insulated thermal plastic air intake above that (Citroen type) the Suzuki setup is same theory but slightly different in design.

A lot of the works build manuals I have in my loft for these have similiar photos to that link. Being the acual book that comes with the kit though, its a lot more detailed. And FYI lol theres just over 540 parts in the DS3R rally pack.... so theres a lot of pages to said book lol

lee303
18-08-12, 08:06 PM
i have already sealed the rad in as efficiently as i could in stock position, but i wanted to do it properly now, i reckon i have a bit more room too with a tubular front end, as i certainly cant afford a titanium manifold!:lol:

Mike
18-08-12, 08:10 PM
i have already sealed the rad in as efficiently as i could in stock position, but i wanted to do it properly now, i reckon i have a bit more room too with a tubular front end, as i certainly cant afford a titanium manifold!:lol:

The manifold is one of the most expensive parts of the kit pack!

Honestly lee, its really easy to do, sheet matierial, same angled Y shaped brackets & a bit of lateral thinking = result. The problems start if you get manifold interference though.

EDIT: Another trick as fook thing aswell.... in the Suzuki Swift JWRC rally pack, the cabin air feed, thats a work of GRP art! No roof vents needed, a proper trick two piece affair that leads from front of bonnet, to bulkhead an then through into cabin. Really simple awesome idea.

lee303
18-08-12, 08:29 PM
i like my roof vent! lol i have enough to do anyway, need to finally make my splitter out of wood so i can get a good radius on the front of it, and a few other things, anyway, enough chit chat in colins thread i would imagine, i am looking forward to seeing this back together though!!

Mike
18-08-12, 08:30 PM
Some maybe useful pics from my facebook...

Note lower front dummy bar, rally pack add on

http://i80.photobucket.com/albums/j181/mikenova/1.jpg

OEM lower valance should look like this, on my old 106

http://i80.photobucket.com/albums/j181/mikenova/2.jpg

C2 R2 works type air cleaner feed with works manifold on my friends C2.

http://i80.photobucket.com/albums/j181/mikenova/3.jpg

lee303
18-08-12, 10:11 PM
**** thats nice!

novarally
19-08-12, 10:08 AM
liking the new tube front end colin, are you planning to keep the rad angled? thats my plan for this winter but with the rad angle forwards with sealed in airflow entry and exiting out the bonnet via some vents like most current GT cars
i think the plan for no ARB will yield interesting results, personally i think you'll need one, or to stiffen the beam in a different way may be a lighter solution

Yes, the radiator will be angled (and possibly the intercooler as well - not discussed this yet).
We will duct in the front end so all the air is forced through the radiator/intercooler.

Not sure yet if the radiator will be better tilted forwards or backwards, we can't decide on this until the engine goes back in and we see what room there is to work with.

The camshaft is being sent off to Cat Cams tomorrow for them to come up with a revised design.

And plans for an alternator have now been shelved in favour of a larger battery.

Mike
19-08-12, 10:17 AM
Braille Batterys are your friend Colin :thumb:

http://www.lindenbatteries.co.uk/braille-batteries/

novarally
19-08-12, 10:35 AM
Braille Batterys are your friend Colin :thumb:

http://www.lindenbatteries.co.uk/braille-batteries/

Thanks Mike. I was intending to avoid the small lithium-type batteries, as I've had nothing but problems with them before. I was even tempted to fit a small lead acid conventional battery under the bonnet.

RACING BATTERIES ended up giving me a full refund on the one I got from them, after replacing it twice and it still wasn't satisfactory.

VAMOS BATTERIES are now being taken to Court by me after I bought two of their batteries, and they were utterly incapable of what they claimed. Under no circumstances should anyone deal with VAMOS, they are quite simply crooks.

I always thought BRAILLE batteries were mega-expensive, but the prices on that website link aren't too bad.

Have you had any personal experience of them?

Because I'm not running an alternator it seems to be a real problem to find something that will keep the car running reliably, without having to keep swapping batteries or charging up whilst at a race meeting.

Mike
19-08-12, 11:57 AM
I always thought BRAILLE batteries were mega-expensive, but the prices on that website link aren't too bad.

Have you had any personal experience of them?

Personally I havent unfortunatly :/ But at a guess if HSV are willing to retail/market there product I wouldnt of though they'd be rubbish. For your application (minial circuitry/lightweight/high CCA) they might be of use but thats something you'd have to work out I suppose.

I never heard any bad reports about there gear mind, but there not very well known here in the UK.

Stupid qeustion, but have you tried a good old Varley item at all?

novarally
19-08-12, 12:12 PM
Stupid qeustion, but have you tried a good old Varley item at all?

Before my unsuccessful experiments with lithium batteries, I used a Varley Red Top 20 (around 5kg), and had no problems.

For a 2-day event I would swap over to a freshly charged one.

I've got a couple of these Varleys, but they are getting rather elderly now and not working nearly so well.

For the moment I may run a lead acid just because they are cheap and powerful, and look at changing to a Braille when (if!) I have more funds available.....

Mike
19-08-12, 12:20 PM
For the moment I may run a lead acid just because they are cheap and powerful, and look at changing to a Braille when (if!) I have more funds available.....

Sounds like a financially viable plan that mate.

Interesting factiod, I know the guys that make the carbon mirrors your selling on eBay lol lol

Jonlem
19-08-12, 12:54 PM
Good to see its still progressing nicely.

From a non aero perspective the rad and intercooler would work better if sat separate to one another, intercooler under the rad for example with the air ducted onto them.

Do you monitor IAT's as I imagine with sprints you must suffer from heat soak a little from sitting stationary at the start line.

Jonlem
19-08-12, 12:58 PM
Like so :

http://i1003.photobucket.com/albums/af157/wellens7/IMG_0295.jpg

novarally
20-08-12, 03:34 PM
Good to see its still progressing nicely.

From a non aero perspective the rad and intercooler would work better if sat separate to one another, intercooler under the rad for example with the air ducted onto them.

Do you monitor IAT's as I imagine with sprints you must suffer from heat soak a little from sitting stationary at the start line.

Good photo of how I would see mine ending up, thanks.

I've never monitored IAT's, but it's possibly something I need to do. I've only occasionally used my intercooler spray system, and I'm sure it's an area where things could be improved.

BRoadGhost
20-08-12, 04:19 PM
I like the way Lee303 has started to implement proper heat transfer / negative lift in / from his engine bay. I'm sure it could benefit a forced induction setup as much if not more so than something n/a.

Don't really want to go over old ground too often in the same thread, but understand that if an alternator could be regulated you wouldn't even need a battery. Modern formula 1 cars have the smallest Lithium batteries for just that. Running a total loss electric isn't the way forward, with the only possible advantage being a few kilos saved.