Rally Car Build

[scottmasterton]

Hi, Only just really started coming on here as a couple of weeks ago late Sunday evening after much searching for a good rolling shell, we found one down near Durham, which looked brilliant besides one or two minor slightly rusty patches
http://ep1.pinkbike.org/p4pb11886777/p4pb11886777.jpg
Trailered it home and here it was on the driveway
http://ep1.pinkbike.org/p4pb11886783/p4pb11886783.jpg

The next thing we did was, stripped the hole car and took out the wiring loom
http://ep1.pinkbike.org/p4pb11886787/p4pb11886787.jpg
After that we started to design and adapt some spare widetrack kit from a corsa that we have,so that its 50mm wider in each corner
http://ep1.pinkbike.org/p4pb11886802/p4pb11886802.jpg
http://ep1.pinkbike.org/p4pb11886805/p4pb11886805.jpg
Then we fitted the widest wheels to see how they sit
http://ep1.pinkbike.org/p4pb11886803/p4pb11886803.jpg
next we bought a mk3 cavalier rear disc axle to combine and fabricate it with a nova axle to put discs on the back,now all we need for the rear disc brake conversion to be complete is mk3 astra axle stubs.Then we can see how well the calipers and pads are working that we have to see if we need to buy some new ones.
I also just bought another nova for dirt cheap with a rotten shell but it came with lots of spare panels,doors and wing mirrors and so on. I am going to use the aftermarket smoothed bumpers that I got on that and cut and space them out 100mm wider then use them as moulds for fibreglass items as I am going to make a wide arch body kit, I will then just be keeping whatever parts I think I may potentially damage and sell or scrap the rest. Just last night I bought a fibreglass tailgate from a member in dumbarton, needs a bit of work to clean it up but it should be great.

Plan next is to try and source axle stubs, fit a chasis plating kit, build a cage, make adjustable seat mounts and then about another million things before the car even moves haha :)

Like our Page on Facebook for links to other projects and for cool updates :D
http://www.facebook.com/MastertonMotorsport?ref=hl

[scottmasterton]

any tips or advice or comments would be greatly appreciated

[scottmasterton]

Managed to Source axle stubs :) ,just finished moulds for wide rear arches will sell copies if anyone is interested once ive finished the final product
Here is photos of the shape I took the moulds from
http://gp1.pinkbike.org/p4pb9400231/p4pb9400231.jpg http://gp1.pinkbike.org/p4pb9400236/p4pb9400236.jpg http://gp1.pinkbike.org/p4pb9400231/p4pb9400231.jpg
Here are the moulds
http://gp1.pinkbike.org/p4pb9400245/p4pb9400245.jpg
Also have taken the rear windows out to be replaced with a polycarbonate window kit and to make it even easier to work on, just need to finish the front wing moulds and then the actual fibreglass panels, then work on the bumpers to finish the wide arch body kit that if it turns out good enough I should be selling for nice and cheap :)

[conad]

looks a real clean shell dude

[scottmasterton]

looks a real clean shell dude

The one that is being scrapped was absolutely riddled but the blue one is in better condition than lots of cars half its age :)

[scottmasterton]

Been pretty busy at work recently but still managed to get a decent amount done
Cut,bent and shaped all the tubing, temporarily put full cage together to see if any slight adjustments needed to be made
http://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-ash4/q71/s720x720/1005999_560570573979997_255964238_n.jpg
http://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-frc1/q71/s720x720/1005763_560570760646645_1801391761_n.jpg
Tacced up the main hoop
http://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash4/q80/s720x720/1209379_579250808778640_546895089_n.jpg
Tacced up the rear turrets
http://sphotos-b-lhr.xx.fbcdn.net/hphotos-prn1/q77/s720x720/1238187_579250802111974_1031516741_n.jpg
And also started the dash build out of wood to get the basic shape before we make the mould
http://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-ash3/1176410_579250898778631_794607002_n.jpg
http://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-frc3/q77/s720x720/1256508_579250815445306_923671757_n.jpg

[mk1nova_rich]

Looks like its gona be quite a serious build :) are you planning on tagging that cross bar on the cage to the exhaust tunnel?

[scottmasterton]

yes it is, long way to go yet, going to use quite a few tags and gussets throughout the build of the cage and that isn't something we had previously thought of, but now we are good idea thanks :)

[mk1nova_rich]

Its just most cages I have seen rather than having one straight bar across have either a bent bar or two half bars forming a shallow V which is welded to the gearbox tunnel if that makes sense?!

[scottmasterton]

The main reason we made it a straight tube was so we could fully weld it out of the car and so that the main hoop section would keep its shape in and out of the car, If we had used a tube with a bend it would have been impossible to fit back in the car after welding it

[John]

Nice! What engine? What series will you run in? :)

[scottmasterton]

Nice! What engine? What series will you run in? :)

We are going to test fit a k20 engine out of a type r and if it'll fit run one of those but if not a c20xe

[phunkynova]

One thing about your cage design with the x bars where they are it will limit how far back you can put the co-drivers seat, as I found out when I fitted a bar from one side of the main hoop to the other side.

Other wise good luck with the project.

[DAVIDKEDENS]

Interesting.

Dave.

[scottmasterton]

Managed to get quite a bit more done today, started sorting out the dash tube, the harness tubes, everything connected to the rear turrets and the tubes connecting from the main hoop section to the rear hoop section, tacced the majority of it but a lot more to do over the next few days
http://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn1/524500_580061885364199_754600691_n.jpg
http://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-prn2/1175582_580061705364217_35349093_n.jpg
http://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-prn2/1185286_580061698697551_31713436_n.jpg
http://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn1/1175398_580061688697552_76616613_n.jpg

[scottmasterton]

Been working on the car more and more, really starting to see things progress,
managed to do the majority of the work on the front strut tops, just need to tac them up then fully weld after any minor adjustments and then plate up the sides
http://ep1.pinkbike.org/p4pb10102708/p4pb10102708.jpg
Still lots more work to do in the engine bay need to finish stripping all the paint and patching/strengthening all the bits
such as where the heater was and where the battery
http://ep1.pinkbike.org/p4pb10136232/p4pb10136232.jpg
Door bar and engine bay cross sections just need cleaned up a bit, sorting out slight spatter
http://ep1.pinkbike.org/p4pb10136234/p4pb10136234.jpg
Also converted the Koni shocks to coilovers with a kit from JJC just to quicken up the process of being able to put
wheels on it when we move projects in and out of the main garage
http://ep1.pinkbike.org/p4pb10136236/p4pb10136236.jpg

[scottmasterton]

Bit more progress, have been working on fibreglass bootlid that I picked up on here as it has seen a lot of filler
and did not have any means of mounting it to the car or a catch and lock, so I cut up a bootlid that I had as a spare to
get the top mounts and the catch and lock. Then fit them to this one, still needs a good bit of cleanup work though
http://ep1.pinkbike.org/p4pb10283042/p4pb10283042.jpg
http://ep1.pinkbike.org/p4pb10283041/p4pb10283041.jpg
http://ep1.pinkbike.org/p4pb10283040/p4pb10283040.jpg

Test fitted the wide arch front wing basic shapes and with my widest wheels it looks like they should be pretty good
once I have widened them a wee bit more as the set up in photo is with the least camber available.
http://ep1.pinkbike.org/p4pb10283039/p4pb10283039.jpg

Also welded on the main strut top strengthening plates that I have fabricated and started seam welding in the engine bay
just need to weld in the side plates and then the strut tops will be pretty much finished.
http://ep1.pinkbike.org/p4pb10283037/p4pb10283037.jpg
http://ep1.pinkbike.org/p4pb10283033/p4pb10283033.jpg

[mk1nova_rich]

Looking good pal, keep it up :)

[scottmasterton]

Looking good pal, keep it up :)
thanks, will do :)

[scottmasterton]

Check out our other project here :D
http://www.gtmdrivers.com/forum/rossa-type-r-build-t2725.html

[scottmasterton]

Been away for a wee while but back now so we've been starting to weld the cage into the car using ratchet straps and porta powers as an aid.
http://scontent-a-ams.xx.fbcdn.net/hphotos-prn1/1528476_635191929851194_767774618_n.jpg
http://scontent-a-ams.xx.fbcdn.net/hphotos-prn1/1012002_635191853184535_1214116950_n.jpg
http://scontent-a-ams.xx.fbcdn.net/hphotos-frc3/1509973_635192026517851_429232949_n.jpg
http://scontent-a-ams.xx.fbcdn.net/hphotos-prn1/1525581_635192343184486_397209502_n.jpg
Been Working on the foot plates and they're all finished so just need to finish welding them in place
http://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-prn2/1544594_635192656517788_994564742_n.jpg
http://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-ash3/1530497_635192956517758_1905521593_n.jpg
few more photos of the cage and the sill stands that we added aswell
http://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash3/1488293_635193136517740_2068512630_n.jpg
http://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-frc3/1546028_635193283184392_718822899_n.jpghttp://scontent-a-ams.xx.fbcdn.net/hphotos-frc3/1536720_635193423184378_1637359156_n.jpg
Also did a tiny bit of work to finish up the rear turrets a bit more and to scrape some of the undersealer out of the arch
http://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash4/1488085_635193583184362_380971408_n.jpg

[Iain]

Lovely shell prep on this, the front and rear turrets look great

[jafanan]

serious cage!

looks a good shell aswel!

[scottmasterton]

Thanks Guys should be pretty much the most mega cage you'll ever see in a nova :) the plan is to completely remove all under sealer and wax oil then get it soda or sand blasted as soon as we've finished the roll cage, then tidy up any patches that appear before we prime it.

[8valve-craig]

Nice work. Have you checked that you 2nd A pillar bar doesnt obscure the N/S mirror from the driving position?

Mine did, so i used a smaller diameter tube.

[scottmasterton]

Nice work. Have you checked that you 2nd A pillar bar doesnt obscure the N/S mirror from the driving position?

Mine did, so i used a smaller diameter tube.

Yes it would do if I was using standard mirrors but im not and all of the tubing has to be the same diameter to meet the blue book regulations for rallying.

[scottmasterton]

have been away again for a while so not much progress till recently where we have got the shell on the spit removing all of the wax oil and under sealer and alternating between doing that and seam welding,welding in roll cage foot plates and welding more of the cage itself
http://scontent-b-lhr.xx.fbcdn.net/hphotos-xfp1/t1.0-9/q71/s720x720/10420165_722507421119644_3128191051901139957_n.jpg
http://scontent-a-lhr.xx.fbcdn.net/hphotos-xpa1/t31.0-8/10550139_723155464388173_4752712036101496115_o.jpg
http://scontent-b-lhr.xx.fbcdn.net/hphotos-xfp1/t31.0-8/10530516_723155137721539_3165150780998633208_o.jpg
http://scontent-b-lhr.xx.fbcdn.net/hphotos-xpf1/t1.0-9/10553431_723155217721531_3596052584126222318_n.jpg
http://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xpa1/t31.0-8/10457470_723155307721522_510722774758197888_o.jpg

[scottmasterton]

Have been distracted by other projects recently as we are currently working on stripping our Corsa engine bay

http://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xap1/t31.0-8/10479945_747887491914970_1536066648670962830_o.jpg

And on our GTM taking it over to Sitech Racing where they have had it on the rolling road mapping it so it idles properly and runs smoother with the custom intake and exhaust, car is making almost 200hp at the wheels which should be 230-240hp at the crank. combined with the cars weight which should be around 720kg when finished we'll have a bhp per ton of 330ish :d
http://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/10645251_747888151914904_2264833944679821945_n.jpg ?oh=17f1f6472ac96df190bdc6413be8e084&oe=54A3310E&__gda__=1420291766_f2d157a17bc7f060f1a390497a23c57 1
http://scontent-a-lhr.xx.fbcdn.net/hphotos-xpa1/t31.0-8/10630589_747734335263619_5947708129684273258_o.jpg

Hopefully we'll be able to get some work done on the Nova tomorrow :)
More under sealer stripping fun :(

[scottmasterton]

Not done much recently till today :) :thumb: we reckon this is a world 1st a Honda K20 in a Nova, going to start making
engine and box mounts in the next few days and hopefully gain some momentum again :d
http://ep1.pinkbike.org/p4pb11886618/p4pb11886618.jpg
http://ep1.pinkbike.org/p4pb11886611/p4pb11886611.jpg
http://ep1.pinkbike.org/p4pb11886605/p4pb11886605.jpg

[corsakid]

love the look of this

[BRoadGhost]

This build's looking good!

So what stops the lower arm movement front to back is where it bolts to the chassis leg?

Do you need the triangulated bulkhead more than a blower?

[scottmasterton]

love the look of this

Thanks :)

[scottmasterton]

This build's looking good!

So what stops the lower arm movement front to back is where it bolts to the chassis leg?

Do you need the triangulated bulkhead more than a blower?

Will get a photo up to show how its been done :)

yeah its not necessary to have one in the car

[scottmasterton]

http://ep1.pinkbike.org/p4pb11890152/p4pb11890152.jpg

[nova.mike]

Seen this on instagram, looks amazing! Keep up the good work.

[scottmasterton]

Seen this on instagram, looks amazing! Keep up the good work.
thanks mike we'll try our best :d

[scottmasterton]

Quite a bit of progress recently :)
Started on hydraulic clutch conversion but we might get a pedal box instead
http://ep1.pinkbike.org/p4pb12031848/p4pb12031848.jpg
http://ep1.pinkbike.org/p4pb12031850/p4pb12031850.jpg
http://ep1.pinkbike.org/p4pb12031851/p4pb12031851.jpg

Fabricated engine mounts
http://ep1.pinkbike.org/p4pb12042091/p4pb12042091.jpg
http://ep1.pinkbike.org/p4pb12042087/p4pb12042087.jpg

Tacced up driveshafts temporarily, lengths to be adjusted a bit
http://ep1.pinkbike.org/p4pb12031853/p4pb12031853.jpg

And modified the Corsa C power steering column to shorten it, waiting on wheel and boss to check positions
http://ep1.pinkbike.org/p4pb11995516/p4pb11995516.jpg

[Benn]

Love the turrets and brace.

[scottmasterton]

Love the turrets and brace.
Thanks Benn :)

[scottmasterton]

Been a long time since I've updated this but things are now slowly progressing :d
managed to grab a set of these 15x7 Team Dynamics for only £80 they need a bit of a clean up/touch up but really happy with the find
http://ep1.pinkbike.org/p5pb14665434/p5pb14665434.jpg

[totalnova]

Wheels look a bargain, I'm also a fan of the turrets, looks a well engineered car.
Nick

[scottmasterton]

Thanks Nick :) trying to work out how to go about tubbing the rear arches

[scottmasterton]

Been working on the brake setup
http://ep1.pinkbike.org/p4pb14795051/p4pb14795051.jpg
http://ep1.pinkbike.org/p4pb14795050/p4pb14795050.jpg

[scottmasterton]

Test fitted the new seat :)
http://ep1.pinkbike.org/p5pb14814193/p5pb14814193.jpg

Got a box for the front of the trailer
http://ep1.pinkbike.org/p5pb14814201/p5pb14814201.jpg
Primered a couple of bits for the brake set up
http://ep1.pinkbike.org/p5pb14814192/p5pb14814192.jpg

[scottmasterton]

Almost finished the brake setup just a few more tweaks needed and to finalise pedal heights
http://ep1.pinkbike.org/p5pb14814203/p5pb14814203.jpg
https://ep1.pinkbike.org/p5pb14814196/p5pb14814196.jpg
https://ep1.pinkbike.org/p5pb14814198/p5pb14814198.jpg

[scottmasterton]

Had to take out support that goes from one side to the other so cardboard templating up a new one and working out where hydro is going to be mounted on top :)
http://ep1.pinkbike.org/p5pb15278824/p5pb15278824.jpg

[Iain]

I love this, the hydraulic clutch looks great. Always been tempted to move to a hydraulic clutch.

Most don't bother putting the cross box back in, I didn't bother with mine.

[scottmasterton]

Thanks Iain :d hopefully it works well, just wanting to make the shell as solid as possible

[scottmasterton]

Left the cross box till later in the week :) Mocked up hoses for the radiator, fabricated slam panel and mounts for top of the radiator
http://ep1.pinkbike.org/p5pb15301199/p5pb15301199.jpg
http://ep1.pinkbike.org/p5pb15301178/p5pb15301178.jpg

Also the cage and rear turrets are pretty much finished just a few bits in front of the firewall to work on
http://ep1.pinkbike.org/p4pb15302812/p4pb15302812.jpg
http://ep1.pinkbike.org/p4pb15302813/p4pb15302813.jpg

[scottmasterton]

Mounted the bottle and started work on the wider front bumper
https://uploads.tapatalk-cdn.com/20171105/37f18bbe2a14b06826cd45d1ea855df2.jpghttps://uploads.tapatalk-cdn.com/20171105/a2b93570d44cb71f8baf0678596c1a29.jpghttps://uploads.tapatalk-cdn.com/20171105/57253023d2f4e9f1524b59fa136061bb.jpghttps://uploads.tapatalk-cdn.com/20171105/fc20de72e34b5bb79f24e439adf333d7.jpg

Sent from my SM-G935F using Tapatalk

[Iain]

Looks good are the arches having moulds for fibreglass panels?


Sent from my iPhone using Tapatalk

[scottmasterton]

Looks good are the arches having moulds for fibreglass panels?


Sent from my iPhone using Tapatalk

Thats the plan :)

[scottmasterton]

More work on the bumper and front wings
http://ep1.pinkbike.org/p5pb15367633/p5pb15367633.jpg
http://ep1.pinkbike.org/p5pb15367640/p5pb15367640.jpg

Had a look at the rear moulds on the car
http://ep1.pinkbike.org/p5pb15367609/p5pb15367609.jpg

[scottmasterton]

Using "CAD" lol
http://ep1.pinkbike.org/p5pb15367584/p5pb15367584.jpg
http://ep1.pinkbike.org/p5pb15367597/p5pb15367597.jpg

[scottmasterton]

Have removed the loom from the saloon and labelled it up, stripped out the unnecessaries and started to label up the honda loom
Fitted bootlid again with seal and it seems to be sitting well just need to work out where to put pins, to keep original holes or not
http://ep1.pinkbike.org/p5pb15417499/p5pb15417499.jpg

Checking a few bits and bobs before finishing the cross brace
http://ep1.pinkbike.org/p5pb15417502/p5pb15417502.jpg

Put both seats in to get an idea of space inside, passenger side just sitting on floor with no rails thats why its so low http://storage.proboards.com/forum/images/smiley/smiley.png
http://ep1.pinkbike.org/p5pb15417501/p5pb15417501.jpg

Made a start on the dash with some 'CAD'
http://ep1.pinkbike.org/p5pb15417500/p5pb15417500.jpg

[BRoadGhost]

Bodywork's gonna look special & unique I imagine.

At this stage I would advise a better steering wheel column / angle and getting the gear shifter in towards the driver more, as if you leave it you'll struggle to improve things once all the dash is back in.

[scottmasterton]

Bodywork's gonna look special & unique I imagine.

At this stage I would advise a better steering wheel column / angle and getting the gear shifter in towards the driver more, as if you leave it you'll struggle to improve things once all the dash is back in.

Looking to do something similar to what we've done before with the dash setup as shown in pic, the column and shifter are in a good position already? [emoji848]https://uploads.tapatalk-cdn.com/20171204/1dd92e637967a3e153145787b2c78039.jpg

Sent from my SM-G935F using Tapatalk

[totalnova]

I always thought the shifter position was strange in the Civic, it's not until you actually drive one you realise it actually feels very nice where it is as it's nice and close to the steering wheel.
Nick

[BRoadGhost]

I can't agree with the steering wheel position / angle

[scottmasterton]

I can't agree with the steering wheel position / angle

Can understand :) have you tried it? The steering wheel position has not been finalised but I'm almost 6ft5 so its not ideal for others, seems to work for me

[scottmasterton]

Made steering column strengthener plate just needs to be sprayed then welded in :)
http://ep1.pinkbike.org/p5pb15458021/p5pb15458021.jpg

Placed loom out of saloon
http://ep1.pinkbike.org/p5pb15457247/p5pb15457247.jpg

Put the wheels back on to roll it in and out
http://ep1.pinkbike.org/p5pb15457251/p5pb15457251.jpg

Started mock up for the dash setup
http://ep1.pinkbike.org/p5pb15457241/p5pb15457241.jpg

[scottmasterton]

Made mount for Honda ECU
http://ep1.pinkbike.org/p5pb15882671/p5pb15882671.jpg

Mounted in car
http://ep1.pinkbike.org/p5pb15879069/p5pb15879069.jpg

Some more wiring done
http://ep1.pinkbike.org/p5pb15882672/p5pb15882672.jpg

[scottmasterton]

Made some flat sheets of fibreglass to progress with dash
http://ep1.pinkbike.org/p5pb15898909/p5pb15898909.jpg

[scottmasterton]

Took the looms out to strip and tidy up a bit more
https://ep1.pinkbike.org/p5pb15915184/p5pb15915184.jpg

Fibre glass sheeting ready to start basic dash shapes
https://ep1.pinkbike.org/p5pb15915186/p5pb15915186.jpg

Picked up a pair of 6 point TRS Harnesses
https://ep1.pinkbike.org/p5pb15915178/p5pb15915178.jpg

Mounted battery and roughly placed anderson leads
https://ep1.pinkbike.org/p5pb15915188/p5pb15915188.jpg
https://ep1.pinkbike.org/p5pb15915187/p5pb15915187.jpg

[RallyMarshal]

Why 2 power cables?

Paul..

[8valve-craig]

Why 2 power cables?

Paul..

Anderson plug?

[RallyMarshal]

Anderson plug?

Aha, Good thought.

Paul..

[scottmasterton]

Aha, Good thought.

Paul..

Plug taped to the roll cage in the bottom pic ;)

[scottmasterton]

Placing harness eyes
https://ep1.pinkbike.org/p5pb15926904/p5pb15926904.jpg

https://ep1.pinkbike.org/p5pb15926903/p5pb15926903.jpg

[scottmasterton]

Started bits of the dash with fibre glass
https://ep1.pinkbike.org/p5pb15942861/p5pb15942861.jpg

[scottmasterton]

Started work on the indicator stalks, looking a bit rough but with a bit of work should clean up.
https://ep1.pinkbike.org/p5pb16117512/p5pb16117512.jpg

Also just been told harness eyes will have to be moved as the harnesses are supposed to be at 45* angle going in to the seat so will need to fix that :wtf:

[scottmasterton]

Made inroads to stripping some weight out of the driver side door, original door sans door card weighed in at 16.81kg with glass. Managed to drop weight down to 10.39kg so far but that is without glass. Still think there is more to come and then to replicate with passenger side.

Further progress with the dash mounted the passenger side panel with 4 tags, hole cut for the kill switch - might need to support panel a bit more there for safety, placed the ignition and starter switch.
Starting to see things coming together more and more. :d
https://ep1.pinkbike.org/p5pb16117558/p5pb16117558.jpg

[scottmasterton]

Some more work on the dash, not sure how the shoes got there lol
https://ep1.pinkbike.org/p4pb16237356/p4pb16237356.jpg

Progress on the switch panel
https://ep1.pinkbike.org/p4pb16237363/p4pb16237363.jpg

Almost finished the pedals just need to make a couple more adjustments then work out wether to add grip tape or similar
https://ep1.pinkbike.org/p4pb16237361/p4pb16237361.jpg

[scottmasterton]

Started work on the IRS setup
https://ep1.pinkbike.org/p4pb16237357/p4pb16237357.jpg
https://ep1.pinkbike.org/p4pb16237353/p4pb16237353.jpg

Need to modify the fuel tank a bit more
https://ep1.pinkbike.org/p4pb16237354/p4pb16237354.jpg

Trying to work out where we can put tubes for triangulation whilst retaining modified tank and wheel well
https://ep1.pinkbike.org/p4pb16237359/p4pb16237359.jpg

[scottmasterton]

Tacced in the IRS support tubes
https://ep1.pinkbike.org/p5pb16255103/p5pb16255103.jpg

[Iain]

So is that going to use both ends of the beam and the original beam mounts? I can’t picture how it’ll it’ll allow the wheel to move if it’s also mounted on the wheel well.

[Seppy]

Can't wait to see this finished.

[scottmasterton]

So is that going to use both ends of the beam and the original beam mounts? I can’t picture how it’ll it’ll allow the wheel to move if it’s also mounted on the wheel well.

We had it the wrong way in the photo lol

[scottmasterton]

Can't wait to see this finished.

Thanks Seppy :thumb:

[Iain]

We had it the wrong way in the photo lol

Ah that explains it! What’s the wheel well mod for then?

[scottmasterton]

Ah that explains it! What’s the wheel well mod for then?

Not quite finished yet but you can see it here
https://ep1.pinkbike.org/p5pb16259731/p5pb16259731.jpg

[House]

What will be the advantages??

I don't see an ability to adjust camber or toe??

I understand the advantage of wanting to have independent rear wheels but unless each wheel is independently adjustable I'm not sure the advantages are worth the effort.

That being said I'll be interested to hear how it feels and how it compares.

[scottmasterton]

What will be the advantages??

I don't see an ability to adjust camber or toe??

I understand the advantage of wanting to have independent rear wheels but unless each wheel is independently adjustable I'm not sure the advantages are worth the effort.

That being said I'll be interested to hear how it feels and how it compares.

Should help by allowing each wheel to move more independently of the other than the standard beam, that's why the 1.6 cooper cup cars handle so well :)

Rear toe can be adjusted by adjusting the turnbuckles from the rose joint to the beam, still looking at options to adjust camber

[House]

Fair play. Be interested to hear how it feels

[paul james]

Interesting set up, bit hard to picture quite how it works. Is the beam split in the middle somehow?

[scottmasterton]

Interesting set up, bit hard to picture quite how it works. Is the beam split in the middle somehow?

Yes right down the middle of the original beam, should be clearer as work progresses :)

[scottmasterton]

Cleaning up and priming grommet holes for little plates to be welded in, took out one of the IRS supports as going to do from rear struts instead :)
https://ep1.pinkbike.org/p5pb16282569/p5pb16282569.jpg

[scottmasterton]

More work on the dash
https://ep1.pinkbike.org/p5pb16282572/p5pb16282572.jpg
https://ep1.pinkbike.org/p5pb16282570/p5pb16282570.jpg

Removed part of the cross from the main hoop as really need the space, going to look at what else we can do here to retain some of the strength
https://ep1.pinkbike.org/p5pb16282581/p5pb16282581.jpg

[scottmasterton]

Tacced in windscreen gussets and slightly modified tach bit on dash board to help with windscreen clearance
https://ep1.pinkbike.org/p5pb16284592/p5pb16284592.jpg

Started mount onto cage for clutch reservoir
https://ep1.pinkbike.org/p5pb16284596/p5pb16284596.jpg

Cut down cross brace as it was a bit too high
https://ep1.pinkbike.org/p5pb16284597/p5pb16284597.jpg

[scottmasterton]

http://www.pngclub.com/forum/images/misc/quote_icon.png Originally Posted by paul james http://www.pngclub.com/forum/images/buttons/viewpost-right.png (http://www.pngclub.com/forum/showthread.php?p=2308227#post2308227)
Interesting set up, bit hard to picture quite how it works. Is the beam split in the middle somehow?



Here we go :)
https://ep1.pinkbike.org/p5pb16290693/p5pb16290693.jpg

[scottmasterton]

Started spraying and welding up the cross brace
https://ep1.pinkbike.org/p5pb16294737/p5pb16294737.jpg

[Iain]

Most don’t bother putting in the cross brace again so fair play for going to the effort. Are you going to weld a top in to box it off?

[scottmasterton]

Most don’t bother putting in the cross brace again so fair play for going to the effort. Are you going to weld a top in to box it off?

Thanks Iain :) of course, maybe this evening

[scottmasterton]

All tacced up :)
https://ep1.pinkbike.org/p5pb16296449/p5pb16296449.jpg

[scottmasterton]

Hydro sat in place
https://ep1.pinkbike.org/p5pb16303282/p5pb16303282.jpg

Petrol tank modifications in progress
https://ep1.pinkbike.org/p5pb16303284/p5pb16303284.jpg
https://ep1.pinkbike.org/p5pb16303286/p5pb16303286.jpg

Sitting nicely under car, working out mounting points for tank sump/guard
https://ep1.pinkbike.org/p5pb16303288/p5pb16303288.jpg

[scottmasterton]

Modifying the cage for better driver seat placement
https://ep1.pinkbike.org/p5pb16334286/p5pb16334286.jpg
https://ep1.pinkbike.org/p5pb16334283/p5pb16334283.jpg
https://ep1.pinkbike.org/p5pb16334284/p5pb16334284.jpg

[scottmasterton]

Started work on the tank guard/ undertray/ flat-ish floor mounts


https://ep1.pinkbike.org/p5pb16348613/p5pb16348613.jpg

Finally tacced in the roof bar to meet MSA regs

https://ep1.pinkbike.org/p5pb16348614/p5pb16348614.jpg

[RallyMarshal]

Is the conversion to IRS allowable with an MSA Category 1 logbook? I ask as MSA Bluebook has the following line under rallying..

48.4.1. The suspension must retain the operating principle and utilise the mounting points as provided by the vehicle manufacturer.

I know you've done a lot of work on it, but wouldn't want you to finish fabrication and get caught out is all.

Paul..

[scottmasterton]

Is the conversion to IRS allowable with an MSA Category 1 logbook? I ask as MSA Bluebook has the following line under rallying..

48.4.1. The suspension must retain the operating principle and utilise the mounting points as provided by the vehicle manufacturer.

I know you've done a lot of work on it, but wouldn't want you to finish fabrication and get caught out is all.

Paul..

Hi Paul from what we've seen this should be ok as it's been done before on novas that have an MSA logbook 1 and harry hockly do it to there swifts and similar.

Under the impression it more means that turret location is not allowed to be altered and similar to prevent things such as inboard setups but will see if can speak to a scrutineer

Thanks :)

[scottmasterton]

Is the conversion to IRS allowable with an MSA Category 1 logbook? I ask as MSA Bluebook has the following line under rallying..

48.4.1. The suspension must retain the operating principle and utilise the mounting points as provided by the vehicle manufacturer.

I know you've done a lot of work on it, but wouldn't want you to finish fabrication and get caught out is all.

Paul..

Hi Paul from what we've seen this should be ok as it's been done before on novas that have an MSA logbook 1 and harry hockly do it to there swifts and similar.

Under the impression it more means that turret location is not allowed to be altered and similar to prevent things such as inboard setups but will see if can speak to a scrutineer

Thanks :)

[RallyMarshal]

Hi Paul from what we've seen this should be ok as it's been done before on novas that have an MSA logbook 1 and harry hockly do it to there swifts and similar.

Under the impression it more means that turret location is not allowed to be altered and similar to prevent things such as inboard setups but will see if can speak to a scrutineer

Thanks :)

I wasnt sure if the Hockly cars were cat2 modified rather than cat1 due to this. I know of a rwd car recently done with bulkhead mods (to move engine back in the bay) that forced it to be cat 2 passported rather than cat1. I guess asking MSA technical would be the best most foolproof way to go at this stage as a written answer from them will be hard to refute when the passporting process is done. Wouldnt have wanted you to finish the whole process then the MSA refuse to issue a passport!

Paul..

[scottmasterton]

I wasnt sure if the Hockly cars were cat2 modified rather than cat1 due to this. I know of a rwd car recently done with bulkhead mods (to move engine back in the bay) that forced it to be cat 2 passported rather than cat1. I guess asking MSA technical would be the best most foolproof way to go at this stage as a written answer from them will be hard to refute when the passporting process is done. Wouldnt have wanted you to finish the whole process then the MSA refuse to issue a passport!

Paul..

Just spoke to someone that used to work for M Sport and they were one of the ones suggesting/agreeing with the IRS in the first place lol he seems to think it'll be fine. Prior to starting we found quite a few cars with their own versions mainly Corsas but most of the corsas were built to a S1600 spec. Not quite sure if thats cat 1 or what.
Agreed that would be a total nightmare! Will keep you updated via the thread as to what we're told by the MSA :)

[scottmasterton]

Had a mate come do some welding, feel like we're really getting somewhere now [emoji16]
More prep work to do before he comes back on Monday and that should be the topside rear work done https://uploads.tapatalk-cdn.com/20180922/93fed39212687a13a3ffd179c209b72b.jpghttps://uploads.tapatalk-cdn.com/20180922/6fd9bb60afd781968e523187ad932dec.jpg

Sent from my EML-L09 using Tapatalk

[scottmasterton]

Thats the floor almost done with the little plates added in to meet the cage

https://ep1.pinkbike.org/p5pb16406420/p5pb16406420.jpg

Seam welding done topside and battery box mounts welded in

https://ep1.pinkbike.org/p5pb16406423/p5pb16406423.jpg

Steering rack strengthener bracket in

https://ep1.pinkbike.org/p5pb16406422/p5pb16406422.jpg

[Iain]

Lots of roll cage! Should be stiff enough!

I saved a good amount of weight and complexity by mounting my battery in passengers footwell. Have you thought about putting it there? Much shorter run to starter motor.

[scottmasterton]

Lots of roll cage! Should be stiff enough!

I saved a good amount of weight and complexity by mounting my battery in passengers footwell. Have you thought about putting it there? Much shorter run to starter motor.

Didn't look at that to be honest, bit late now lol plenty of other ways to save that sort of weight :)

[scottmasterton]

Got the shape for the rear tank guard and the front sump guard

https://ep1.pinkbike.org/p5pb16406417/p5pb16406417.jpg

https://ep1.pinkbike.org/p5pb16406418/p5pb16406418.jpg


Compression tested the engine, It's goosed as we thought - making around 60 psi on each cylinder :tard:
Took the engine out and stripped everything else off the shell to get shell back on the spit

https://ep1.pinkbike.org/p5pb16406414/p5pb16406414.jpg

[scottmasterton]

Pedals just needing last bit of cleanup, a spray and some grip tape


https://ep1.pinkbike.org/p5pb16436356/p5pb16436356.jpg

https://ep1.pinkbike.org/p5pb16436515/p5pb16436515.jpg

Started mount for wiper motor

https://ep1.pinkbike.org/p5pb16436322/p5pb16436322.jpg

[scottmasterton]

Some more progress :)

https://ep1.pinkbike.org/p5pb16621902/p5pb16621902.jpg
https://ep1.pinkbike.org/p5pb16621930/p5pb16621930.jpg
https://ep1.pinkbike.org/p5pb16621922/p5pb16621922.jpg

[millworm]

Top work mate

[scottmasterton]

Not a huge amount of progress as there has been this sat in the way :tard: christmas etc

https://ep1.pinkbike.org/p5pb16774241/p5pb16774241.jpg

Got the old guy a nice christmas present though which will be hung somewhere in the garage not the best picture but you get the idea

https://ep1.pinkbike.org/p5pb16774242/p5pb16774242.jpg

Think that gave him a bit of motivation, got the Porsche sorted, out and cracked back into some more work on the Nova

https://ep1.pinkbike.org/p5pb16774239/p5pb16774239.jpg

[totalnova]

Two of my favorite cars in one post. Looking good.

[scottmasterton]

Stripped the engine down nothing seems too bad, pistons and bore good, shells look pretty new, exhaust valves just really pitted

https://ep1.pinkbike.org/p5pb16815094/p5pb16815094.jpg
https://ep1.pinkbike.org/p5pb16815087/p5pb16815087.jpg
https://ep1.pinkbike.org/p5pb16815013/p5pb16815013.jpg
https://ep1.pinkbike.org/p5pb16814993/p5pb16814993.jpg
https://ep1.pinkbike.org/p5pb16834381/p5pb16834381.jpg
https://ep1.pinkbike.org/p5pb16834385/p5pb16834385.jpg

[scottmasterton]

Modified tank all welded up :D just need to test it does not leak next

https://ep1.pinkbike.org/p5pb16834384/p5pb16834384.jpg
https://ep1.pinkbike.org/p5pb16834383/p5pb16834383.jpg

Mounts as well just need a bit of a clean up then primed

https://ep1.pinkbike.org/p5pb16834382/p5pb16834382.jpg

More welding in the engine bay

https://ep1.pinkbike.org/p5pb16834380/p5pb16834380.jpg

[scottmasterton]

Chassis plating kit finished welding in :d Just little holes on top of wheel arch, any rust holes, big holes around cage at bulkhead then finalise wiper mounting to complete the engine bay

https://ep1.pinkbike.org/p5pb16857410/p5pb16857410.jpg

https://ep1.pinkbike.org/p5pb16857414/p5pb16857414.jpg

[jackosnovaturbo]

Love it! some serious fabbing going on there.

What radiator is that you have there? I've been looking for one about that size.

[scottmasterton]

Love it! some serious fabbing going on there.

What radiator is that you have there? I've been looking for one about that size.

Thanks Jacko :d think it is from a diesel Nova could be way off though had it for years

[scottmasterton]

Finalised boot stay location and welded in, Using bonnet stay rubber to secure does anyone know where to get a new one?

https://ep1.pinkbike.org/p5pb16880477/p5pb16880477.jpg

Cracking on with wiring for a bit

https://ep1.pinkbike.org/p5pb16878162/p5pb16878162.jpg

[Iain]

Nice idea adding a stay rod. I might do something similar.

You'd be crazy to use the orignal rubber part though they're all broken!

[scottmasterton]

Nice idea adding a stay rod. I might do something similar.

You'd be crazy to use the orignal rubber part though they're all broken!


Have some spare brand new rubbers just need to work out how to put one of them in once its been welded in :tard:

https://ep1.pinkbike.org/p5pb16878164/p5pb16878164.jpg

[scottmasterton]

Redoing the brackets for bootlid

https://ep1.pinkbike.org/p5pb16989928/p5pb16989928.jpg

Cylinder head for a bit of a clean up in parts washer to get rid of carbon build up/general tidy up

https://ep1.pinkbike.org/p5pb16989927/p5pb16989927.jpg

Looking pretty good so far

https://ep1.pinkbike.org/p5pb16989926/p5pb16989926.jpg

[millworm]

Hmm think my garage could benifit from a parts washer

[scottmasterton]

Hmm think my garage could benifit from a parts washer

Great thing to have :thumb:

[scottmasterton]

More work on the rear arches :)

https://ep1.pinkbike.org/p5pb17005133/p5pb17005133.jpg

https://ep1.pinkbike.org/p5pb17005143/p5pb17005143.jpg

https://ep1.pinkbike.org/p5pb17005131/p5pb17005131.jpg

Got rid of some holes that are no longer required in the bulkhead

https://ep1.pinkbike.org/p5pb17005142/p5pb17005142.jpg

Just about finished cleaning up the head

https://ep1.pinkbike.org/p5pb17005139/p5pb17005139.jpg

[scottmasterton]

Been too busy with other projects of late but now they are done hopefully we'll see some progress lol
More work on the dash

https://ep1.pinkbike.org/p5pb17797337/p5pb17797337.jpg

Started work on sump guard/flat floor things for front and rear of the car

https://ep1.pinkbike.org/p5pb17785440/p5pb17785440.jpg

https://ep1.pinkbike.org/p5pb17785444/p5pb17785444.jpg

[scottmasterton]

Pressure tested the tank after a bit more work - Its looking to be good now :d

https://ep1.pinkbike.org/p5pb17926597/p5pb17926597.jpg

More work on the bumpers

https://ep1.pinkbike.org/p5pb17926595/p5pb17926595.jpg

https://ep1.pinkbike.org/p5pb17926593/p5pb17926593.jpg

And the front sump guard/flat floor thing

https://ep1.pinkbike.org/p5pb17926592/p5pb17926592.jpg

[scottmasterton]

Some work on the fuel setup :)
As you can see few more bits need welded + tidied up

https://ep1.pinkbike.org/p5pb17969460/p5pb17969460.jpg

Bulkhead area almost finished

https://ep1.pinkbike.org/p5pb17969467/p5pb17969467.jpg
https://ep1.pinkbike.org/p5pb17969471/p5pb17969471.jpg

[scottmasterton]

Half tank getting there :)

https://ep1.pinkbike.org/p5pb18351175/p5pb18351175.jpg
https://ep1.pinkbike.org/p5pb18351174/p5pb18351174.jpg

Due to front cage cross brace we are having to make new bonnet hinge setup

https://ep1.pinkbike.org/p5pb18351172/p5pb18351172.jpg
https://ep1.pinkbike.org/p5pb18351173/p5pb18351173.jpg

[scottmasterton]

17s would not fit in standard spare wheel well so we're making an alternative setup

https://ep1.pinkbike.org/p5pb18351168/p5pb18351168.jpg

https://ep1.pinkbike.org/p5pb18351164/p5pb18351164.jpg

[scottmasterton]

Fibreglass bonnet almost finished :d
https://ep1.pinkbike.org/p5pb18653478/p5pb18653478.jpg

[millworm]

Looking good, would it have not been easier to just make the bonnet removable?

[JoeWak98]

Coming on now, has the shell already been MSA log booked?


Sent from my iPhone using Tapatalk

[The Simps]

Cracking project this, never seen it before. You’ve been at it a long time too! Have you found yourself having to resist going back a redoing stuff you did years back?

In for more :)

[scottmasterton]

Looking good, would it have not been easier to just make the bonnet removable?

Definitely would have been easier lol Better for on stage etc if necessary to just be able to prop it up then pop it back shut

[scottmasterton]

Coming on now, has the shell already been MSA log booked?


Sent from my iPhone using Tapatalk

Thanks Joe :) Not yet while to go before we're there

[scottmasterton]

Cracking project this, never seen it before. You’ve been at it a long time too! Have you found yourself having to resist going back a redoing stuff you did years back?

In for more :)

Thanks! Yes it has been a while, lots of delays and life along the way. There has a been a couple of bits but not too much from what I can recall

[Iain]

17s?

[JoeWak98]

Thanks Joe :) Not yet while to go before we're there

Just a heads up but you probably already know but there not wanting the captive floating nut style seat bars on new builds now. Lad I know had to cut his out as they changed the Regs 2 weeks after he put them in!


Sent from my iPhone using Tapatalk

[scottmasterton]

17s?

Hi Iain :) we've got a selection of 15s but recently got some 17s to try out as well

https://ep1.pinkbike.org/p5pb18671098/p5pb18671098.jpg

[scottmasterton]

Just a heads up but you probably already know but there not wanting the captive floating nut style seat bars on new builds now. Lad I know had to cut his out as they changed the Regs 2 weeks after he put them in!


Sent from my iPhone using Tapatalk

Thanks Joe :) sounds like a nightmare :tard: the nuts are captive but not floating think whats done will be OK

[scottmasterton]

Front wing moulds coming along nicely :d

https://ep1.pinkbike.org/p5pb18695939/p5pb18695939.jpg
https://ep1.pinkbike.org/p5pb18695937/p5pb18695937.jpg

[scottmasterton]

Fitted brake bias adjuster to dash

https://ep1.pinkbike.org/p5pb18694432/p5pb18694432.jpg

Just need to source something to fit this to work together
https://ep1.pinkbike.org/p5pb18694434/p5pb18694434.jpg

[The Simps]

Good to see more progress!

How much wider will those fronts be over stock?

[scottmasterton]

Good to see more progress!

How much wider will those fronts be over stock?

Not 100% sure have you got a standard arch to measure the width lol

[scottmasterton]

Wings out of the moulds pretty happy with how they've turned out :d:d

https://ep1.pinkbike.org/p5pb18705350/p5pb18705350.jpg
https://ep1.pinkbike.org/p5pb18705351/p5pb18705351.jpg
https://ep1.pinkbike.org/p5pb18705352/p5pb18705352.jpg

[Iain]

Taking your own mould and making wings is pretty impressive. They've turned out great.

[scottmasterton]

Taking your own mould and making wings is pretty impressive. They've turned out great.

Thanks Iain :d did the same with the bonnet as well, Front bumper then rear next :)

https://ep1.pinkbike.org/p5pb18653479/p5pb18653479.jpg
https://ep1.pinkbike.org/p5pb18653480/p5pb18653480.jpg

[scottmasterton]

Finished trimming doors and put seals in, Used Corsa B main rubbers and I think part of a Mk1 focus rubbers

https://ep1.pinkbike.org/p5pb18749401/p5pb18749401.jpg

Trying the bonnet & wings together

https://ep1.pinkbike.org/p5pb18749399/p5pb18749399.jpg

Fitted Aerocatches

https://ep1.pinkbike.org/p5pb18753625/p5pb18753625.jpg

[scottmasterton]

Picked up some coilovers and rear shocks :d

https://ep1.pinkbike.org/p5pb18777496/p5pb18777496.jpg
https://ep1.pinkbike.org/p5pb18788203/p5pb18788203.jpg

[scottmasterton]

Got another seat for a great price on Ebay :d

https://ep1.pinkbike.org/p5pb18793137/p5pb18793137.jpg

https://ep1.pinkbike.org/p5pb18793134/p5pb18793134.jpg

Fitted aerocatches to the bootlid

https://ep1.pinkbike.org/p5pb18793135/p5pb18793135.jpg

[scottmasterton]

CAD ;)lol to make air box setup

https://ep1.pinkbike.org/p4pb18852765/p4pb18852765.jpg

Tried the 17s on the front

https://ep1.pinkbike.org/p4pb18852764/p4pb18852764.jpg

[Nova_Tek]

That's some high tech shizzle right there!

[scottmasterton]

Bit more progress with the CAD ;) Only issue is will need to change bonnet stay setup once again :tard:

https://ep1.pinkbike.org/p5pb18858383/p5pb18858383.jpg

https://ep1.pinkbike.org/p5pb18858384/p5pb18858384.jpg

Rear bumper out of the mould pretty pleased with how its turned out :d needs a bit of a trim/sand and need to workout best way to mount

https://ep1.pinkbike.org/p5pb18858382/p5pb18858382.jpg

Rear arches on as well think moulds need work to meet bumper better. Also managed to pick up some tyres to try 17s on :d

https://ep1.pinkbike.org/p5pb18858386/p5pb18858386.jpg

https://ep1.pinkbike.org/p5pb18858387/p5pb18858387.jpg

[Nova_Tek]

Skills!

[scottmasterton]

Fuel setup all pretty much done. Will hopefully be able to get it running soon just a bit of wiring still to do
- For anyone wondering this is the K20 out of another project car, the K20 for this is still to be rebuilt

https://ep1.pinkbike.org/p5pb18863468/p5pb18863468.jpg
https://ep1.pinkbike.org/p5pb18863469/p5pb18863469.jpg

Rolled it outside to use the lift for a few minutes, arches definitely need a good bit more trimming

https://ep1.pinkbike.org/p5pb18868621/p5pb18868621.jpg

[8valve-craig]

Good work, Looks a bit like a Renault 5 now at the back. I have build a cold air feed similar to that on mine, go take a look at my project. I lowered my rad and took the air from behind the grill.

[scottmasterton]

Good work, Looks a bit like a Renault 5 now at the back. I have build a cold air feed similar to that on mine, go take a look at my project. I lowered my rad and took the air from behind the grill.

Thanks Craig! Have seen it looks good, any updates on your car? The car is going to look a bit peculiar at the front due to space/setup but function over form lol

[scottmasterton]

Progress on the air intake setup just need to get some sort of rubber seal to use around the top where it meets the bonnet and work on where the 2 pieces come together
All the pipework and sensor setup is done for the air filter itself

https://ep1.pinkbike.org/p5pb19011308/p5pb19011308.jpg

https://ep1.pinkbike.org/p5pb19011305/p5pb19011305.jpg

https://ep1.pinkbike.org/p5pb19011300/p5pb19011300.jpg

Front and rear undertray progress too :d

https://ep1.pinkbike.org/p5pb19011299/p5pb19011299.jpg
https://ep1.pinkbike.org/p5pb19011301/p5pb19011301.jpg

[Iain]

Cold air intake looks great. Is fibreglass strong enough for the underside of a rally car?

[scottmasterton]

Cold air intake looks great. Is fibreglass strong enough for the underside of a rally car?

Thanks Iain! We'll see how it goes with the 3 layers and current mounting points and go from there :tard:

[scottmasterton]

Front undertray progress

https://ep1.pinkbike.org/p5pb19172139/p5pb19172139.jpg

Picked up some 17x7s for the rear - If anyone knows of any Team Dynamics 17x7 or 17x8s for sale please let me know

https://ep1.pinkbike.org/p5pb19172140/p5pb19172140.jpg

Front brake lines installed

https://ep1.pinkbike.org/p5pb19172142/p5pb19172142.jpg

Rear undertray almost finished

https://ep1.pinkbike.org/p5pb19172152/p5pb19172152.jpg
https://ep1.pinkbike.org/p5pb19172145/p5pb19172145.jpghttps://ep1.pinkbike.org/p5pb19172156/p5pb19172156.jpg

[scottmasterton]

Started on the grill piece

https://ep1.pinkbike.org/p5pb19188443/p5pb19188443.jpg
https://ep1.pinkbike.org/p5pb19223922/p5pb19223922.jpg

Started to work out how much to trimming needed on rear arches

https://ep1.pinkbike.org/p5pb19223920/p5pb19223920.jpg

[scottmasterton]

More work on the grill piece pretty much have it finished, not sure on the look of it but it will do for now :)
Mounted and wired up light bar :d

https://ep1.pinkbike.org/p5pb19392633/p5pb19392633.jpg

https://ep1.pinkbike.org/p5pb19392604/p5pb19392604.jpg

Fit exhaust tip & cut bumper

https://ep1.pinkbike.org/p5pb19392610/p5pb19392610.jpg

[House]

Love how well all your spanner's are organised in the back ground. That takes effort.

[scottmasterton]

Love how well all your spanner's are organised in the back ground. That takes effort.

Thanks House :d:thumb:

[Iain]

Like the bumpers but the grille's really not doing it for me.

[torquey]

Looking good what's going on with the grille though?

[scottmasterton]

Looking good what's going on with the grille though?

Its due to the position of the radiator :tard: will most likely redo at some point

[scottmasterton]

Got it running :d:d


http://www.youtube.com/watch?v=7N8a4jPfEOE&feature=youtu.be

[novarally]

So the undertrays are simply sheets of fibreglass?

I'm curious as my Nova now has a flat bottom and we are inclined to skin it with aluminium sheet, but other options will be considered. I'd do it in carbon fibre but the cost is high.

[scottmasterton]

So the undertrays are simply sheets of fibreglass?

I'm curious as my Nova now has a flat bottom and we are inclined to skin it with aluminium sheet, but other options will be considered. I'd do it in carbon fibre but the cost is high.

At the moment yes :) will see how they hold up and go from there

[scottmasterton]

Took a mould from the Corsa side light pods to do something similar for the nova

https://ep1.pinkbike.org/p5pb19437551/p5pb19437551.jpg

https://ep1.pinkbike.org/p5pb19437550/p5pb19437550.jpg

https://ep1.pinkbike.org/p5pb19437547/p5pb19437547.jpg

[Iain]

Assume you're planning some night events then!

[House]

Assume you're planning some night events then!

Is the plan to melt the trees out the way with radiated heat, would make stage times faster!!

I will agree you can't have enough light though!!

[scottmasterton]

Assume you're planning some night events then!

At some point yes :thumb:

[scottmasterton]

Is the plan to melt the trees out the way with radiated heat, would make stage times faster!!

I will agree you can't have enough light though!!

There's always space for more lights ;)lol

[scottmasterton]

Further progress on the pods

https://ep1.pinkbike.org/p5pb19470798/p5pb19470798.jpg
https://ep1.pinkbike.org/p5pb19470799/p5pb19470799.jpg

[Nova_Tek]

Assume you're planning some night events then!


Is the plan to melt the trees out the way with radiated heat, would make stage times faster!!

lol

[Nova_Tek]

Further progress on the pods

https://ep1.pinkbike.org/p5pb19470798/p5pb19470798.jpg
https://ep1.pinkbike.org/p5pb19470799/p5pb19470799.jpg

Looking a bit mental :thumb:

[scottmasterton]

Looking a bit mental :thumb:

Getting there :d:d

[scottmasterton]

Got the new front caliper brackets :d

https://ep1.pinkbike.org/p5pb19480735/p5pb19480735.jpg
https://ep1.pinkbike.org/p5pb19480734/p5pb19480734.jpg

[Iain]

Liking those, what size disc they for? Guess you just shim it out for a bigger disc?

[scottmasterton]

Liking those, what size disc they for? Guess you just shim it out for a bigger disc?

295mm the same as we have on the corsa, pretty sure the calipers are only suitable up to around 300mm need to check that though for future but these should be plenty big enough for now :thumb:

[scottmasterton]

Got some discs and pads from Questmead as the previous were borrowed from Corsa :d

https://ep1.pinkbike.org/p5pb19505612/p5pb19505612.jpg

Front brake setup on

https://ep1.pinkbike.org/p5pb19504894/p5pb19504894.jpg

Side light pods out of the moulds and tested on the bumper, pretty happy with how they have come out

https://ep1.pinkbike.org/p5pb19504891/p5pb19504891.jpg

Not much more progress other progress today as been distracted modifying the blast cabinet to get more use out of it
Previously you could not see to well due the limited light inside so have added these 2

https://ep1.pinkbike.org/p5pb19504897/p5pb19504897.jpg

Looking like it has worked quite well

https://ep1.pinkbike.org/p5pb19504899/p5pb19504899.jpg

Also trying to add an extraction system

https://ep1.pinkbike.org/p5pb19504895/p5pb19504895.jpg

https://ep1.pinkbike.org/p5pb19504898/p5pb19504898.jpg

[scottmasterton]

About finished with the side lights :djust need to finish wiring :):)

https://ep1.pinkbike.org/p5pb19521861/p5pb19521861.jpg

https://ep1.pinkbike.org/p5pb19546650/p5pb19546650.jpg
https://ep1.pinkbike.org/p5pb19556981/p5pb19556981.jpg

[scottmasterton]

Rear calipers sand blasted

https://ep1.pinkbike.org/p5pb19634264/p5pb19634264.jpg

Sprayed and on the car

https://ep1.pinkbike.org/p5pb19633730/p5pb19633730.jpg

[scottmasterton]

:)Not a huge amount of progress as of late, managed to get some rear Gaz coilovers and some polycarb windows for a good deal :):)
Waiting on driveshafts being made and a couple of electric bits n bobs

https://ep1.pinkbike.org/p5pb19749736/p5pb19749736.jpg

[House]

Where you getting your driveshafts made??

[scottmasterton]

Where you getting your driveshafts made??

Hi House :):)

It's a bloke from Dundee can't remember what his company is called off the top of my head

[Shamish82]

Hi House :):)

It's a bloke from Dundee can't remember what his company is called off the top of my headIs it Agra engineering

Sent from my SM-G950F using Tapatalk

[scottmasterton]

Is it Agra engineering

Sent from my SM-G950F using Tapatalk

No another company, Tayside something

[House]

What sort of money you paying? Just had 2 shafts made by Berrisford.

[scottmasterton]

What sort of money you paying? Just had 2 shafts made by Berrisford.

Not sure, worried to find out. Will let you know
How much were they from Berrisford? How'd they do it, What grade?

[scottmasterton]

Been working on the wheel/tyre rack making it a bit bigger :)

https://ep1.pinkbike.org/p5pb19839587/p5pb19839587.jpg

https://ep1.pinkbike.org/p5pb19839586/p5pb19839586.jpg

[scottmasterton]

Been working on the wheel/tyre rack making it a bit bigger :)

https://ep1.pinkbike.org/p5pb19839587/p5pb19839587.jpg

https://ep1.pinkbike.org/p5pb19839586/p5pb19839586.jpg

[scottmasterton]

Been working on wiring so not really any pictures, Got this Intercom for a good deal just waiting on 12v adaptor

https://ep1.pinkbike.org/p5pb20011207/p5pb20011207.jpg

[scottmasterton]

Got all the lights sorted and the new reg put on

https://ep1.pinkbike.org/p5pb20191136/p5pb20191136.jpg

[8valve-craig]

Needs more lights.

[prs]

Needs more lights.

+1

[torquey]

Wow that is bright!!

[scottmasterton]

We managed to get up to Crail on Sunday just there for a 1st test, only appear to have pictures of the car on the trailer haha
Was brilliant to finally get a shot :D
Had an issue with what seemed to be fuel starvation, Ebay cheap 'walbro 255' looked to not be up to the job so has since been replaced with a proper item from Torques Hopefully that sorts that
Some tweaks to be made before next test in a few weeks, Front to be dropped 25mm, Play with adjustment on rear coilovers to stiffen up, Replace rear hub bearings and look at rear bushes - got some from Floflex whilst we wait on the Powerflex coming but they are a terrible fit - there is a lot of movement overall at the rear wheels
Ordered LSD from Gripper Diffs and a 5.84 final drive to pop in at the same time
Also need to suss out why the brake fluid reservoirs are weeping out the bottom

https://ep1.pinkbike.org/p5pb20604155/p5pb20604155.jpg
https://ep1.pinkbike.org/p5pb20604154/p5pb20604154.jpg
https://ep1.pinkbike.org/p5pb20604157/p5pb20604157.jpg
:)

[novarally]

I'd highly recommend some doors and windows for aerodynamics.

And safety!


;):);)

[scottmasterton]

I'd highly recommend some doors and windows for aerodynamics.

And safety!


;):);)We'll get them on at some point [emoji3]

Sent from my VOG-L09 using Tapatalk

[scottmasterton]

Engine and box out, Hopefully LSD and Final Drive will arrive today or tomorrow

https://ep1.pinkbike.org/p5pb20627745/p5pb20627745.jpg

[scottmasterton]

Gearbox apart

https://ep1.pinkbike.org/p5pb20647672/p5pb20647672.jpg

Gripper diff arrived :D

https://ep1.pinkbike.org/p5pb20647673/p5pb20647673.jpg

Waiting on new diff bearings and final drive to be delivered

[Jonesfach]

Big job!

[scottmasterton]

Put the gearbox back together, Couldnt get 1st and 2nd which wasnt ideal but it meant we could get back testing at Crail
After lowering the front and putting in the LSD, even 3rd up the difference was monster
Unfortunately somewhere about an hour into testing the n/s front tie bracket ripped itself apart, tore through the hub and messed up the inner arch a bit
Was a bit of a nightmare getting it back on the trailer but we managed :D

https://ep1.pinkbike.org/p5pb20997641/p5pb20997641.jpg

https://ep1.pinkbike.org/p5pb20997645/p5pb20997645.jpg

https://ep1.pinkbike.org/p5pb20997643/p5pb20997643.jpg

https://ep1.pinkbike.org/p5pb20997649/p5pb20997649.jpg

[scottmasterton]

Since then we have made new brackets which should be bombproof, took the box back apart, had no end of problems sorting that but it looks to be working so fingers crossed
Lots to do tomorrow for testing again at the weekend

[House]

How did that knuckle break? Especially on what looks like an airfield/tarmac stage, must have been giving it beans

[scottmasterton]

How did that knuckle break? Especially on what looks like an airfield/tarmac stage, must have been giving it beans

Having too much fun & the previous mounts were not up to the job tore themselves apart and the tie/castor bar went through the knuckle, new ones below

https://ep1.pinkbike.org/p5pb21069271/p5pb21069271.jpg

[scottmasterton]

Got up to Crail for a proper rally test day, previous 2 tests had just been on one bit of runway but this was approx 3 mile laps
Went out repeatedly for about 3 or 4 laps at a time throughout the day making adjustments and checks as we went. What a car! :D
All was going brilliantly until just after lunch time when we were then to do the opposite direction, around a third of the way round the first lap went to change gear and all of a sudden no drive.
Quickly realised that one of the shafts had sheared, jumped out to locate the bits of it on the track once it was safe to do so but could not understand as to why could not get one wheel drive so had to wait for a tow
:cry::cry:
Turned out once we got the car back to the garage up on the ramp that the other shaft had been spinning inside its sleeve, they must have both gone about the same time haha

https://ep1.pinkbike.org/p5pb21025252/p5pb21025252.jpg

Manta trying to chase us down

https://ep1.pinkbike.org/p5pb21025256/p5pb21025256.jpg

[Iain]

Having too much fun & the previous mounts were not up to the job tore themselves apart and the tie/castor bar went through the knuckle, new ones below

https://ep1.pinkbike.org/p5pb21069271/p5pb21069271.jpg

Surprised you don't want the metal bracket supporting that bolt from both ends given the forces on it?

[scottmasterton]

Surprised you don't want the metal bracket supporting that bolt from both ends given the forces on it?

Ideally they would be, however they need to be lower down than most people have them at the front to clear the gearbox which with other factors makes them already pretty difficult to access so we opted to use higher grade bolts and cds steel tube through with a couple of other things, the brackets should be more than capable

[House]

Having that bolt in single shear is dangerous, regardless of the bolt strength.

Can you not box it in on 3 sides

https://uploads.tapatalk-cdn.com/20210805/3eff940fdda35e656d37f16e6f93ac14.png

Would be a lot safer, especially if you're using 10.9 or 12.9 bolts

[total_vauxhall]

As said pal that bolt will be under so much stress. Im still only poly bushed and on some vids you can see my wheel move from its stationery position and touch the back of the inner arch on launch. had i mounted like this i dare say it would shear that bolt clean off. cant you bring another bracket to the lower side of the rose joint.

Sent from my MAR-LX1B using Tapatalk

[scottmasterton]

This is what we've got so far, will look to see if we can box it in more or redesign

https://ep1.pinkbike.org/p5pb21205926/p5pb21205926.jpg
https://ep1.pinkbike.org/p5pb21205929/p5pb21205929.jpg

[scottmasterton]

Picked up some MO5s 17x8 ET49 for a good price :D popped some of the Hankooks on

https://ep1.pinkbike.org/p5pb21069187/p5pb21069187.jpg

https://ep1.pinkbike.org/p5pb21205540/p5pb21205540.jpg

Mocking up strut mods

https://ep1.pinkbike.org/p5pb21205973/p5pb21205973.jpg

[The Simps]

Love the MO?s! [emoji41]

[The Simps]

Re front tie rod mounts, couldn?t you do something like this, extending the box section down to the other side of the rod end. You can then run some diagonal plating?

https://uploads.tapatalk-cdn.com/20210828/29a4713debc4648b7f884914cf98c97d.jpg


All your stress is still at the bottom near the rod end joint. I would say you need to box it in at the bottom?

https://uploads.tapatalk-cdn.com/20210828/ff375c7f3c5f18106d1fbd85744d3947.jpg


I?m no engineer tho, but I?m sure other clever people on here can offer their opinion too.

Keep up the good work :)

[scottmasterton]

Re front tie rod mounts, couldn?t you do something like this, extending the box section down to the other side of the rod end. You can then run some diagonal plating?

https://uploads.tapatalk-cdn.com/20210828/29a4713debc4648b7f884914cf98c97d.jpg


All your stress is still at the bottom near the rod end joint. I would say you need to box it in at the bottom?

https://uploads.tapatalk-cdn.com/20210828/ff375c7f3c5f18106d1fbd85744d3947.jpg


I?m no engineer tho, but I?m sure other clever people on here can offer their opinion too.

Keep up the good work :)


Will look at this with our engineer pal and see what they reckon :)

[scottmasterton]

Custom radiator arrived which looks the business but it needs some slight alterations

https://ep1.pinkbike.org/p5pb21485061/p5pb21485061.jpg
https://ep1.pinkbike.org/p5pb21485057/p5pb21485057.jpg

We stripped the struts down and welded them up, tested them through the travel on the car and had to make some further changes

https://ep1.pinkbike.org/p5pb21373172/p5pb21373172.jpg

We then after looking at the strut design on other cars decided to try a different route to improve things
Looked at the setups on newer Hondas and then Renaultsport cars, Megane 225 being the easiest to come by

https://ep1.pinkbike.org/p4pb21205992/p4pb21205992.jpg

https://ep1.pinkbike.org/p5pb21205562/p5pb21205562.jpg

[scottmasterton]

Removed spring collars to turn into a coilover setup

https://ep1.pinkbike.org/p5pb21205541/p5pb21205541.jpg

Did not document progress from here all that well but see below different iterations
Calipers from the MK3 Megane RS

https://ep1.pinkbike.org/p5pb21331575/p5pb21331575.jpg

https://ep1.pinkbike.org/p5pb21331577/p5pb21331577.jpg

https://ep1.pinkbike.org/p5pb21331579/p5pb21331579.jpghttps://ep1.pinkbike.org/p5pb21373182/p5pb21373182.jpg

[Iain]

What are the benefits of that over a Nova knuckle?

[House]

What have you been trying to improve in regards to suspension geometry??

Seems like a huge amount of work for possible gains over a proven available adjustable suspension kit.

We can get between +1 and -3 degrees camber and 5 degrees of caster with out kits. Admittedly bump steer is still an issue but are working on that.

[scottmasterton]

Similar to below is the idea

https://global.honda/innovation/technology/automobile/Dual-axis-strut-suspension-picturebook.html

[Iain]

Interesting read thanks. So in short:

"By positioning the steering axis closer to the wheel center, a major cause of torque steering, the amount of center offset, was drastically reduced."

So this is all about reducing torque steer rather than giving extra geometry adjustment. You find the torque steer particularly bad on your test days?

[scottmasterton]

Interesting read thanks. So in short:

"By positioning the steering axis closer to the wheel center, a major cause of torque steering, the amount of center offset, was drastically reduced."

So this is all about reducing torque steer rather than giving extra geometry adjustment. You find the torque steer particularly bad on your test days?



Correct!
It wasn't terrible but this will hopefully help eliminate as much as possible

[scottmasterton]

Further developments with the new setup

https://ep1.pinkbike.org/p5pb21690450/p5pb21690450.jpg

Bells and discs arrived

https://ep1.pinkbike.org/p5pb22026056/p5pb22026056.jpg

https://ep1.pinkbike.org/p5pb22052554/p5pb22052554.jpg

Now to check again that there are no rubbings etc

Just need to get the Corolla off the ramp to get back into it

https://ep1.pinkbike.org/p5pb22035278/p5pb22035278.jpg