Sport Rep Road Rally Build

[Peredur]

Some of you may know that I was building a 4dr mk2 loon for road rallies (Clicky) (http://www.pngclub.com/forum/showthread.php?198134-Project-Group-4-Door#post2135755)

However, a few weeks ago a friend (dionbee on here) offered me a hatch shell with a cage etc already in so I decided to pack in the 4dr and use the hatch shell as a base.

Aforementioned shell:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/null_zps039fe836.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/null_zps039fe836.jpg.html)

The aim is for it to be a road rally legal, stage rally car so that I can compete on local road rallies then eventually progress to stages.

As with the loon, I'm keen to get this on quite light, my target is ~700-720kg in full road rally trim. Bit of a tall order but I'll give it a go.

Spec wise the plan is as follows:

Engine:

C14SE based
AST3 Cam
L&B Bottom end
Split Webers or Dellortos

Box:

F13 CR
Swap a few cogs about from various other F13s
4.53 FD (Hopefully)
Cable Gear Linkage

Suspension & Brakes:

HHMS Bilstein Coilies
Gravel spec springs
GSi Rear ARB
4 pot front brakes
Golf rear discs
Lotus Bias Pedal Box
13" Wheels

Shell/General:

Weld-In Roll Cage (already in shell)
Bucket Seats
6 Point Harnesses
Fuel and Brake lines inside
Fuel pumps in box behind seat
Battery inside
Sump and tank guards
FG Bonnet + Tailgate
Spotlamps
Dual Reverse lenses
Misc rally wiring
Dual cowl dash
Lightened doors
Polycarb Windows
Misc Lightening

Any comments welcome, I hope to get this one done by my local event in March

Thanks

[AndrewC]

Spec sounds ok, any particular reason for the c14se? I wanted to go 1.4 16v but I already had the 1.6 8v...assume the 1.4 was what you had or is it a class choice. What's the budget? What ever it is based on my experience double it!!
Good luck....subscribing now...

[Peredur]

Well, it's going to be a 1400 8v based on a C14SE with some 12ST components thrown in for good measure and running on split webers or dellortos - aiming for about 120bhp, reason being that 16v's have to keep the standard (unbelievably restrictive) manifold for road rallies, I want to keep it 1400 to be eligible for 1400 class awards and that an 8v can run a carburetor rather than fuel injection.

Budget is roughtly £4.5K but I've got a fair few of the bits I need and thus is why there isn't a sccr box or diff on the spec list as i simply can't afford to at the moment.

Also, due to the budget I'm going for the lightweight approach as lightening components is virtually free :)

Thanks

[Connor]

Looks like a similar spec mine will be hopefully. Cage looks nice any more pics? :thumb:

[Peredur]

Not got any more pics at the moment Connor, thb I think the spec I've outlined should be plenty competitive for road rallies and I've a view to do BTRDA events in the 1400C class so it should be competitive there as well.

Got a few bits coming my way next week so should have a proper update then. Will start on it properly in the next few weeks

[boffer8]

Looks good, good spec coming together. There was a set of split webers on Facebook for sale the other day and laddo wanted quite a bit for them, think they sold though. Wouldnt bother with a rear disc conversion, extra weight over drums and no real gain especially if you will be using the handbrake :-)

[Peredur]

Thanks Boffer, that was a lad I know selling the splits but I've read up on the old school mini way of doing it so might have a bash at making up a set myself.

From what I've heard on rally forums, drums tend to lose their handbrake effectiveness over the course of and events hence why Protec developed the golf disc conversion.

With a hydraulic handbrake I would have thought discs would provide more consistency than drums :confused:

[boffer8]

Yea, they can be easy to do depending which way you do it, some people think its a waste ( me also ) but can see why you need to do it for regs.

To be honest, with the weight of your car i dont think you will need the discs. I ran drums on the night rally car/autotest car with a hydraulic handbrake and never had a minutes drama with them, operated fantastically well and they got a **** load of abuse on the BTRDA autotests, a lot more grief than you will give them on a night rally for sure!

[Peredur]

Long overdue update time!

So, Not much has happened other than gathering more parts for the build and getting the shell rolling.

Got some windows off Top BTRDA contender Justin Lawson:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/null_zps265396bd.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/null_zps265396bd.jpg.html)

Lightened a door handle for lack of anything better to do:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/null_zps746ad06d.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/null_zps746ad06d.jpg.html)

And just an engine bay shot to show the extra bracing etc.

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/null_zpsef805789.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/null_zpsef805789.jpg.html)


So... Hoping to get a bit more done in the coming weeks, few bits to do on the shell before paint.

Hoping to be done by a local rally in March or failing that one next September.

[jimbob-mcgrew]

nice design that, tidy and out the way :thumb:

you can drill a few more holes in that handle surely lol

[Peredur]

nice design that, tidy and out the way :thumb:

Thanks but, what do you mean? Sorry if I'm being a bit dense :tard:

[jimbob-mcgrew]

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/null_zpsef805789.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/null_zpsef805789.jpg.html)

^ the bracing and boxing i meant. its tucked away at the sides, nice and tidy. it wont get in the way of anything :thumb:

[Peredur]

Thanks, whoever prepped the shell did a good job. Few bits to tidy up and lighten but a really solid base

[Peredur]

Yet again, Not much actual progress has been made however, I have gathered a few more pieces for the puzzle.

Some shell work will occur soon hopefully... :d, But for now, here are some of the latest bits:

Tilton Lever Bias Valve, preferred over a screw type as it has finite settings which are easy to adjust on the go

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/BED85411-4492-4427-94E9-96724E6B67BB-9139-0000036208B40F69_zpsbd2c1a01.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/BED85411-4492-4427-94E9-96724E6B67BB-9139-0000036208B40F69_zpsbd2c1a01.jpg.html)

Terratrip 303 with carbon mount, has a clock feature as well as a trip for use on road rallies

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/E190CA63-1D67-4566-A934-5E4A68170A66-9139-00000362010F8C21_zps871eef4d.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/E190CA63-1D67-4566-A934-5E4A68170A66-9139-00000362010F8C21_zps871eef4d.jpg.html)

AP 4 pots, I hope to use these with 260*24mm discs under 14" wheels. Calipers are a very similar model to those used on the GrpA cars

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/CC97AF25-DA48-4EDD-B765-6960D6028F86-9139-00000361FAFCF28B_zps4ea15978.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/CC97AF25-DA48-4EDD-B765-6960D6028F86-9139-00000361FAFCF28B_zps4ea15978.jpg.html)

HHMS Solid Tie bar mounts and Uniballs, Offer much more precise handling and won't put you in the trees when a standard ball joint breaks

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/973273C6-D2CC-4EFE-B38B-94354102E759-9139-00000361F21E4FB8_zps725f303e.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/973273C6-D2CC-4EFE-B38B-94354102E759-9139-00000361F21E4FB8_zps725f303e.jpg.html)

Sparco Prodrive bucket, as used in the works Subarus, out of date but ideal for Road Rallies.

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/86218E86-964F-4337-B275-8A680D43D8FB-9139-00000361EAECD3F6_zps77d713ce.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/86218E86-964F-4337-B275-8A680D43D8FB-9139-00000361EAECD3F6_zps77d713ce.jpg.html)

[toymex]

Nice brakes ,I am after a set of AP,s if you know of any for sale

[Peredur]

Got a set of pistons today for my slightly experimental 1400 build:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/4A8E57D6-65D9-471C-B9C5-A7B52C9B0D22-4086-000001776CA3E032_zps902f160e.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/4A8E57D6-65D9-471C-B9C5-A7B52C9B0D22-4086-000001776CA3E032_zps902f160e.jpg.html)

And compared to a standard 12ST piston - Roughly 10mm less compression height:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/60491DCE-BF3A-4124-AA11-8CB6AD6CA5A3-4086-000001776727DF05_zpsb19ac2c3.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/60491DCE-BF3A-4124-AA11-8CB6AD6CA5A3-4086-000001776727DF05_zpsb19ac2c3.jpg.html)

[Peredur]

Got a pair of LEDA 2.25" coilovers to put on the back, They need seals etc but otherwise pleased with them. Good range of adjustment from what I can feel on them.

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/C86A769E-AEFF-4443-89EB-52B74D8CE576-26461-00000994C9755521_zpsec8d86b6.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/C86A769E-AEFF-4443-89EB-52B74D8CE576-26461-00000994C9755521_zpsec8d86b6.jpg.html)

[jimbob-mcgrew]

what are you upto with 78.0mm pistons ?

[Peredur]

Hoping to use them in my 1400 build as they're lighter than standard and as they're shorter they allow for a longer rod to be used, all in all helping towards a revvier engine that's safer at high revs. If you're talking about capacity then it'll be a true 1400.

[jimbob-mcgrew]

ah i see...

73.4mm crank stroke x 78.0mm pistons - for a 1403cc

yeah, the lighter the better :thumb:

[novatracker]

what calliper model are these? think there the same as mine.

what bells on planning to run?

[Peredur]

Ye Jimbob, it's a gnat's cock over 1400 but neither here nor there really.

Tracker - They're CP3345's, I've sold them on now as I got an offer I couldn't refuse

[Peredur]

Sooooo, not much actual real progress has occurred between uni work and everything however some plans have been mad for the coming weeks.

Shell will be getting blasted and fabrication can begin with a view to having all the metalwork done and painted by the end of the summer.

The engine is now going to be a 1300 short stroke screamer based on a 12ST :d (Similar spec to Arne Schiermeister's old engine but without all the expensive steel), parts are already being gathered ready to build over the summer.

So, managed to get myself to the workshop for a bit this afternoon and attacked my big-bore throttle body to see as an exercise more than anything how much weight could be shaved from the casting by removing unnecessary waterways and simplifying the linkage.

Before: 640g

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/9208EB69-3D2B-4ABB-9ECE-CDCBE53A0137_zpstv1gst8w.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/9208EB69-3D2B-4ABB-9ECE-CDCBE53A0137_zpstv1gst8w.jpg.html)

Pleasantly surprised that I managed to drop 200g :d so this is now the aim with all components it to drop some weight off everything rather than just bolting them on.

After: 440g

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/F40B0C30-29E6-4AE0-A5F6-A71B69D5A872_zpsn7uccrvw.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/F40B0C30-29E6-4AE0-A5F6-A71B69D5A872_zpsn7uccrvw.jpg.html)

[Peredur]

Got some 13S Rods & Pistons. Pistons are junk from munching a valve but rods are nice having been deseamed, balanced and with ARP bolts. :thumb:

Recently got some Newman Solid lifters too.

Should help me see 8500-9000RPM from the 1300 build.

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/13S%20Rods1_zpsxyljd19v.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/13S%20Rods1_zpsxyljd19v.jpg.html)

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/13S%20Rods2_zpsp7afdegg.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/13S%20Rods2_zpsp7afdegg.jpg.html)

[boffer8]

I wouldn't trust even those rods at 9000rpm, i have steel H beam rods in my 8v and i don't rev it to 9000rpm as there is no benefit to doing so, the cam runs out at 8200rpm anyways

[Peredur]

Thanks Ben,

My logic is that the mean piston speed is still in a safe region at 9000RPM according to the charts in the book I've got by Graham Bell. Chances are my cam will run out of puff at 8500 according to ENEM's website so doubt there'll be any point me reving any more. This is on a 62.9mm stroke crank BTW.

[boffer8]

The mean value maybe so, but the peak will most definitely not be and the stresses you will exert on the rod will be compounded by your use in the forests. With short sharp useage it probably would be fine (1/4 mile dragging for example) but over a 12 mile stage round sweetlamb it may be reaching the end of its tether....

It will also come down to the other parts as well, as around 9000rpm you have to consider piston sizes, weights and friction that's are going to be en-counted beyond what they were initially designed for.

What crank are you using to get that stroke, im sure 62.9mm stroke was the 1.0L engines iirc?

[Peredur]

So I suppose it's not a question of if it'll take it but how long for.
Anyway, the proposed spec is:

81mm Bore
62.9mm Stroke
12ST Block
Ported C16SE Head with 40mm Inlet, 31mm Exhaust Valves
Suzuki Hayabusa Pistons
13S De-Seamed + Balanced Rods with ARP Bolts
L&B 12ST Crank & Flywheel
ENEM A2 Cam
Newman Solid Lifters
Kent Double Valve Springs
Piper Vernier Pulley
Port matched MPI Inlet
Pectel T2 ECU

62.9mm Crank is from a 12ST (Early 1.2 Carb)

Tbh I'm not wanting to sit at 9000 but if it's usable up to 8000 it's nice to have a safety margin on top.

[boffer8]

Seems like a good engine spec, would be interesting to see the Hayabusa pistons, weight and size wise.

What size is the gudgeon pin on a hayabusa piston?

Just out of curiosity, whats the centre to centre length on a 13s rod?

[Peredur]

Busa pistons should be nice and light, I've yet to see them in the flesh but a friend of my machinist has some that I can have so I'll have them shortly.

20mm Pin and 25mm Comp Height
13S is 129.75mm C-C with a 20mm pin, apparently from posts on here by the likes of C612DMN they're stronger than 1400 and 1600 rods.:thumb:

[Peredur]

So, managed to get 5 mins in the shed again so measured up my C14SE and C16SE heads to see which one would be most suitable.

After CC'ing both I came out with 21.8cc for the C14SE which seems about right abd then 41.1cc for the C16SE which seemed a little high but the chamber is much deeper :confused:

Aaaanyway, having measured the CC and the depth of the valve heads in the chamber, it seems like the C14SE head will fit the bill just nicely and depending how much piston I decide to have poking out (0.4mm ish) I should have a compression ratio of about 11.5-12:1 :thumb:

Quick shot of the CC'ing in progress.

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/125CB89D-AA8D-4199-8E6A-FD395E630339_zpsslea2xd6.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/125CB89D-AA8D-4199-8E6A-FD395E630339_zpsslea2xd6.jpg.html)

[Peredur]

So, following on from a drastic lack of progress in any shape or form I've set myself a deadline that will be met come hell or high water :roll:

Having been out on a local novice event a couple weeks back as a nav and won it I want the nova out on it next November.

Pic of us on the event this year:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/trenholmes15_zpskasdfacm.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/trenholmes15_zpskasdfacm.jpg.html)

The shell is going to be going to a friend's to get the fabrication sorted and get sprayed, in the meantime, I've acquired a few bits ready for the rebuild:

Quaife F10 SCCR Cluster and Solid Engine Mounts:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/22660469-87A6-49D5-95E5-FBCFD6510880_zps54stobrw.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/22660469-87A6-49D5-95E5-FBCFD6510880_zps54stobrw.jpg.html)

Pectel T2 ECU out of a Formula Ford:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/E572C3BD-ACC1-49B2-B8AA-FC7AA8950BD8_zpsmze64fgx.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/E572C3BD-ACC1-49B2-B8AA-FC7AA8950BD8_zpsmze64fgx.jpg.html)

Dave Brooks Split 40 Manifold:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/FC9D7BBC-3B26-45CF-A94D-FEDEF46E32E7_zpsn3czbmtc.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/FC9D7BBC-3B26-45CF-A94D-FEDEF46E32E7_zpsn3czbmtc.jpg.html)

Prodrive Aston Martin GT1 Pankl Rods - Dimensions are nigh on spot on if used with a motocross forged piston:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/pankl_zps1lm1xx6u.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/pankl_zps1lm1xx6u.jpg.html)

Pair of Wilwood Dynalited which I should be able to squeeze under 13's with a 240mm disc (might try a 256*20):

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/B56AD774-825C-40B5-9CC6-879496117BFD_zpsxr4eewdv.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/B56AD774-825C-40B5-9CC6-879496117BFD_zpsxr4eewdv.jpg.html)

Set of 13" Compomotive TH's should complete the look nicely:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/59989F11-4C8F-4CC1-AA90-23CB679438C3_zps60v2wkoo.png (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/59989F11-4C8F-4CC1-AA90-23CB679438C3_zps60v2wkoo.png.html)

So, I hope to make some actual progress whilst I'm home over christmas and have the shell all sorted and rolling on it's competition suspension ASAP

[Peredur]

Got a bit of time on my hands over Christmas now so headed to the shed to crack on.

Stripped/cleaned the bottom arms, struts and rear ARB and gave them a couple coats of hammerite

Before/During stripping - knot wheel made light work of it

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/E649CC32-D98E-4171-8668-5534EA3F00C0_zps7acxq8vd.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/E649CC32-D98E-4171-8668-5534EA3F00C0_zps7acxq8vd.jpg.html)

All hung up being painted

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/7565F59F-F889-4379-AD92-7AD12BB9C36F_zpssls3e5rd.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/7565F59F-F889-4379-AD92-7AD12BB9C36F_zpssls3e5rd.jpg.html)

End result, chuffed with the finish for only 2 coats with a brush. Struts will be built up once my sleeve nuts from CompBrake turn up.

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/2F798BBD-C592-47D7-BB5C-1C64842AB5DB_zps1zjlhycc.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/2F798BBD-C592-47D7-BB5C-1C64842AB5DB_zps1zjlhycc.jpg.html)

Altered/reversed the stud spacing on my split manifold so that I don't need to cut up the carbs at all, and it allows me to use a generic linkage (cheaper)

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/882D3A26-7DDB-48C1-9A1D-64733DD28980_zpspvw305my.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/882D3A26-7DDB-48C1-9A1D-64733DD28980_zpspvw305my.jpg.html)

Turned an adapter to drive a TPS (first time using the lathe, few more bits to come hopefully)

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/4271D483-865E-4C17-BF4B-A281724176EC_zpsttedlui7.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/4271D483-865E-4C17-BF4B-A281724176EC_zpsttedlui7.jpg.html)

Fashioned an alloy bracket to mount the TPS

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/00AC74CE-297C-4B9F-8E28-C4F81844D48E_zps714znzuq.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/00AC74CE-297C-4B9F-8E28-C4F81844D48E_zps714znzuq.jpg.html)

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/058120DE-F82F-44A4-99C1-C51ADF857C69_zpshwbkn6du.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/058120DE-F82F-44A4-99C1-C51ADF857C69_zpshwbkn6du.jpg.html)

Then I took the bumper from the shed and split the iron from the shell, cut down the ends (down to the mounting legs) and then driled and swaged the remaining section. Still need to weld on a plate for spotlamp brackets to be attached to prior to repainting it. Shaved 765g off the iron in the process.

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/387E4238-32D8-4B0B-9915-E6193C80E232_zps2osqwqla.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/387E4238-32D8-4B0B-9915-E6193C80E232_zps2osqwqla.jpg.html)

Then the plastic shell also got the holesaw treatment (will be covered by the numberplate) didn't save much weight but every little helps I suppose.

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/8C4F3CFC-B89D-48B5-AE60-CF14CDB28C56_zps4ma3ef8j.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/8C4F3CFC-B89D-48B5-AE60-CF14CDB28C56_zps4ma3ef8j.jpg.html)

Hope to continue the progress now into the new year.

Appreciate any feedback guys :thumb:

[RallyMarshal]

Appreciate any feedback guys :thumb:

Whats the Manifold off originally? I didnt realise Dave Brooks did Vauxhall fitment as only really seen them on Pintos and the like..

Keep it going. The more progress you make, the more you will enjoy it

Paul..

[Peredur]

Manifold is designed for a smallblock 8v vaux, Brooks does them for allsorts, seen them for pintos, xflows, 2.0 8v vaux, allsorts.

Yes, genuinely enjoying making good headway and planning jobs out now, getting bits ordered etc, makes it seek like the goal is actually achievable.

[Peredur]

Managed to get the front struts built up and welded some brackets for the spotlamp brackets in the bumper iron

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/coilovers_zpsptb7iqm9.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/coilovers_zpsptb7iqm9.jpg.html)

[Peredur]

Made myself a compact, lightweight heater assembly. Quite pleased with the result considering the bits were only about £60 all in. Good airflow through it and as it uses a proper matrix there should be some good heat too

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/AFED6C86-9F46-4431-B7A6-8329633D46E1_zpslygnw8wl.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/AFED6C86-9F46-4431-B7A6-8329633D46E1_zpslygnw8wl.jpg.html)

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/044CE109-0BD5-4253-BEDC-D02936E07F53_zpstltyavjz.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/044CE109-0BD5-4253-BEDC-D02936E07F53_zpstltyavjz.jpg.html)

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/B3BA8883-8CBB-4ADB-98AF-E86ED4A1EA36_zpsh8y5zqsp.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/B3BA8883-8CBB-4ADB-98AF-E86ED4A1EA36_zpsh8y5zqsp.jpg.html)

And modified the dash to suit, and to lighten it a bit (knocked off ~360g of the dash shell itself + all the redundant ducting)

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/055EA4C7-17E9-4245-8A2A-08190E99EB88_zpse3npguls.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/055EA4C7-17E9-4245-8A2A-08190E99EB88_zpse3npguls.jpg.html)

Big news though: Bough another shell, much fresher, bit of a minter really. All caged up etc.

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/C1986C93-0046-4BC4-BD28-F697BA35052D_zpsitynli4w.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/C1986C93-0046-4BC4-BD28-F697BA35052D_zpsitynli4w.jpg.html)

That was taken straight to my fabricator's place so he's cracking on with a few bits and then he'll throw some Polar White at her.

Also got this beauty as part of the deal (genuine local one owner car believe it or not), it'll either be sold as a complete donor or I'll break it for spares - only after being used as an autotest shlag first :d

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/44516299-AC26-4F8B-982F-3B6C24DD2978_zpszfhopeam.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/44516299-AC26-4F8B-982F-3B6C24DD2978_zpszfhopeam.jpg.html)

[Peredur]

So, work is progressing on the new shell, works strengthening kit is now on, column mount is done.

I've attacked a few brackets with a spot weld drill to save a bit of weight (~1.5kg with a couple of other brackets)
Hopefully there's a bit more to come out of the shell but on a nova there's surprisingly little to get out of the shell itself.

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/B4DE1983-5DB7-4F7C-B089-ED524B95732D_zpsha0egxiy.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/B4DE1983-5DB7-4F7C-B089-ED524B95732D_zpsha0egxiy.jpg.html)

Mocked up my new Tilton pedal setup - proper mount and false floor will be fabbed up this week.

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/681CD278-9C72-408B-9A6A-2623AE605161_zpsjmr6c4ah.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/681CD278-9C72-408B-9A6A-2623AE605161_zpsjmr6c4ah.jpg.html?sort=3&o=4)

Modded my Mondeo cable shift lever to reduce the throw, the 10-12mm added at the bottom has taken 1/3 to 1/2 off the the throw of stick (same done for the side to side)

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/stick1_zps1j9rilvq.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/stick1_zps1j9rilvq.jpg.html)

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/1E4145D3-132C-4319-807E-47E59EA0B52A_zpsqr1etdzg.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/1E4145D3-132C-4319-807E-47E59EA0B52A_zpsqr1etdzg.jpg.html)

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/CCC899FE-A17A-4DE8-B42D-C276C499D6D1_zpsdkdqefqb.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/CCC899FE-A17A-4DE8-B42D-C276C499D6D1_zpsdkdqefqb.jpg.html)

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/0322D72E-BC0B-48CC-BE64-B954CFBBC51E_zpsjeayroi7.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/0322D72E-BC0B-48CC-BE64-B954CFBBC51E_zpsjeayroi7.jpg.html)

Trying to keep up the progress now!

[ben doodar]

Nice work. I fancy a rally car myself.

[Iain]

Ace work, weight saving is satisfying.

[Peredur]

Ace work, weight saving is satisfying.

Thanks! It is satisfying but I was a bit disappointed that all I could pull out was 1.5Kg, might get the step drill and swagers out next weekend.

Messed about trying to lighten the door striker bolts to see what could be done:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/77A6B671-A4AD-4698-8413-8D6D8ECAD9C7_zpsh0nr9zix.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/77A6B671-A4AD-4698-8413-8D6D8ECAD9C7_zpsh0nr9zix.jpg.html)

Knocked half the weight off each one, every little helps!

[Iain]

Ok you've taken it too far now h ha

[Peredur]

Having read up on Mazda's "Gram Strategy" and seen builds like Colin's hillclimber and Fostek's new Escort, the savings have to be found everywhere for them to actually amount to anything. It's all well and good chucking on a FG bonnet and boot but the real savings come from trying to literally "shave" weight off everything.

If you aim to lighten each component by 10-25% then hey presto, the finished article will be 10-25% lighter. I know it's not achievable everywhere but it's a good theory to build by

[Iain]

Good explanation I'm sold off to get the grinder out! Look forward to the final weigh in

[Peredur]

I'm hoping for 700Kg which might sound high but this will be a rally car as opposed to the usual lightweight track cars - 2 seats, hefty cage, extinguishers, spotlamps etc.
Hence why I'm going into the finite details to find the weight as I don't think I'd get there otherwise

[jimbob-mcgrew]

this has had some interesting updates since i last saw it.
its good to see your still going with this mad scientist project :thumb:

i hope the 1.2 will bore out to 81mm alright, enough meat on it you think ?
i guess your having a custom head gasket made up, to go with that.

whats going on with that random mash potatoes of half used carbs and inlet manifold, lol :)

[phunkynova]

One thing I don't understand is why use split 40's and not just a single 40 as the split 40's must be more expensive and have a good few more Kg's.

[Peredur]

The mad-spec 1.3 engine is not going forward. Would've been an interesting development engine which I may potter with at a later date as it its possible to go to 1400 on a short stroke just about. Might try to build one just to see if it can be done.
It'll now have a long rod, short piston std bore & stroke 1400 which is what the Pankl steel rods are for. I'm still aiming for 140+ at the fly.
Head gasket would've been a Commetic 82mm bore one.

The split cabs are to comply with the MSA tech regs for Road Rallying:


18.2.2. A maximum of two carburettor chokes (two single or one double).

The split setup is a superior setup to a single as a you have issues with fuel ix distribution to the outer cylinders (1&4) depending on your manifold design.

The dave brookes split setup is one of the most proven induction setups in road rallying, being used VERY successfully by all the top escorts.

Usually half a choke is machined off the carb and both outer barrels are used however, I've altered the stud spacing on the manifold so as to offset the carbs rather than chopping them up.

Cheers for the comments guys :thumb:

[jimbob-mcgrew]

Head gasket would've been a Cometic 82mm bore one.

nice, didnt know about those.

will that gasket work with an 8v head ?.. as it looks like the tiny coolant or oil passage (not sure which), by the center head bolt, uses a different opening, that contacts the headbolt, like the 16v's.

it might be fine tho, maybe im just paranoid :)

out of curiosity, which longer rods where you going to use alongside the shorter pistonheads ?

[Peredur]

I'm using Pankl steel rods from an Aston GT1 car with motocross forged pistons.

[Peredur]

Managed a bit of progress again this weekend. Got my modified linkage parts painted and reassembled.

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/2110B1A1-5EC5-42EB-ACBC-68978168C3C1_zpsirdkqvmu.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/2110B1A1-5EC5-42EB-ACBC-68978168C3C1_zpsirdkqvmu.jpg.html)

Turned my attention to the handbrake, due to the tunnel mount being chopped to make room for the seat rail, I had to get a Mk2 Escort unit which will sit on top of the tunnel.

Firstly, I set about altering the pivot and release mech to covert it to a "fly-off" action.

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/eb025082-b51a-4653-b172-05b94419552d_zpszvdfxlmw.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/eb025082-b51a-4653-b172-05b94419552d_zpszvdfxlmw.jpg.html)

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/2e12a08e-fdf6-4a08-a0cc-432459204c1f_zpsijlnz0mt.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/2e12a08e-fdf6-4a08-a0cc-432459204c1f_zpsijlnz0mt.jpg.html)

Then I commenced a step-drill attack, not sure how much was actually saved but I don't think I could've gotten much more.

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/877156A4-B1AF-45B1-B259-3077F5A2E3DD_zpsrqo8j36n.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/877156A4-B1AF-45B1-B259-3077F5A2E3DD_zpsrqo8j36n.jpg.html)

Then I realised that I'd primed it without welding the hydraulic cylinder bracket on so that's another job to do once it's mocked up in the car.

Also, my fabricator has now buttoned up the pedal box rails using threaded inserts in the box sections - very satisfied with the whole install:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/pedalbox_zpsplanjchz.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/pedalbox_zpsplanjchz.jpg.html)

[Peredur]

As can be seen in the previous pics, my Tilton pedal box (as nice as it is) is drastically Throttleless so, armed with a stock of carbon, I set about rectifying the situation.

Stainless hinge to provide a solid pivot - which was machined to lighten it, might take a bit more off too:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/EE6CB878-FF4E-4351-BEF8-B3C51E72ABBB_zps5aqnsbeo.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/EE6CB878-FF4E-4351-BEF8-B3C51E72ABBB_zps5aqnsbeo.jpg.html)

Cut a nice slab of carbon and bolted it on (bolts will be replaced with button headed allen drive ones):

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/4D26E118-26DB-452B-B780-F594CA7D5CC3_zpstkbd3jyb.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/4D26E118-26DB-452B-B780-F594CA7D5CC3_zpstkbd3jyb.jpg.html)

Came in at 173g which is pleasing.

There's a little bracket to go on the back to operate a pushrod setup that'll operate the modified std pedal as pivot bar to pull the cable.

Much progress to occur in the coming weeks hopefully!

[jimbob-mcgrew]

vrumm vrumm ! :)

[Peredur]

So, my fabricator's managed to get 5 mins to spend on my car

Spare wheel well chopped at 1/2 height to improve clearance:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/12948487_455399244656958_1288092215_o_zpswttffzsx. jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/12948487_455399244656958_1288092215_o_zpswttffzsx. jpg.html)

Fitted some gussets to the A and B pillars:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/12948567_455399314656951_965444101_o_zpsncn3cjfw.j pg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/12948567_455399314656951_965444101_o_zpsncn3cjfw.j pg.html)

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/12948507_455399254656957_1957417280_o_zpslgj2q4f8. jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/12948507_455399254656957_1957417280_o_zpslgj2q4f8. jpg.html)

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/12970341_455399354656947_2138949357_o_zpsywhzba3r. jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/12970341_455399354656947_2138949357_o_zpsywhzba3r. jpg.html)

Really hoping to have this in paint before the end of the month if at all possible.

Taking engine bits down to Country Engineering by Bristol (builds damn good autograss and rally engines) to have mine built too.

[Peredur]

Got a bit more time on the car this weekend, shell is still with the fabricator having the last few bits done. Engine will be getting built in july and I'm trying to sort a 6 speed crunchy clacky Dawg box lol

So, this weekend's bodging was looking for hidden grams, of which I found a few in the wiper motor (mostly in the carbon baseplate):

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/0270644F-9501-40DA-9528-A1C4765A73CE_zpsstxd6qgd.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/0270644F-9501-40DA-9528-A1C4765A73CE_zpsstxd6qgd.jpg.html)

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/7aa2fdf3-7724-4ab4-9c9c-291d4ef60e0f_zpsgzw6gmsu.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/7aa2fdf3-7724-4ab4-9c9c-291d4ef60e0f_zpsgzw6gmsu.jpg.html)

And then I reprofiled the car side of the boot hinges which resulted in a good saving (given the initial weight):

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/d9f1e74a-8ab3-4007-ada7-0a32484d6b0b_zpsyekg5w2n.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/d9f1e74a-8ab3-4007-ada7-0a32484d6b0b_zpsyekg5w2n.jpg.html)

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/9A87F2C4-38C9-455F-8A8E-EE3A2E899B66_zpsdfccagki.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/9A87F2C4-38C9-455F-8A8E-EE3A2E899B66_zpsdfccagki.jpg.html)

[peester]

Great work, never seen anyone go to this detail with weight saving.
Liking the 8v engine spec.
Also your Colin Chapman quotes in sig.

[Peredur]

Great work, never seen anyone go to this detail with weight saving.
Liking the 8v engine spec.
Also your Colin Chapman quotes in sig.

Cheers

Engine won't be to that spec now as I'm going for reliability so will be a fairly lairy 1400 8v with std length steel rods etc. Should still make about 145-150bhp

I've decided I want to get the car down to 700kg and having recently been reading on mini forums its inspired me to look for the hidden grams everywhere. I've got some Titanium, aluminium and nylon bolts on order too which should help towards the end goal.

[peester]

That sort of figure from a 1.4 8v must be full on, race spec .

[Peredur]

It won't be far off a full race engine. The builder usually does them for autograss cars so this one will be a similar spec - steel rods, flat top pistons, +1mm Ivey valves, kent springs, solid lifters, Enem A2 cam, Spit 40 dellortos

[Peredur]

Made some worthwhile progress this weekend

Got my spare beam out, stripped and splashed some hammerite in its general direction. Doesn't look to bad even if I say so myself:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/e08b4d64-3adf-47a9-97d9-b8ffa6243462_zpss15n0irk.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/e08b4d64-3adf-47a9-97d9-b8ffa6243462_zpss15n0irk.jpg.html)

Inbetween coats on the beam, I managed to tart up my rear dampers. I've had them fully serviced by LEDA so just gave them a quick lick of paint:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/f9df21cc-81ef-49fc-b29d-bcba28a73ef9_zpsaezdubmt.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/f9df21cc-81ef-49fc-b29d-bcba28a73ef9_zpsaezdubmt.jpg.html)

And I lightened the wiper linkage to see what could be done. Only took off 48g but hey ho, it's a saving. Gave it a quick spray to tidy up too:
http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/978901cd-c457-4203-a768-51554168cafc_zps52jt5dlr.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/978901cd-c457-4203-a768-51554168cafc_zps52jt5dlr.jpg.html)

[Southie]

Are you sure that your wipe linkage arms won't fold in under the strain of the motor, they're not the strongest of items at the best of times?

[Jonesfach]

Are you sure that your wipe linkage arms won't fold in under the strain of the motor, they're not the strongest of items at the best of times?

Yes I don't think they will last too long...:eek:

[Peredur]

I'm hoping they should be fine as the stength is carried through the fact that they're U sections. We'll see, if they fail then I've a spare linkage I can put on.

[kenny_afh]

why bother lightening the boot hinges and wiper linkage when you are welding on double gussets on the B pillar and your pedal box is sat on box section? surely single gusset (or even just a small tab?) and a bit more ingenuity with your pedal box would have been a better use of your time and effort? for what its worth, i know that comment is a rather catty, but i do like the rest of the car so far, i just dont quite understand the benefits of drilling or shaving such small amounts of dead weight when you have the option of engineering out more of the excess with your fabrication work. having said that, if you are happy when you are doing it then maybe thats enough to justify it.

[Peredur]

why bother lightening the boot hinges and wiper linkage when you are welding on double gussets on the B pillar and your pedal box is sat on box section? surely single gusset (or even just a small tab?) and a bit more ingenuity with your pedal box would have been a better use of your time and effort? for what its worth, i know that comment is a rather catty, but i do like the rest of the car so far, i just dont quite understand the benefits of drilling or shaving such small amounts of dead weight when you have the option of engineering out more of the excess with your fabrication work. having said that, if you are happy when you are doing it then maybe thats enough to justify it.

Fair point, not catty at all mate.

On the pedal box, I prefered to have the mounts be a bit more substantial for the sake of preventing anything from twisting or giving way during use. Overall, compared to a standard pedal setup I think a net weight loss has been made (even if not much) so I'm happy to compromise there to ensure a proper mount is used.
Again, same logic on the gussets really, just wanted to make sure that the shell is as strong as can be, hence why you'll find that I've not teabagged the shell with a holesaw, only removed surplus bracketry so as not to compromise the strength of the shell.

Appreciate the feedback though :thumb:

should have some worthwhile updates soon enough now.

[jimbob-mcgrew]

i think your doing a good job mate. keep it up :thumb:

like southie said, im interested to see how many swipes you can get out of those wiper linkage arms, lol

if, or when they break, maybe replace them with aluminium rods. will be stronger than drilled, and still lighter than original, without forking out a packet on ridiculously expensive carbon bollox

[Peredur]

So, Some progress has been made,

Modified the carbon throttle pedal with some countersunk titanium fasteners, may end up with some grip take on it to prevent slippage:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/4329b2bb-6b31-43fe-a94c-769ee6308020_zpslwaxuwbk.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/4329b2bb-6b31-43fe-a94c-769ee6308020_zpslwaxuwbk.jpg.html)

Then did some intricate CAD work to mock up a false floor/heel plate for the pedal box setup:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/bdfc2d06-3c6c-481d-948f-485e28486d8b_zpsfixsvv4v.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/bdfc2d06-3c6c-481d-948f-485e28486d8b_zpsfixsvv4v.jpg.html)

Which was duly transferred to carbon:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/5abcfb83-8b7a-4acc-9dc1-5e9e2b405508_zpsycjeqqok.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/5abcfb83-8b7a-4acc-9dc1-5e9e2b405508_zpsycjeqqok.jpg.html)

Then the shell has been away to be blasted and etch primed, quite pleased with the result as there's very minimal patching to be done, and overall its a nice solid clean shell:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/24692514-f2de-4077-b7e8-85e178622b82_zpso5dkboiw.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/24692514-f2de-4077-b7e8-85e178622b82_zpso5dkboiw.jpg.html)

Aaaand finally, I stripped the 12ST donor engine ready to be sent off for machining as the an alternative 1200 build is afoot. Block came up nicely after a quick degrease and pressure wash, will be dipped before the machining and build:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/b64b0806-a585-4ea1-bc6f-226e5a293975_zpsgihvza3p.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/b64b0806-a585-4ea1-bc6f-226e5a293975_zpsgihvza3p.jpg.html)

Axle was mocked up yesterday but the Golf caliper carriers were the wrong ones so new ones are on order, ready to be fully built next weekend hopefully.

[Peredur]

Managed to get some progress done

Finished off the lightened handbrake with cylinder bracket:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/e33d80de-78fb-4bc5-bbab-ab86d9306978_zps9ji2dlov.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/e33d80de-78fb-4bc5-bbab-ab86d9306978_zps9ji2dlov.jpg.html)

Got the stubs and caliper brackets cleaned up and painted:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/1c2325a6-5bbe-48b2-af43-b19a03281b54_zpsyhmhiv6u.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/1c2325a6-5bbe-48b2-af43-b19a03281b54_zpsyhmhiv6u.jpg.html)

Then built up the rear beam, golf discs and calipers on Pro-Tec brackets. Just need to slip the ARB and polybushes in and the beam is good to go:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/efba1475-4fd4-45af-9a6d-387d1342566e_zps7zgi6i1z.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/efba1475-4fd4-45af-9a6d-387d1342566e_zps7zgi6i1z.jpg.html)

And then got the shell back on the spit to remove all the pipe clips & studs off the underside and trimmed down the rear valance. Still a bit to lighten on the shell but I'm not going too mad on it:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/54fa2247-c847-4940-a39a-958a0dd9ddb4_zpstgj7pdma.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/54fa2247-c847-4940-a39a-958a0dd9ddb4_zpstgj7pdma.jpg.html)

Decided to dry build most of the interior considering there's a lot to go in (extinguishers, battery, heater, footrest, seats etc.) and I need to mock up the engine and box for the airbox, gear linkage rods and strut brace. Decided it won't be ready for November so going to get it ready (fully run in, setup, ready to rally) for July 2017 for my Dad's charity classic car run, where it'll run with his mint, 16,000 mile 1.2L :

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/7c74c14d-2dd1-4d66-84c1-e20be3fa0775_zps5ilifg9z.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/7c74c14d-2dd1-4d66-84c1-e20be3fa0775_zps5ilifg9z.jpg.html)

[Botedly]

Blimey! That 1.2L is clean! Great work on the build so far.


Sent from my iPhone using Tapatalk

[Peredur]

Been a while since I updated this, managed to get some progress done at the weekend following buying a new welder (CWS BestMig 160i - top bit of kit)

Popped in to see my machinist/engine builder to take some measurements of the new pistons & rods in the newly bored block, currently doing calcs for final piston crown machining & comp ratios etc. - The beginings of the S1202 build :d :

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/f7b852d3-eb90-4716-b908-929abb99e6f4_zpsjyrc7glc.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/f7b852d3-eb90-4716-b908-929abb99e6f4_zpsjyrc7glc.jpg.html)

Welded in my captive inserts for the HHMS linkage on the custom platform:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/980f7b22-af39-414d-ad85-13b099e80380_zpsc7vgfz87.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/980f7b22-af39-414d-ad85-13b099e80380_zpsc7vgfz87.jpg.html)

Did a bit of CAD for mocking a carbon centre console, it'll be transferred to carbon next time I'm back home on the car:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/c2c8e906-a59f-488d-b8f3-f3b15108760e_zpsaxe8qfmk.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/c2c8e906-a59f-488d-b8f3-f3b15108760e_zpsaxe8qfmk.jpg.html)

Drilled the penetration for the HHMS linkage rod then sleeved the rack mount with some 1.5mm wall tube:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/f55c7953-7b3c-4475-884e-52075a3a62f2_zpssdwmbion.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/f55c7953-7b3c-4475-884e-52075a3a62f2_zpssdwmbion.jpg.html)

Finally, decided to utilise the empty space where the servo would usually reside to mount my battery so set about mocking up a tray there however the bulkhead slopes outward, therefore I chopped a whacking great big hole there to sink it back in. Will box it all off in a couple weeks:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/0d44f47d-6995-4c2d-b47e-493bc24d8645_zpsngmrh7l2.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/0d44f47d-6995-4c2d-b47e-493bc24d8645_zpsngmrh7l2.jpg.html)

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/90492228-3074-43c6-956d-4ba20d2b3ccd_zpsw0gcctrv.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/90492228-3074-43c6-956d-4ba20d2b3ccd_zpsw0gcctrv.jpg.html)

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/2cc8e738-863d-4730-86e8-ae10396839dd_zpszgqf7ln6.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/2cc8e738-863d-4730-86e8-ae10396839dd_zpszgqf7ln6.jpg.html)

[totalnova]

Really like the idea with the battery, should look neat and tidy once it done.

[BRoadGhost]

N/S front is the heaviest corner on the car.

[Peredur]

N/S front is the heaviest corner on the car.

Care to elaborate?

O/S front would be heavier wouldn't it, with the engine over on that side. Also, if you're having a jib at the battery placement then I chose there as it's accessible and reduces the cable lengths needed significantly. Recent regulations with rallying prevent you putting it in front of the navigator's footrest which would've been my 1st choice.

[Iain]

Great battery position. Might be worth getting measurements of the equivalent Varley and Odyssey batteries to make sure the hole accommodates future battery changes.

[Peredur]

Great battery position. Might be worth getting measurements of the equivalent Varley and Odyssey batteries to make sure the hole accommodates future battery changes.

Thanks :thumb:

I believe that this Lucas one is the same dimensions as a RedTop20 (or 25) and the equivalent Odyssey. If it turns out that I need a higher capacity battery then we may need some rehashing. A Saxo I use to co-drive in ran an Odyssey (20/25 equivalent) and that would crank over the high comp S1600 lump no bother. If need be I believe there's a gear reduction starter I can get off a z18xe engined zafira

[BRoadGhost]

The O/S front you would think is the heavier side but it isn't; could the battery not be put any lower and or further back in the car?

[Iain]

Corner weight proof required broad, I would be amazed if the drivers side wasn't heavier especially when seated

[Peredur]

The ideal position would've been behind the navigator's footrest but with the impending rule changes it would be stupid to put it there and have to move it when I apply for an MSA logbook.
There is room behind the nav's seat however I don't see the point of it if I have to run an extra ~1kg of cable. Where it is now is lower than standard and easily accessible. Given these constraints I think it's a fairly reasonable location for it

[Peredur]

Long overdue progress update!

Got a hold of a pair of ex-Prodrive WRC Sparco Carbon buckets and couldn't pass on them, got them back home and mocked up - it'll be cosy in there to say the least! Never realised how small they are inside 'till you put two huge winged seats in:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/SeatMock1_zpsogk0czil.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/SeatMock1_zpsogk0czil.jpg.html)

Fitted my Plumbed-in Extinguisher using M6 Rivnuts behind the drivers seat:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/PlumbedIn_zpsr43axzng.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/PlumbedIn_zpsr43axzng.jpg.html)

Made a recess in the back panel to accommodate a 2nd spare wheel, then fitted spreader plates for wheel strap mountings:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/WheelCutout_zps4ea0tnwc.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/WheelCutout_zps4ea0tnwc.jpg.html)

Got myself a Kevlar sump guard plate from Hifibre. It's a direct copy of HHMS's alloy offering:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/KevlarSG_zpsn6twzukc.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/KevlarSG_zpsn6twzukc.jpg.html)

Then I fitted it with some UHMWPE (abrasion resistant plastic) rubbing strips which I beveled on the router before bolting down with Titanium Hi-lok fasteners and aluminium nuts:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/SGStrips_zpskobontgs.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/SGStrips_zpskobontgs.jpg.html)

Eventually, after a long time looking (and saving up) I got a biiiiiiig jigsaw piece that I'd been hankering for for a fair while. A 6 speed, Crunchy, Clacky Dawg Box :d :d :d

It's a Quaife 6 Speed F13/15 Gearkit with a 4.86 CWP and a HHMS 90% plated LSD with F20 side gears, which should mate up nicely to the shafts I got off Will Foy :thumb:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/DogBox_zpsswcfyoxs.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/DogBox_zpsswcfyoxs.jpg.html)

And finally, trimmed back the last of the lip in the bulkhead before seaming it all up. Quite surprised with how it came out given how little I've welded up to now:

http://i1279.photobucket.com/albums/y528/Peredur_Wyn_Davies/BHeadSeam_zpsro4txgwl.jpg (http://s1279.photobucket.com/user/Peredur_Wyn_Davies/media/BHeadSeam_zpsro4txgwl.jpg.html)

So, I hope that I can carry on with the shell over the rest of Feb and in to March to hopefully get her off to paint before April comes around.

[8valve-craig]

The O/S front you would think is the heavier side but it isn't; could the battery not be put any lower and or further back in the car?

This is not true.

[Iain]

I think you need to redo the seat rails lots lower looking at that mock up.

Parts look great. Nice gearbox.

[Peredur]

I think they look worse in the photo. They're positioned quite nicely IMO, and the nav side one is quite deep so you sit very low within the seat. TBH, the one on my side is fine for me as if it were any lower you'd be compromising what you see really

Thanks though :thumb:

[Iain]

All good if your helmet clears then. Just trying to save you the grief I'm having currently cutting out my seat rails! Easier to adjust up on side mounts than down once painted.

[Peredur]

Good point, I'll take my lid with me next time I'm there. Thanks for that

[AndrewC]

I think you need to redo the seat rails lots lower looking at that mock up.

Parts look great. Nice gearbox.

Agree with Ian, I was surprised how much was needed to take me down to a suitable position. Ended up cutting into the floor


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[Peredur]

Agree with Ian, I was surprised how much was needed to take me down to a suitable position. Ended up cutting into the floor


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Cool, I'll check with my lid on next time I'm down in the garage. Like I say, the seating position is nice where it is (could be a tad lower, but not enough to warrant re-doing the rails). We'll see!

[total_vauxhall]

Was also going to mension the seat hight but didnt want to sound like a **** lol . im only 5ft3 and had my old seat sat directly onto were you have your tubes . and my skid lid still used to hit the roof over bumps ect . iv gone even lower with my new seat but could do with dropping the steering wheel a tad more aswell now

[Peredur]

Update on the helmet situation: Helmet clears!........ But the top of the helmet is higher than the top of the cage :( So the ralis will be being re-done. Thanks to all who spotted it, I would have carried on obliviously. :thumb:

Slight progress update: taking 2 pairs of hubs to Pro-tec to be machined for the Audi bearings this week too.