Building a Corsa C C20XE 1600cc Rally Car

http://img.photobucket.com/albums/v5...t/SP_A0131.jpg
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Proflex front struts with works OPC AP Calipers/355mm Discs

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IRS beam with Alcon rear calipers/discs

Oh - forgot about this little purchase
http://qedmotorsport.co.uk/qed-shop/...m-engine-block
Now back with Martin Bowyer for the final build after a trip to Millington for the rebore for the special pistons :)

Dave

nom nom nom

Alloy block too, shweet

Very very nice!

A few pictures of the latest progress


Pedal box and a few few brake lines fitted


http://img.photobucket.com/albums/v5...ll_Prep002.jpg
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Front subframe painted and steering rack fitted

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Roof vent fitted


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Kevlar tailgate trial fitted


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Seat roughly in position


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Dave

Sequential Gear lever mount fabricated to bring lever to optimum position


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Brakes/Hubs etc fitted

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Check out the width :thumb:

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I'm just in the process of creating a wiring loom at the moment seeing as the corsa C uses Multiplex wiring :doh:- So bining that and using a mixture of Corsa B & C looms as we only need Lights and wipers to function - pictures to follow soon

Dave

:eek: How the hell did I miss this 5 year old thread lol

Looks a proper build Mr France, plenty of nice upgrades I must say, what's happening engine wise with it? Also any completion date or is that a silly question.

Brilliant work regardless and proves that the best things do come to those who wait and wait and wait and yes wait, that little bit more.

Engine is being built as we speak by Martin Bowyer

Will be an Alloy Block C20XE destroke to 1600cc - Steel Crank etc, Throttle bodies - Martin expects around 230bhp on his dyno - reving to over 9000 Rpm

Should be quite entertaining


Hoping to have it up and running by the end of this year

Sounds an expensive bit of kit but sod it your only here once. Is the destroking of a 2.0 a common thing to do these days in a 1600 class?

Keep at it nearly there. :cool:

De-stroking the C20XE Block should produce a stronger 1600 that will hopefully be more reliable and not as highly stressed as a 1600XE version

Not sure of the figures of a 1600 compared to a Destroked 1600 - I don't think its a common mod but Bowyer speaks highly of it

If its not quick enough it will probably end up with a rebore to 2000cc/new pistons and crank - and then wait for the gearbox to blow !!!! :)

this is so cool. good luck

Dude that looks amazing! Got some proper width on her ass...

Any chance of a pic of the wiper motor...

Quote:

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Originally Posted by Southie

:eek: How the hell did I miss this 5 year old thread lol

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I missed this one too, incredible.

Lovely bits of kit the Corsa C tarmac cars.

Dave - if you get fed up waiting on Mr. Bowyer, or need a spare engine, I know where there is a 1600 all-steel destroked C20XE ready to go..........

Give me a shout.

Not much of an update - but prepped the shell ready to throw a bit of paint at it
Masked up and all good to go :)

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fearlless, the corsa b stalks fit the c cloumn, so you can use the full in car loom, and jjust change the light plugs over and extend it where needed.

Quote:

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Originally Posted by Rob

fearlless, the corsa b stalks fit the c cloumn, so you can use the full in car loom, and jjust change the light plugs over and extend it where needed.

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Great minds think alike Rob


Already done that - Used the Corsa B loom from fuse box across the dash - and then used Corsa C loom for lights Front and rear

Stripped out all extra wiring for CDL/speakers/airbag etc - so now have a quite a simple basic loom for Lights and front wiper - not much to go wrong hopefully

Engine loom will be MBE - Dash Display has its own loom with sensors so a hell of a weight saving over the standard loom :thumb:


Dave

you have pm dude.

Managed to put a bit of colour on it (bright orange if your viewing on a black and white monitor lol)

http://img.photobucket.com/albums/v5...intside001.jpg

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Threw some filler primer on the front wings and headlight surrounds

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Started to prep the rear bumper

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Look its the real deal :thumb:

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Trial fitted the Fibreglass tailgate - fitted the flush latches and fitted the S1600 spoiler

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Dave

cool colour.. cool workshop ; all the ammenities

Not really an update - just remembering the good old days (page 1)

Spotted the old Astra GSI rally car back up for sale again - different colour (used to be orange) - slightly different spec -but still looking good

http://www.pistonheads.com/sales/2206117.htm

Sent the link to my mate who's car it was - His responce "Any way corsa should be faster and look better!!!!!! don't dwell on the past, need to go forward." :thumb:

Dave

Proper job Dave, loving this thread, hope you don't have to wait too long for the engine, Bowyer is known for his lead times.

5 months to get pistons, but tbf i can get hold of him pretty sharpish now for parts:D

Told Bowyer we need engine by Christmas - he has all the bits and the block is machined - he just needs to throw it together and map it

He's good friends with my mate so I don't think he will let us down

Top work.

one hell of a car this! will be nice to see it in action!

More of the boring bodywork prep for final paint

Rear bumper almost ready for some colour

http://img.photobucket.com/albums/v5...bumpers004.jpg

Front works wide kevlar bumper needs a bit of TLC before repaint and new mesh and lower skirt will be added :thumb:

http://img.photobucket.com/albums/v5...bumpers006.jpg

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And a couple for Benn - requested Front wiper motor/linkage pictures - Whats he got planned lol

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http://img.photobucket.com/albums/v5...bumpers011.jpg

Basically a standard RHD Corsa C front wiper motor/linkage but the mounting plate for the motor has had the spot welds drilled out and the plate moved further along the bar due to having to relocate the motor to clear the cage :thumb:
All the linkage bars remained the same - works in theory but yet to power up the motor to test


Dave

It's a beauty, keep going ;)

Sh!t the fooking bed, ive not seen this build thread before but will be keeping an eye on it, some awesome work going on in here and the old astra looks sexy as hell, keep the updates a little more regular though if you can :p


Oh and have another blob of rep too:thumb:

A splash and dash of green from me also Mr Fearless.

Quote:

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Originally Posted by Southie

A splash and dash of green from me also Mr Fearless.

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Ner ner you didnt give him a blob, but i did :p





lol

Cheers boys - Its good to be bolting stuff back on

Got the new bonnet intakes from Germany - very good quality - just need to cut some holes in the kevlar bonnet and bond them on

Thanks for the rep !!!!


Dave

More that welcome bud, ill definately be keeping a close eye on this:thumb:

Quote:

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Originally Posted by Spudly

Ner ner you didnt give him a blob, but i did :p

lol

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:(

So what's the deadline now on this Dave and what events/area will you be attending next year, would love to see this in the metal whilst in action.

Engine all paid for with Martin Bowyer - told him we need it by christmas - then we can plumb in radiator and coolant system etc

Will be running Acusump system so need to find a home for that

Still loads to do but have most of the major components - but all the finishing touches can add £££ to the final bill !!!

Expect the car to be finished by early next year - following a trip to Harry Hocklys Motorsport to set up Geometry/suspension hope to a do a track day somewhere to do a shakedown and explore the limits

Rally events will be Tarmac based in UK mainly in the north (Single venues /epynt etc) - along with trip back to Belgium montebourg rallysprint

Can't wait for a drive :)

Dave

Coming along nicely Dave ;)

Nick.

Plans sound cracking, where in the North are you running?

Quote:

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Originally Posted by Nick J

Coming along nicely Dave ;)

Nick.

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Cheers Nick


Not ideal painting it in a garage - but for a rally car where we expect some panel damage we feel its acceptable

Quite a few tiny silicon marks if you get up close in the orange paint - whats the best remedy for these - touch in with paint - flat and buff ?

It's difficult to decide whether to repaint for a perfect finish - but in the back of your mind you think you might have a slight 'off' on the next rally and have to paint/re panel it anyway !!!:confused:


To be honest - the finish isnt that bad - using a small smart repair gun - managed to get quite a good shine :thumb:


Once the final paint scheme/ stripes / stickers etc are on the car I don't think it will be that bad

Saw a Ford WRC Stobart Focus with a rear quarter panel riveted on over the original panel - the close up finish was terrible - but the overall car was amazing

If its good enough for the works rally teams - Our home garage work of art shouldn't be that bad :thumb:


Ps - I'm sure i've seen a Anti Silicone paint additive - is it any good - does it work (still using Cellulose Paint !!!)


Dave

Quote:

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Originally Posted by Southie

Plans sound cracking, where in the North are you running?

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Will be the usual single rally venues - North west stages / mamby / croft / Mira / 3 sister (Wigan) / Melbourne Airfield / IOM /Blyton etc

Maybe a trip to ireland to see how the real loonies do it lol

Quote:

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Originally Posted by fearless

Cheers Nick


Not ideal painting it in a garage - but for a rally car where we expect some panel damage we feel its acceptable

Quite a few tiny silicon marks if you get up close in the orange paint - whats the best remedy for these - touch in with paint - flat and buff ?

It's difficult to decide whether to repaint for a perfect finish - but in the back of your mind you think you might have a slight 'off' on the next rally and have to paint/re panel it anyway !!!:confused:


To be honest - the finish isnt that bad - using a small smart repair gun - managed to get quite a good shine :thumb:


Once the final paint scheme/ stripes / stickers etc are on the car I don't think it will be that bad

Saw a Ford WRC Stobart Focus with a rear quarter panel riveted on over the original panel - the close up finish was terrible - but the overall car was amazing

If its good enough for the works rally teams - Our home garage work of art shouldn't be that bad :thumb:


Ps - I'm sure i've seen a Anti Silicone paint additive - is it any good - does it work (still using Cellulose Paint !!!)


Dave

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Hi Dave,

The way I usually remedy silicone is to..... 1. Flat the silicones and the small area around them using 1500/2000 wet/dry 2. Touch them in with activated topcoat. 3. Lastly give it a few days to dry then block off the touch ups until flat with 2000 wet/dry then polish with the machine/cutting compound to bring your finish back to life and with a bit of luck it should be spot on.

Hope the above helps. Ive never used the anti silicone additives so I cant comment on how well they work Im afraid. Im sure the car will look great when finished as you say its a rally car your building not a show winner so function over form at the end of the day. You will have to let us know when the cars at melbourne as thats only a few miles from me so Id like to see the car put through its paces etc.

Nick.

Not too far for me to travel to then Dave, well apart from Ireland lol

Nearer the time get some venue dates up and I'll plan a day or two out for next years calendar.

Edit: Are they still going to be running Melbourne next year, I know they've had a bit of a commotion with the farmer for the last couple of years.

Quote:

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Originally Posted by fearless

Will be the usual single rally venues - North west stages / mamby / croft / Mira / 3 sister (Wigan) / Melbourne Airfield / IOM /Blyton etc

Maybe a trip to ireland to see how the real loonies do it lol

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These are very, very local to me so would love to know dates you intend to be there as id love to see this in action:thumb:

Thanks for the info Nick - will give it a try

Still a long way off hitting the stages yet - but will keep you all informed of when its out