[race_prep] Guernsey Hillclimb 205 Build

[allye 530 3 Cars]

ALL OF WHICH TO DO IN LESS THAN 2 WEEKS BEFORE MY FIRST HILLCLIMB

 

I feel a breakdown coming on :wacko:

 

What you need is a MONTAGE!!!!

[wardy18 33 1 Cars]

Update:

 

Engine Mount / Alternator Bracket made (will take pictures once fitted as it took ages to work out) this will be fitted tomorrow and alternator fitted and lined up.

 

Gearbox mount has been test fitted so the gearbox can be fitted to the engine tomorrow and then engine will be ready to drop in which should happen in the afternoon.

 

Exhaust component parts have all been ordered with Ashley Competition so it will be a full Ashley 2 1/2" system. The only trouble is because i havent been able to get the car onto a ramp i have had to order the parts with a best guess 90% sure its everything i need, ie buying 3 45deg elbows to cut up and re-work to get over the rear beam with minimum clearence due to the car being so low i do not want the over-axle section to hit the ground.

 

Most new hoses have been ordered which again has been a nightmare without the engine in and being able to measure exactly the lengths i need. I just dont have time to wait until the engine is in to get the hoses in time, as it is i need a 25-16mm reducer hose which i just cant get hold of as they are made to order @ 4 weeks waiting time so ill be sourcing an alternative.

 

Wiring loom look pretty simple after having a proper look at it, so thanks to Sandy for the great loom he made for me, the little labels are a lifesaver!!

 

All seems to be on track but until the engine is in i have no idea if the deadline of a week monday can be met for my first event!!

 

Watch this space

[wardy18 33 1 Cars]

ENGINE IS IN AND FITS LIKE A GLOVE

 

The throttle bodies sit perfectly under the slam panel and above the panel over my radiator

 

Very happy

 

Just a million things to fit now

[tomcolinjones 26]

got it in

Any pictures? or are you just going to tease

[wardy18 33 1 Cars]

Here's a shot of the bracket my dad made for me to attach the top engine to the block and not just the head an also the main anchor point for the alternator plus a shot of the engine hanging ready to or the arduous task of shoe horning it in, I'll get mote detailed shots as I go over the next week!!

 

http://i868.photobucket.com/albums/ab247/Wardy18/56ed204a.jpg

 

http://i868.photobucket.com/albums/ab247/Wardy18/d0c0e284.jpg

 

http://i868.photobucket.com/albums/ab247/Wardy18/ec91859a.jpg

[wardy18 33 1 Cars]

Had some very good progess over the past 2 days.

 

All engine mounts are now complete, the engine is completely solid mounted now, my design for the gearbox stabiliser bar failed though, it was all fitted very nicely and then i realised the driveshaft would clear it so it had to come back out, onto to the next design!!!

 

All fuel lines, fuel filter, fuel pump, fuel regulator (including making a bracket to mount the regulator) now run and fitted and secured through the engine bay and interior.

 

I had to re-fit the oil catch tank somewhere else due to having it fitted under the slam panel had a few serious issues, the main being that the oil return pipe back to the sump on the XUD9Y block is just over half the way up the block at the front and so the oil return hose from the catch tank would have been lower than the block return pipe which would rapidly fill up the catch tank, as you will see it is now fitted against the scuttle panel so it has a great gravity fed flow back to the block return, much hapier!!

 

Driveshafts all fitted back ready to snap!!

 

Starter motor mounting hole shaved down to clear the block crank breather which sticks out the front of the block right behind the damn starter motor.

 

My new Magnecore KV85 8.5mm Competition HT leads arrived this morning so thats the next job to make up a bracket to secure the coil in place.

 

One issue i do have at the moment is that my new inlet manifold does not have a hose attachment to fit the hose to from the Brake Servo unit, not sure what to do here and not sure what affect it has on the pedal with no vacumn in the servo??? ANYONE???

 

Here's the pics so far anyway:

[wardy18 33 1 Cars]

Some more:

[wardy18 33 1 Cars]

and lastly:

 

 

Any my elec board so far:

 

[wardy18 33 1 Cars]

Fitted my coil pack last nite with some lovely ally brackets and also incorportated the bracket for my throttle cable to attach to.

 

Also started fitting up the new coolant hoses.

 

Coil Pack 1

 

Coil Pack 2

 

Coil Pack 3

 

Coil Pack 4

[tri_longer 25]

Hi Simon

 

Build looking great

 

one question, how do you manage to get away with running the fuel tank inside the car? I thought it had to be seperated by a bulkhead or at least enclosed in another box to pass through scrutineering.

 

Cheers

Chris.

[wardy18 33 1 Cars]

Erm well yeh this is an issue i am looking into, i have trawled through the MSA Blue Book and for Hillclimbing it says nothing about having an enclosure around the tank (last years car did have an ally box built around this fuel cell but it got crumpled in the crash so i removed it and didnt replace it)

 

For rallying is states in black and white in the blue book regs that you need it enclosed but there is nothing stated like that for hillclimbing so im making enquries as we speak.

 

If anyone can find it in the Blue Book Hillclimbing regs then please let me know where?!?!?

 

Simon

[tri_longer 25]

There is nothing in the Hillclimb section, which means that general conditions for cars take precedence. I believe it is covered by

 

Section K Safety

 

6. Tank fillers and caps must not protrude beyond the

bodywork or be situated within the driver/passenger

compartment. The caps must have an efficient locking

action to reduce the risk of opening during an accident

and to ensure closing after refuelling (14.1.2). Air vents

must be at least 25cm to the rear of the cockpit and

must be designed to prevent the escape of fuel should

the vehicle be inverted. It is recommended that a non

return valve is incorporated in the vent system. The

entire fuel tank area ‘Licked by the open air stream’

must incorporate a crushable structure as follows:

[wardy18 33 1 Cars]

Yeh i have just had it confirmed by someone else too over here, like you said, must comply with General Regs + Specific Regs.

 

My dad is heading down to measure up and get a box made so its in the process!!

 

Thanks for the Confirmation

[welshpug 1,670]

finally, an 8v with a proper length intake tract

[wardy18 33 1 Cars]

Well if it was going to be done i wanted to do it properly so the only way forward was a phone call to the very talented Mr Satchell!!!

[wardy18 33 1 Cars]

A few updated pics of the build, never imagined how much work would be involved, every new bracket needs to be made, new hoses need to run with new lengths etc, new exhaust, literally everything needs to be made from scratch.

 

Im going to have to miss my first hillclimb monday as i still have to do:

 

Wiring in loom to the cars switch panel and remaining cars wiring

Fit up the exhaust

Cut and fit back diffuser

Plus 100+ little jobs

Then fill the fluids and fire it up

 

All in one day just isnt going to happen so will miss the first hill and aim for the next so i have time to shake the car town and test it properly, i dont want to fire it up for teh first time and drive it straight to an event.

 

Edited April 22, 2011 by wardy18

[Cameron 16]

Looks awesome!

 

Do you still have the moulds for those sill extensions?

[wardy18 33 1 Cars]

Yeh i can make some up no problems, thing is you need the 4" arches front and rear to fit them to as they are moulded to the arches.

[wardy18 33 1 Cars]

Oh and also the fuel tank is now enclosed and the fuel lines over-braided as i couldnt race without either, have takes many hours to sort but its to the regs now!!

 

Ill try and get loads of detailed pics tomorrow

[wardy18 33 1 Cars]

Very productive day, exhaust fitted and looks amazing, diffuser fitted back, engine bay gone over and all hoses checked for clearences etc, oil pre-heater fitted, boot and spoiler fitted, paint compounded, ECU mounted.

 

Literally just needs to be wired up and fluids added then its ready to test and fire up.

 

Also i dont think i have ever seen such a nice looking race 205, and ive spent alot of time looking through images in Yahoo, will get some good quality pics taken monday!!

 

Simon

[wardy18 33 1 Cars]

Electrics finished this mornin and tested, nothing blew or set on fire so happy days, adding all fluids tomorrow morning and firing up for the very first time, very anxious that all goes well and no leaks etc

 

Will report and get some proper pics up soon

 

Electrics finished this mornin and tested, nothing blew or set on fire so happy days, adding all fluids tomorrow morning and firing up for the very first time, very anxious that all goes well and no leaks etc

 

Will report and get some proper pics up soon

[wardy18 33 1 Cars]

I HAVE A PROBLEM.......…

 

Engine started and runs and sounds out of this world however I am unable to select any gears, it's as if the clutch just isn't working at all.

 

Pulled the box off and found the release bearing had dropped off so fitted it back and got the box back on but to no avail, still no gears!! It grinds as soon as you try to select reverse and just won't even attempt to go into any forward gears.

 

I have adjusted the clutch cable as far as it'll go each direction and still nothing.

 

I can see that when my dad presses the clutch pedal when the engine is off the clutch housing plate retracts and the clutch plate spins freely when it's in gear and clutch pedal is down so the plate isn't jammed.

 

I am running a Helix ally flywheel with a STD clutch housing and a paddle plate all 200mm.

 

All I can think is wrong that Mass Racing fitted my paddle plate the wrong way round so even though the release bearing is maxxed out against the housing it's still not enough to completely release the plate to allow gear selection however I'm confused as to why it all seems to work fine when the engine is off,

 

Please any help or suggestions will be greatly appreciated as im at a loss an this means ANOTHER race meeting on Monday missed!!!!

[wardy18 33 1 Cars]

Ok so the latest on the gear selection issue, finally managed to adjust the clutch and start it in gear with the clutch depressed so i finally got gears and gave it a bit of a run round the industrial estate and my god didnt it go well, so responsive however i was still getting some clutch slip when starting off.

 

It appears that the paddle clutch plate has deformed slighly and is not sitting flat inside the housing. With the car off and in gear and with the clutch pedal down you rock the car to spin the clutch plate between the clucth housing diaphram and the flywheel you can can see that one paddle will be touching the clutch diaphram then rock it to the next paddle which will be touching the flywheel then rock it to the next paddle which will be touching the clutch diaphram then to the last paddle which is touching the flywheel. So the plate is actually twisted somehow, this could have happened in storage whilst waiting to be fitted or by Mass Racing either before or even whilst fitting but it certainly didnt come like that.

 

So because 2 paddles are touching the clutch diaphram and 2 the flywheel there is always too much friction for the clutch plate to be relese to allow gear selection.

 

It could also be due to the centre sprung plate of the clucth plate fouling on the inside diameter of the clutch housing diaphram.

 

So plan now is to remove it all and check whats happened and check for clearences etc, this will be done tomorrow morning.

 

As i speak now there is a Hillclimb running and im sat at home writing this, in a way im quite happy as its pi$$ing it down at the moment, so a small conselation!!

 

Anyway had this issue before????

[allye 530 3 Cars]

I do look forward to reading/seeing your updates! It looks soooo agressive

 

engine looks awsome, can't wait to see some videos of this going up some hills

[wardy18 33 1 Cars]

Cheers mate, im very happy with the way it has turned out, once i get it out in the sun ill get some decent details pics taken to post up

 

Has anyone ever used the Aeroquip AQP Socketless Push On Hoses and Fittings???

 

I want to use them for my Dry Sump set up but am a little unsure about them, the fact that the hose simply pushes on the fittings with no jubilee or any sort of clamp is a little concerning to me, i cant see why you couldnt throw on a jubilee clip to clamp the hose down onto the fittings even though it says they are not needed. The hose is rated at a working pressure of 250psi so the hose and fittings and cant this type of pressure which is suprising to me with no clamps.

 

Has anyone had experience of using these hoses and fittings??

 

Cheers

 

Simon