My road/track car project. VERY PIC HEAVY

[Dan1720v]

I'm sure this wont bring many good replies lol, but here is my car...
Basic spec was:
45mm ITB's
120mm Ram pipes
Cat Cam 421's (wildest possible on standard pistons)
Standard exh Mani
Decat, into a full 2.5" exhaust
Lightened flywheel
Pico 350cc Injectors
Cometic H/G
No AC
No PAS
Omex 600 running it all, all mapped by me.


Carbone Lorraine Pads
HC Discs
R888's
KW Coilovers set up with 1' Toe out(f) 2.5 neg camber, 2 neg at the rear
Polybushed

Stripped interior with fibreglass seats 4 point harnesses
Sparco 300mm Wheel
oil temp and pressure guages
Wideband guage

Think thats it...

My CL Pads []
http://s432.photobucket.com/albums/qq49/dunlop172/?action=view&current=SS100018-1.flv


Looks wonky, but its the angle of the pic/road.

Midway through running in and re-wiring engine loom:

A few vids on my local airfield of when it was ITB'd, all for the new owner of the engine, just wanted vids...

2nd gear pull
http://www.vimeo.com/7660242

0-80
http://www.vimeo.com/7660282

And whats going in(all will be come clear now...)

BAM engine, on 22k [:y:]

K04 with TT downpipe

With 02J Box.

 

[Dan1720v]

Well lil update:

Its in. Just.

Now i have a BIG decision to make, what to cut to allow clearence...

If i chop an inch x 3 out of the chassis rail i'll have clearence for the driveshaft.

A view from the diff flange on the box.

Or i chop the subframe(about 1 inch x7) to clear the sump:

I guess you could say its in properly:

Just waiting on steel to weld up some mount adapters and box the subframe.

Well made a start on the wiring while im awaiting the steel.

My electrician decided to help.

Omex loom

Subframe barstardisa... i mean modification.

one mount adapter:

 

[Dan1720v]

Did some more:
Mount adapters

Subframe finished:

My electrician helped out again yesterday

Loom pretty much done, just need pluigs now. waiting on heatshrink.

Engine is in on its mounts we're halfway there as Mr Simpson would say!

Ordered some goodies from ebay yesterday, they arrived this morning!

Yeap, shes going white.

 

[Dan1720v]

Well...

After 2 weeks of waiting, SOME of my cage turned up, they seem to have missed most of it...

and its in on its own mounts, look mum no crane!

welded abit more of the cage:

I'm not keen on how gasless wire welds, takes alot of setting up but its still not perfect. i'd have argoshield and regualr wire anyday of the week!

 

[Dan1720v]

Well a little more progress done on the wiring side.

It started like this, a few weeks ago, and amongst other things ive been doing, spending a little time here and there on it, and tonight, it was pretty much finished, bar a few plugs/sensors i'm waiting on to be able to fully finish it. but heres a few pics.

How it started:

Mid way:

And how it ended up tonight.

The air bypass valve will be acting as the idle control valve, also the air bypass for the ALS [}]


Still need to do the relay box, but otherwise its 95% done.

Just Purchased this for the pricey sum of £30

Mercedes Sprinter intercooler.


Should be fine on the 280 i hope for...

Not much of an update, I have recently received:

A big box of bits, no pics, which contains:-
Starter
Driveshafts
Shifter and cables

Merc Sprinter intercooler:

Painted black, better effeciency, and is stealthy... didnt quite realise how BIG it was. in that pic its resting on the floor! so alot of chopping of the main cross member...

All in all no progress really, just have no interest in it at the moment

 

[Dan1720v]

Well, lil update,

Been busy on it today...

First off, was to see if i could get the cooler to fit.

Bad thing was, got a bit trigger happy on the old grinder...

lol.

But on the plus point, it fits now. the bit ive shopped, was only a crash bar anyway, but i;ll add some bolt in box section to restore some strength.

Bit of mocking up on the front bumper/wings etc - Stealthy...

Ive seen on a modded RS4, the letters cut out of the number plate, to provide flow to the cooler. I'm copying this idea. i love it.

Cut out most of the number plate recess, to provide flow once there is a nmber plate with holes in.

Driveshafts...

Well, everyone knows, that equal length shafts provide less torqesteer etc, well mine are 300mm different lol. this'll be fun...

Need to machine off 1mm on one shaft to enable it to slot inside like the other.

I then decided to remove(read as smash) the rear windows, as the chees wire tactic wasnt working.

And how far i have got with the cage. ordered another 8m of tube from a supplier on ebay.

Ive fitted 4m, now got to decide where and how to make the other 4m fit lol.

heres what ive got so far.

so suggestions please...

Quick tester to make sure the seat still fitted lol...

 

[Dan1720v]

Harness bar finished.

From inside

Picked up a finishing piece to my puzzle tonight.

Not much left now!!!!

K04 return pipe. around £140 from vw.

Many thanks to dUff for that!!! not much left now, need an 02j shift tower(gearbox side mk4) and a rear mount, and then to fabricate the exhaust. but thats all stuff that can be done after the shell have been painted.

well update,...

Cage finished! ish.

Had help from a mate today as i helped him all day yesterday on his. he was cutting/profiling tubes while i was welding and doing my dash.

SO pics of the cage and dash(didnt for some reason get a pic from my normal camera, so will have to do with a picture from my phone i sent to a mate...)

I'm up midlands tomorrow and dropping my dash in for Flocking by Jolfa.

 

[m0rk]

This is cool. There was a ratty Mk1 with a 1.8T - but this should be well nippy

 

[Dan1720v]

Pretty much ready to take the shell for paint now...

A quick first coat on the cage, was very quick, not sure on the colour :-/

Oh and a BIG(albeit little update...)

....

One done!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!


Need to get hold of a mk4 o/s AUM driveshaft, with the cv joint like that in the pic, so the reanut one can slot in like so, ground it down about 1mm before welding to i had a nice deep place to weld, properly got the heat into it, couldnt touch it for over half an hour lol


Well have been doing a fair bit of shopping! Have received an agu fuel rail, no pics of that, removed the abs and associated parts, have picked this up this morning:

I have remanufactured the gearbox mount with help from mattyo and his dad, as my version 1 was interfering with the gear linkage. We also lifted my engine out(literally) so I can get it in the stand and get it built up!

I have also put a deposit down on some 525cc injectors


Well slight update:

Dash back from SBP, slight blemish on the top, but i think that was in transit, its not in a noticeable place so i'm not bothered. Very good service though! feels soo nice! cant stop touching it lol.

Oh and managed to get 2 sheets of 8'x2.5' 4mm lexan polycarb from work. for free slight scratches here and there, but i dont really care its free!!!


Quick tester fit of the dashboard with the bias valve in position...

Brake lines started..

 

[Dan1720v]

And said polycarb

spent more (but dont tell wifey! lol) on a new paint gun, etch primer, scotch brite and thinners.

got a bit done on the engine last night, fitted the headgasket, and new bolts. all genuine

What are the torque settings for the head? and sequence?
fitted the k04 with new gasket and bolts

Can i just say what a ****e idea it is to put the coolant banjo bolt in such a position that if you say, wanted to take the pipe off, you have to remove the turbo!

More tonight. I hope.


Did a very quick paint tester earlier, need to mix it up a bit thicker as i got a few runs, but this was only 1 coat to give me an idea of the colour.

I like

Very pleased with the finish though! got a very good shine to it.

 

[Dan1720v]

Sooo! New bits!

525cc Injectors

New (big)brakes!

Intercooler

G60/ABF Flywheel(known as dave apparently)

Cambelt, Oil filter housing gasket and rocker cover gasket.

Intercooler fitted(with rad)

Got a spare hub I've dropped off with a mate so he can design some brackets in solid works for me. Not sure what to do myself, do I run bigger discs? 280's standard, biggest I know of on a Clio are 295 to fit behind 15" wheels. Would like to retain them, but if necessary I'll go to bigger wheels and go 330mm discs!

Well, had a quick session on the car today.

Engine bay painted, was supposed to have the car in for paint this weekend, but couldnt get it down there as i've lost my steering rack brackets

Engine bay painted:

 

[Dan1720v]

And test fitting the bumper/intercooler with the engine in.

Fitting it up has made me realise i do have a distinct lack of room for therad due to the oil filter and housing.

so i have 3 options
1 - find and fit a smaller rad
2 - Move the intercooler forwar and do a bit of chopping of the bumper
3 - Move the rad to the boot floor, run an electric pump and plumpbing under the car.

Have been in contact with a seller in the us willing to send OBX helical diff's over here for £300 delivered. so will be buying one of those next month.

Well, got myself a grinder in hand and this was the end result...

To hopefully pan out to house...

The reason

Another bay shot:

Was close...

 

[Dan1720v]

Plans for the wide arches are like this:

My quick knock up in paint (lol) of my wishbone idea.

 

[Dan1720v]

Right, had a quick mock up of the widetrack.

the bbj holes are 48mm centres. so nigh on 50mm, so moved the bbj to the outer bolt hole to get an idea of what i'll need to do in terms of arches.

Before:

After:

The plan with the arch:

ANd thst upto tonight...

 

[Dan1720v]

This is cool. There was a ratty Mk1 with a 1.8T - but this should be well nippy

Thanks mate, Its taken alot of time, effort, money and swearing to get to here. that and alot, and i mean alot of patience from my fiance!

 

[Martin M]

This is a nice project. I'll keep an eye on the rest of the build

 

[jenk]

Caught the start of this on clubgti, looks cracking. Like the idea of the rad in the back, shifts some weight too.

 

[DannyC87]

this is a brilliant project. Massive credit to you for doing all the work yourself! Do you work in the trade or just do this as a "hobby"?

 

[MIkey kc]

BLOODY HELL! thats a massive project you have there! its like you do one thing then start a another without finshing the other thing tho im just you have it all mapped out in your head tho. Its gonna be awesome!

not keen on the colour of the cage ether, id go black or white simples!!

 

[Dan1720v]

Used to be a renaultsport specialist tech. Not anymore, installation engineer for clean rooms and fume cabinets now. Got a few mates who did panel beating and engineering so between us we're pretty sorted.