Brake hoses arrived yesterday from Earls so they will be fitted today. Also front grill going in for painting today.
Bought a spare front subframe as are going to make a lower engine steady like was used on the Golf GpA cars, and also on some Rallye's. Still get some engine movement when launching hard, even with race-spec Vibratechnics mounts fitted, so are going to try and reduce this. Instead of fitting a solid engine steady bar as used on the GpA Golfs, are going to use a torque damper.
Exert from Golf GpA manual showing subframe mount and solid steady bar
Torque damper already bought from US - Ingalls 'Stiffy' damper
Back from paint - quite like it like it is actually - will cut some black paper and mock it up to see what it looks like with black grill and lights
Brake hoses fitted so back on its wheels over xmas. Oh yeh.
Bought a spare front subframe for messing about with. There is a bracket that normally holds a big block of steel (vibration damper apparently ) - well it's almost like its made for the job , with a bit of chopping down - has a groove in the middle where the damper can sit and is perfectly placed to allow the damper to fasten to the back of the engine - just need to mock a bracket up for this next.
Then will get it shot blasted and powdercoated after a bit of chopping wherever possible to lighten.
Interesting development.....midland Speed champs are adding a new class next year, basically for production saloons that have had engine swaps. This is following requests for people with rally cars who wpuld like to come sprinting, and engine swaps are allowed in rallying.
So time to rethink that ali-blocked FSI headed Corrado then.....
This could be a really exciting class as there are some very highly developed rallycars out there like Mk2 escorts with Honda s2000 / duratec/ vaux redtops.
All of the engines mentioned have more potential than mine. I dont think i'll get much more out of it, probably about 250-260 now ( pending dyno with new exhaust) but all those are good for 300+, more torque, and lighter.
But the FSI head has more potential even on my existing block, but this would be expensive and just as easy to do a whole engine and use an ali block for lightness.
Be interesting to see what turns up next year and how the times compare with the 'Std' mod prod cars where I play.
Well finally got the car down to my local rolling road - Mikeanics in Congleton - to see if that exhaust manifold managed to unlock the DTH 48's that never really delivered as much as I hoped. My engine man said that 48's gave more power on the dyno than 45's, on similar spec engines, so I was hoping for an increase when we fitted them. As I said, this increase never really materialised and the verdict at the time was that the exhaust manifold was probably now the restriction. So this is what prompted the new manifold described earlier in the thread.
So down to the rollers and the map needed changing quite a bit. Promising start....
I am staggered by the result. There was not much increase in peak power (4hp) but the midrange has been massively increased - by as much as 30hp at 5500rpm!
Power increases shown below.
Absolutely bang on, well chuffed. Exactly what I was hoping for.
To further my explorations into aero effects, following on from the front floor/airdam/splitter, I thought it might be a good idea to try and give the rear end a help by stopping the air coming in under the sides of the car with some sideskirts. These will also give something to hang a flat floor off if I eventually go down this route.
So there is a nice 20mm wide seam that runs down the underside of the sill that looks good to fasten a skirt to. Have ordered some nice nylon threaded inserts that I will bang into 8mm holes. Pics when they arrive.
So the skirt is made slightly tricky by the fact that the seam is not level - took quite a bit of measuring to get it right, and both sides were different (of course). Flat garage floor helped a LOT with this.
So tonight we have two skirt panels cut out of 3mm ABS plastic ready to go on when the inserts and fasteners arrive hopefully tomorrow.
Skirt is currently 50mm from the ground but will end up 70mm when the race wheels are on. Regs say min clearance is 40mm so well clear of this.
Nylon snap-in-nuts and stainless screws arrived - the nuts are actually a VW part and push into an 8mm hole taking a no.8 screw. Got stainless screws with a flanged head as well to make the job proper.
All from excellent on-line car fasteners firm Bresco nr Leicester. All kinds of useful fasteners in their on-line catalogue.