dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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quote:
Originally posted by Steve
Did you get the special coated stuff for the windscreen as it will get cloudy over time due to small scratches and scuffs etc
I'm keeping a glass front screen but the rest is just normal polycarbonate. The mayguard scratch resistant coating is good stuff but expensive, when these get bad I will just remove and replace, my front windows cost about £50-60 a pair delivered so if they last a couple of years I'll be happy at that, mayguard ones for the fronts are about £300 a pair 
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Steve
Premium Member
Registered: 30th Mar 02
Location: Worcestershire Drives: Defender
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Oh yeah i didnt look closely enough i thought the back window pic was the front 
That ordinary polycarb will be fine for side windows etc
[Edited on 21-12-2016 by Steve]
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dewismotorsport
Member
Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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So todays mod was to chop up the inlet and convert it to air to air using a intercooler instead of a charge cooler.
I've never rated the charge cooler system and once on track it just wasn't effective at all.
So out came the grinder and got chopping, wasn't easy getting the lamnova holders out.
I was then left with this
Next up was to improve the flow
Before:
After:
First divider made with 2" tube
Then second air chamber made
All welded up just need to make the return pipe from the actuator. I purposefully left the tubes long as I wasn't sure on intercooler pipe runs but once fitted I could then remove 2" from their length. Inlet still retains the support bracket underneath.
Mocked up with intercooler and pipes cut to length
And then with the radiator in, all fits nicely and actually has more free space than standard.
Will finish it the rest tomorrow!
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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Turned myself down some billet so I could make a actuator return
Used some rectangle box to make the extension, gave it a taper and then welded it on
Made up some O rings to act as the seal
All going well until I snapped a manifold bolt, after much swearing I drilled and helicoiled a new one in
And fitted, weighs a lot less than standard which is a bonus and also has more clearance.
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chris_uk
Premium Member
Registered: 8th Jul 03
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Bloody hell..
Should of just fit water injection lol.
Be interested to see how it works!
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dewismotorsport
Member
Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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quote:
Originally posted by chris_uk
Bloody hell..
Should of just fit water injection lol.
Be interested to see how it works!
 that's plan b if the temps are still too high. Races are 40 minutes so would need a decent amount and if it had meth in I'd have to have it in a sealed box in case of roll over.
I have spoke to a guy in America who has done similar and he report good results so fingers crossed.
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dewismotorsport
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Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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Slowly working my way down the to do list, next up was to make a catch tank. Msa blue book states that anything over 2000cc must have a 3 litre catch tank so with space tight and wanting to keep as much weight over the gearbox side I measured up and made a start.............once body was welded I decided to check my maths was correct and filled it with water and it holds exactly 3 litres to the drop!!!!!
Welded the fittings and breather tubes on
Made up some braided lines and fitted, I'm running a gearbox, cylinder head and block breather
Also fitted the air filter, electrical and fire extingusher pulls in the scuttle, just got to fit a few grommets and that's that finished bar the battery wiring. Waiting on another clamp and then rad and intercooler can go on and be filled with coolant then a start up.
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dewismotorsport
Member
Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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Been cracking on with it, made some front windows but then needed to hold the shape, so made some 3mm alloy window frames, these will be riveted to the polycarb. Windows are due to be bonded in on Tuesday.
Finished the intercooler pipework and gave the cooler a quick paint I re fitted it
Finished off the extingusher pull cords
Came to start the car and would crank, had fuel.and spark but wouldn't run. Turned out to be a cut immobiliser wire from the transponder to bulkhead connector which then goes to the ecu. After some greatly appreciated help from various users I got to the bottom of it and once re connected it started straight up
Took the car for a quick test drive, with no windows I decided safety first so donned some goggles lol
Diff definitely works
Car drove really well and pulled nicely due to the diet, the map seems to be fine if still a little rich and there are no noticeable side effects from the intercooler setup so really happy with that.
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dewismotorsport
Member
Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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Finished the electrical cut off and external pull, also fitted the switch for the demister and mounted the traction control button
Fitted the front windows, had a bit of a mare trying to hold the curve in the middle, once shut it poked out slightly so had to just add a extra bit of polycarb in the centre and rivet it whilst I bent it. I will re visit this at a later date and worst case buy some pre curved ones at an extortionate price
Had the window guy back to bond the windscreen, rear sides and rear screen. Got them to prime a boarder on to hide the metalwork behind. Also fitted the sunstrip and race decals, still have a load to put on for the race series and my sponsors but don't have all of the stickers yet
Got the car to minimum race spec now but have 2 1/2 days left so will crack on with the rest of the mods I want to do.
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djgritt
Premium Member
Registered: 1st Nov 07
Location: Dorset Drives: Focus ST / Hyundai i20N
User status: Offline
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Awesome work on this recently!
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dewismotorsport
Member
Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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quote:
Originally posted by djgritt
Awesome work on this recently!
Cheers
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dewismotorsport
Member
Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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So today I corner weighted the car, was always hoping for around 1050kg so this was pretty close to that, this is the weight without me in and car has about 6 litres of fuel in it.
Car has a good front to back ratio which should help the handling
And after lots of coilover adjustment I settle on this, almost 50/50 but I'm tight on time and knowing I will re do again after I get round to fitting a front splitter
Weight with me in it, I imagine race weight will be closer to 1185kg with the extra fuel
My last dyno was 243bhp but I have a slightly smaller charger pulley on now so I imagine power to be 250bhp, so that makes 215bhp per ton and 182whp per ton so I'm 18bhp inside my class B category of 200whp per ton
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Simon_16v
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Registered: 14th Aug 06
Location: Yorkshire
User status: Offline
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This may sound incredibly stupid, but I've seen before people adjusting coilovers to get corner balancing as close as possible. But how does adjusting coilovers adjust the weight distribution?
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tom130691
Premium Member
Registered: 13th Sep 08
Location: Daventry
User status: Offline
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the lower you make a single corner vs the others the more weight it will have on it,
imagine having a flat rear tyre the car leans over on to it, putting more weight on the flat tyre and lift the opposite front tyre
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SteveoBC
Premium Member
Registered: 22nd Feb 07
Location: Bucks
User status: Offline
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impressive metal fab work going on in here, starting to look like a right weapon
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IvIarkgraham
Premium Member
Registered: 27th Mar 04
Location: Ellesmere Port, Cheshire
User status: Offline
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When can I drive it?
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Jed D
Member
Registered: 15th Mar 11
Location: Durham
User status: Offline
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mega, just mega!!
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dewismotorsport
Member
Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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Cheers lads, no chance of driving it but happy to give passenger laps lol
Finished off the last few mods, replaced the old battery and gave the insides of the doors a quick squirt and modded the door pull wires to open the door with a pull on any part
Then made myself some spoiler uprights, I've copied the original btcc astra design which allows three adjustment settings
Test fit after drilling the boot
Made some spreader and strengthening plates, the spoiler is strong enough for me to do pull myself onto it with all my weight
Squirt of paint
And final fitting
So race day at Donington Park, few pics from the day, was a very wet qualifying which put me about middle of the pack which was good to say it was my first drive on the track and of the car and in the wet.
The track dried out a bit in the afternoon and had a dry line so put the drys back on
Race was going well climbing up a few places and having a good battle with the skyline r32 gtr (480bhp) realing him in on the braking and corner speed but he had the legs on the straight. Going into the sixth lap the car spat the oil cooler feed hose off mid corner chucking oil onto the tyres and causing me to spin into the gravel. Only damage to shell was a cracked wing mirror glass but the engine is toast.
Put it on the trailer and cracked open the beers to enjoy the rest of the weekend of racing and will deal with the engine this week. Next race is at Silverstone in 5 weeks.
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Ad Blue B
Member
Registered: 9th Jan 10
Location: Northop Hall/ Chester
User status: Offline
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Shame about the engine but the car looks awesome mate! keep it up!
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dewismotorsport
Member
Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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So put the oil hose back on today and filled her up with some oil and ran her up and no knocking so happy days. Will be making some better hoses up to prevent it happening again.
Removed all the gravel and gave it a wash
Few pics my friend took on the day, the coupe is just a timeless shape imo
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Haimsey
Premium Member
Registered: 8th May 05
Location: Nottingham Drives: Corsa B
User status: Offline
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Loving this. Great work
Marcy Marc 
White Sport Progress Thread
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CorsaSport1.416v
Member
Registered: 27th Jan 03
User status: Offline
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This is an awesome thread , awesome work gone in to the car , please keep the updates coming.
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dewismotorsport
Member
Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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Cheers guys! A lot of hard work has gone into it but it's starting to pay off, few more mods to do before its next race at Silverstone but I'll keep it updated
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SteveoBC
Premium Member
Registered: 22nd Feb 07
Location: Bucks
User status: Offline
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No onboard vids?
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dewismotorsport
Member
Registered: 16th Feb 08
Location: Coventry & Poole
User status: Offline
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quote:
Originally posted by SteveoBC
No onboard vids?
My Internet is down at home so not had chance to upload anything to you tube yet 
[Edited on 26-03-2017 by dewismotorsport]
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