Kyle T
Premium Member
Registered: 11th Sep 04
Location: Selby, North Yorkshire
User status: Offline
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Wow that must have been heartbreaking, when scrambling out of the car I bet you were both thinking along the lines of total loss. Car REALLY seemed to get of lightly, and no serious injury - so double bonus.
Saying that, I think I'd have traded a few weeks in hospital in exchange for years of hard work 
Lotus Elise 111R
Impreza WRX STi
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flybikeslee
Member
Registered: 2nd Jan 07
Location: Liverpool
User status: Offline
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YIKES!
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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So Hamish decided to start with the worst bit of the damage the roof. Once he got it off and had a good look, decided to seperate the skin where it was spot welded to the frame in the gutters and along the top of the windscreen piece. So out came the spot weld drill and after a lot of time it was free!
So he chopped into the old skin to see what was damaged. The top screen pressing had been pushed in badly so, decided he might as well replace that as well.
So a new one was pulled out of the new roof.
Old one just about chopped out.
New one plug welded into place.
Old roof spot welded drilled out in the gutters to leave it ready for the new skin.
Sprayed some weld through primer into the seams
Back of the old roof was punched so it could be plug welded onto the new skin.
Back edge of the new skin was joggled to go under the old roof. Cleared up the sound deadening and surface rust and primed it.
Then it was all plug welded on. Needs a good grind up but you get the idea.
So its done baring a grind up to flush off all the plug welds. He's not going to run any spars under the skin this time but use some packers from the cage to support the skin. Its welded in without warping or dropping so is am very happy. Used cold front when joining the two skins. It works brilliantly to soak up the heat from the metal.
He has also started to fix a few other bits that were damaged from the crash and the testing. Obviously the column was bent so, got the metal to do a new one. Also got a new universal joint as he wasn't very happy with the old one. Split it down and bored it on the laithe to take the steering shaft. So thats ready to assemble and weld.
The next bit he found was that the diff mount he made to hang the alternator off had bent under the power. This had caused the propshaft to rub on the transmission tunnel! He would have built it with a lot more strengthening to begin with but its tight for space with the alternator getting in the way!
So decided it needed some extra metal adding to stop that happening again! He now cant get any more metal around the alternator but is happy thats going to solve the problem. Sorry for the crap picture, should have taken some before paint!
Also to help with this he decided to machine up some alloy bushes for the rear diff mount to help stop any twist.
They are different thicknesses as he runs the rear diff offset to get the larger prop lined up down the tunnel.
So thats where its currently at. Going to get the rear diff bolted back up this week and get it back onto its wheels. The roof needs finishing off. Then the door needs to be cut up to lightening it and a few fibreglass repairs to the wings and it can go for paint!
April '06' Corsasport Feature Car  | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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Gary
Premium Member
Registered: 22nd Nov 06
Location: West Yorkshire
User status: Offline
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Nice to see he's not messing about and getting back on it!
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SVM 286
Member
Registered: 13th Feb 05
Location: pain
User status: Offline
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quote:
Originally posted by Daniel_Corsa
quote:
Originally posted by VrsTurbo
what the fuck won if that got runner up!?
A Grey MK1 TT - THIS ONE
  
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3CorsaMeal
Member
Registered: 11th Apr 02
User status: Offline
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Well the Audi is a cut and shut to be fair.
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SVM 286
Member
Registered: 13th Feb 05
Location: pain
User status: Offline
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quote:
Originally posted by Daniel_Corsa
Here is the video of it going wrong:
Vid 3
JESUS that went over quick!
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SVM 286
Member
Registered: 13th Feb 05
Location: pain
User status: Offline
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quote:
Originally posted by 3CorsaMeal
Well the Audi is a cut and shut to be fair.
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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Hamish got a bit more work done on the car lately. The roof is now ready for a skim of filler. The welds are all ground down and the seams have been sealed up with tiger seal. He also shaped some roll cage padding to support the roof skin off the roll cage as not putting the spars back in.
Next job he moved onto before it gets sprayed again was the sealer used around the bulkhead. Don't have any before pictures of it but the last time it was painted the guy decided to make it look like weld. No idea why he did it but it looked crap and has wanted to sort it ever since so now was the perfect time.... So its now smoothed in nicely with a finger.
The final job he's been on with is the steering column. It got bent in the crash and was never happy with its height so decided to make it adjustable this time. Also went for a different universal joint which looks a lot stronger.
Tig'd in place.
Couple of bits of angle cut and shaped to allow the column to move up and down.
2 bosses machined up, knotched and welded into the tube.
All together.
He has lightened the new drivers door and welded in the plate for the mirror as per before. So next its onto the front bar which holds the bumper and wings. It got bent on one side and he wants to remove the Dzus clips this time and bolt them on so they will be quicker to remove.
Bodyshop is booked for 3 weeks time so looking good to make GTI International.
April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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SteveoBC
Premium Member
Registered: 22nd Feb 07
Location: Bucks
User status: Offline
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Tidy work, did a nice job on the roof
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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Hamish has been on with repairing the damage to the panles. First up was the front bar which took a hit to the out-riggers that the wings/ bumper bolted to. They used to have Dzus fastners on them but they were a pain to use so he decided to weld some bosses on and bolt them instead. Ignore the bolts he will be using some alloy bolts and washers.
Bolted back together.
Rear wing around the exhaust cut out fibreglassed back together.
The swage line on the passenger rear arch was always low compared to the door. He decided to take the chance to line it up as it always annoyed him.
Crack in the other rear wing repaired.
Front wing stuck back together and worked on the shut lines to improve them.
Same done to the other side.
Panels stripped off and taken to be sprayed.
The car is now up at a friends house having the roof filled then its going in this week to get painted.
His new dash binicle landed this week. Motec CDL which will actually work with the Motec ECU unlike the race technology which gave no end of trouble and their customer service was shocking.
Dash comes with shift lights, GPS module for speed and odometer. It also comes with a proper wiring loom so is an easy fit.
Hoping to make GTI international and have some fun on the strip!
April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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Dale
Member
Registered: 7th Oct 07
Location: Swindon
User status: Offline
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I have CDL 3 in my car with M400 he should have got that first time around he will love it over the race crap.... Can't fault mine...
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gez bay
Member
Registered: 14th Feb 08
Location: South Wales drives: Vxr
User status: Offline
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Amazing car, shame about the crash, but these things happen.
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craig8
Premium Member
Registered: 31st Dec 04
Location: Glasgow
User status: Offline
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Really don't know why I read comments on YouTube videos, some of the goons on there are unreal
Car I a real credit to your mate and its great that he's just got straight back on it again
E36 328
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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Bit of an over due update. The car went up to his mates to get the filler work done.
He ran out of time to get the shell painted before inters so got him to primer the shell at his house so I could use the car:
Panels came back from being painted and I got it built back together ready for inters:
Welded a plate onto the steering column to mount the dash and its buttons:
All working which is a big difference to the old dash!
Got the car to inters after a full weeks work. It was lacking some bits of trim and grills etc, but it was good to use it.
First run on Saturday it went off the line well but then in 3rd and 4th it had a missfire. Then on the return road he could hear a clunking from the rear end so suspected a shaft or diff. Got it back to the pits and it was just the rear diff lock not fully disengaged (had forgot to lock it).
Whilst under there we could see that the rear tie rods had hit the anti roll bar on launch so it was off with the roll bar for the weekend.
Hamish did further runs at the weekend but all were with the same issue in 3rd and 4th. Tried a new set of plugs, and got hold of a new set of coil packs from the guys at PSI who did a cracking deal so thanks to them. In the end with some help from Keith Murray of Dialynx we discovered the issue was low voltage causing the ecu all sorts of issues with the injectors and coils. The rear alternator just couldn't get the voltage up in time so its back to the drawing board on that one. A big thanks to Keith Murray who was a great help all weekend!
The car managed to do an 11.5 at 123 which is 10mph slower than normal. Also managed a few other 11 second runs at around 110 due to lifting in 3rd. It was 60 footing in 1.6 range and I am sure it would have run a 10 if the terminals were in the usual 130+ range.
The only video I can find from the weekend running against a mate in his highly tuned stripped TTRS. Had to lift in 3rd so handed him the win but showed him how to launch! The lady in the video tells us it might be the gearbox!
http://www.youtube.com/watch?v=87VFNqMZs4Y
So going to look at putting the alternator back onto the engine with a ribbed set up to get around it chewing up the v belt. He is also making some new rose jointed rear arms which bolt under the hub pick up to give more clearance for the bladed anti roll bar.
Entered ten of the best at Elvington in 2 weeks time so hoping to get some good times out of it there.
April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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Hamish cracked on with the work to fix the issues from GTI international.
Started with sorting the rear track control arms so they didn't hit the bladed anti roll bar. The track control arms needed to bolt under the hub pick up rather than on top to give some extra room. Whilst he was changing things around decided to make the arms as long as possible like the fronts so the geometry change under compression is reduced.
Cut the old pick up points off the subframe and welded them into the centre of the subframe so that the arms were level at ride height. They are central its the diff mount thats not. Whilst cutting and welding he decided to plate over the rear of the diff mount to strengthen it up and give something to weld the pick ups onto:
Rear diff strengthening plate:
Link arms made up and bosses tig'd in place, using rose joints either end.
Quick coat of paint and bolted back in place.
Both ends have misalignment spacers to stop the joints necking under movement.
That has given plenty of clearance to the anti roll bar and hopefully should help with having longer bars.
He has also moved the alternator back onto the engine. Moved it to the back V on the front pulley as its a deeper V so hoping that might help with it flipping the belt and throwing it off. Over the winter Hamish is going to take the pulley off and convert it to a ribbed one.
So the car is just about ready for Ten of the best at Elvington!
April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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Hamish had a superb weekend at Ten of the Best. Got there on the Saturday and had the same issues with the missfire in 3rd and 4th. Changed a few things and eventually cured it by closing up the plug gaps.
Saturday night there was a storm and it was soaking wet but luckily it dried up in time for running. The only problem was that the wind had come around 180 degrees from the Saturday and was now a huge headwind. Did 3 runs with the car set up for the handling course and ran an 11.09 @ 128mph.
Decided at that point to go and do some runs on the handling. The car did 6 runs and ended up finishing 20th out of 120 so he was happy with that considering the quality of the field.
Decided after that to call it a day as it was starting to rain and the car was still running well so it went back on the trailer! The alternator belt stayed on all weekend without issue so glad to have sorted that issue!
One from the handling track
A video of his fastest run from the weekend against a very quick elise.
Video
Showing a GTR how its done
Video
And some footage of the weekends event which includes a couple of clips of mine.
Video
Just need to get the roof and rear 3/4's painted now and then it will be down to Edition 38 at the very start of September. Hopefully will have some new wheels on it by then as well!
[Edited on 02-08-2013 by Daniel_Corsa]
April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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M Sutton
Member
Registered: 11th Jan 03
Location: Northamptonshire
User status: Offline
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Such an awesome car! 11 sec 1/4 is good! The video links dont appear to work for me though.
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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quote:
Originally posted by M Sutton
Such an awesome car! 11 sec 1/4 is good! The video links dont appear to work for me though.
Fixed videos.
11's are good but can see it getting 10's easy once its running right.
1.6sec 60ft
130+ mph
April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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3CorsaMeal
Member
Registered: 11th Apr 02
User status: Offline
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No drifting videos this time then?
only messing, car looks amazing when it launches against the GTR. Is it road legal?
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Daniel_Corsa
Premium Member
Registered: 21st Apr 04
Location: Wigton, Cumbria
User status: Offline
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quote:
Originally posted by 3CorsaMeal
No drifting videos this time then?
only messing, car looks amazing when it launches against the GTR. Is it road legal?
No drifting this time.
Yup its MOT'd etc.
April '06' Corsasport Feature Car | Aug '08' Total Vauxhall Feature Car | Spring '09' Fast Car Feature Car
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Nic Barnes
Member
Registered: 5th Apr 04
Location: nowhere near ginger people
User status: Offline
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Did he not have a crack at the standing kilometre?
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Robin
Premium Member
Registered: 7th Jan 04
Location: Northants Drives: Clio 182 Cup
User status: Offline
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Wtf is in that Elise?
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Marc
Member
Registered: 11th Aug 02
Location: York
User status: Offline
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I reckon I could sex wee if he got it in to the 10's.
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SVM 286
Member
Registered: 13th Feb 05
Location: pain
User status: Offline
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So glad he fixed her up. 
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