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Here we go a standard mk2 1100 still on cross ply tyres |
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The plan is to strip the car down blast it jig it and see what independent suspension we can fit on the rear end we have plenty of time as the car is booked in at the historic motor sport show in Febuary 2006 it is now November 2005 so 4 months to go |
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So we have borrowed a rear x member and some hubs of a 2001 wrx subaru.
After laying the x member on the car it looks like it will fit.
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It's all his fault Neal runs a Subaru rally car and this conversion was his idea |
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We looked at going down the road of the ford diff and bespoke set up on the rear but the parts are very dear and the geometry would be hard to set up.
We brought a Subaru donor car and made a set of jigs from it this way we new that the geometry would be there or there about
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This is the jig fitted to the car we have measured the ride hight of the subaru and fitted the jig to that hight the jig picks up on the x member mountings the trailing arms, diff and suspesion tops so all the mountings are the same as a wrx sti Subaru. |
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These are the boxes to be welded to the car and will take all the power so they had to be made well the bushes are webbed to give extra strength
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Then the boxes were fitted to the jig and tig welded together.
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Heres one we made earlier |
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With all the boxes fitted on the jig we placed the jig back on the car and welded the boxes to the car
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Then fitted the turret jigs and made the rear tubs and turrets |
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The Subaru x member will fit without any modifications to the floor
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The chassis needed little modification |
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On with the roll cage a mix of CDS and T45
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All Tig welded in |
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Here you can see one of the boxes with the roll cage welded through it
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The roll cage was made to fit this car even the diff pick up point was braced. |
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The engine was to be set back 300mm so the bulk head was removed and a fair hole cut in the floor. |
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roll cage finnished and the front tubs in it is now late December and we need to push on with this project.
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We are using a cosworth 2.3 duratec engine so we asked cosworth for a dummy engine |
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The seat mountings were next because we have moved the engine so far back we need to sort out where my feet will end up as it turned out there is plenty of room.
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A new bulk head and gearbox cover all fitted and fully welded.
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A new prop tunnel |
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The drivers side of the bulk head was a bit more complicated we needed to leave some room for the exhaust manifold
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This is the veiw from the engine bay |
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At last late January and the car is looking like a car again the steel wheel arches will have to be finished in paint we only have 2 weeks left to paint and build this car
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All the floor finished and ready for the paint shop boys |
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We now have a week to paint this car and build it ready for the show the paint shop boys are really mad with the fabricators for taking so long on the fab work
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After hours of prepping, priming and rubbing down the car is ready for some bass coat |
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Here it is in our own colour kermit grey
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Now some clear coat |
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Then the outside the first time we painted this car it was imperial blue
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After some long nights building the car with the cosworth dummy engine and the running gear on there was no time left both cars had to go to the show. we had a great show if only people new the effort we all made to get this one to the show they would not believe it. Thanks again boys |
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After the show we started looking at the working of the front end and found that we did not have enough bump for the 17" subaru wheels and the geometry was a way out on the front so after a trip to the amazing John Edwards a plan was hatched we needed to move the front turrets and extend the wheel tubs to give us enough bump and lock, then John could build us a bespoke set up for the front all was going so well untill it came to fitting the forest arches no way they would fit so we had to re- design the front wings which meant we had to do the same to the rear wings and that meant the car would look to heavy in the blue so a respray was ordered and a new colour scheme thought of
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Here is the rear wing |
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And the new colour scheme this was a mix of my own it is a Honda metalic yellow with some xyrelic powder in the paint
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About this time I met an old freind from my touring car days Jamie bull Jamie owns a company called m-cal and they supply dash displays and ecu's infact anything to do with electronics on a race car this chat cost me a packet the car now has more electronics than a world touring car (full spec soon ) |
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Here we are nearly a year after the car was started we have fitted the new cosworth engine (with a promise from cosworth the engine will make 280+ bhp ) so off to the rolling road with my mate jamie to map the engine 220 bhp well pissed off after many calls to cosworth and some helpfull tips back to the rolling road still only 220 bhp some more phone calls more tips back to the rolling road still 220 bhp jamie has tried every trick in the book to get more power so what do we do now I know lets go to the rolling road one more time if still no joy we will have the engine inspected by Stuart cresswell from premier power.
so that is what we did still only 220 bhp and after a chat to Stuart he came along with his magic box and checked the cam timing all seems ok I went out side to find some rope as this was getting stupid and then a call from Stuart Mick I have found out why this engine only gives 220 bhp great what is it I asked the engine is f**cked.
OH good !!!
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So we take the engine out and back to cosworth they strip it down and sure enough the engine is scrap new block and all internals later and a bill from cosworth (cost price so not to bad ) with lots of help from them installed the new engine booked a rolling road sesion at Bob watsons invited cosworth and they turned up with there head engineer took a look at the car and said what a great job we had done on building the car so lets see what this engine will do guess what 220 bhp After many hours looking at the car the cosworth engineer said the only thing that can be sapping that much power out of the engine is the exhaust and manifold if you change the exhaust and manifold the engine will make the power after some discussion we all thought that BTB exhausts would be the ones to make the manifold and exhaust as they have some experience with the duratec engine. |
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Some of you might have seen the car at the historic show in March this year after the show we fitted a new 6 speed tractive gearbox wow what a bit of kit they are
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Bespoke interior with all the right buttons to push!!! Grin factor 5. |
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Tuesday the 30th October 07 off to the rolling road at Bob Waston's, with Jamie from M-Cal with his lap top, and Andy from Cosworth, we hope to get the full 280+ from the engine, fingers crossed watch this space. I hope all the hours have been worth it over 2000 hrs from the start, were so close now.
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After the new manifold and exhuast was fitted we took the car to Bob watsons ran it up on the rolling road and bingo 275 bhp well pleased it just goes to show if you want good power and 91 dbspl go to BTB exhausts recomended by CBC more pictures soon. |
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Here we are at oulton park for the final test we have had the new reiger suspension fitted by Jems Race and wow what a diferent car we now have more bump and droop.
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Here Olly allen is putting Jack through it's paces the car looks and sounds great with the flat shift. |
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This test was on Friday 31st of October and on Saturday Olly went to Donnington for the final round of the british saloon car championship in his mk3 fiesta came fourth overall won his class and the championship well done Olly.
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We are trying to put a deal together so Olly can race Jack next year watch this space
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Jack with his new reiger's fitted |
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Jack now has a new front and rear anti roll bar fitted the front is a blade type and the rear is a fixed bar type. |
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Jack at my house on his stands
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You to could have a sticker like this if you ring the number below |
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Thanks to all at jems and Olly allen my car is now owesome
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After a trip to Bruntingthorpe with Classic ford we set up the launch control and the traction control and the pit lane limiter so all the buttons on the steering wheel work now. |
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