[trackday_prep] Roland Garros Hillclimb/trackday Project

[AdamP 0]

Great progress! Out of interest how much do you reckon its cost so far?

 

Oh dear....

 

Probably the best part of £1300. I know... I could probably have bought a ready prepared one for that but the fun is in the building experience isnt it?

 

Biggest money saving part was buying the XS. No need to go out and buy all the small things (bolts, relays, switches, brackets etc) because they're all there on the car. Cost £50 and wasnt worth putting back on the road, but as parts its great

[AdamP 0]

Wiper is a bit to the left!

 

It's actually dead central... but because it sweeps right then left then back and i did it in the dry it's slightly bent to the left.

[AdamP 0]

Did a couple of little jobs again this weekend.

 

Changed the RG alloys back for the steels with ACB10s:

 

 

So that I could rescue these from the XS:

 

 

Which have 4 good tyres and will go on for the MOT/road.

 

And I got the cage back in Needs bolting up properly but at least it's out of the way now!

 

[AdamP 0]

Got up this morning and decided I wanted to drive the 205.

 

So I bolted the seat in, stuck the steering wheel on and dadahhhh ready to drive! Still a couple of things that need doing before the MOT though.

 

Pictures:

 

 

Even just driving it to the end of the road I can tell that it handles 200 times better than the Polo

[AdamP 0]

Got lots of 'little details' done this weekend, getting it almost ready for the MOT.

 

I put it up on ramps and:

 

1) Secured the brake/fuel lines

2) Waxoiled bits that needed waxoiling

3) Bolted in all the harness eyes

4) Secured the handbrake cables (biatch of a job).

5) Sealed the blowing exhaust

 

Also:

 

6) Finished mounting the seat

7) Put the harness in

8) Mounted the fire extinguisher

9) Plumbed in the winscreen washer bottle

10) Attatched the air filter

11) Sorted out the indicator and headlight bulbs

12) Adjusted the handbrake

13) Fixed the sticky dash buttons

14) Finished wiring the cut-off switch

15) Torqued up the roll cage mounts

 

 

Things still to do before MOT:

 

1) Change wheels

2) Align headlights

3) Check over rear brakes

4) Trim cut-off pull cable

 

Things to do before hillclimb (22nd June):

 

1) Buy new harness

2) Fit cage diagonals

3) Buy cage padding

4) Wire in coil cut off

5) Get slicks fitted and balanced

6) Fit timing strut.

 

All systems go!

[josh1990 0]

Looks really good mate, can see alot of effort has gone in

[AdamP 0]

Looks really good mate, can see alot of effort has gone in

 

Probably too much.... got my AS's starting in less than a week

[AdamP 0]

Did a quick engine service on it today including:

 

Oil change

Filter change

Spark plug change

Valve clearance adjustment

Rocker cover gasket

 

The tapping noise has now gone so must have been the inlet valve that was supposed to have 0.20mm clearance that I could get a 0.60mm feeler in

 

Also trimmed down the battery cut off pull cable, sorted some more wiring and connected up the breather catch tank

 

Progress is great!

[AdamP 0]

Well then, a few pics!

 

 

MOT next saturday!

[AdamP 0]

[Modify] [Delete]

This afternoon I got a few more little jobs done.

 

Removed fouling wing mirror handle

Got fuel guage working

Wired in coil cut-off

Aligned headlights

 

Also done a bit of shopping on tinternet. Best part of £350 gone

 

Bought:

 

OMP race suit

Roll cage padding

Battery box (for boot)

TRS 4pt harness

 

MOT is booked for Thursday, hopefully the insurance and tax will then be sorted by half term

[danpug 1]

What does the air filter sound like? I've recently bought myself a garros, going a different route to you though.

[AdamP 0]

What does the air filter sound like? I've recently bought myself a garros, going a different route to you though.

 

Well i've been sat listening to my air filter for the past 25 minutes and it hasnt made a single noise

 

 

 

 

 

 

 

 

 

 

It definately increases intake noise alot!

 

 

It failed it's MOT on a leaky exhaust, should be able to weld it up though I hope.

[AdamP 0]

Took the exhaust off today. Took centre and backbox off first and checked them over and they're fine.

 

So then I set about taking the downpipe off, which turned out to me a bit more of a challenge than I expected! The bolts were pretty well seized so I ended up taking the manifold off as well, and I found some nice holes at the bottom where the bracket attaches. Probably weldable but not great!

 

So I set about taking the downpipe off the XS. Again, everything corroded together making it as difficult as possible and when I got it off I found the same holes in exactly the same place!!

 

So tomorrow the welder comes out.

[danpug 1]

Well i've been sat listening to my air filter for the past 25 minutes and it hasnt made a single noise

 

Lol. Muppet!!!!

[RyszW 0]

Exams all over then Adam?

 

Surely, this is the perfect time to get yourself a new manifold?

 

Rysz.

[AdamP 0]

Exams all over then Adam?

 

Surely, this is the perfect time to get yourself a new manifold?

 

Rysz.

 

On half term, then a week of exams next week and I'm done!

 

I'll be getting a 4 branch manifold when I get the head sorted over the summer, for the moment i've just welded it up It's all back on the car and nicely sealed.

Edited May 27, 2008 by AdamP

[AdamP 0]

Got a nice green MOT certificate yesterday

[AdamP 0]

This afternoon was spent removing the all ali TU3S engine from my spares XS. It was surprisingly easy, manageable by a single teenager armed with a socket set and a jack! The process went something like this:

• Remove all pipes and ancillaries
  
• Jack up front of car and put it on axle stands
  
• Remove wheels.
  
• Undo top mounts
  
• Undo subframe bolts and support engine with jack
  
• Undo engine mounts
  
• Drop the jack
  
• Wrestle the engine off the subframe
  
• Winch, leaver and drag the engine onto trolley.
  

The great thing about the all ali engine is that I can lift if on my own, with gearbox attached ;D

 

Here's the pictures....

 

Empty engine bay:

 

Subframe:

 

Rot!:

 

Selection of parts:

 

And the prize:

 

The plan for it is:

 

Rebuilt, flowed head.

Catcams 286 cam.

Stiffer valve springs

Mikuni 40s.

4 branch manifold.

Lightened flywheel.

Lots of other new standard bits.

 

First thing is to nab the engine stand from school so I can strip it down and see what condition it's in. It's a 100,000 mile engine (as most of them are....) so I'm not expecting it to be perfect, but it ran nicely without any smoke before hand . Feel free to give me any advice as I far far from experienced at this engine malarky!

[swordfish210 20]

when i rebuilt my engine (152,000mile TU3-A) i rebuilt it with the original bearings, rings and liners because they were in a perfectly servicable condtion and there was no point in replacing them so i wouldnt write them off yet I wouldnt bother getting the flywheel lightened because it's allready light as fook and taking any more material off of it could comprimise rigidity. I would get the crank assembly balanced though as i did. With a balanced crank and Grp N engine mounts it's less vibratey inside than it was standard.

[taylorspug 7]

when i rebuilt my engine (152,000mile TU3-A) i rebuilt it with the original bearings, rings and liners because they were in a perfectly servicable condtion and there was no point in replacing them so i wouldnt write them off yet I wouldnt bother getting the flywheel lightened because it's allready light as fook and taking any more material off of it could comprimise rigidity. I would get the crank assembly balanced though as i did. With a balanced crank and Grp N engine mounts it's less vibratey inside than it was standard.

 

If you used the original bearings and rings its not really a rebuild though is it?

[swordfish210 20]

fine if you want to get pedantic about it. I took it apart, cleaned everything, replaced all of the oil seals and o-rings, had the crank assembly balanced, replaced the water pump distribution pipe, replaced all of the gaskets, fitted the ancillaries from my old cylinder head to the ported and gas flowed one and then put it all back togeather again.

[AdamP 0]

Mr Swordfish, what sort of power are you getting from your setup? And are you running the standard cam?

[swordfish210 20]

at them moment....bugger all I'm wating for a manifold to be made to fit my R6 carbs so i'm using the standard carb which runs as lean as a bastard. I'm using the standard ignition system (because i can't afford DTA stuff at the moment) and i'v got a gas flowed and ported head with a Dr Shrick 284 cam with an 11.4mm lift. I'm also using standard valves with Piper 240lb valve springs.

[DaveW 6]

Dont let jordan see that gearbox...

[AdamP 0]

Dont let jordan see that gearbox...

 

Don't tell him i've actually got 3 of the buggers