Tuesday 29 June 2010

Monday 28 June 2010

Stuttering investigations

After a post on the forum, speaking to Andy Bates and a hunt on the net, I took the car for a blast up a private road, and it showed no problems. It has to be fueling or electrical, but i'm not going to be able to test it properly until qualifying at Cadwell, so i need to investigate/repair as much as i can now. I have ordered a new set of plugs as a precaution which i will fit and have a spare fuel pump and set of coils which i will take with me to cadwell. I cleaned the fuel filters and removed the tank and cleaned it out, there were some small particles in there but nothing severe so doubt it was the cause.  Dave (the old owner of the car) suffered something similar when he owned the car. It only happened when the car was hot, but that problem turned out to be a vapour lock in the fuel line caused by the pump being in the engine bay, so he moved it to the rear, so it can't be that again, unless the pump is on the way out. I tested the flow rate of the pump which worked out to be about 2 litres per minute, so that seems fine. Derek has suggested it could be rubbish in the float bowls as he suffered a similiar problem back in his class C days, so i'll have to whip the carbs out and have a look.


Brands Hatch 19/20th June

With the car all stickered up i went to get to Brands early on Friday so i could get some good pictures of the car and meet up with Lee from Q20. It also meant i could borrow some corner weight scales and set the car up properly.


The journey down was easy and we arrived at 10.30am and set about unloading and setting up camp. The paddock was surprisingly empty and managed to get a spot on the edge of the paddock next to the power points and saved Bob a place next to us. I had 2 test sessions booked for the afternoon, but as this wasn't until 2.45pm we had plenty of time to set the car up. We took the car upto the flat area next to the scrutineering bay and borrowed a set of corner weight scales from Paul Nightingale (Spire sports cars). First off we went round setting the ride heights, i had been suffering a little understeer at silverstone testing so decided to up the rake from 20 to 25mm. After setting the heights we put it on the scales, this was the first time i had ever done this and was amazed that the diagonals were out by 20kg! After twiddling the spring seats i got it within 0.5kg, a quick check of the ride heights now showed it sitting 10mm too high all round, so i backed off all the springs seats 3 turns and rechecked the weights. This time it was very slightly out, so half a turn here and there sorted it out to within 0.5kg again. Just as we were finishing, we turned away and the car rolled off the scales and into some handrails!!! None of us wanted to look, the front of the bonnet had taken the full impact and there was now a 150mm crack, stress cracks and a big chunk out of the nose of the bonnet!!!! And guess where the damage was, right in the middle of all the stripes! BOLLOX!!!

As i was scrabbling round trying to patch up the bonnet Lee from Q20 turned up. Luckily she thinks the battered and scared looks will just enhance its appeal at the show as it proves its a real race car. We'll have to wait and see quite how scarred it is by September and reserve judgement on that ;-)

The first session of testing proved very useful, the rear end of the car was all over the place coming out of Graham Hill bend, and felt very squirrely when powering out of any of the corners. I suspected the rear suspension was bottoming out, so popped into the pits and added a couple of clicks to the rear dampers. This instantly settled the car down, but makes me think that i may be slightly too soft at the rear. The problem with the rear suspension is the lack of travel available due to the pick up points of the dampers, if you soften it off, you run out of bump, so its a trade off between compliance and grip at the rear and not hitting the bump stops. I may try a set of 200's at the rear and see how that goes. But with the dampers stepped up slightly the car was behaving well, the handling was a lot less twitchy and it inspired confidence. Rather than it feeling like it was trying to spit me off the circuit and kill me every time i tried to put the power down, it squatted down and gripped at the rear, although the front didn't feel quite as positive as before. The one place i felt a lot happier was Paddock hill, here i could really push on through the apex and knew that if i was running a bit wide i could back off the power slightly without worrying about a visit to the gravel. This meant i could use every inch of tarmac (including the green strip), so much so both Dad and Dan said they couldn't watch anymore as they thought i was going into the kitty litter! Personally i felt fine through there and never felt like i was close to going off.  Laptime showed i was about he same times as before, which i was slightly disappointed with, but more significantly i was lapping at a constant time of low 53's. Consistency has always been my problem, i could put one fast lap in, but then the next one would be way off. So if the new set up has helped this then i've not wasted my money!

The 2nd test session went OK, i managed to get down to a 53.29 which was faster than my best qualifying time last time, although slightly down on my fastest race lap (53.12). I did have a couple of moments at surtees and clearways, and had to come in to try and sort my head out, but 30mins is a long time out there, and i'm now pretty glad we don't have the 28min races!!

I gave the car a check over and grabbed some photos of the car in the empty paddock before we popped out to get a chinese in readiness for the England game. Phil had generously given me a portable travel TV for the bus so we could watch the game, although i wish he hadn't as it was an appalling performance and I vowed to forget the World cup and only watch cricket in the future!! During the dinner and the game Bob arrived and set up next to us, with our new pull out awning and bobs gazeebo we had a nice little set up which if we repeat should keep us fairly protected and dry at future meets.

Saturday was a fairly laid back day with scruitineering not until 10.30, qualifying at 11.30 and race at 4.30. But somehow managed to ourselves very busy, messing with the car and Miles and Dan buffing up the paint work on the bus! The bus actually has a shiny reflection on the nearside now!!!

Qualifying didn't go great, i ended up at the back of the queue in the paddock so held back for a few laps to get some clear track ahead. Trouble was, within 2 fast laps i would start to catch people up again, so only really got 1 flying lap at a time, and only managed 3 or 4 quickish laps. I wasn't overly confident in my grid position, so when it came out that i was 2nd in class for both race i was chuffed but my best time was a 53.45, and Al was a long way ahead (0.6 seconds) of the rest of class C. Colin was suffering with some handling issues after his repairs post Anglesey crash and Matt was having engine problems, so it wasn't a great performance from me!

As we pulled into the holding area it started to spot with rain, and by the time the red lights went out it was raining properly and the track was wet. I got a decent start and held my position coming into paddock where i decided to tuck in behind Tony on the inside and try and hold the inside line up to Druids, but Paul Rogers decided that winning every race was too boring span coming down hill out of paddock, i backed off as i wasn't sure which way he was going to go, letting Matt and Colin come through. The track was slippy for the first few laps but it had stopped raining and dried out pretty quickily. I was tucked up behind Colin for the entire race, although dropped back from him a few times due to back markers or a mistake on my behalf. Dad had been telling me just to try and pressure Colin and hope he made a mistake, unfortunetly for me, he never did and i had to settle for 4th in class right behind him.

The camera stopped on lap 3, and the rear veiw camera was empty for most of the race, so heres the first few laps only.



The excitement of the race was nothing compared to seeing Bob pull up along side me at the bus, next to the BBQ gas cylinder with his rear calliper on fire! I panicked like a girl and ran into the bus to get the extinguisher, but as Bob pointed out, steel and brake carbon doesn't burn very well and it extinguished itself. The evening was spent with a few beers and a BBQ while watching Bob and Dad disassemble and rebuild the rear calliper several times, which was actually far more entertaining than the England game the night before!

Race 2 on Sunday was dry, and after slightly better start than the day before i ended up losing out to Matt and Colin again as i slowed for a spinning Tim coming out of Druids on lap 1. The rest of the race was again tucked up behind Colin, but this time we reeled Matt in (i think he had fueling problems at the end of the race again) and both passed him, i was also pleased that i constantly stayed with Colin, only dropping back once after getting stuck behind a back marker but quickly caught back up. I just couldn't find away past Colin he drover very consistently and took some good defending lines, i definitely could have been more aggressive, but after our history of collisions this year i didn't want to risk it! So i ended up 3rd in class again, had a fantastic race and really enjoyed myself, but next time Colin.... next time!!! ;-)



The car performed faultlessly again, until the last few yards of the race, as i was coming up the straight to the finish line the car started stuttering in 5th as if i was hitting the limiter, i tried to replicate it on the cool down lap but didn't manage it and it ran fine in the pits with no load on the engine. I'll have to have a hunt around see what i can come up with.

Transformations

After spending a few more hours with the cutting paste, a sharp knife and a water spray gun, the car was finished. I am very happy with the outcome!!!



Wednesday 16 June 2010

Winning one battle!

Another evening, another unhappy wife, another apology for being in the garage all night!! If my wife reads this, i apologise again, and its nearly done so you will see me for more than a fleeting moment soon, well as long as i don't destroy it at Brands this weekend!!  Last night i actually ended up eating my dinner over a 3 hour stint in the garden and garage. So to match the bacon fat on the camera lens i know have some chicken grease on the body work. But the hard work is paying off, she is starting to look the part now, the rear is complete apart from a few web address stickers and inserting a hamster bowl (i kid you not!!) around the filler neck. Its a good job there was a sale on at Pets 'R' Us! You can also see the lights poking through the body work, and the pig tail strap towing eye on the left hand side.


As you can see the nearly sprayed roll cage is now back on and really looks the business, another big thumbs up to dads DIY spray skills and his time and effort!!!
The front and sides are WIP, with just the red lines attached so far, its amazingly time consuming!!!!




Tuesday 15 June 2010

Illuminating

Just a quick piccy showing the rear lights now mounted in the brackets and fitted to the car. The body work is not square and impossible to true up to the chassis, the holes in the body work are not symmetrical and i'm not so sure the chassis is straight and true, so lining everything up is horrible!! To make it fit the bodywork, the bare chassis looks terrible, but if you square it up to the chassis it looks shite from the outside!! So in an attempt to make it look OK, I ended up doing neither, so now it doesn't look quite right in any situation!!!!




It wasn't a very good night in the garage last night, Dad came over to lend a hand (again) as we are getting tight on time now, but it took him all night to reconnect the the front lights up due to various reasons (wires too short, GRP resin on bolts, crap connectors etc). Meanwhile i had to tidy the garage up a bit as i couldn't find any of my tools as they were all over the place, and then attack the no oil pressure issue after changing the oil and filter. Its a known issue that when you change the oil and filter you can get an air lock in the system, so you should always remove plugs and turn the engine over until you get pressure. If you can't get pressure you need to unscrew the filter slightly and turn it over again and release the lock. Now normally this is simple, but i had bought one of the K&N filters with the socket on the end so i could tighten the filter up easily and lockwire it in place, but unfortunately when i went to unscrew the filter, the socket rounded off. No matter how much i tried by hand or with a filter wrench it would not come off, so in the end had to knock a screwdriver through it and twist it off. I had got a spare filter that day as i knew this was probably going to be the outcome. With that sorted i turned the engine over and pressure resumed. I cut a hole for the fuel filler in the body work, but at the moment don't have any more filler hose to extend the cap above the body work, so there will be just a hole for this weekend I also removed the undertray as its too small now due to the cut out in the body work, and i want to make a nice flat undertray anyway in the future, and finally i cut and glued the very fine mesh (under 1mm holes) i had sourced for the side and rear vents on the bonnet.

Monday 14 June 2010

Bodywork Progress

With all the bodywork now sprayed up and transported back home it was time for a trial fit!!




The stripes had be masked out off the car, so we were a bit concerned they wouldn't match up once back on the car. As it turns out its only the drivers side, side stripe that doesn't quite line up, so a quick airbrush in will be required.

I had trimmed the the middle tub to fit the rear but hadn't actually sorted out the fixings before spraying. To keep things simple i pop riveted 2 pieces of angle onto the rear tub and then dzus fastners hold the sides to these. The drivers side went ok, but passenger side required 3 attempts as the curvature of the panels didn't quite match and looked horrible. I have had to position the fixings to as to bend the side panels into more of a curve to match the rear.


Another thing i noticed is that the drivers side rear body work seemed to be sitting sligtly higher than the passengers, so redrilled and moved the bonnet pins to try and level it up. But from doing this exercise i am now aware how non symmetrical the body panels are!! It is impossible to get everything mirrored exactly due to the body mouldings being different shapes either side!! My job is BIW design and everything is nicely mirrored in CAD, meaning that you can make everything nice and symmetrical, so I find these errors very annoying, but have to accept its all part of the kit car and hand built nature of these cars!!

With the body now fitted, it was time to bolt all the nice shiney bit back on!! This is very satisfying, especially doing it on the lawn in the nice sunshine





Wheelarch extensions now fully fitted and trimmed. The edges are lethal, hopefully Tim can catch his leg on them as he walks past and we can have matching scars inflicted from each others cars! ;-)  I have some rubber edging to glue on after this has been achieved!




The lights are being mounted to the chassis rather than the bodywork, so made up some mounting plates and strengthened them by bending the edges and creating a box. I have got to mount these in mid air of the chassi to line up with the holes in the rear body work.

Thursday 10 June 2010

Plastic Surgery

During dads prep of the body he had filled all of the holes i had made for mounting the body, so after a bit of redrilling i got the back end inplace and set about fitting the aluminium closing panels i had made


I was worried these would be a bit flimsy, but now they are rivetted in place they are fine, and also help the loading/fitting of rear body as the return edges on help line up the wheel arch inners.

As i mentioned in my previous post the wheels stick out by about 60mm from the body work, so i need to address this with some wheelarch spatts. Making the off side one has pointed to something being different between the mouldings of the original spider type tub and the door type tub i now have. I am assuming the spider tub must have more flared wheel arches or they were modified, as the wheels never stuck out this far before and the spats were a lot smaller. Now the rules state that class C should be standard body work, which this obviously isn't, but i need to enclose the wheel so they will have to be fitted, or revert to a spider tub. I haven't got time to do anything else, and seeing that most other furys have extended arches (see Bobs car) i can't see why it would be a problem.



To make the spatts/extensions i bent a strip of aluminium in to a curve to match the wheel arch, lined it up on the outside edge and scribed the outline of the bodywork the aluminium. I then cut up to this line on the inside edge every 30mm so that i could bend the tabs inside the car and then pop riveted it through the body.


Dad had also been busy prepping up the front end ready to mask out the stripe. The tricky part of the stripe is where it passes over the bumps, and at the same time keep the line straight and an equal width. To do this, rather than just trying to get the edging tape to look straight by eye, we stood the bonnet up on its rear edge, and ran a laser from a parallel piece of wood in front of it and marked the line ever few centimetres. This worked a treat and line has come out looking very neat. Unfortunately the hole for the air intake isn't central so is offset compared to the stripe, but hey ho, i'll probably destroy the bonnet next time out anyway ;-)


The Brand new lights took a bit of a battering last time out, and at £35 per corner i was happy just to bodge them back in. But Dad wasn't happy with this, and to be fair the rest of the car looks so good they would ruin it, so he took it upon himself and surprised me by making these out of a stainless  steel dog bowl and a cheap large torch!!! The bulbs in the torch have been replaced with proper headlight bulbs and a side light added. OK, these wouldn't pass an MOT as stated due to the beam pattern, but they still have the side, dip and main beam required, and more importantly cost about £3 and are extremely lightweight. So next time Colin destroys one i won't be that bothered about running round the marshals trying to find who picked it up and hoping it is still in 1 piece ;-)


So i've still got plenty to do, but from one of the ugliest, scruffiest looking cars on the grid a beautiful white, blue and red swan is emerging!! No doubt I will ensure it returns to the dog like looks within 30 seconds of driving it!!!!!

Forwards, backwards then slowly forwards

After getting back from holiday I realised i don't have that much time left to get this lot finished!! Dad had been busy while i was away spraying up the body, which again he has made a excellent job, especially considering he isn't a painter or have a spray booth. So here's a sneaky peek of the mid tub tub and rear


The initial idea was to have a wider centre stripe, but due to the lumps and bumps on the bonnet, applying the red and light blue stripes would have been impossible, so opted a narrower strip that only goes over relatively flat surfaces.

The recent TV coverage from the last Brands race featured a lot of my onboard footage (mainly because only 2 of us submitted any), so i thought i'd make the effort to improve the stability of the cameras hoping to recieve further good coverage and please Q20! So i weld a couple of brackets on for the cameras and while  its off, we decided the shabby looking roll cage would look a lot better if sprayed up in white.






So the car is looking pretty bare at the moment and further away from completion than before i started!!! I have at least now checked the car over mechanically, changed the oil and replaced the rear pads so other than body work the car is actually ready top race.