Dedicated Track Car Progress Thread

Do you have a Puma that is a project? Do you want to track the progress with your own thread? Feel free to do it here.

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Dedicated Track Car Progress Thread

Postby Puma Babe » Thu Mar 31, 2016 8:57 pm

I'll see you there, I'll come in the Puma to offer moral support
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Postby trublustu » Fri Apr 01, 2016 8:22 pm

That`s great Yvonne.
It`ll be good to see you again..
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Dedicated Track Car Progress Thread
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Dedicated Track Car Progress Thread

Postby KoNLaR » Sat Apr 02, 2016 12:33 am

That grille looks great, have some mesh laying here as well. How did you go about fitting it? Some helpful tips would be appriciated :)
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Postby trublustu » Mon Apr 04, 2016 1:16 pm

Hi KoNLaR,
Fitting the mesh was quite straightforward.
Once the lower grille is removed the lugs are quite easy to cut off, I used a dremel to tidy the bits that were left.
I was quite rough with this as my car is not built for show, but it can be tidily done I`m sure.
The back edge of the `hole` is quite flat and the bumper moulding around it is quite chunky.
so with the mesh laid out I simply used 15mm self tapping screws with washers every 4 or 5 holes around the edge, starting from the middle.
I would recommend painting the lower lip at the back of the black `filler` bit of the bumper black for best effect.
Here`s some pics..

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5604

The other mod is the `MkIII splitter`

As I`m still coming up with the `perfect` design (in my eye)
Once again I`ve gone from `free out of the skip` materials.
In this case its a piece of 9mm MDF.
Yes I know, it`ll almost explode as soon as it gets wet! But thats long enough to give this version a few track sessions.

The mk3 has a few changes from the mk2.
I still have half of a Richard Mansfield fiberglass splitter which I used as a starting point.
One thing I wanted to combat was at the splitter ends.
The high pressure air being `split` would have been `folding` under the splitter ends in front of the front tyres, which I figure can`t be good.
So I extended the splitter, FRP style, so this air is dumped beyond the tyre.

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I ditched the `D` shape and went for something more like the `C` shape of the FRP and most aftermarket versions.
Mainly so I can get the the oil filter and rest of the engine with the bumper on.

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I thought long and hard on the negative effects bolting a splitter to the front of your car.
An obvious one being air resistance.
On a standard car all the air that hits the front of the car below the black bumper filler piece just folds under the car with little resistance.
By fitting the splitter it `splits` the air pushing it around the sides, but the area in the middle of the car isn`t doing much except catching air.
Now I didn`t want to remove the rubber skirt as this would be too much, cancelling out all the positive effects of fitting a splitter.
So I drilled a few rows of 10mm holes (95 of `em!) to relieve some of the pressure in this area.

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Once fitted they are invisible (you can see the light shining through them here)

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Finally I Added some splitter stays,
I used the same builders strapping as on the Mk2, as this is mega strong, aero friendly and I have a huge roll of it...
I attatched it behind the number plate `lugs` (now removed) through the holes in the black plastic filler and through holes in the splitter.
Attatched with bolts, out of sight.

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Fitted it looks the part and it seemed to work really well at Blyton park.
Though I`ll need to see the pro photo`s to see whether its holding together on track.

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I`ll probably fit end canards to the splitter when I make some canards for the bumper.
and possibly some rubber skirt as seen on ebay to catch a bit more air at the sides,

The car evolves..
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Dedicated Track Car Progress Thread
viewtopic.php?t=26160
YouTube track sessions and `incidents`
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Trackheads facebook group
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Dedicated Track Car Progress Thread

Postby moondustka » Mon Apr 04, 2016 1:49 pm

Nice info there Stu :ok:
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Postby grayfox » Mon Apr 04, 2016 2:12 pm

Love homemade R&D, great work mate
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Postby trublustu » Mon Apr 04, 2016 2:22 pm

You`ll notice that my R&D deparment is based in my kitchen..
As I`ve been working `till 8pm all week, and I needed this done, my house has looked like a garage / joiners workshop.
My 18yr old daughter is not very happy, but hey..
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Dedicated Track Car Progress Thread

Postby grayfox » Mon Apr 04, 2016 3:39 pm

:lol: all my work used to be in my 3rd floor one bed flat in North London until I moved to a house in August, you'll notice in my recent updates a stone paving background which is my now patio area/garden! :grin:
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Postby trublustu » Mon Apr 04, 2016 7:34 pm

Show off..
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Dedicated Track Car Progress Thread
viewtopic.php?t=26160
YouTube track sessions and `incidents`
https://www.youtube.com/channel/UCC5QLi ... 4GCrMVmmlQ
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Dedicated Track Car Progress Thread

Postby trublustu » Wed Apr 20, 2016 8:53 pm

I`ve been lapse in producing a track report but here goes..

Our small group arrived the evening before and camped at the track.
This is a first for Blyton as I`ve previously used a campsite just up the road.
I must say that staying at the circuit is a really good shout.
No really early start and you can leave the tent where it is `till later :thumbs:
With this being a sprint meet, it`s a different process to sign on etc. First thing is to get your car scrutineered.
So apart from forgetting to clip my harness in (they thought this was hilarious) I soon got my little scrutineering sticker.
Then it`s time to get a wristband and sit through a briefing.

The day is made up of a couple of sighting laps, 2 untimed practice runs then up to 8 timed runs, with lunch in the middle.
To my absolute delight the car sailed through the sighting and untimed runs without any clouds of smoke, so the weepy seal on the gearbox was finaly cured.
The seat took some getting used to, as now I was `grabbed` and not moving around,
So now it was down to business.

Leading out my group (Puma, Escort & 2 Clio`s)
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So off we went. I was really REALLY disappointed with my first run of 1:25.53, which is about SIX seconds off my PB. (1:19.44)
So I started getting to grips with the new tyres/seating/driving style and took 1 1/2 seconds off my next two runs.

I was starting to really push it before lunch and managed to end up with all 4 wheels going sideways through The Wiggler chicane. :o
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After lunch I had two decent runs, setting my best time of the day in run 5. (1:21.93)
Run 6 was a void run as I over cooked it into the final corner and wend off quite sideways in a cloud of tyre smoke!
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Run 7 was a fraction slower than my best so far and I was fully psyched for my final run,
When some pillock in a MR2 managed to hit the timing gear.
No 8th run. Bugger.

11th in class. very average :cry:

So, onto car development.


My FRP cams have GOT to be fitted before this car turns out again.
Also, my gearbox was a absolute nightmare. :?
Going for 2nd from 3rd was a lottery! Getting any of 1st, 3rd or 5th. :lol:
That really slowed me as I was tentative changing gear.

It`s getting a new gearbox. Priority A1*...
At the same time the cams will go in.

I was almost neck and neck with a couple of MX5`s (just beating them both)
so at the next meeting I should be able to guess just how much time I lost in this round.

As for the cars handling, it was exemplary.
As you can see in the photo of me drifting above (which I saved) the car is quite balanced.

Here It`s cornering at 75-80 mph and looking absolutely planted
(I`m no fan of hanging a wheel in the air mid corner, I like my tyres ON the tarmac!
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And the new splitter looks solid as a rock :grin:

Here, I`m giving it silly power out of the final corner, it`s understeering slightly, but with the back simply following the front.
5620

I may play with tyre pressures very slightly, but I`m delighted with the chassis, I just need to get the motor up to speed.
(Oh yes, and smooth out the spare tyre well gap)
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Dedicated Track Car Progress Thread
viewtopic.php?t=26160
YouTube track sessions and `incidents`
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Postby moondustka » Wed Apr 20, 2016 11:15 pm

Good report Stu, keep up the updates :-)
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Postby Puma Babe » Sat Apr 23, 2016 6:18 pm

It'll be interesting to see how it goes with the new cams and gear box next time
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Postby grayfox » Sun Apr 24, 2016 5:52 pm

Nice report, car looks so wrong without wing mirrors though :pose2:

How did you make that tight corner doing 80mph, or didn't you? :P photo makes it look like your already entering it!
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Postby trublustu » Sun Apr 24, 2016 6:51 pm

That corner is the left following Port Froid at Blyton, in my car your a second or two away from the rev limiter in 3rd (84mph) It`s dead easy to drift wide, correct and spin. It takes a bit of bravery, but its a flat out corner. Bang on the apex in that shot.

One of my mirrors is forever part of the scenery at Oulton Park,
so I just removed the other (don`t need em sprinting!)
I have a pair of silver oe mirrors for trackdays.
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Postby Puma Babe » Sun Apr 24, 2016 7:13 pm

grayfox wrote:Source of the post Nice report, car looks so wrong without wing mirrors though :pose2:

How did you make that tight corner doing 80mph, or didn't you? :P photo makes it look like your already entering it!


I could show you a series of pics of Stewart coming through that corner if I could remember how to post them on here :D
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Postby trublustu » Sat Apr 30, 2016 11:44 am

I Had originally booked a coulpe of days off before this (Bank Holiday) weekend in order to slip in a sneaky Cadwell Park trackday.
But with my car giving me so much trouble with it`s gears and missing the punch that comes from the FRP cams I booked myself into my mates unit for a few days to get it sorted.
So Thursday I dropped the car off and pulled out a rather cruddy looking 80k gearbox. I also dusted off my cams.

Now I figured two days should be good to drop the motor and do these said jobs..
Unfortunately, my mates landlord didnt see it that way so I had to get this done in double quick time.
I was working alone so cracked on...
I`ve taken the motor out a few times and it took just 2 1/4 hours to have the powerplant sat on the floor in front of the car

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The gearboxbox, which I thought would be a 10 minute job turned out to be a pita!
Mine came off dead easy and I took my almost brand new clutch slave cylinder to transfer to gearabox number FOUR!
When I went to fit it. It just wouldn`t go on!
I an certain it`s a 1.7 Puma box as I took it off it`s engine. but this thing just wouldn`t go.
Upon closer inspection I found that the two holes in the bell housing for the hydraulic pipe/bleeder, were smaller on my new box (16mm compared to 20mm on my other box)
So with my time constraints I set to work with a round file.
Twenty minutes later the slave was fitted and the box ready to go.

The cams which I`d struggled to sort in the car were almost easy with the motor out.
undoing the cam bolts and water pump pulley bolts (which had beaten me previously) were easy to do with room to swing on the spanners.
They went in nice and easy and I timed them up without too much of a problem.

So I started throwing it all back in the car.
At about half seven (ten hours after lifting the bonnet) I connected the battery and was relieved and happy to hear it fire up first turn :-)
Still with no radiator, coolant, gear oil or cluch bleed.
So I just threw all the bits into the car.
Wiped up my oil puddles and brought it home.
With the big jobs done I can finish it off at home.
And it`s three weeks till the next sprint, and raining/hailing/snowing!
So I was very glad to have got this done in the warm and dry.

I was very close to a couple of other cars in the first sprint, so it`ll be interesting to see just how much faster I might have been.
I`m looking at going back to Blyton for an Ad-hoc sprint in September, to see what time I should have run with Javelin.
Last edited by trublustu on Sat Apr 30, 2016 1:02 pm, edited 1 time in total.
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Postby moondustka » Sat Apr 30, 2016 12:20 pm

I've had to do that in the past too Stu, for the slave cylinder. I used a cone bit in a drill to enlargen the holes.

Good progress there and not easy circumstances by the sounds of it :ok:
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Postby trublustu » Sat Apr 30, 2016 12:45 pm

At someone elses place with the toolbox I`d brought I was quite impressed that I managed to pull this off so quickly.
Just got make sure you remember all your tools and not have to rush off home for your timing pins. Erm.....

Between hailstorms I`ll have it fully back together today (what is going on with this weather?)
I should be able to give the car a couple of shakedown sessions before my next sprint.
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Dedicated Track Car Progress Thread
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Postby moondustka » Sat Apr 30, 2016 7:58 pm

Nice.

Yes the weather is interesting at the moment.
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Postby trublustu » Sun May 01, 2016 10:40 am

So yesterday, once the clouds blew away I cracked on.

I had a small issue bleeding the clutch.
Nothing to do with the car.
My Gunson pressure bleeder is a couple of years old and when I connected it up, it was leaking air so badly that it just didn`t work, plus it flattened a spare tyre in minutes...
The lid seal looked like a dried up doggie-doo. Must be that brake fluid and chinese rubber seals don`t mix.
A good wrapping with plumbers ptfe sorted it right out and I was happy to see `milky` fluid being expelled when I pumped the pedal.
Clutch good, so I moved onto the Radiator.
With all the space round the engine bay, this went together easily.
I found, when I refilled my saved coolant that I`d lost about half a liter. As I run with quite a `rich` solution, I just topped up with Manchester tap water.
With the battery and airbox on, I decided It would be a good idea to make sure it gets up to temperature properly.
So I fired it up and ran it for ten minutes or so and found all good :-)

But...

Once warm I gave it some revs, up to about 5500 and back to tickover a few times.
No banging or grinding but it didn`t quite sound right.
A quick look under the bonnet revealed a huge (and growing) puddle of engine oil depositiong itself on the drive from the cambelt end of the motor.
Oh Sh** I exclaimed and stopped the engine.

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From this I could tell it was coming from under the cam cover and I had visions of a missing plug/oil seal.
there was oil seeping out onto the top engine mount bracket, So I guessed it must be at the cams (makes sense)
I have snapped my timing cover to make it easy to get to the cam pulleys and with the cover off I found the problem straight away.

5635

The plug, sealing the VCT cam pulley wasn`t tight,
so when the VCT kicked in, it just puked the oil straight out :roll:
Explaining why it didn`t show up at tickover..

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Thankfully it didn`t fall off!!!
Tightened up and with a liter or so of Formula-F, I tried again.
This time with no mess.

Thank god for that..

The rest of the car soon went back together and I spent the end of the day with some Daz and hot water cleaning up my mess.
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Dedicated Track Car Progress Thread
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YouTube track sessions and `incidents`
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Postby trublustu » Tue May 03, 2016 1:00 am

Well we`ve got to the last day of my long car building bank holiday weekend.
As I`ve got the mechanicals pretty much how I want them I turned my attention to some modest weight saving.

Quite a while back I stripped the bulb and lens assembly out of the headlights.
This took about a kilo per side out of the lights.
Not enough for me!

So I split the lights down the seam, leaving just the outer plastic cover.
Making the frame that the light attaches to, redundant. and strips another 1.5 kg out of each light.
This is what I`ve just discarded

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I cut and tigerbonded the lug from the top of the light inner so it can attatch at the top.

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The bottom of the lens was now flapping loose, so I drilled two holes at the bottom of the light and two matching holes in the bumper.
I put two 6mm bolts through and tightened them up. Like this.

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The lights have been rubbed down with 1000 wet & dry with a view to polishing the outer and painted black on the inside.

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Should look quite good, but most importantly it`s another 3 kg out of the front of the car..

Back to work tomorrow :?
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Postby TGPlayer1 » Tue May 03, 2016 10:21 am

You'll have to strap it down on the drive Stu or it'll float away!
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Postby trublustu » Tue May 03, 2016 12:40 pm

That's where the sticky tyres come in handy Tom..
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Dedicated Track Car Progress Thread
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YouTube track sessions and `incidents`
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Trackheads facebook group
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Postby trublustu » Sun May 15, 2016 10:19 pm

Next weekend is Round 2 of the Javelin Sprint Series.
Following my dissapointing outing last time I`ve been busy getting the car right since I got back.
Because of this I`ve not had a last minute rush of jobs, giving me chance to do a few of the niggly jobs that want doing.

I did a bit more on the lights,
A couple of layers of black smooth hammerite on the inside of the lens has left an even finish outside.
At the moment they`re just rubbed down with 1200 wet and dry. I`ll try to polish the lens outers before weekend.

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I touched up a few bits of silver bodywork that was poking out around the grilles. (purely for aestetics...)

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I finally got round to fitting my custom rear plate and I`m delighted with the look.

5651

Other jobs were to add some spacers to stop the coilovers fouling the top mounts (lightened the steering no end)
Add some grip tape to the pedals and drivers footwell. I`ve been meaning to do this for a while..
And clean the wheels (my god they were grotty,)
So The car is right up to speed for next week, just need to find my camping stuff now...

5652
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Dedicated Track Car Progress Thread
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YouTube track sessions and `incidents`
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Postby moondustka » Wed May 18, 2016 8:46 am

I was literally thinking about something like your rear lip on the boot the other day. Should be a huge improvement on air flow off the rear of the car and should make it detach at that point, rather than stumbling over the edge.

:thumbs:
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