My Puma.. Maximum Track Attack!!

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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My Puma.. Maximum Track Attack!!

Postby PumaJay » Mon Sep 05, 2016 7:30 am

gingerdave wrote:Source of the post Blimey hope it doesnt. rain,coz you wont be going round many corners those.


I've driven on semi slicks in the wet before, its not as bad as you'd imagine but still.... not great!

Spent a couple of hours under the car yesterday afternoon and got a few more bits done, the underside/exhaust and side of the fuel tank tunnel is now finished in gold heat tape, such a fiddly and time consuming job to do!

The exhaust centre sections and also back on the car with the front pipe now also heat wrapped. I used to get a lot of heat soak around the gear stick/hand brake area on track days so I'm hoping that I've now reduced that a bit. If I had more time I would've taken the manifold off and done that as well.

Next job is stop the oil leaks using the new seals/gaskets I've got and I'l more than likely do the cambelt, tensioner and water pump while I'm at it.

No pics as it was almost dark when I finished last night but will get some later.
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My Puma.. Maximum Track Attack!!

Postby PumaJay » Tue Sep 06, 2016 12:57 pm

More time spent on the car last night, I feel like im really getting the love back for the little Puma again now.

Changed the rocker cover gasket from a pattern part to a genuine Ford jobby and the fit is so much better. I'm hoping that is one of the leaks now fixed.

While I was at it I also cleaned the rocker cover up, lots of gasket sealer had been used to try and stop the old one leaking. I've also got a fair bit of the gold heat tape left over so added a strip to the back of the coverm going to do the underside of the strut brace as well.... I cant tell you how many people have lean't on it and got very hot hands!!

Few pics...

ImageUntitled by Jay Hardy, on Flickr

ImageUntitled by Jay Hardy, on Flickr

ImageUntitled by Jay Hardy, on Flickr
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Postby PumaJay » Tue Sep 20, 2016 11:59 am

Had a pretty mental afternoon/evening on the car yesterday to get it ready for Blyton Park this weekend, most of the effort was focused on stopping the oil leak which I think I've managed by changing the crack seal, while I was at it I also changed to cambelt & tensioner. Pig of a job when your not on a ramp and its raining!!

I also replaced the "flexi" part of the fuel filler system as one of the hoses was rotten and split in a couple of places, I used some fluro lined silicone hose in 40mm & 19mm sizes to replace both parts.

No pictures as I was desperate to get the job done asap but I will grabs some snaps over the next few days of the car and the work I've carried out.

.... Debating whether to rebuild the front calipers before the weekend as I've got a full seal kit for them. Not sure I can be bothered though.

One final job to do is charge the battery, start it up and run it for a few days to make sure everything is ok!
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Postby PumaJay » Tue Sep 20, 2016 1:42 pm

Couple of poor pictures...

new cambelt on

ImageUntitled by Jay Hardy, on Flickr

Fuel hoses replaced

ImageUntitled by Jay Hardy, on Flickr

ImageUntitled by Jay Hardy, on Flickr

And one of me caught in the act of doing something!!

ImageUntitled by Jay Hardy, on Flickr
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Postby PumaJay » Sun Sep 25, 2016 1:39 pm

Another track day done and it didn't start all that well....

The car was performing nicely on the drive over, until we got about 10 minutes away from blyton park and the car suddenly decided it no longer wanted to run on 4 cylinders and it would be much happier on 2!

We ended up on the side of a dual carriage way diagnosing what was a broken coil pack.

ImageUntitled by Jay Hardy, on Flickr

I had to get a friend up and out of bed to bring me a new coil, leads & plugs. Thankfully he was coming over for the day but he left sooner than he'd planned. Cant beat having a great bunch of friends!

Once the car was sorted and back up and running the car was going very nicely, handling was spot on and the new tyres we're super grippy.

The day did show up a few issues, there is a quite a knocking noise coming from the front when cornering hard left which I think might be a drive shaft. Will check the CV joints and see if there is anything wrong with them.

The car is still over fuelling or something, it starts to smell of fuel in the car after a few laps and it becomes very strong! I also think the heater control valve is broken, hot air was pumping into the cabin for most of the day.... Not what you want on a track day.

All in all a great day and the car is still putting a massive smile on my face. Heres some pictures.

ImageXSP_0905 by Jay Hardy, on Flickr

ImageXSP_0094 by Jay Hardy, on Flickr

ImageXSP_0009 by Jay Hardy, on Flickr

ImageXSP_0010 by Jay Hardy, on Flickr

ImageXSP_0394 by Jay Hardy, on Flickr
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My Puma.. Maximum Track Attack!!

Postby PumaJay » Sun Sep 25, 2016 9:55 pm

Video from one of yesterdays session.

https://youtu.be/DL4gdYZGVso
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My Puma.. Maximum Track Attack!!

Postby moondustka » Mon Sep 26, 2016 10:54 am

Looks like you had the track to yourself!

Nice top see a decent video too that's not blurry or the camera shaking like some on youtube.
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Postby PumaJay » Mon Sep 26, 2016 12:29 pm

I just have it attached to windscreen with a sticky pad, seems to be the best for stability although it does generate a small rattle/vibration with the gopro in the case.

The track was very quiet at times, a lot of people had packed up and gone by 3pm which seemed very odd.
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Postby PumaJay » Fri Dec 09, 2016 1:11 pm

little bit of an update as I've been rather quiet lately.

Car is having a few new parts developed for it all of which will be revealed in the next few weeks.... Its something I'm quite excited about and the parts will also be available for all to buy.

In other news, I've now got a full set of vibratechnics mounts that I'l be fitting once I get the car back home. I've also agreed in principle to buy a 2.0 engine, gearbox & drive shafts from a Mondeo. I'm just waiting for it to be removed from the car and then I'l go pick it all up. I'm now on the hunt the parts I need for a turbo build.

Other things to come in 2017 will be Tarox 6 pot brakes up front, roll cage and a tidy up to the bodywork.
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Postby Bentleya » Fri Dec 09, 2016 2:17 pm

Sounds awesome Jay, I look forward to seeing it all come together.
Do you intend to have it all done for Rockingham in March?
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Postby PumaJay » Fri Dec 09, 2016 5:40 pm

No chance.... How ever it looks at Autosport show will be pretty much how it goes to Rockingham. I'm hoping I might have the Tarox brakes on by then though.

The engine will be a bit of long process, planning a bullet proof zetec turbo conversion with the emphasis on maximum drive-ability rather than power figures. Will also be building the gearbox properly as well. Lucy and me are currently in the process of buying a much bigger house with a garage so I'm trying to cram as much spending in before I have to stop and spend it on new sofa's!

If I can complete the engine build in 18 months then I'l be happy with that, the car will remain with the 1700 in the meantime... not worth ripping it apart until I really have to and I still want to use it.
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Postby PumaJay » Fri Dec 16, 2016 10:15 am

I'm finally able to update as to whats going on at the moment with the Puma. As part of a magazine article I'm writing for Track Car Performance the car is having a full aero kit design, tested & built by BYC Designs - http://bycdesigns.co.uk/

Mark of BYC has modeled the car and ran the standard car through his CFD software to highlight where the best position is for the rear wing to sit and be mounted.
ImageFord Puma CFD simulation STATIC AIR PRESSURE_resized by Jay Hardy, on Flickr
ImageFord Puma CFD simulation VELOCITY TURBULANT_resized by Jay Hardy, on Flickr

The next stage was to get mock up the rear wing mounts, these will be adjustable so I can change the angle of the rear wing to suit individual circuit demands.
Image20161207_150921_resized by Jay Hardy, on Flickr
Image20161207_150837_resized by Jay Hardy, on Flickr

As part of the kit a set of the BYC side skirts have been fitted, along with the wing mounts these will all be powder coated satin black.
Image20161207_150754_resized by Jay Hardy, on Flickr
Image20161207_150722_resized by Jay Hardy, on Flickr

The car is still in the build stage at the moment, Once Mark sends me the next batch of pictures through I'l get them uploaded, I'l be doing a bit of testing with the wing to check how much downforce it generates using BYC's own load cell system.

Mark has also done a little video that shows the CFD program doing its work.


Before I dropped the car off with BYC I noticed that the rear arches have started to rot.... AGAIN! So to end the problem I'm going to fit wide fibreglass rear arches but it will be something that has never been fitted a Puma before so expect something a bit different.

As and when the increase in power comes from the 2.0 turbo I'l also move to a bigger wheel and tyre package, probably 17's with sticky rubber, this will also help to fill out the bigger arches. Nothing set in stone yet but I am thinking these...
Image

Lots planned and a lot currently going on.... In other news I've just bought a bigger house with garage so I'l finally have a space to work on the car thats warnm & dry!
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Postby PumaJay » Mon Dec 19, 2016 3:26 pm

Just had an update from Mark at BYC of the skirts now fitted after coming back from paint

ImageUntitled by Jay Hardy, on Flickr
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Postby Bentleya » Sun Dec 25, 2016 2:37 pm

Jay, I'm a little bit lost for words.... This is all getting a tad bonkers and I absolutely love it.

With your engine, what was your motivation for opting for a Zetec and not something a little newer and possibly lighter, like a 2.0 or 2.3 Duratec?

The move to 17 inch wheels seems like a odd choice. I can see the advantage if the Puma weighed more, but I'm assuming what's everything is done, you'll be around the 1ton mark?
What gains are you expecting from having a bigger wheel, apart from being more visually pleasing?
I've come down from 17's on the Fiesta, I'm running 15's and it's more stable, the tyres are cheaper and the rotational mass has decreased. Also, with the AST's coilovers i'm only able run 15's.

Also, what rubber do you intend to go for?

I look forward to catching up with you in March, hopefully I'll be on track in the Fiesta - but it's currently a shell plus 1000's of little bits.
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Postby PumaJay » Mon Dec 26, 2016 5:31 pm

Hey,

Thanks, the car is starting to get a little bit mad, but as I've pretty much fitted every bolt on part for a puma I felt the need to do something a bit different..... Its about time this car had a turbo!

In terms of picking the 2.0 zetec it came down to just how easily available the engines and parts are, I was going to go duratec but a zetec engine, gearbox, driveshafts (basically the front end of a mondeo) came up for a price I couldn't really refuse. That and the fact that a friend of mine is a Zetec Turbo god and I know that with his knowledge and the right parts I can build a bullet proof, 100% driveable engine with around 300bhp. Which is the aim.

The reason for the move to 17's is in part to be more visually pleasing but will also become appaerent once the bodywork on the car has had a bit of a make over, I'm looking at wider arches all round but not FRP, it will be a first for a Puma, but this is all a little bit further down the line. I terms of rubber I'l use Nankang AR-1's. I use them on my 15's and are awesome. Easily on a par with 888's.
The other reason for 17's.. brakes, what I've got coming probably wont fit behind a 15 inch wheel.

I'l also be switching to KW variant 3 coilovers as well, the AP's I've used are not bad for a budget but its time to get serious now.

2017 will be a year of parts gathering, some I've got, some are on order. Im currently in the process of sorting a 6 pot calliper a 2 piece disc setup with Tarox. Just bracket design and they'll be sorted and I'm speaking with a local company about producing a single piece radiator and intercooler unit.
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Postby Brian' » Mon Dec 26, 2016 7:07 pm

Really cool Jay! 2017 is going to be a great your for you then! 300bhp in a stripped out Puma, madness!
Currently there's a set of KW variant 3's for sale on Facebook. The guy is asking £450 for it. So might be useful to you?

Looking forward to your progress Jay! Looks like it's going to be a really serious car once you're done.
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Postby PumaJay » Thu Dec 29, 2016 9:39 am

I'm hoping its going to work out nicely. I did spot those KW's but they we're wrong fitment.

I'm hoping to get the car back from BYC in the next few days so I can get it cleaned up and looking good for Autosport International show in Jan.
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Postby PumaJay » Tue Jan 03, 2017 8:18 am

Got a bit bored yesterday so I unwrapped this little box I've had for a few weeks now.

ImageUntitled by Jay Hardy, on Flickr

Just wanted to inspect the quality of the vibra-technics engine mounts I bought and see what additional hardware they came with. I'm going to order a new set of bolts for the gearbox torque link as one of mine is quite heavily rounded.

ImageUntitled by Jay Hardy, on Flickr

ImageUntitled by Jay Hardy, on Flickr

ImageUntitled by Jay Hardy, on Flickr

In other news I'm picking the car up this weekend so I'l some of the completed rear wing and side skirts.
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Postby Wild E. Coyote » Tue Jan 03, 2017 3:05 pm

Will these mounts make car noisier?
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Postby PumaJay » Tue Jan 03, 2017 4:31 pm

Not noisier as they dont make a noise but I imagine the engine vibrations will resonate a bit more being as its a close to solid mounting the engine as you can get. The standard mounts have pretty much had it so race spec it is!
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Postby siju » Tue Jan 03, 2017 5:36 pm

They make two versions. The competition which they advise to use only on track and the fast road. My brother has the fast road(set of 3) in his puma and they make the vibration from engine a little more pronounced but definitely bearable. As an added bonus the front end of the car feels more connected/rigid, the gear change more precise and the throttle response more direct.
Quite pricey but well worth it.
Last edited by siju on Wed Jan 04, 2017 1:04 pm, edited 1 time in total.
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Postby PumaJay » Wed Jan 04, 2017 9:13 am

I went for the race spec ones, being as I barely use the car on the road I think I can handle the compromise. I'm looking forward to seeing how much difference they actually make.
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Postby siju » Wed Jan 04, 2017 1:04 pm

Obviously i meant that the vibrations from the engine are more pronounced not less (i made a mistake in my previous post-now edited).
For a track car i would also definitely go for the race spec ones.

Looking forward to seeing how this project evolves.
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Postby PumaJay » Wed Jan 04, 2017 2:06 pm

Its going to evolve quite rapidly on Saturday when I finally get the car back home, big wing and side skirts will be properly revealed.
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Postby grayfox » Wed Jan 04, 2017 2:34 pm

Was going to be a bit of a smart arse before I read the comments below saying; orange paint dot for race, blue for track/fast road. I only know that as I emailed the company after receiving my used set as I didn't know which I had lol (blue for me)

This project really is reaching new heights now! will make mine look real amateur/budget soon but it is what it is :pose2:
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