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Author Subject: Track Cars for Dummies
owain

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Post #151
Well so you got to bed at 1am, so what? Man up, it's 4:30am, tanking it down with rain and you've got a car to get under.

After some poking, fiddling and testdriving (and a fair bit of nearly giving up and dousing the thing in petrol) a couple of things became clear - some of the rattling was the new bit of brake pipe knocking against the old in a couple of places - this was solved with cable ties.

Having checked everything was tight (which it all was), I could only come to the conclusion that I was overreacting and that the "extra" noise I wasn't used to is simply the noise of going from battered soft old mounts, thin torsion bars and a standard ARB to solid mounts, thicker ARB and torsion bars and new KW dampers. What the hell - trackday a-go-go. That's a surefire way to find anything that's not bolted on properly.

Well, the day was awesome fun. Nothing fell off, the car was amazing, and generally had a very good time. Also managed to fit in a quick chat with Mankee who was a thoroughly nice guy - also he didn't black-flag me for very much overcooking it and ending up on the wrong side of the cones, which was good of him.

Plus a mate of mine hired an Arial Atom for the afternoon, which was a bit of a hoot. Took out a bollard, but no major damage done.

Just got to give the car a final checkover tonight to make sure it's all still tight, then tomorrow it's Rockingham.

What a fantastic little car the GTI-6 really is.

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Posted 9th Aug 2010 at 20:30
daveyboy

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Post #152
Nice job mate.

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Posted 9th Aug 2010 at 21:36
owain

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Post #153
Cheers Davey! Was a relief that the thing even moved once I'd finished.

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Posted 9th Aug 2010 at 22:15
mankee

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Post #154
Nice to meet you at the weekend Owain. Car seemed to be going well considering you finished it at 4am that morning!

A pal of mine is going to the Rock (ingham) on Tuesday as well. His dad has caught the trackday bug after my mate took him to Bedford in his 106 Rallye, so has gone and bought his own trackday car, a Porsche 924 I think it is.

Have fun and see you again soon. Smile
Posted 9th Aug 2010 at 23:28
6waysforward

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Post #155
nice to see the beam was not to bad fella. cant say much as i only owned the car for a few months.

will have to pop round and see the car one night and get some of them famous beers you seem to purchase Thumbs up

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Posted 12th Aug 2010 at 05:14
rallyeash

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Post #156
good work! need some action pics though...

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Posted 12th Aug 2010 at 21:04
rallyeash

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Post #157
good work! need some action pics though...

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Posted 12th Aug 2010 at 21:05
owain

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Post #158
Heh, annoyingly the guys at Rockingham had another gig to go to and we had to peg it to Halfords at lunchtime, so didn't manage to get any pics from there.

All I can find is one from Woodbridge:



Pretty much no roll at all considering that's a pretty hefty corner there.

And Ben - apart from a bit of mud the beam was much better than I'd expected, so was pretty chuffed with that. Heavy thought Wink

You decided what you're doing with that engine yet? I work in Rochford so let me know if you're ever going to be passing and I'll bring the Pug in with me if you fancy a look. Not sure what the boss'd say about cracking out the beers in the office, but oh well Smile

O.

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Posted 13th Aug 2010 at 00:07
rallyestyle

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Post #159
How did you find Woodbridge? Good for beginners? Thinking of doing a day with some friends there Yes

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Posted 31st Aug 2010 at 15:21
owain

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Post #160
Woodbridge is an absolutely brilliant day for beginners. It's cheap, the track's wide, there's plenty of run-off where you need it, and they're not too fussy about you making mistakes.

Only thing to watch out for is the scrubland around the track, it's not as innocent as it looks. There are countless lumps of metal, lights and bits and pieces that'll rip the bottom off your car if you end up there. Avoid that and you're golden; a good mix of tight bends, long corners and big straights.

It's an airfield rather than a track, so expect to get through tyres a little quicker than you would on a track as the surface isn't great in most places, but I've had a set of tyres for four trackdays now, two of which were Woodbridge and they're still fine, so it's not like it completely destroys them.

It's a right laff for beginners and cheap too, so get yourself down there sharpish Wink

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Posted 31st Aug 2010 at 15:26
rallyestyle

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Post #161
Cheers Thumbs up

Was thinking of letting a few friends have a go in the rallye but obviously dont want to make it too easy for them to stack it into a tyre barrier LOL

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Posted 31st Aug 2010 at 15:28
rallyestyle

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Post #162
Oh and how many laps did you roughly do? Use lots of fuel? Cheers Smile

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Posted 31st Aug 2010 at 15:29
owain

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Post #163
A lap only takes a couple of minutes - I do a reasonable lap:rest ratio but easily get maybe 50+ laps in? Never really counted tbh Wink

I've never had to refuel during the day but then I do tend to back off on the straights just as I'm not fussed about the big speed, there is a Shell a few miles down the road if you need fuel and you're free to come and go throughout the day, even though it is a military base.

I reckon if you were really on it all day you'd probably need to refuel, but if it's a beginner session you'll not want to be out there constantly anyway Smile

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Posted 31st Aug 2010 at 15:38
rallyestyle

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Post #164
owain wrote:
A lap only takes a couple of minutes - I do a reasonable lap:rest ratio but easily get maybe 50+ laps in? Never really counted tbh Wink

I've never had to refuel during the day but then I do tend to back off on the straights just as I'm not fussed about the big speed, there is a Shell a few miles down the road if you need fuel and you're free to come and go throughout the day, even though it is a military base.

I reckon if you were really on it all day you'd probably need to refuel, but if it's a beginner session you'll not want to be out there constantly anyway Smile


Legend Thumbs up

Think i will get me and my mates booked in for the 23rd of October Yes Best make sure the Rallye passes its MOT! Laugh

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Posted 31st Aug 2010 at 15:40
owain

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Post #165
Damn right you should Smile

If you'd liken Woodbridge to anything, it'd be the dirty bit-on-the-side fcukbuddy of the trackday world. Whereas places like Brands and Snett are the girls of class, demanding a big financial outlay and decent planning Woodbridge is just your nasty piece of stuff who's always there, costs you very little and does what it says on the tin.

You wouldn't want it to be the *only* track you do, but it'll still leave a smile on your face.

And maybe a couple of crabs. But that's all part of the fun.

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Posted 31st Aug 2010 at 15:54
rallyestyle

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Post #166
owain wrote:
Damn right you should Smile

If you'd liken Woodbridge to anything, it'd be the dirty bit-on-the-side fcukbuddy of the trackday world. Whereas places like Brands and Snett are the girls of class, demanding a big financial outlay and decent planning Woodbridge is just your nasty piece of stuff who's always there, costs you very little and does what it says on the tin.

You wouldn't want it to be the *only* track you do, but it'll still leave a smile on your face.

And maybe a couple of crabs. But that's all part of the fun.


Laugh

And to think im going to be sharing her with my mates, dirty slut LOL

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Posted 1st Sep 2010 at 14:23
cwspellowe

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Post #167
As far as the dodgy calliper's concerned, sounds daft but did you wind the piston all the way in before fitting it? That cant cause the pads to be out of line and lock up Dunno

Epic read once again though mate, I presume the track day was worth all the bllod, sweat and tears?

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Posted 1st Sep 2010 at 14:51
lotek

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Post #168
cwspellowe wrote:
I presume the track day was worth all the bllod, sweat and tears?


Trackdays are ALWAYS worth the blood sweat and tears...
just not always the finacial oulay Laugh my ass off
Posted 1st Sep 2010 at 15:09
owain

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Post #169
@lotek +1, so true.

@cwspellowe - it's weird, I checked again after the trackday and it now lines up and I can tighten up the carrier properly. As far as I was aware I'd gotten the caliper all the way back in, but it was pretty dark and late by then so it's not impossible I'd just messed it up.

And yes, every time I get onto a track it makes every single second of the pain worth it. I forget the bleeding and swearing, and I just spend the day grinning like an idiot Smile

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Posted 1st Sep 2010 at 16:52
cwspellowe

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Post #170
Probably was the piston then, especially if the callipers haven't been refurbed in a while the last half an inch can take some force to wind it. Especially without the right tools, i tried a screwdriver and nearly snapped my wrist

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Posted 1st Sep 2010 at 17:36
owain

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Post #171
Stupidly I actually have a rewind tool, but completely forgot this at midnight when I was trying to get it sorted Big grin

Annoying, but sorted now.

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Posted 1st Sep 2010 at 17:39
owain

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Post #172
Right, I haven't been slacking I promise, just been accumilating some photos and getting some things done.

First up - I got myself some new wheels from Silky; he'd picked them up on a car he was breaking and didn't need them, so I liberated those for some cash. Not the best of condition I'm sure you'll agree, but I reckon they'll look alright on the car:



So first up, orbital sander on the face to get rid of all the horrible peeling lacquer. That's the simple satisfying bit. Next up is the rubbish bit - it's Dremel time. It's very easy to take lots of bit gashes out of the wheels if not being careful, and careful I was not. Still, the old paint has to come off and I really don't care too much about how these end up looking. As long as they're roughly the same colour all over, I'll consider that a job well done.

Half an hour later:



I've done a wheel refurb once before, and forgot to do the centre caps. Me being me, I never got round to doing them and then lost them. I was not about to make the same mistake again, so sand down the nasty old caps, removing the "Dotz" logo while I was there. Primer those bad boys up...



The wheels had plenty of kerb marks round them, so I bought some epoxy putty stuff which I've used before; it's very easy to work with yourself but I do believe means you can't get the wheels powder coated, so don't use it if you're ever going to want that done.

Basically just squidge it into any kerb marks:



Leave it a couple of hours, then sand it down. Leave it 24 hours to dry, sand again and wash then primer it up.



That picture's quite flattering, they're not as great as they look but then they're cheap nasty track wheels, so I really don't care all that much. They didn't lose any air sat in Silky's garage, so that's good enough for me.

By this point you'll have lost any will to complete this job you ever had, but you know deep down that primer'd wheels will not fare well against brake dust, so just get the hell on with it and quit your whoring. Useless dog as always:



No help whatsoever.

It's then painting time. What a frickin ballache this turned out to be. I went down to Halfords and picked out a colour I liked that they had two cans of. Done. Got home, started painting up the wheels. Turns out Halfords standard size cans actually come basically empty, so two cans didn't even get me a single coat over all four wheels. Call up Halfords but oh no, why *would* you keep more than two cans in stock ever?

Anyone who's ever worked in a shop knows full when the pain-in-the-ass that is only being able to get any product in packs of 6, 12, maybe even 20 when you can fit only 2 on the shelf. This is the case everywhere I know except Halfords, who get in individual cans, and only on one delivery a week. Poor.

Get on the phone, call around most of Essex. Basildon have ONE CAN. Braintree have ONE CAN. Both are in OPPOSITE DIRECTIONS.

An hour and a half's driving and a most unhappy girlfriend later, I return with the two cans and finish up the wheels, having forked out for a Harvester to make amends. Did a pretty poor job of the insides of the wheels, but the faces look okay and that's all I care about.

Sleep for 24 hours.

Not being stupid enough to run out of cans again, I've picked up two cans of Halfords Heavy-Duty lacquer, made for alloy wheels.

Or at least I thought I did.

Oh no, just because you've colour-coded your cans, why *would* that mean that the two yellow-banner'd cans in the same place on the shelf are the same thing? Turns out only one was the Heavy-Duty, and other was just standard.

By this point I'd opened the latter to fcuk it, that'll do. Luckily I didn't quite finish up the first one in case of splatter, so had enough to give all the faces (of the wheels, not the idiots in Halfords) and quick once-over with the hard stuff.

Doesn't matter too much as I'll probably be running RC-6 pads anyway, which create brake dust nasty enough to melt through the world, let alone some pikey Halfords primer.

Ideally you want to leave the primer a couple of weeks to harden properly, so I've booked Event Tyres for tomorrow. I *might* be on a trackday this Friday but might have to cancel that for a mate's personal reasons. Either way, let's plough on as if we're going.

I don't have any pictures of the finished wheels as of yet, they'll follow later today.

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Posted 7th Sep 2010 at 12:45
owain

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Post #173
Wassat? You want to fit thinner door cards so you can eventually get a roll cage in? And so your car looks like a RACING CAR!?

Hell yeah you do. But paying for someone else to make them? That's not what we do here, we can do a more than good enough job ourselves.

Buy yourself as much glazing acrylic as you need for the cards, using your old cards as a template. I got two sheets from B&Q - £15 each.

The next bit is an pretty precise science, so be careful. I took a look at the door and saw there was about 10mm all round the door card where the metal showed, so I used a thick pen to draw round the old card onto the plastic. Done.

You should now have a template drawn on the plastic about 10mm bigger all round. The top will need to be trimmed down as it'll be lower now, as the top won't go all the way up to the glass - worry about that later.

I'd done a few test faffs with this stuff before, cutting it out with a dremel and all sorts. Whilst that works it's slow. What you *really* want to do is find someone with a bandsaw. Fortunately my dad has one, so quick trip over to the rents to cut out the cards - a hundred times quicker than a dremel and gives a much better edge.

Take it out to the car and measure how much you need to lop off the top - then lop it off. I again used the original cards as templates to cut out the handle holes with a dremel. If you wanted to you could easily drill holes for electric window buttons, or for manual winders if you have those. I'm soon to be replacing mine with fixed polycarb ones, so I didn't bother. Just be careful drilling this stuff, whist it's tough it's not Lexan, and it will crack if you're not careful.

Repeat all for second card.

Bit of sanding later, and you've got these:



If you don't want the edges to show up you might want to go round them with some black spray paint, but I'm not too fussed about that, I'd rather get on so I can get the bangers & mash in the oven.

For a covering, I bought myself a 5m roll of self-adhesive flocking material which'll do nicely for the flat surfaces. This stuff was extremely easy to use, just peel off the backing and apply it slowly along the sheet, making sure it's flat. Don't forget to take the protective film off the plastic first, else you'll end up with a clear door card and a flocked bit of protective film.

I definitely did not do this.

Scalpel round the edges, and ta-da:



Much as this looks just splendid in your kitchen, best get it on the car. Again, be very careful drilling this stuff and don't go too near the edges. I clipped the card in place using the door handle surround and a couple of g-clamps. I then made a load of holes around and into the metal with a 2mm drill, so I could use self-tappers into the door. I then carefully enlarged the holes in the card to make clearance holes.

Watch out when drilling the holes around the hinge end; there are a few bits of double-skinned door which you just won't get through. As a result the corner nearest the wing mirror is not really attached, but it's held in place more than enough by the other screws and it held tight against the door seal anyway.

Whilst you could cut holes for and fit the arm rests if you wanted to, they'll get in the way of a roll cage; you're therefore left with no way of closing the doors from the inside. Not to fear, cut off about eight inches from the end of a loading strap and melt the ends with a match to stop them fraying.

Screw through the two ends of that using a couple of penny washers to spread the load, fit the old handle surround and hey presto, you've got yourself some door cards:



Hell yeah you have.



As you can see my edges are still visible, hence I say if you care about the looks of the car you might want to paint those up before applying the fabric.

All in all, not too shabby methinks. Difficulty of 2, Cost of maybe 2, Time of 3 makes for a Ballache Scale of 12, which is very respectable indeed.

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Posted 7th Sep 2010 at 13:12
cjm_harris

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Post #174
Want to make me some of those door cards? Whistle

Looking good mate Thumbs up

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Posted 7th Sep 2010 at 13:25
owain

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Post #175
Honestly mate they're so simple to do you can knock them up yourself in a few hours!

I'm more than happy to ruin my own car, not sure I should be trusted with anyone else's though Wink

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Posted 7th Sep 2010 at 13:31

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