So having got the new engine in we took the car for its dyno at TDI. Dyno went reasonably well however the car was running quite lean so need to get that mapped out. Unfortunately when we pushed the car back we noticed a large pool of oil which was coming from the flywheel area. The rear main seal had perished. Great. We only had 6 days to get it fixed before we were to test at Rockingham so time definitely was not on our side. I must admit, I was pretty downbeat at this point. 7 weekends straight of working on the car was getting a little frustrating and the darn thing just would not make things easy.
The day after the dyno test we pulled the gearbox out, not the most fun job but we got it done. That 6 speed box is a heavy b**ch! Also sorted the fibreglass bonnet to have two sets of aerocatches so we can remove it and not have hinges.
During the week I bought a new clutch, fork bushes and rear main seal. Work began to refit it all on Thursday evening at about 4pm. After a bit of slow progress lining the box up, we finally had the car on the trailer and loaded up at 1:30am. During that time we also took out the power steering pump, aux belt idler and tensioner and fitted the replacement belt that just goes round the crank pulley and alternator.
Finally we get to testing. 5x 20 minute sessions, the first one being just a simple bed in session with all the changes. First session went really well, car performed faultlessly. Obviously we were reasonably far off the pace but not to worry, early days. The remaining sessions we upped the pace and ended with a fairly competitive time of around the 1m:51s mark. I was a little uncomfortable in the car with the brake pedal and it cost me about 1s a lap but hopefully we can fix that.
On to race day, exciting stuff. I was pretty anxious having screwed up at Snet and being slightly unhappy with the brakes but time to get on with it. We qualified 17th out of 31 which wasn't too bad however we were 3s off the class leader. Unfortunately we really struggled without an LSD at the track so had to do our best. Quali was also faultless with several good clean runs in.
The race itself was fantastic. A great start and a proficient pitstop contributed with us finishing 9th on our debut! The opening few laps were hectic battling several other fairly evenly matched cars. The second stint was a little more relaxed and just a case of holding off a Mondeo ST220 to make sure we had a top 10 finish (we crossed the line 10th but someone further up the field got a penalty).
All in all, a great weekend. Little bit of work to do on the brakes and to get the map adjusted but otherwise awesome.
Few photos from the weekend are below. Videos to follow when I can sort them out.
Oh yea, our air filter fell off and got run over during testing. Straightened it out and put it back on the car
Missing PAS pump and replacement aux belt:
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Rallye Race Car