welshpug!
Post #1
I posted a few pics of Satchell Engineerings most recent wide track front suspension kit recently which has been fitted to a Saxo kitcar type Rally car I will be servicing for a few times this year.RetroPug wrote:
WP, got any more info or specs on the saxo rally car?
Seems like it would be an interesting read.
Seems like it would be an interesting read.
SO here's a brief (maybe not so brief) ramble about how we got to this stage.
Owner is Garry Elswood, a guy I met through fellow PSCUK member Pugtop (Kev) as he was after an extra pair of hands for servicing on the rallies he does in Belgium.
here's his web page - http://garryelswoodmotorsport.co.uk/index.html
I've been servicing for Garry for about 5 maybe 6 years now for his first Saxo that he has had for over ten years
Started off life as a fairly low mileage car owned by a Teacher
then in 2002 iirc Garry got hold of it and did a road trip to Citroen Sport in France to get a few choice goodies, torsion bars and a short MA final drive and crown wheel iirc, plus a group N ecu and cams, Quaife diff.Bilstein dampers all round, rallydesign wilwood front brake kit.
Safety devices multipoint welded in cage, short of the custom cages Saxmax cage probably one of the most comprehensive ones I've seen.
About 5 or 6 gearbox failures in 3-4 years on a mildly tuned engine including three Belgian DNF's and Garry finally got fed up and took the plunge and cracked on with a BE conversion in the winter of 08-09.
A few rallies came and finished without any drivetrain issues which was quite novel given previous history!
The inevitable search for more power started then, we were more regularly coming up against R2 spec C2's and the occasional Fiesta, these are all Works cars with 180-190 bhp single throttle 1600's running trick dampers and usually sequential gearboxes...
late 2010 and a new engine was finally in and mapped, Garry had managed to get hold of some early Satchell GSXR throttle bodies and as KMS ecu, we now had a respectable 171 bhp 142 lbft, not as much as Garry had wanted really, but it was still a standard head casting.
PEC rods, wossners and catcam 850's and solid lifters:
garry's saxo engine by WELSHPUG, on Flickr
A few more seasons go by, a few small mods here and there and a new set of rings as there was a problem with the original ones, IIRC one DNF from an understeer into a concrete block rendering the drivers door inoperable, one from an oil fire caused by oil surge in the original J4 cam covers an an engine that was breathing a bit too heavy filling the catch tank up.
a swap to DTA S40 over the unreliable KMS ecu and a few more mapping sessions.
Garry by this point wasnt comfortable with the quite basic suspension to got some AVO 3 ways all round, this improved confidence a fair bit, the rear beam was rebuilt over winter 2012.
Last event I was out with them in 2013 we had an unfortunate DNF following a bottom damper nut coming loose and going missing, and the next event the lower torque link decided to part company with the bodyshell leaving an 8x4" hole in the floor
Garry left the car in the Barn for a few months umming and ahing about whether to go for a new gearbox, as he;s seen that Citroen sport were doing a 5 speed Sadev sequential gearbox for 5.5k, or have a more powerful engine built, though he was quite hesitant in asking Sandy Brown for a full build given the fairly large outlay and timescale, Garry decided to have the current head reworked to see if it would help, whilst the engine was pulled apart over the winter for a refresh as it had done 4 years without being touched other than oil changes.
The next I hear a few month later into the winter is an email entitles "options"
All it said was is this car worth £*****
Errrr.
IMG_5902042399945 by WELSHPUG, on Flickr
LHD shell which I found out much later on was built by Badger Motorsport, Sadev Sequential gearbox, LAD engine with Longman head throttlebodies etc, meant to be "190" bhp...
Proflex 3 way dampers all round, 330mm AP Rotors and Bremsport calipers, some kind of wide ish track wishbone setup.
Garry and Kev made the trip to Birkenhead early in November last year and came back with20 17" spare wheels and tyres, and one pretty wide Saxo
The car had only done one rally back in 2009 with its previous owner, who bought it from Ireland a few years before!
fast forward to early January this year and Garry had sorted a load of stuff for it to get an UK MOT, and managed to get hold of its original registration number which is quite distinctive to many in the pug world.
Garry had test driven the car a few times and heard from its previous owner about its suspension setup, to say it was a bit sketchy o drive was an understatement, the wishbones were longer lacing the struts at quite an angle, meaning all sort of bump steer torque steer and scary behaviour!
Issues were found with the engine, luckily although the old car was now sold Garry had kept hold of its engine as a spare though it also needed attention, so the head from that was sent to a local firm to be reworked and the bottom end checked over, new pistons due to signs of melting.
Late January after a few emails back and forth about suspension solutions Garry gave Colin satchell a call, which is where this pic I posted came in
IMG-20140403-WA0000 by WELSHPUG, on Flickr
its a full satchell engineering widetrack setup, with new custom driveshafts to suit, the widest 106/saxo kit they had done so far.
looks much like this but longer wishbones.
you can see the new top mounts reinforcing plates and Satchell strut brace in this pic, as well as the refreshed 170 bhp engine, which was mapped two weeks ago and made a decent amount more than before, its now running MOTEC which came with the car.
-4 by WELSHPUG, on Flickr
a week ago, 2 days after getting it mapped Garry, Kev, teresa (navigator) and Ian (teresa's other half, a mechanic by trade) made the trip out to Belgium for a small event called the Monteberg rallysprint, a few teething troubles as to be expected from a fresh car, and some scary moments for Teresa when Garry went a bit deep on a few cuts from not being used to a LHD car, they came home with a finish and posting half decent times, certainly a lot more to come and a few more changes, but definitely looking forward to 2014.
10014865_10202842646045478_8858845277990621307_o by WELSHPUG, on Flickr
10177500_585937018180778_1216928438187837912_n by WELSHPUG, on Flickr
IMG_9289 by WELSHPUG, on Flickr
135468_320689381413105_9125048534816695890_o by WELSHPUG, on Flickr
I'll be out on the next event which is the ORC Rally on the 1st of June, and another one barring any issues on the 13th/14th of June called Wervik, this date is a Belgian bank holiday which takes place whichever day in the week it arrives, I think last year it was a Wednesday!
Hope I didn't bore you guys with the ramble!
Note, this is NOT my own car, not my money nor is it my final word on the parts used, I try my best to find Garry the best and cost effective solutions as and when required, Garry being based in West Sussex and myself in South Wales means my input is not as large as it would be if it were something I actually had a hand in building myself.
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need a part number? get on here - http://public.servicebox.peugeot.comBring on the Trumpets.
Posted 14th May 2014 at 15:51
got that soldered up which did make the needle move, but nowhere near the right amount, unfortunately due to the shift light working off the same RPM input there was no shift indication 
