180 Track Car Build

[ZS Phil]

As promised, this is the thread for the new track toy.

As I'm sure some of you know, I also own a highly tuned diesel ZS however it is the result of 4 years work and progress so I couldn't bear to risk blowing it up on a track day, plus it is far too straight to risk a ding!

So a few weeks ago I ended up with a 180 to do that job.

The initial problem I had was this is also too good to track so I was in a bit of dilemma, do I sell it on and find a suitable shed or do I make the most of a shell/ platform which I will struggle to improve on. Needless to say, I had fallen for the new car so decided to go ahead with the plans.


A bit about the car itself...
Its a 2003 registered 180 hatch in Platinum silver
Despite this reg date, it was built in 2001 making it pre project drive. The build quality is so much better than the later cars (another reason i was reluctant to track it).
Just 1 previous owner on the log book
Full service history with absolutely everything its ever had documented. So much paper work!
Even a receipt for almost £1400 for a huge service it had including belts etc and the original bill of sale along with all the old tax discs and MOTs etc.
Immaculate interior.
Pulls really well.

Anyway, some pics from the day I picked it up from Callum (Skillen).

The non-identical (for now) twins.

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0381_zpsc38f4fd1.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0381_zpsc38f4fd1.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0383_zpseb7c893e.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0383_zpseb7c893e.jpg.html)



With the journey home completely trouble free, the next job was to get some baseline power figures so on Christmas eve I headed over to WG tuning.

To be fair I think the figures are a bit optimistic for a standard car never the less, they confirmed my gut feeling that shes a healthy one. I was chuffed!

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0387_zps24f02a87.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0387_zps24f02a87.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/WGtuning_zps632fd44d.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/WGtuning_zps632fd44d.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/180powerandtorque_zps2438f01c.jpeg (http://s276.photobucket.com/user/zsphil/media/Track%20180/180powerandtorque_zps2438f01c.jpeg.html)



So we had our baseline power run, now we needed our baseline track day so Blyton park was booked for a very cold and frosty 28th December.

The car completely outdid any expectations I had of it. Kept up with some cars you would expect to be a fair bit quicker such as stripped out Clio cups, 328i to name a couple. Safe to say I wasn't slowest on tack by a comfortable margin.
At this point the only changes to the car are a wheel change for track only (still on the silver wheels for road) and removal of the rear seats, carpet and parcel shelf.

Arriving at the track:
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0394_zps9530b8f0.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0394_zps9530b8f0.jpg.html)

On the track:
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/Blytonpark_zpsc03b230c.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/Blytonpark_zpsc03b230c.jpg.html)

Leaving the track:
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0396_zps56ef3e59.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0396_zps56ef3e59.jpg.html)


Much more to come, watch this thread :)

[peterzs]

Thanks for the post, sounds like a good buy and a healthy car to start modding.

:clap::clap::clap:

[Dan1971]

Another track car ... it's catching !

Great healthy car to start with - great on track pic too.

[Skillen]

It is so weird to see it with someone else but I'm glad you're enjoying it!
I always thought it pulled well so it's good to see it was healthy and it wasn't just me and placebo.

It felt so much better with the exhaust and ITG too.

[Lukeus101]

Can't wait to see some more progress mate :)

[ZS Phil]

Got the car up on the ramps on Sunday and started to make her mine.

First job was a swift oil and filter change. The service history said it was only done in summer but after thrashing round Blyton I felt she deserved it.

Given it was built in 2001, the underside is in very good condition, from my experience the early cars are so much better in terms of build quality.

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0399_zps99eecf36.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0399_zps99eecf36.jpg.html)


Next on the hit list was the oil catch tank plumbing. It has obviously been fitted for years, Callum said he never emptied it over his ownership so this is the sum total of what it will catch plumbed into the larger breather (sweet FA):
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0409_zps5d11679a.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0409_zps5d11679a.jpg.html)

Engine bay before:

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0402_zpsb464945e.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0402_zpsb464945e.jpg.html)

Wrong breather, wrong colour:

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0404_zps2738e81a.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0404_zps2738e81a.jpg.html)

Correct colour:

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0410_zpsa83cb8e8.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0410_zpsa83cb8e8.jpg.html)

Correct breather:

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0414_zps60d37ce5.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0414_zps60d37ce5.jpg.html)

Engine bay after:

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0416_zpseea5721f.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0416_zpseea5721f.jpg.html)


Next job was the exhaust...

Nom nom nom

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0430_zps5adb63e1.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0430_zps5adb63e1.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0431_zps7e24480a.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0431_zps7e24480a.jpg.html)

Out with the old

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0432_zpsf0d6ac74.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0432_zpsf0d6ac74.jpg.html)



In with the new...

Custom de-cat pipe
Scorpion center section
Janspeed X-Power back box

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0419_zpsa78d46e7.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0419_zpsa78d46e7.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0421_zpsc73a8c2b.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0421_zpsc73a8c2b.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0422_zps01049bae.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0422_zps01049bae.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0423_zps30814623.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0423_zps30814623.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0425_zps86545427.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0425_zps86545427.jpg.html)



Unfortunately ran out of light for a fitted pic.


As a final point, the standard baseline RR graph perhaps wasn't as standard as I thought. No resonator box fitted!! Glad I've not been through any deep puddles!

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0437_zps0690d6a9.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0437_zps0690d6a9.jpg.html)

[Skillen]

Oops! The resonator was my fault!! It's in the shed
I took it off when I did the ITG and sorted the fog lights due to moss growing and I forgot to refit lol!
It was on the to-do to make it standard again but didn't have time to do it one day and then forgot! Sorry about that!
Do t think it'll make a huge difference to power anyway not sure about puddles lol. :hmmm:

I never checked that catch tank! Assumed it worked because the ITG was never covered in oil when I checked lol.
Good find! Always thought that was meant to be like that as it said that it was fitted in the dealership! Shows how much the dealer knew!

How's the exhaust sound?

[ZS Phil]

No worries :) no harm has come from it and I'm sure it can only make the induction sound better. The rest of the intake will be removed as soon as poss anyway to make room for the CDA I've ordered and the custom hose which I can hopefully get made.

The catch tank wasn't doing any harm either, just wasn't doing anything really.

As expected, the exhaust sounds incredible. Seems to have a bit more torque low down since fitting it as well as revving much more freely.

The sound doesn't quite fit with a car that essentially looks like a Rover 45 with a spoiler to the un-trained eye, very 350Z like.

[pervavore]

Hope to see more things going forward with your next build :)

[Lukeus101]

Do you have any need for a ITG panel filter Phil? :)

[talkingcars]

Hope to see more things going forward with your next build :)

Hi and welcome to the forum, pop an intro thread up.

James

[talkingcars]

Nothing wrong with that catch tank plumbing, personally I'd of left it and added a second tank for the post throttle body breather.

[ZS Phil]

Hope to see more things going forward with your next build :)

You found us then! Glad you signed up, it's a good site. Loads of info about for when you do your T16 conversion ;)

Do you have any need for a ITG panel filter Phil? :)

Hey dude, I did consider one however my CDA and custom silicone set up idea has come to fruition... post to follow :)

Nothing wrong with that catch tank plumbing, personally I'd of left it and added a second tank for the post throttle body breather.

I agree, nothing wrong with it in terms of it doing harm directly however given how many years it has been plumbed like that and how little oil it has trapped suggests that it wasn't doing anything at all!
I did consider a second tank however I couldn't find one to match, my ocd wouldn't allow that (sad I know). I didn't see the point in forking out £40 for a matching pair when one of them would be purely for show.

[ZS Phil]

A quick parts update.

If you've seen the thread "do we concur", you'll know I've been trying to organise a custom made silicone intake pipe to work with the BMC CDA filter to avoid the need for separate 90 degree bends and breather filters etc.

The idea was to have a pipe made which would make the CDA a direct fit to give people an alternative to the £400 ITG set up.

So, first of all I needed a CDA 85-150, decided to get a new one:

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/2d1457ef-15fb-488f-bc04-d37f098c12b5_zps89a44e0b.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/2d1457ef-15fb-488f-bc04-d37f098c12b5_zps89a44e0b.jpg.html)

The custom pipe was delivered towards the end of last week, looks a bit like this:

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0466_zpse0d2c33a.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0466_zpse0d2c33a.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/ac855259-37c8-452d-90e6-5eec2d27916d_zpsec23fa2f.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/ac855259-37c8-452d-90e6-5eec2d27916d_zpsec23fa2f.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0473_zpsa87637a6.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0473_zpsa87637a6.jpg.html)

Perfect fit onto the air box:

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0475_zps6b428370.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0475_zps6b428370.jpg.html)

[Skillen]

Looks ace that! Nice work on the digging.
Can they do purple?
Need to hit them up for a group buy on these and/or on coolant hoses.

[ZS Phil]

Cheers :) Really pleased with it so far, yet to see how well it fits on the car though.

I can't see why it wouldn't be available in purple :)

No need for a group buy, once i confirm it fits he said he will list it on the website so it can be bought "off the shelf".

[Skillen]

Cheers :) Really pleased with it so far, yet to see how well it fits on the car though.

I can't see why it wouldn't be available in purple :)

No need for a group buy, once i confirm it fits he said he will list it on the website so it can be bought "off the shelf".

Excellent. I may replace my ITG's hose. Though the ITG's hose doesn't have a reduced section that I remember. :/
Just thinking of a group buy to save costs was all.

It looks like the hose is glowing in the last picture!

[ZS Phil]

Ahh, fair enough, see what you mean with the group buy idea.

As long as 85mm is suitable for the maxogen, I cant see why this wouldn't work. Obviously just need to check the other measurements.

If you want it to be purple I guess it's the only cost effective way of doing it, weather its worth the sacrafice of the small step over the ITG hose is another matter.

[ZS Phil]

I've been slowly tinkering over the last few months so a bit of an update is in order:

I'll try not to write too much, pictures say a thousand words.

Coilovers have happened, got some second hand GAZ at a price I couldnt say no to. One had a slight leak and they had been set up for a 1.8 ZS with 325lb/in front springs and 225 rears.

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0502_zpsavj2605g.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0502_zpsavj2605g.jpg.html)


I sent them off to GAZ for a full rebuild with new rods, seals and oil.
Perhaps most importantly I decided to go stiffer with the spring rates but not too silly. I requested they use the old front 325 springs on the rear and then supply some new 550 lb/in springs for the fronts.
The valving has been adjusted to suit the new spring rates.
They came back looking like this:

Absolutely superb service.

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0589_zpskl4gbcms.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0589_zpskl4gbcms.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0590_zpsbr8oc4rl.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0590_zpsbr8oc4rl.jpg.html)


The interior did look like this:

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0515_zpstf50eu8t.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0515_zpstf50eu8t.jpg.html)

Then things started to happen:

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0525_zpsziszwvig.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0525_zpsziszwvig.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0526_zpsub6w9bdt.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0526_zpsub6w9bdt.jpg.html)


Custom light weight center console with just the bear essentials:

Doing the template.

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0557_zpsxj9jdhes.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0557_zpsxj9jdhes.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0568_zpsknn1izot.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0568_zpsknn1izot.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0574_zpsbe1vaih7.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0574_zpsbe1vaih7.jpg.html)


Next I went and got me some seats:

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0511_zpsas5jl1kd.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0511_zpsas5jl1kd.jpg.html)

Getting them attached to some ZS rails:

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0528_zpslmfovtuc.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0528_zpslmfovtuc.jpg.html)

Painted and belt clip added using proper 7/16 UNF bolt:

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0550_zpsk581rikc.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0550_zpsk581rikc.jpg.html)

Ready to roll:

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0552_zpsykhlc2fd.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0552_zpsykhlc2fd.jpg.html)


Decided I didn't like the Scorpion center section as it was only 2". Replaced it with a custom straight through pipe in stainless 2 1/4" to match the rest of the system, this has the benefit of being lighter and the sound is unreal. Feels much better although I fitted my BMC at the same time so not sure which has had the biggest impact (post to follow about the BMC).

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0579_zpsgotbqhv6.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0579_zpsgotbqhv6.jpg.html)


Had a bit of a do with these guys over the last couple of days:

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0671_zpsnd73e3kz.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0671_zpsnd73e3kz.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0676_zpsohfs8wev.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0676_zpsohfs8wev.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0677_zpsjtaye2xv.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0677_zpsjtaye2xv.jpg.html)


And this is what all that horrible sound deadening looks like when its all in a pile:

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0686_zpsgn0zgirz.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0686_zpsgn0zgirz.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0688_zpsasgxhqlq.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0688_zpsasgxhqlq.jpg.html)


And the weight!!!!

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0696_zpsnvuevnoz.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0696_zpsnvuevnoz.jpg.html)

This is how she looked as the sun was going down tonight:

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0693_zpsiapt82qj.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0693_zpsiapt82qj.jpg.html)







And a random pic of the twins looking cold and filthy.

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0487_zpsejhbwlyd.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0487_zpsejhbwlyd.jpg.html)



Much more to come :D

[Skillen]

Poor little razor with nothing left in him :( haha.
Good to see you're progressing with it all though!
The carpet. What have you done with it? Mines leaked in a lot again and I'd like to swap it out again as its a tad damp atm.

Nice work from Gaz there! I'll be getting mine back in the next week or so and I'm hoping the look as good as them!!

[ZS Phil]

Poor little razor with nothing left in him :( haha.
Good to see you're progressing with it all though!
The carpet. What have you done with it? Mines leaked in a lot again and I'd like to swap it out again as its a tad damp atm.

Nice work from Gaz there! I'll be getting mine back in the next week or so and I'm hoping the look as good as them!!

Haha, you wont recognise him at POL!

I have the carpet in the shed, I was toying with the idea of putting it in the TD because as you know it's in awesome condition. That said, I'm not sure when I'll get chance at the moment as its quite low on the priority list so was actually going to post it for sale along with the headlining.

I made sure I removed them both carefully and nothing was cut etc.

If you want it, let me know :)

Yeh, I dealt with a guy called Andy at Gaz, seemed very on the ball. Have you sent yours off already then? What spring rates etc you gone for?

[Skillen]

Yeah they're all done. Just need to pay up Monday and they'll be sent back.
The cars getting its belts done and cams fitted this weekend :)

I just asked for them returned as standard but if they're a bit soft I'll ask what they recommend as I'm not sure what I'll need for road use.

[ZS Phil]

Yeah they're all done. Just need to pay up Monday and they'll be sent back.
The cars getting its belts done and cams fitted this weekend :)

I just asked for them returned as standard but if they're a bit soft I'll ask what they recommend as I'm not sure what I'll need for road use.

Standard should be the same as the ones on my TD (400 lb/in front 225 rear). Playing with the damping can have a fairly big influence on how hard they feel.

I paid at 4:30 and they arrived the next morning first thing so either they made a **** up and sent them out before I paid or they use a really good courier!

I bet you cant wait to get the cams in and have piece of mind with the belts. It'll have all the main mods done then!

[Skillen]

Must have been a hell of a courier!! Haha
Your TD didn't feel too hard at all tbh.
I can't go too low atm due to the spacers but hopefully with a bit of rolling they'll be fine.
They won't be on for PoL though I don't think as there's a lot needing done.
Mapping is the main one following the cams.
And my splitter is all sprayed up now too and I'm picking that up on Wednesday so it'll need fitted and then a damn good clean, clay, Polish and wax.
If I can get the shocks on then I will but I don't wanna ruin anything before the drive down, but I do have the Friday before it off work so maybe some leeway there.

[Mark S]

nice choice of seat.

[ZS Phil]

Sounds like its all go!

Would you not be tempted to take the spacers off so you can fit the coilovers, see how it looks and then if you think the wheels still aren't filing the arches enough put them back on and then start rolling? Suppose its as broad as it is long really but you saw how low the TD is, it never scrapes and no arches have had a roller anywhere near them... just a thought but I'm sure it will look awesome either way :)

Unless you are 100% sure the rear fork bolts aren't seized in you would have to be pretty brave to attempt coilover fitment the day before POL as you may end up having to cut the bolts out which will obviously ruin the bolts and possibly the bush (unless you have all the spares lined up beforehand of course but then you might not need them).

Have you found anywhere more local to do the mapping than Reidy yet?

[Lukeus101]

Phil....how easy were the seats to set up with the mounts etc? I ask as we are tempted to ditch the OE seats. :)

[ZS Phil]

nice choice of seat.

Cheers :) They seem pretty good so far.

It's a go ahead for the 29th, are you likely to be there?

[Mark S]

Cheers :) They seem pretty good so far.

It's a go ahead for the 29th, are you likely to be there?

yes, I will be at donington for the 1st race of the civic cup, then straight down to mallory for the race there!

[ZS Phil]

Phil....how easy were the seats to set up with the mounts etc? I ask as we are tempted to ditch the OE seats. :)

The rails are just standard, they just un-bolt from your current seats and the custom brackets bolt to the rails in place of the seat.
It's a bit of fiddling and trial and error but relatively straight forward. Took me a day of playing about with different bolt hole combos until I was happy with the position.

I purchased the brackets from Mark S who had them made so he may be able to give you a contact/ supply you some if you ask?

As far as I know, nobody makes an off the shelf bolt in solution.

[ZS Phil]

yes, I will be at donington for the 1st race of the civic cup, then straight down to mallory for the race there!

Busy day then! Hope people don't mind me coming to pick their brains but its the best way to avoid potentially expensive errors I guess.

[Mark S]

I still have the cad files for those and a modified cad version of the ones in the vvc track car build so either can be laser cut.

[Mark S]

Busy day then! Hope people don't mind me coming to pick their brains but its the best way to avoid potentially expensive errors I guess.

they will enjoy that, you just need to cut through the bs, talk to as many as poss and make an informed choice on what's good and what really works.

my money is on the red car of clackets followed by the white car of the pensioner being the fastest zs's on the day.

[ZS Phil]

they will enjoy that, you just need to cut through the bs, talk to as many as poss and make an informed choice on what's good and what really works.

my money is on the red car of clackets followed by the white car of the pensioner being the fastest zs's on the day.

I trust the latter is Howard's car who had the cage done at SW? (based on car colour rather than driver description :D).

[Mark S]

yes, but trust me, he is an o.a.p. too (Old And Putrid!!!)

[Skillen]

Sounds like its all go!

Would you not be tempted to take the spacers off so you can fit the coilovers, see how it looks and then if you think the wheels still aren't filing the arches enough put them back on and then start rolling? Suppose its as broad as it is long really but you saw how low the TD is, it never scrapes and no arches have had a roller anywhere near them... just a thought but I'm sure it will look awesome either way :)

Unless you are 100% sure the rear fork bolts aren't seized in you would have to be pretty brave to attempt coilover fitment the day before POL as you may end up having to cut the bolts out which will obviously ruin the bolts and possibly the bush (unless you have all the spares lined up beforehand of course but then you might not need them).

Have you found anywhere more local to do the mapping than Reidy yet?

I'm not sure tbh. I absolutely love how it looks wider.
Something definitely needs to give though. Maybe 10mm off each of the rears and an arch roller.
The mk1 has.5inch less width on the wheel too so I was pushing it really but hey. I love with it.

Yeah it won't be getting done the day before. I'll be travelling down in daylight to stop the midges getting me and doing final prep work (quick detail at the Mrs in Lymm)
If I get chance I'll do it well before and I'll get some stainless bolts sorted for the suspension too.
No not yet. I'm hoping the local guy will see fruition but I'm not sure until then.
I read a few threads saying that the ECU has enough capacity to learn the 270's not sure how true that is though.
Also that it'll run lean top end but again I've heard they're all that way but I guess with a different cam it'll be leaner still.

[peterzs]

Dont understand half of it, but good to see the skills and commitment.

:smile1::smile1::smile1::smile1:

[Dan1971]

Dont understand half of it....

:smile1::smile1::smile1::smile1:

Glad it's not just me Pete ... ;)

[Lukeus101]

+1....

[Mark S]

and I'll get some stainless bolts sorted for the suspension too.


stainless bolts are not very strong, stick with the oe bolts in stress areas, stainless are fine for pretty things, like holding a fairing on a motorbike.

[Skillen]

stainless bolts are not very strong, stick with the oe bolts in stress areas, stainless are fine for pretty things, like holding a fairing on a motorbike.

Okie doke :) will do.
Just didn't want them seizing up but I guess if i clean up the parts properly it shouldn't be too much of an issue. Also I won't be going another 13 years without touching them again!

[ZS Phil]

I'm not sure tbh. I absolutely love how it looks wider.
Something definitely needs to give though. Maybe 10mm off each of the rears and an arch roller.
The mk1 has.5inch less width on the wheel too so I was pushing it really but hey. I love with it.

Yeah it won't be getting done the day before. I'll be travelling down in daylight to stop the midges getting me and doing final prep work (quick detail at the Mrs in Lymm)
If I get chance I'll do it well before and I'll get some stainless bolts sorted for the suspension too.
No not yet. I'm hoping the local guy will see fruition but I'm not sure until then.
I read a few threads saying that the ECU has enough capacity to learn the 270's not sure how true that is though.
Also that it'll run lean top end but again I've heard they're all that way but I guess with a different cam it'll be leaner still.

I'm actually really looking forward to POL, so much to do yet though.
Hope you do manage to get the coilovers on, it will look incredible :)
I've heard talk of learning regarding the ECU too, I don't think the word learning is strictly true to be honest but rather the ECU will pluck different values from a pre-determined range dependent upon input sensor values such as lambda, temp, engine speed etc.
As long as these pre-determined ranges contain suitable values for the different input values due to the mods then you should be ok. If not, that is where a re-map comes in.

The above isn't based on experience with the 180 ECU but rather my understanding of how an ECU works in general.

Anyway, I'm talking too much. Re-map for race car points.

[Skillen]

I'm actually really looking forward to POL, so much to do yet though.
Hope you do manage to get the coilovers on, it will look incredible :)
I've heard talk of learning regarding the ECU too, I don't think the word learning is strictly true to be honest but rather the ECU will pluck different values from a pre-determined range dependent upon input sensor values such as lambda, temp, engine speed etc.
As long as these pre-determined ranges contain suitable values for the different input values due to the mods then you should be ok. If not, that is where a re-map comes in.

The above isn't based on experience with the 180 ECU but rather my understanding of how an ECU works in general.

Anyway, I'm talking too much. Re-map for race car points.

I'm getting more excited at the prospect too! Just wish the paintwork was in better condition but that will come with time.
Just paid for the coilovers this morning and they'll be with me by tomorrow so their courier is ace! They needed a rod doing so more than I was expecting but I paid far less overall than buying new so I'm pleased.
I also just ordered so gear to do the arches which will be with me by the end of the week so if the car is done (saw it on the garage forecourt this morning which may be promising) I'll try and get it all widened, trimmed and fitted this weekend! I'll spray penetrating fluid everyday I have the car back up till its time and I have a blow torch which may help with the bolts.

Glad the car is serving you well though! It'll be good to see it in the flesh!
When my saloon was stripped out it definitely felt sharper so it should be good!

[Mark S]

how much extra was the rod from gaz? i have 2 or 3 rusting away!!! luckily out of the working zone.

[Skillen]

how much extra was the rod from gaz? i have 2 or 3 rusting away!!! luckily out of the working zone.

£36.50 unit price +vat so actually pretty reasonable.
I needed two.

[Silverdreamracer]

I trust the latter is Howard's car who had the cage done at SW? (based on car colour rather than driver description :D).

Phil, just ignore the buffoon, ....... he'll be chuckling away to himself like a demented slug!!!!

[ZS Phil]

*Update time*

So the car is still at SW having lots of work done, it's been there just over 3 weeks so hopefully I should get it back relatively soon... he did say a week but obviously don't want anything to be rushed so playing it cool for now.
There will be another update to follow but this one is to cover the work I did before I dropped it off.

Like last time, I'll try not to write too much and tell the story with pictures where I can:

This is the continuation of my cold air feed...

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0705_zpssmmvfq7c.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0705_zpssmmvfq7c.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0709_zpsukpofjjk.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0709_zpsukpofjjk.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0719_zps1dj7be1e.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0719_zps1dj7be1e.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0702_zpsisjdpubm.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0702_zpsisjdpubm.jpg.html)

Light weight fuel hatch release cable:

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0724_zps7kl12ic8.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0724_zps7kl12ic8.jpg.html)

Just to show the vent holes... the MK2 grille was just a temp fix while the mesh was away getting powder coated. MK1 grille is back on now (no pics yet though).

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0727_zpsvhf9zlol.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0727_zpsvhf9zlol.jpg.html)

Look at this pile of scrap...

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0795_zpsispahg3u.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0795_zpsispahg3u.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0799_zpsezimuxgj.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0799_zpsezimuxgj.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0801_zpsk5quuw1k.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0801_zpsk5quuw1k.jpg.html)

Sheared bolt 1 of 1 thankfully :)

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0797_zpscovprqpq.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0797_zpscovprqpq.jpg.html)

Next there be fire.

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0806_zpsmyq43you.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0806_zpsmyq43you.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0809_zpsdtrx7k7j.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0809_zpsdtrx7k7j.jpg.html)

Then some presents came.

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0831_zpsidsrtq0o.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0831_zpsidsrtq0o.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0832_zpsgxbvyrvo.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0832_zpsgxbvyrvo.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0836_zpsoyffiaoj.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0836_zpsoyffiaoj.jpg.html)

Then remember that scrap?

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0839_zpsfloz7zst.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0839_zpsfloz7zst.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0842_zpsqhjpfisv.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0842_zpsqhjpfisv.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0844_zpsxdboh0ce.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0844_zpsxdboh0ce.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0850_zps3fcut5xs.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0850_zps3fcut5xs.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0913_zpsfy8qvdci.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0913_zpsfy8qvdci.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0902_zpsonpasjuw.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0902_zpsonpasjuw.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0907_zpsutgddwud.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0907_zpsutgddwud.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0897_zpswugadzt1.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0897_zpswugadzt1.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0900_zps1irwsw3s.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0900_zps1irwsw3s.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0894_zpsxwq67hot.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0894_zpsxwq67hot.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0904_zpsy5tncisv.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0904_zpsy5tncisv.jpg.html)

She got a thorough undersealing while I was at it, minus 10 racecar points for added weight :(

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0891_zps3ybupv8p.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0891_zps3ybupv8p.jpg.html)

Did a bit of gardening in the wing first though...

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0885_zps25lqwdhu.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0885_zps25lqwdhu.jpg.html)

Going back together

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0860_zps1pm7ontr.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0860_zps1pm7ontr.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0857_zpserdb82td.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0857_zpserdb82td.jpg.html)
http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0920_zpsevsqwx0f.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0920_zpsevsqwx0f.jpg.html)

Complete aircon system completely removed, absolutely everything: This is where the compressor used to live and the pulley, running the shorter belt works a treat.

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0911_zpsw6yvd7gf.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0911_zpsw6yvd7gf.jpg.html)

More weight saving inside, all window mechanisms and motors gone along with a large proportion of door skin. Windows secured with old seatbelt, will do fine until I get some polycarbinate windows but that can wait for the weight it will save (crash bars are staying)

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0925_zps2nwrnpdl.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0925_zps2nwrnpdl.jpg.html)

Seats back in:

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0924_zpsydyo4leh.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0924_zpsydyo4leh.jpg.html)


Lets not forget her mate...

http://i276.photobucket.com/albums/kk11/zsphil/Track%20180/DSC_0781_zpstobtetcf.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20180/DSC_0781_zpstobtetcf.jpg.html)


And that's where she was up to. Ran out of time to take more pictures of the front sus set up but they can come later.

Can't wait to get her back now... watch this space.

[Skillen]

Awesome work Phil!
We're the bushes easy to do? Mine want doing as the harder suspension has exposed so much knocking and banging going on all round but I don't have access to a vice :/

Good to see that even though it's now a track slag that so much work is going into it and it's probably getting more love than if I'd sold it locally.

[ZS Phil]

Cheers :)
Yeh, its having plenty of time and effort spent on it so no chance of it being neglected.

To be honest, the bushes are really easy to fit although a vice does make life 10 times easier. Thinking about it, its the tool I use most without a shadow of a doubt, certainly worth you investing in one.

The tricky bit (or the bit which CAN be tricky) is getting all the components off without shearing seized / rusty bolts. I soaked everything in Plus Gas at least 3 times and drove it for about 2 weeks before even attempting it... seemed to work.
The other part that took a bit of time was getting the old bushes out, obviously if you have a bearing press its not an issue but the "burn and cut" method worked fine for me... again, you need a vice though really.

But yeh, its all "doable".

[stamford]

Coming along nicely there Phil. It's very pleasing when everything gets stripped, cleaned, painted and fitted with new parts. I've a few more bits to play with myself yet, just leaving it until my dodgy arm tendons heal. Are you replacing the brakes hoses? I would if I were you, HEL ones are priced very well and good quality, added bling too ;)

[Dan1971]

Great work .... :bow:

[Mark S]

what shore rating are those yellow bushes?

its like looking into a pack of bertie's allsorts, - all those colours!!!

Nice work :)

[sneekyparrot]

what shore rating are those yellow bushes?

its like looking into a pack of bertie's allsorts, - all those colours!!!

Nice work :)

agree superb work, your putting me to shame :crazy:

yellows will be 90sha
red will be 80sha

P.

[ZS Phil]

As always, thanks for the comments :).

Coming along nicely there Phil. It's very pleasing when everything gets stripped, cleaned, painted and fitted with new parts. I've a few more bits to play with myself yet, just leaving it until my dodgy arm tendons heal. Are you replacing the brakes hoses? I would if I were you, HEL ones are priced very well and good quality, added bling too ;)

Cheers, yeh its always a nice feeling when it all just fits together "like so".
The brake hoses will be changed however I need to decide on my set up first because I will obviously get the hoses to match. At the moment I think the most likely candidates are the twin pots from the accord type r with 300mm discs. Heard nothing but good things about them.

what shore rating are those yellow bushes?

its like looking into a pack of bertie's allsorts, - all those colours!!!

Nice work :)

Yeh, the colour scheme is a bit of an "acquired taste"haha.

As sneakyparrot confirmed, the yellow bushes are the stiffer 90sha ones.
Went with genuine Rover trailing arm bushes though... like you said, some complex movements going on there so stiffening up the pivot is probably not a wise move (that is the only bush not polybushed though)

agree superb work, your putting me to shame :crazy:


I'm really not mate, your build is part of the inspiration for this truth be told.

Once a few of us have finished these projects, we should really organise a site track day.

[stamford]

These projects are never finished...........10 years and still counting :laugh:

[sneekyparrot]

These projects are never finished...........10 years and still counting :laugh:


Now there is the voice of experience [emoji1][emoji1]

[top_man_eldo]

Been there done that! All the undersealing, burning out all of the bushes and replacing with new, painting the suspension components! Well worth it though, great work!

Since removing all of my aircon system, it's made me realise how much all of that stuff got in the way when working in the engine bay!

[stamford]

Now there is the voice of experience [emoji1][emoji1]

Experience and indecision! One minute commuter, next part track, then comfort again, now stripped again! I think I know where it's going now! Wish I had two, one for modifying and one for keeping standard!

[p_b82]

Looking good there Phil - much love gone in there!

[ZS Phil]

Again, thanks or the comments chaps :)


Been there done that! All the undersealing, burning out all of the bushes and replacing with new, painting the suspension components! Well worth it though, great work!

Since removing all of my aircon system, it's made me realise how much all of that stuff got in the way when working in the engine bay!

I followed your thread closely, in fact the part number you listed for the rear ARB bush got me out of a sticky situation, turns out the Civic ones are too small but luckily that company do a ZS specific one... so cheers :)

[ZS Phil]

Got these sent through the other night, hopefully be picking the car up either tomorrow night after work or Monday. Excited is not the word

Sneaky peaky :D

http://i276.photobucket.com/albums/kk11/zsphil/180%20cage/FB3_zpssbicangg.jpg (http://s276.photobucket.com/user/zsphil/media/180%20cage/FB3_zpssbicangg.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/180%20cage/FB1_zpsztccrhfo.jpg (http://s276.photobucket.com/user/zsphil/media/180%20cage/FB1_zpsztccrhfo.jpg.html)

[adam]

Excellent! Looks smashing, can't wait to see it done.

[Mark S]

have you still got the original heater/fan setup?

[ZS Phil]

Excellent! Looks smashing, can't wait to see it done.

Cheers mate, neither can I :bounce:

have you still got the original heater/fan setup?

For now yes minus the aircon bits

[stamford]

Looking pukka! :thumbsup:

[Supercharged_Z]

nice cage

[BRMFUN]

Great colour choice!

[ZS Phil]

Time for a quick update:

Got the car back and was really pleased at first, just found a few niggly issues once I got it home. The boot leaked, there was a dent which wasn't there before and front was too low (my fault).
Minor issues really which were put right over the last 3 weeks by SW, obviously free of charge so really cant complain. The boot just needed re-positioning, the dent has been sorted and the fronts raised slightly and the camber re-set.
The have done a really good job overall and offered lots of tips/ advice.




So, after 7 weeks of being without it, I've been able to crack on with a few jobs today and take some pics.

First of all, I wasn't happy with the crappy cardboard/ tin foil air ducting which BMC supply with the filter so I changed it for some proper stuff. As you can see, the old ducting makes for a nice protective shield in places it could rub...

http://i276.photobucket.com/albums/kk11/zsphil/180%20cage/DSC_1522_zpsn9dguyjt.jpg (http://s276.photobucket.com/user/zsphil/media/180%20cage/DSC_1522_zpsn9dguyjt.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/180%20cage/DSC_1528_zpsxn9aoa0o.jpg (http://s276.photobucket.com/user/zsphil/media/180%20cage/DSC_1528_zpsxn9aoa0o.jpg.html)




Next, I wanted to make a cheap, good looking and different splitter for it.
What I've come up with is certainly cheap and will hopefully push some air out of the way... good looking is a matter of opinion.

The top half is 2 x Fabia splitters (because 1 isn't long enough) which are joined in the midline.
The bottom half is garage door seal imported from America at a cost of £8 delivered! It is just like universal splitter material in cross section but much stiffer.
As you can see, it is riveted to the plastic fabia splitters using large pop rivets and big washers behind the rubber to spread the load. I also added double sided foam tape so it aint going to budge!

http://i276.photobucket.com/albums/kk11/zsphil/180%20cage/DSC_1534_zps7hfv7iub.jpg (http://s276.photobucket.com/user/zsphil/media/180%20cage/DSC_1534_zps7hfv7iub.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/180%20cage/DSC_1535_zps9ckd49dl.jpg (http://s276.photobucket.com/user/zsphil/media/180%20cage/DSC_1535_zps9ckd49dl.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/180%20cage/DSC_1538_zpslhamsqgq.jpg (http://s276.photobucket.com/user/zsphil/media/180%20cage/DSC_1538_zpslhamsqgq.jpg.html)


And finally, some interior pics.

http://i276.photobucket.com/albums/kk11/zsphil/180%20cage/DSC_1512_zpscwtkbt57.jpg (http://s276.photobucket.com/user/zsphil/media/180%20cage/DSC_1512_zpscwtkbt57.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/180%20cage/DSC_1514_zpsvvua1hs7.jpg (http://s276.photobucket.com/user/zsphil/media/180%20cage/DSC_1514_zpsvvua1hs7.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/180%20cage/DSC_1508_zpsf5cgnstc.jpg (http://s276.photobucket.com/user/zsphil/media/180%20cage/DSC_1508_zpsf5cgnstc.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/180%20cage/DSC_1505_zps2zklpril.jpg (http://s276.photobucket.com/user/zsphil/media/180%20cage/DSC_1505_zps2zklpril.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/180%20cage/DSC_1507_zpsycxh0awj.jpg (http://s276.photobucket.com/user/zsphil/media/180%20cage/DSC_1507_zpsycxh0awj.jpg.html)



Just need to get the brakes sorted now ready for Blyton on Sunday... Can't wait.

[jc600]

Nice build thread, looks awesome.....good luck on the track. :)

[ShireRoller]

Cant wait to see this at Blyton on Sunday!

[ZS Phil]

Nice build thread, looks awesome.....good luck on the track. :)

Thanks, yeh, I think shes come out alright. Just hope all the upgrades make for a significant improvement on the track.
I need to learn to drive next!

Cant wait to see this at Blyton on Sunday!

Are you out at Blyton too?

[deano ZS180]

What paint did you use on the interior to black it out?
looks great!!!

[ZS Phil]

I'm not sure what paint it is exactly but it just looks like regular automotive paint. If you got in touch with SW motorsport I'm sure they would be happy to tell you :)

[sneekyparrot]

Superb Phil,
Its really taking shape.

you nicked my colour scheme for the inside:thumbsup:. Got both gloss and satin black plus a litre of kawasaki green for cage etc.

things have stalled a little with me at moment, still waiting for brakes :-(

throttle body off being bored out but hoping to get a crack on with stichingwelding the rear end over the next 2 weeks so i can get it all painted.

be good to get some track time next year.

i have done both 4 and 2 wheel race school and cant recommend them enough, its amazing how you can strip seconds off lap times yet it feels like you are driving slower !

cheers
P.

[Lukeus101]

Just keeps getting better Phil :D Love it!

[ZS Phil]

Superb Phil,
Its really taking shape.

you nicked my colour scheme for the inside:thumbsup:. Got both gloss and satin black plus a litre of kawasaki green for cage etc.

things have stalled a little with me at moment, still waiting for brakes :-(

throttle body off being bored out but hoping to get a crack on with stichingwelding the rear end over the next 2 weeks so i can get it all painted.

be good to get some track time next year.

i have done both 4 and 2 wheel race school and cant recommend them enough, its amazing how you can strip seconds off lap times yet it feels like you are driving slower !

cheers
P.

Honestly, your car is an inspiration. I would love to see it in action sometime, it will be an absolute weapon once its done.

In terms of the colour scheme, there was never a choice to make, lime green all the way! Just a little nod at the ZS's racing pedigree I suppose.

Just keeps getting better Phil :D Love it!

Cheers Luke, I hope to get it to a show at some point :).


This has just reminded me, I need to update this thread as things have happened since!

[ZS Phil]

So, Blyton Park happened before we went away in the TD on our road trip.

The car is simply awesome, I wont ramble on about what could keep up and what couldn't but I'm over the moon with the results of the changes over stock. It's a different beast.

A few more tweeks before the track day...

http://i276.photobucket.com/albums/kk11/zsphil/Track%20brakes%20and%20wheel/DSC_1555_zpsaapfbfzg.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20brakes%20and%20wheel/DSC_1555_zpsaapfbfzg.jpg.html)

Before:

http://i276.photobucket.com/albums/kk11/zsphil/Track%20brakes%20and%20wheel/DSC_1551_zpssgguuacz.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20brakes%20and%20wheel/DSC_1551_zpssgguuacz.jpg.html)

After:

http://i276.photobucket.com/albums/kk11/zsphil/Track%20brakes%20and%20wheel/DSC_1580_zps7y4ur8px.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20brakes%20and%20wheel/DSC_1580_zps7y4ur8px.jpg.html)


De-wipered:

http://i276.photobucket.com/albums/kk11/zsphil/Track%20brakes%20and%20wheel/DSC_1542_zpssf3bu3sb.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20brakes%20and%20wheel/DSC_1542_zpssf3bu3sb.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Track%20brakes%20and%20wheel/DSC_1547_zpscne0zes3.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20brakes%20and%20wheel/DSC_1547_zpscne0zes3.jpg.html)



Old discs...

http://i276.photobucket.com/albums/kk11/zsphil/Track%20brakes%20and%20wheel/DSC_1576_zpsyuaxd7kz.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20brakes%20and%20wheel/DSC_1576_zpsyuaxd7kz.jpg.html)


New discs and Yellow stuff pads up front:

http://i276.photobucket.com/albums/kk11/zsphil/Track%20brakes%20and%20wheel/DSC_1566_zpsgyvhxlox.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20brakes%20and%20wheel/DSC_1566_zpsgyvhxlox.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Track%20brakes%20and%20wheel/DSC_1569_zpsluctmsbu.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20brakes%20and%20wheel/DSC_1569_zpsluctmsbu.jpg.html)


Blue stuff pads rear:

http://i276.photobucket.com/albums/kk11/zsphil/Track%20brakes%20and%20wheel/DSC_1578_zpssgypaapb.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20brakes%20and%20wheel/DSC_1578_zpssgypaapb.jpg.html)


Just to show how much the cage has stiffened it up

http://i276.photobucket.com/albums/kk11/zsphil/Track%20brakes%20and%20wheel/DSC_1557_zpsce06gnaa.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20brakes%20and%20wheel/DSC_1557_zpsce06gnaa.jpg.html)


Quick wash before Blyton:

http://i276.photobucket.com/albums/kk11/zsphil/Track%20brakes%20and%20wheel/DSC_1606_zpsogx2dyaq.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20brakes%20and%20wheel/DSC_1606_zpsogx2dyaq.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Track%20brakes%20and%20wheel/DSC_1603_zpszumucfuc.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20brakes%20and%20wheel/DSC_1603_zpszumucfuc.jpg.html)



Safety first:

http://i276.photobucket.com/albums/kk11/zsphil/Track%20brakes%20and%20wheel/DSC_1613_zpspkt6wybd.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20brakes%20and%20wheel/DSC_1613_zpspkt6wybd.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Track%20brakes%20and%20wheel/DSC_1617_zpsxrsmiz28.jpg (http://s276.photobucket.com/user/zsphil/media/Track%20brakes%20and%20wheel/DSC_1617_zpsxrsmiz28.jpg.html)



And some action pics:

http://i276.photobucket.com/albums/kk11/zsphil/Blytom/DSC_2849_zpsar2j4zqb.jpg (http://s276.photobucket.com/user/zsphil/media/Blytom/DSC_2849_zpsar2j4zqb.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Blytom/DSC_2975_zpslacwmhxi.jpg (http://s276.photobucket.com/user/zsphil/media/Blytom/DSC_2975_zpslacwmhxi.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Blytom/DSC_3260_zpsvkracjnr.jpg (http://s276.photobucket.com/user/zsphil/media/Blytom/DSC_3260_zpsvkracjnr.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Blytom/DSC_3619_zpslzs7y42y.jpg (http://s276.photobucket.com/user/zsphil/media/Blytom/DSC_3619_zpslzs7y42y.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Blytom/DSC_3071_zpseuemblai.jpg (http://s276.photobucket.com/user/zsphil/media/Blytom/DSC_3071_zpseuemblai.jpg.html)

http://i276.photobucket.com/albums/kk11/zsphil/Blytom/DSC_3401_zpsibysoiky.jpg (http://s276.photobucket.com/user/zsphil/media/Blytom/DSC_3401_zpsibysoiky.jpg.html)

[ZS Phil]

A quick video which Adam Baxter took.

It was a pleasure to meet him that day before he was taken all too soon. Such a nice guy with such love and passion for these cars. We've lost a good one, RIP mate.

https://www.youtube.com/watch?v=8NrHp_WQRoI

[peterzs]

All I can say, is WOW!!!

Such attention to detail and getting everything built and fitted.

Glad it went as well as you wanted and bet it turned a few heads on track.

Well done on a great build and thanks for putting all the pics and words up here. I hope we will see it in the flesh sometime.

:clap::clap::clap: :thumbsup::thumbsup:

[peterzs]

Great sound and looks the Biz.

As you say, great loss.

[Skillen]

Still scrubs up a treat!

Even though it's stripped and chopped I'm glad it's gone to you knowing even though it's racing and a track car I know it'll be better used and loved for the cars they are and not a throwaway buy!
Maybe when I move I'll buy another for tracking haha!

[jc600]

Love it, looks really good!!!........can I have your wheels please! :D

[stamford]

Looks well sorted now, great attention to detail.

[p_b82]

looking good there Phil! :)

[Lukeus101]

Phil...if you decide to sell...let me know ;) perfect ZS for me...

[Mark S]

when and where are you out next phil?

[ZS Phil]

As always, thanks for the comments folks :). I know I'm a bit of a photo whore but I like to use the thread as a bit of a diary almost.

Luke, if ever I sell you have first refusal! What was the black MK1 that was sitting on your drive (you posted on FB)?

Jason, I don't have a time or place set just yet. We have a house move imminent so hopefully the first free Sunday I have after that. What about yourself? I did say to Howard before I went away that I'd like to get something sorted on my return so I don't want to leave it too long.

[Lukeus101]

That PBT MK1 was bought just for the seat lol, she wont be staying but will be broken for bits :(. For the first time ever im at the front of the line

[Mark S]

As always, thanks for the comments folks :). I know I'm a bit of a photo whore but I like to use the thread as a bit of a diary almost.

Luke, if ever I sell you have first refusal! What was the black MK1 that was sitting on your drive (you posted on FB)?

Jason, I don't have a time or place set just yet. We have a house move imminent so hopefully the first free Sunday I have after that. What about yourself? I did say to Howard before I went away that I'd like to get something sorted on my return so I don't want to leave it too long.

Howard is working a bit with Javelin, so its worth a chat with him.

I am in two minds about this year, I would like to be out in anger, yet I am considering putting both cars in a unit for work until next year! Like you, I have no time at the mo but would like a day out somewhere just for fun, donny, oulton, croft, somewhere with a bit about it.
Whilst I would like to challenge the record at croft, the sensibleness is saying no to a set of slicks just for 1 race weekend this year - its not like tyres are at their best 6-months on.
Dilemma, I just don't know what to do!!! so I'll prob just do a trackday.

[ZS Phil]

That PBT MK1 was bought just for the seat lol, she wont be staying but will be broken for bits :(. For the first time ever im at the front of the line

The seats are lovely. Is there anything wrong with the rest of it? Seems a shame to see another one getting broken :(. Not fancy stripping it out and making your own track car... mine isn't going to be for sale any time soon :P

Howard is working a bit with Javelin, so its worth a chat with him.

I am in two minds about this year, I would like to be out in anger, yet I am considering putting both cars in a unit for work until next year! Like you, I have no time at the mo but would like a day out somewhere just for fun, donny, oulton, croft, somewhere with a bit about it.
Whilst I would like to challenge the record at croft, the sensibleness is saying no to a set of slicks just for 1 race weekend this year - its not like tyres are at their best 6-months on.
Dilemma, I just don't know what to do!!! so I'll prob just do a trackday.

Did you get your race car repaired in the end?
I've just had a look on the Javelin page, there is one at Croft this Sunday- a bit pricey but could probably stretch to it?
Failing that, I know you don't really like Blyton but I'm attracted by the relative low cost and massive run-off areas as a novice. There are spaces Sunday 2nd and a Wednesday has just come up on the 12th. The Wednesday is only £90 and plenty of notice so that could be a winner for me.
Have you got any in mind?

[ZS Phil]

Been collecting parts over the last few months so decided this week to get her in the garage and make a start.

Planned list of changes to make:

- Change coilovers
- Raise ride height slightly to accommodate slicks
- Improve brakes (new pads, hoses, fluid and rear discs)
- Improve gear ratios and fit LSD
- Fit light-weight flywheel and diesel clutch
- Fit manifolds
- Change the belts and possibly cams at same time
- Change broken balance VIS motor
- Remap to avoid running too lean
- Remove more weight

Since the last update I have had it on a weigh bridge. Not doing too bad but could lose more.
1120kg with both seats in and 3/4 tank fuel.

In this department next steps are to further lighten panels, particularly the bonnet, fit plastic windows and a light weight blower unit.


For now though I've started with jobs on the chassis.

Slightly controversially and in some ways against my own principles I have decided to try modified dampers (fronts shortened and valving to suit stiffer springs) as I felt body roll was too much with the previous set-up. On very hard cornering the fronts were sat on the bump stops.
There were a few options-
-Raise it up and keep the springs and dampers the same
-Maintain the ride height and just shorten the front dampers (this would do nothing for the body roll)
-As above with the addition of stiffer ARBs to address body roll
-Maintain standard ARBs and fit stiffer springs/dampers

The last track day I did there were 2 other ZS's out, both running significantly higher spring rates than me and the difference in pace through the corners was marked (one was a respected Cockshoot car the other a keen "hobbyist"). OK, there are lots of other variables to consider however after talking to the owners and taking these into consideration I was suitably convinced to at least give it a try. I had my other set of GAZ coilovers off the TD (now SORN) so off they went with a list of changes:

New specs:
850 lb/in front (Previously 550)
600 lb/in rear (Previously 330)
Front dampers shortened by 10mm
All new rods / oil / seals
Valving to suit new spring rates
Helper springs all round

So this is how they came back (shame they didn't paint them this time)

http://i683.photobucket.com/albums/vv192/philzs/track%20car%205%2012%2015/DSC_0132_zpsrft2aetv.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%205%2012%2015/DSC_0132_zpsrft2aetv.jpg.html)

http://i683.photobucket.com/albums/vv192/philzs/track%20car%205%2012%2015/DSC_0135_zpsa8j9xgyo.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%205%2012%2015/DSC_0135_zpsa8j9xgyo.jpg.html)
http://i683.photobucket.com/albums/vv192/philzs/track%20car%205%2012%2015/DSC_0138_zpsfiq0g5hv.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%205%2012%2015/DSC_0138_zpsfiq0g5hv.jpg.html)

To show the difference in damper length, standard on left, shortened on right:

http://i683.photobucket.com/albums/vv192/philzs/track%20car%205%2012%2015/DSC_0140_zpshpesgsnc.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%205%2012%2015/DSC_0140_zpshpesgsnc.jpg.html)


I have also raised the ride height slightly too
From center of hub to bottom of wheel arch is now 31.7cm front and rear. This was previously 30cm front and rear so the rake has remained constant. This should create enough space at the front to accommodate the extra width and profile of the slicks I've acquired.
Once I've got them mounted on some rims I'll re-assess this.


I've also made a start on the brakes:

After the last track day the rear discs and pads (blue stuff) were looking pretty sorry for themselves and the front pads (yellow stuff) were just over half worn so figured since I have now SORN the car and it isn't being used on the road, I might as well upgrade to Blue Stuff all round.

http://i683.photobucket.com/albums/vv192/philzs/track%20car%205%2012%2015/DSC_0147_zpsuvz5uszs.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%205%2012%2015/DSC_0147_zpsuvz5uszs.jpg.html)

http://i683.photobucket.com/albums/vv192/philzs/track%20car%205%2012%2015/DSC_0150_zpspenzsv6g.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%205%2012%2015/DSC_0150_zpspenzsv6g.jpg.html)

http://i683.photobucket.com/albums/vv192/philzs/track%20car%205%2012%2015/DSC_0153_zpsn3qvatxy.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%205%2012%2015/DSC_0153_zpsn3qvatxy.jpg.html)

Rears- bin:
http://i683.photobucket.com/albums/vv192/philzs/track%20car%205%2012%2015/DSC_0156_zpsbkxut309.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%205%2012%2015/DSC_0156_zpsbkxut309.jpg.html)

Fronts (do as spares)
http://i683.photobucket.com/albums/vv192/philzs/track%20car%205%2012%2015/DSC_0157_zpstoic63ph.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%205%2012%2015/DSC_0157_zpstoic63ph.jpg.html)

Decided to give some "Wezmoto" lines a try whilst I was at it, heard good things about the motorcycle stuff they do and from pictures look identical to HEL:

http://i683.photobucket.com/albums/vv192/philzs/track%20car%205%2012%2015/DSC_0162_zpsci6vo6qz.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%205%2012%2015/DSC_0162_zpsci6vo6qz.jpg.html)

http://i683.photobucket.com/albums/vv192/philzs/track%20car%205%2012%2015/DSC_0164_zps5ayucyr8.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%205%2012%2015/DSC_0164_zps5ayucyr8.jpg.html)



Quality seems great although I was concerned by this "double flare" fitting they share with HEL. Check out the standard cone shape on the standard hose compared to the concave fitting of the new hose.
After a bit of research it seems lots of people who have fitted HEL hoses have been in a similar dilemma (various makes and models) however in all cases people have been reassured by HEL that it works with both bubble flare and double flare hard pipes and will seal. Just to be 100% sure I contacted Wezmoto who said exactly the same thing so decided to fit and push like Chris Hoy on the brake pedal to test- they don't leak.

http://i683.photobucket.com/albums/vv192/philzs/track%20car%205%2012%2015/DSC_0175_zpsf9bgb2dv.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%205%2012%2015/DSC_0175_zpsf9bgb2dv.jpg.html)
http://i683.photobucket.com/albums/vv192/philzs/track%20car%205%2012%2015/DSC_0169_zpseiw219ve.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%205%2012%2015/DSC_0169_zpseiw219ve.jpg.html)

http://i683.photobucket.com/albums/vv192/philzs/track%20car%205%2012%2015/DSC_0184_zpsfafoa3tu.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%205%2012%2015/DSC_0184_zpsfafoa3tu.jpg.html)

http://i683.photobucket.com/albums/vv192/philzs/track%20car%205%2012%2015/DSC_0192_zpsswfgddnv.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%205%2012%2015/DSC_0192_zpsswfgddnv.jpg.html)

Routing the front hose required some improvisation so I took a few pics for the benefit of anybody else wanting to use these:

http://i683.photobucket.com/albums/vv192/philzs/track%20car%205%2012%2015/DSC_0197_zpsjeg76mob.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%205%2012%2015/DSC_0197_zpsjeg76mob.jpg.html)

Nifty little trick using the old copper sealing washer and cable ties, stops any chafing against the surface that the hose is tied to.

http://i683.photobucket.com/albums/vv192/philzs/track%20car%205%2012%2015/DSC_0207_zpsr6iff5fy.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%205%2012%2015/DSC_0207_zpsr6iff5fy.jpg.html)

Just to show the clear run:

http://i683.photobucket.com/albums/vv192/philzs/track%20car%205%2012%2015/DSC_0208_zpspj9woi3m.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%205%2012%2015/DSC_0208_zpspj9woi3m.jpg.html)

http://i683.photobucket.com/albums/vv192/philzs/track%20car%205%2012%2015/DSC_0210_zpsy9fjakqd.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%205%2012%2015/DSC_0210_zpsy9fjakqd.jpg.html)

http://i683.photobucket.com/albums/vv192/philzs/track%20car%205%2012%2015/DSC_0193_zpssitdq4mt.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%205%2012%2015/DSC_0193_zpssitdq4mt.jpg.html)

Other side to do tomorrow :)

[Mark S]

all that green hurts my eyes.

for road and track I would say your old spring rates were fine, the new rates are mega hard, even for slicks.
I would first look at driving style/technique for you roll issues.

how have you calculated your shortened damper?
How much does it drop with the weight of the car?
Can it provide adequate bump & rebound?

[talkingcars]

Good to see that the brake hoses come complete with the fixings.

[JOHNDQ]

Looks good mate :happy2:

[ZS Phil]

Lime green is a guilty pleasure haha :sick:

Yes, I'm a bit concerned with how stiff the springs are as the previous set-up felt nice and smooth and predictable on track, just the issue of excess body roll and damper length.
Shaun said from the off that the he thought the fronts were too soft and from having seen the difference in cornering pace between mine and Howards and Martins cars at the last track day, both of which run stiffer springs I'm happy to at least give it a try.
If I don't like it I'll just change them back over :)

I'm aware that it's probably a less than ideal "quick fix" to get the most out of an otherwise stock chassis (apart from the geometry settings- which hopefully camber at least will be held more constant with the stiffer suspension).

How have I calculated damper length: Truth be told it's a guesstimate based on the fact that there was no point removing more than I have done because the tyre would be getting too close to the top of the arch, it only bottomed out previously on the longest hardest corners not all the time, combined with the new stiffer springs and raised height I think I've removed enough to allow the piston to sit more mid-travel without the risk of bumping out.

How much does it drop with the weight of the car? I haven't measured sag. At the minute though, because I've only done one side the helper springs are fully compressed with the wheel off. I figured this is either because they are not required at the new ride height or because the other side is lower and compressed because of the way the car is jacked so the ARB will be compressing the side I was working on.

Can they provide adequate bump and rebound? At this stage I don't know. I have asked for valving to suit the spring rates so only track time will tell. If you mean will the dampers cope with the extra stress of the increased bump and rebound resistance I've no idea. I have taken advice from others who use this set-up and theirs seem to do ok in terms of longevity.

Without the luxury of computer modelling it's all "best guess" factoring in what has worked for others over the years. Whether it will work for me is another matter but at this stage I'm happy to take advice :)

[ZS Phil]

Good to see that the brake hoses come complete with the fixings.

The rears bolt straight on but the fronts require some improvisation if you have coilovers without the brackets. My biggest concern was that difference in the mating surface between the pipes.

Looks good mate :happy2:

Thnaks! Hopefully it will feel better too :)

[Mark S]

I would be surprised if gaz changed any valving in the dampers.

You will find a one or two 'click' window with the gaz dampers, people talk about wet and dry settings on the gaz with x number of clicks from zero, in my mind they either don't work or don't work unless they accidentally stumbled on that perfect click!
I found 2 extra clicks (even 1 click at times) took you out of the window and into the non working zone, either they were as hard as scaffolding poles or offered no damping whatsoever.

Could it be that the front end feels/felt soft because the dampers weren't damping?

[Mark S]

the pbs pads are well worth a look (and the guy is up your way) when the blue stuff stop working with 50% pad left.

[ZS Phil]

I must admit, I was a bit suspect as to what they actually do so I called them up and spoke to the guy doing the work. He assured me that the valving has been changed, on the minimum setting they certainly put up more of a fight to move the rods by hand than the other set do.
No dyno report or anything like that tough.

That said, he also said that they were out of stock of helper springs so would send tender springs instead. Either he doesn't know the difference or was just trying to fob me off. Made sure they sent helpers once they arrived in stock.

The more I read and learn about these things, the more I realise that GAZ are not the weapon of choice if I was going to take this to the next level.

I'll have to experiment to find this window but as a start point they will all be set to the middle number of clicks and adjusted from there. I know the knob alters both bump and rebound together but how exactly it is altered and by how much is all a bit vague.

Yeh, Shaun mentioned PBS pads or even carbone lorraine, is that what you ran?

[Mark S]

the silver car ran blue then pbs, after 3 hours of racing and a few track days the pbs are still there and working!

you get one or the other (bump or rebound) with gaz, it is a comprimise and they are called dampers in the loosest possible sense.
But they can still be made to work and the car can still be fast, the silver 1800 is evidence of that.

[JOHNDQ]

How did you get on with the EBC's? I tried yellows on track RS2000 and the ZR before I put the brake kit on and in both cars I thought they were worse than standard tbh so I never tried the blues just run DS3000's now but they are due a change for 2016 :happy2:

[talkingcars]

I liked the yellowstuff for road use, defiantly sharper than O/E spec.

[Mark S]

blue are good but need changing at 50% wear

[ZS Phil]

the silver car ran blue then pbs, after 3 hours of racing and a few track days the pbs are still there and working!

you get one or the other (bump or rebound) with gaz, it is a comprimise and they are called dampers in the loosest possible sense.
But they can still be made to work and the car can still be fast, the silver 1800 is evidence of that.

Lots of trial and error to be done then with the dampers. Can't wait to get out in it again. It's been too long.

How did you get on with the EBC's? I tried yellows on track RS2000 and the ZR before I put the brake kit on and in both cars I thought they were worse than standard tbh so I never tried the blues just run DS3000's now but they are due a change for 2016 :happy2:

I thought the yellows were ok. Didn't last very long but other than that they were fine. I was doing no more than about 20 mins at a time on them though. I'll see how I get on with the blues and depending on how long they last might try the PBS ones.

[pervavore]

Damn I shall be doomed :D once again your build thread with the Track ZS is awesome Phil :D So much love put into details I like it and may come handy maybe with my ZR VVC track car :)

For the old bushing is really a hydraulic press in handy :) Burning them out is also an option :D

Few questions where did you get the braided hoses ?
Is on the V6 a crankcase valve or something similar ? May you got some pics of it need this detail for my derv project :)

The backbox is a straight through box from Janspeed? Never looked inside to be honest when got one in my hands :/

[ZS Phil]

Damn I shall be doomed :D once again your build thread with the Track ZS is awesome Phil :D So much love put into details I like it and may come handy maybe with my ZR VVC track car :)

For the old bushing is really a hydraulic press in handy :) Burning them out is also an option :D

Few questions where did you get the braided hoses ?
Is on the V6 a crankcase valve or something similar ? May you got some pics of it need this detail for my derv project :)

The backbox is a straight through box from Janspeed? Never looked inside to be honest when got one in my hands :/

Thanks :D a long way to go with it yet but it's all good fun.

Yes, a press would have been better for the bushes and certainly less smelly! Some nasty fumes came off them.

To answer the questions:
-The braided hoses are from eBay but you can deal with Wezmoto direct I imagine.
-Not really sure what you mean with the crankcase valve? do you mean the breather system?
-I don't know if the back box is straight through. It's quite light and quite "raspy" in sound after the decat and straight through center section so I wouldn't be surprised. No good for the derv though, only 2 1/4" diameter.

[pervavore]

Ahh ok I will try to find maybe over here a supplier for braided hose.

Sure I mean how does the breather system work on the KV6 there should be a PCV somewhere.

[ZS Phil]

Before I post another update, I should finish off the previous update for the previous lot of changes.

I finished changing the pads, lines and coilovers on the other side too and thought I'd try some brake fluid marketed as "racing quality". DOT 4 still but wet and dry boiling points are still higher than the minimum requirement for DOT 5.

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2028%202%2016/DSC_1973_zpsecvudwjv.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2028%202%2016/DSC_1973_zpsecvudwjv.jpg.html)

Also, I wasn't happy with the doors which looked like this, note the rods as handles and tatty wiring:

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2028%202%2016/DSC_1952_zpsh400ignc.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2028%202%2016/DSC_1952_zpsh400ignc.jpg.html)


So I set at it with my new light weight door handle kit which I've been co-developing with McLaren:

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2028%202%2016/DSC_1958_zpsjfklporj.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2028%202%2016/DSC_1958_zpsjfklporj.jpg.html)

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2028%202%2016/DSC_1957_zps1sxg12v4.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2028%202%2016/DSC_1957_zps1sxg12v4.jpg.html)

Note the tidied loom, central locking and electric mirrors still connected, just thinned out all the electric window and speaker wires.

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2028%202%2016/DSC_1955_zpsw44feufv.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2028%202%2016/DSC_1955_zpsw44feufv.jpg.html)

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2028%202%2016/DSC_1960_zps7hzivg4u.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2028%202%2016/DSC_1960_zps7hzivg4u.jpg.html)




Acquired some lightly used slicks and got them mounted on another set of straights:

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2028%202%2016/DSC_1946_zps8u5umgr5.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2028%202%2016/DSC_1946_zps8u5umgr5.jpg.html)



Decided I'd do another day at Blyton so gave it a quick clean and wax... not sure waxing a track car is the "done thing" but its my pride and joy so who cares. Note trial fit of slicks too :D

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2028%202%2016/DSC_1966_zpsaobpgpbs.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2028%202%2016/DSC_1966_zpsaobpgpbs.jpg.html)

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2028%202%2016/DSC_1965_zpsv4hky94p.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2028%202%2016/DSC_1965_zpsv4hky94p.jpg.html)

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2028%202%2016/DSC_1964_zpsu22g9uka.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2028%202%2016/DSC_1964_zpsu22g9uka.jpg.html)

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2028%202%2016/DSC_1967_zpsraku6skz.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2028%202%2016/DSC_1967_zpsraku6skz.jpg.html)



Had another day at Blyton, took it on a trailer for the first time, much better for the back, the new spring rates are a bit extreme for road use really.

Early start
http://i683.photobucket.com/albums/vv192/philzs/track%20car%2028%202%2016/DSC_1969_zps8yjqpixz.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2028%202%2016/DSC_1969_zps8yjqpixz.jpg.html)



Don't think I've shared any pics of the rep mobile yet but here it is in all of its German blandness:

http://i683.photobucket.com/albums/vv192/philzs/Blyton%207%202%2016/DSCF1641_zpsu8wgrxsd.jpg (http://s683.photobucket.com/user/philzs/media/Blyton%207%202%2016/DSCF1641_zpsu8wgrxsd.jpg.html)

http://i683.photobucket.com/albums/vv192/philzs/Blyton%207%202%2016/blyton%207.2.16_zpshffcajp8.jpg (http://s683.photobucket.com/user/philzs/media/Blyton%207%202%2016/blyton%207.2.16_zpshffcajp8.jpg.html)

http://i683.photobucket.com/albums/vv192/philzs/Blyton%207%202%2016/DSCF1652_zpsnawoljtl.jpg (http://s683.photobucket.com/user/philzs/media/Blyton%207%202%2016/DSCF1652_zpsnawoljtl.jpg.html)




Put the slicks on at lunch time and managed to get about 6 laps before it started raining. Here I am waiting to get on track with slicks for the first time watching a grey cloud come over.
As soon as the rain started I was straight in. Managed to get them warm and really go for it the last couple of laps. Pleased is an understatement, they performed incredibly.

http://i683.photobucket.com/albums/vv192/philzs/Blyton%207%202%2016/DSCF1665_zpsnyxs40fp.jpg (http://s683.photobucket.com/user/philzs/media/Blyton%207%202%2016/DSCF1665_zpsnyxs40fp.jpg.html)


The brakes, suspension and tyres all performed really well. Difficult to compare progress I know but going by the types of machinery I'm playing with now, I think were going in the right direction.









*NEXT ROUND OF CHANGES- ENGINE/ EXHAUST*

The belts were just coming up to be changed and "top-man-eldo" was breaking his 180 which had piper 270 cams only a couple of thousand miles old. Timing was right so purchased the cams and the various other supplies to do the cams and belts together.

Props to the club for the loan of the timing tools:

Got as many new genuine parts as I could, all belts, tensioners, pulley bolts, cam seals, gaskets etc are genuine, the water pump is a continental one with metal impeller and pulley. Its amazing how the cost of all the little seals required adds up, something which I didn't really factor in.

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2028%202%2016/DSC_1992_zpsz3xma3lp.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2028%202%2016/DSC_1992_zpsz3xma3lp.jpg.html)

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2013%203%2016/ad08f6bf-b5da-454b-b135-a49b6a0af2b0_zpsvhkwhzh9.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2013%203%2016/ad08f6bf-b5da-454b-b135-a49b6a0af2b0_zpsvhkwhzh9.jpg.html)

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2013%203%2016/11649ea0-914b-4a41-91e2-fc0c73e64941_zpsh3lvhnmz.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2013%203%2016/11649ea0-914b-4a41-91e2-fc0c73e64941_zpsh3lvhnmz.jpg.html)


An interesting comparison, piper 270 cams vs stock.

Inlet:

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2013%203%2016/DSC_2035_zpskcy8mue0.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2013%203%2016/DSC_2035_zpskcy8mue0.jpg.html)

Exhaust:

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2013%203%2016/DSC_2033_zps0palgkhu.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2013%203%2016/DSC_2033_zps0palgkhu.jpg.html)


Strip down...

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2013%203%2016/DSC_2008_zpsdazyuyuw.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2013%203%2016/DSC_2008_zpsdazyuyuw.jpg.html)

[stamford]

Looking good. Some tracks don't allow slicks for track days. Part of the fun of doing this is seeing what the little changes make.

[ZS Phil]

*Continuation of above*

Unfortunately when removing the dip stick tube this happened because it was rusted solid:

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2013%203%2016/9df1ee91-bb6b-4e40-be27-8c68280c7b90_zpscvlm2png.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2013%203%2016/9df1ee91-bb6b-4e40-be27-8c68280c7b90_zpscvlm2png.jpg.html)

Of course a tiny piece of plastic fell into the sump which meant taking the sump off...

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2013%203%2016/DSC_1990_zpsbfpd2pu4.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2013%203%2016/DSC_1990_zpsbfpd2pu4.jpg.html)


To get the sump off the standard manifolds had to come off which was perfect because I had a set of janspeed manifolds waiting to go on anyway which I've had for a few months:

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2013%203%2016/DSC_2063_zpsydvr0exl.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2013%203%2016/DSC_2063_zpsydvr0exl.jpg.html)


Some comparisons, no words required:

Stock-

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2013%203%2016/DSC_2070_zpsfxnqv2ar.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2013%203%2016/DSC_2070_zpsfxnqv2ar.jpg.html)

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2013%203%2016/DSC_2073_zps1ajgvtxj.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2013%203%2016/DSC_2073_zps1ajgvtxj.jpg.html)

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2013%203%2016/DSC_2069_zpsuwp7q7u5.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2013%203%2016/DSC_2069_zpsuwp7q7u5.jpg.html)

Janspeed- Still crude but far better

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2013%203%2016/DSC_2068_zpsw5vixwub.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2013%203%2016/DSC_2068_zpsw5vixwub.jpg.html)

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2013%203%2016/DSC_2074_zps94auon4p.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2013%203%2016/DSC_2074_zps94auon4p.jpg.html)

Comparison of port size-

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2013%203%2016/DSC_2076_zpsxsdsdnnz.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2013%203%2016/DSC_2076_zpsxsdsdnnz.jpg.html)




Going back together-

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2013%203%2016/DSC_2045_zpsmqga6gwz.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2013%203%2016/DSC_2045_zpsmqga6gwz.jpg.html)

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2013%203%2016/DSC_2048_zpswbn9fnpr.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2013%203%2016/DSC_2048_zpswbn9fnpr.jpg.html)

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2013%203%2016/DSC_2057_zpsdlihpjnn.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2013%203%2016/DSC_2057_zpsdlihpjnn.jpg.html)

Since the old one was destroyed

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2013%203%2016/DSC_2043_zpse9xxth04.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2013%203%2016/DSC_2043_zpse9xxth04.jpg.html)

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2013%203%2016/DSC_1998_zpsmdhfukc1.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2013%203%2016/DSC_1998_zpsmdhfukc1.jpg.html)


Tools

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2013%203%2016/DSC_2060_zps6wxibwot.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2013%203%2016/DSC_2060_zps6wxibwot.jpg.html)

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2013%203%2016/DSC_2062_zpsynir5bbh.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2013%203%2016/DSC_2062_zpsynir5bbh.jpg.html)

Manis and sump back on, also changed the decat pipe for a Janspeed one- just a bit neater.

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2013%203%2016/DSC_2079_zpsmfvfs21h.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2013%203%2016/DSC_2079_zpsmfvfs21h.jpg.html)


I also changed the power steering pump for a non-noisy one (no pics)

Since the car will probably running lean on the standard map, I originally planned to get the car mapped but as luck would have it, "top-man-eldos" car was exactly the same spec as mine to every last engine/ exhaust mod. We therefore came to a deal on his ECU set which has been rolling roaded at 211bhp

http://i683.photobucket.com/albums/vv192/philzs/track%20car%2013%203%2016/b0d59c5c-0118-4ee8-997c-4a06c09a1e2f_zpsdnfkyif1.jpg (http://s683.photobucket.com/user/philzs/media/track%20car%2013%203%2016/b0d59c5c-0118-4ee8-997c-4a06c09a1e2f_zpsdnfkyif1.jpg.html)



So, it's all back together again with fresh oil and fluids and fired up straight away. I was toying with doing a track day today at Anglesey but I left it too late to get a trailer sorted so would have to have driven there which I don't really fancy.
Instead, I've taxed and insured it for a year last night so I can now easily take it to a few local places for some jobs I want doing. For example its booked in at a local rolling road later today just to make sure its running as it should- will be interesting to compare to the original dyno graph (going back to the same place in the interests of a fair test).

Will update later with numbers but it feels and sounds incredible :D

[talkingcars]

Lots of progress, and the photos make it more interesting.

[Skillen]

The cams and janspeed definitely make it sound different! I still need to get my piper pulleys on and take it for mapping! Thanks for reminding me of yet another damn job lol!

Hoping to see you two and the car if we go to PoL!

[ZS Phil]

The cams and janspeed definitely make it sound different! I still need to get my piper pulleys on and take it for mapping! Thanks for reminding me of yet another damn job lol!

Hoping to see you two and the car if we go to PoL!

I've got a straight through center section too so the only silencing is the back box... it's pretty loud.

I read the standard file from the standard ECU before I took it out, do you want me to email it you so your guy can take a look at it?

Hope you can make POL, I'm all set to go.

[petet16]

Some good work been going on there, I don't like using that style flexi pipe for the intake, it doesn't flow so well, I prefer using silicone and hard piping as much as possible

[Skillen]

I've got a straight through center section too so the only silencing is the back box... it's pretty loud.

I read the standard file from the standard ECU before I took it out, do you want me to email it you so your guy can take a look at it?

Hope you can make POL, I'm all set to go.

I've moved away from Cumbria to Chester now so nowhere near him anymore unfortunately as he was into his k series engines! Even DjWilma sent his Elise up to him so he must have been decent!

Entirely new area means I know nothing about good car places and local mechanics!

It's gonna be a push for PoL,
Got the kit for the mk2 brembodge now and no paint for the calipers so may not get those on before

Need the new bumper sprayed up and fitted

Need front wing sorted as it's just glue and bare where the kit used to be :/

Would like the Clio splitter on

Wash and polish

:mad:

[ZS Phil]

So in the last year there have been quite a few developments.

I'll post some pictures if/ when I get chance but the main thing is, I went and raced it.

My driving needs work but what a buzz!

Video here: https://www.youtube.com/watch?v=PdaZfVAlelw

[Dan1971]

That is awesome ! For your first time out - you did really well mate.

The driving at 2.30 by both you and "ashley" in the blue ZS was impressive. Meddling little old red MG ..... :devil:

[redzed]

Nice work, you just got standard mods i.e. Piper cams and standard gear set?

Ash must have removed his wheel well for that centre exhaust!

[ZS Phil]

Cheers guys, was completely blown away by it. In qualifying did a low 1:23 which put me third on the grid and then to finish second overall was nuts. I think a few retirements helped but still very happy.

Mods wise it's got all the suspension work as per this thread but with different geometry and spring rates now.
Lots more weight reduction than documented here.
Engine wise it's pretty standard other than the air filter, piper cams, janspeed manis, FIA 100cpi race cat, cat back exhaust and a reidy remap.
Gearbox has the "G" ratios from a ZR 160 and 4.2 final drive. There is a gripper limited slip diff and light weight flywheel modified to take a diesel clutch plate.

Got no idea what ash has done under his there was the exhaust and some sort of extra brace I could see peeping down, I'll ask him next time.

[p_b82]

Congrats, it looked like you had the pace to get past Ash in a few places, but he defended well to hold you up just enough.....

I love donnington as a circuit - albeit only with pc sim experience! :)

[stamford]

Stunning drive Phil. Looked well balanced. Close call as Dan pointed out!

[Mark S]

you got your **** together towards the end, more racing experience and you'd have took the win there.

ash's car handles hideously on the circuit, its corner exit speed is pants and he missed every apex by a country mile!!!

try and get some seat time at a fairly technical circuit, like oulton park

[Supercharged_Z]

you got your **** together towards the end, more racing experience and you'd have took the win there.

ash's car handles hideously on the circuit, its corner exit speed is pants and he missed every apex by a country mile!!!

try and get some seat time at a fairly technical circuit, like oulton park

i saw that and even took a screenshot of it, not saying i would do any better but jeez some lines were crazy.

still looks great fun and has me looking for a car to build haha

[p_b82]

I didn't think I was suitably qualified to comment on his "interesting" lines - but I knew that they were not ones I've taken through there - not repeatedly or intentionally LoL

[peterzs]

great vid, had my foot to the floor a few times.

Well done.

:):):)