180 Track Car Build
 

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/k...psc38f4fd1.jpg

http://i276.photobucket.com/albums/k...pseb7c893e.jpg



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/k...ps24f02a87.jpg
http://i276.photobucket.com/albums/k...ps632fd44d.jpg
http://i276.photobucket.com/albums/k...s2438f01c.jpeg



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/k...ps9530b8f0.jpg

On the track:
http://i276.photobucket.com/albums/k...psc03b230c.jpg

Leaving the track:
http://i276.photobucket.com/albums/k...ps56ef3e59.jpg


Much more to come, watch this thread :)

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

:clap::clap::clap:

Another track car ... it's catching !

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

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.

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

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/k...ps99eecf36.jpg


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/k...ps5d11679a.jpg

Engine bay before:

http://i276.photobucket.com/albums/k...psb464945e.jpg

Wrong breather, wrong colour:

http://i276.photobucket.com/albums/k...ps2738e81a.jpg

Correct colour:

http://i276.photobucket.com/albums/k...psa83cb8e8.jpg

Correct breather:

http://i276.photobucket.com/albums/k...ps60d37ce5.jpg

Engine bay after:

http://i276.photobucket.com/albums/k...pseea5721f.jpg


Next job was the exhaust...

Nom nom nom

http://i276.photobucket.com/albums/k...ps5adb63e1.jpg
http://i276.photobucket.com/albums/k...ps7e24480a.jpg

Out with the old

http://i276.photobucket.com/albums/k...psf0d6ac74.jpg



In with the new...

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

http://i276.photobucket.com/albums/k...psa78d46e7.jpg
http://i276.photobucket.com/albums/k...psc73a8c2b.jpg
http://i276.photobucket.com/albums/k...ps01049bae.jpg
http://i276.photobucket.com/albums/k...ps30814623.jpg
http://i276.photobucket.com/albums/k...ps86545427.jpg



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/k...ps0690d6a9.jpg

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?

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.

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

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

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

James

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

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

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

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.

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/k...ps89a44e0b.jpg

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

http://i276.photobucket.com/albums/k...pse0d2c33a.jpg

http://i276.photobucket.com/albums/k...psec23fa2f.jpg

http://i276.photobucket.com/albums/k...psa87637a6.jpg

Perfect fit onto the air box:

http://i276.photobucket.com/albums/k...ps6b428370.jpg

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.

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!

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.

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/k...psavj2605g.jpg


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/k...pskl4gbcms.jpg

http://i276.photobucket.com/albums/k...psbr8oc4rl.jpg


The interior did look like this:

http://i276.photobucket.com/albums/k...pstf50eu8t.jpg

Then things started to happen:

http://i276.photobucket.com/albums/k...psziszwvig.jpg

http://i276.photobucket.com/albums/k...psub6w9bdt.jpg


Custom light weight center console with just the bear essentials:

Doing the template.

http://i276.photobucket.com/albums/k...psxj9jdhes.jpg

http://i276.photobucket.com/albums/k...psknn1izot.jpg

http://i276.photobucket.com/albums/k...psbe1vaih7.jpg


Next I went and got me some seats:

http://i276.photobucket.com/albums/k...psas5jl1kd.jpg

Getting them attached to some ZS rails:

http://i276.photobucket.com/albums/k...pslmfovtuc.jpg

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

http://i276.photobucket.com/albums/k...psk581rikc.jpg

Ready to roll:

http://i276.photobucket.com/albums/k...psykhlc2fd.jpg


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/k...psgotbqhv6.jpg


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

http://i276.photobucket.com/albums/k...psnd73e3kz.jpg

http://i276.photobucket.com/albums/k...psohfs8wev.jpg

http://i276.photobucket.com/albums/k...psjtaye2xv.jpg


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

http://i276.photobucket.com/albums/k...psgn0zgirz.jpg

http://i276.photobucket.com/albums/k...psasgxhqlq.jpg


And the weight!!!!

http://i276.photobucket.com/albums/k...psnvuevnoz.jpg

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

http://i276.photobucket.com/albums/k...psiapt82qj.jpg







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

http://i276.photobucket.com/albums/k...psejhbwlyd.jpg



Much more to come :D

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?

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!

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.

nice choice of seat.

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?

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

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!

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.

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.

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.

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).

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

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.

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

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

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

+1....

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.