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MK2 MG ZR160 Track car
Hi all just jointed with my MK2 ZS but a few people have asked about the ZR track car so here it is......
Started with buying the car in summer 2013 just as a everyday car for £800 as i already had a Evo 7 RS Sprint for trackdays and a MK5a RS2000 Escort i was using on track with the plan on doing some amateur motorsport but i gave up on that because getting hold of good parts was just to much trouble so decided to use the ZR :idea: Few the Escort.... http://i276.photobucket.com/albums/k...psdae3451c.jpg http://i276.photobucket.com/albums/k...ps13a61bf3.jpg http://i276.photobucket.com/albums/k...ps9d5286f2.jpg As first brought.... http://i276.photobucket.com/albums/k...ps464d70bb.jpg http://i276.photobucket.com/albums/k...psc72172b7.jpg Anyway back to the good stuff first jobs were Avo springs, B&G rear camber plates, at this point i wasnt planning on going all out so took her as was to Bedford just for fun.... http://i276.photobucket.com/albums/k...ps294d4902.jpg http://i276.photobucket.com/albums/k...psed8c2e95.jpg http://i276.photobucket.com/albums/k...ps6d9c9240.jpg http://i276.photobucket.com/albums/k...ps8725ede3.jpg http://i276.photobucket.com/albums/k...ps8c1514f6.jpg http://i276.photobucket.com/albums/k...ps466a728c.jpg http://i276.photobucket.com/albums/k...ps17e355aa.jpg |
So after a few months i done a few basic things to the car and as a few friends were going to Bedford Autodrome again i thought i would once again take the ZR....
In the mean time i had picked up a cheap set of rally tyres.... http://i276.photobucket.com/albums/k...psf85d57b1.jpg Put on some grooved disc's and EBC yellow stuff pads.... http://i276.photobucket.com/albums/k...ps6f353844.jpg Made a loom for gauges and added into the ISO loom for radio.... http://i276.photobucket.com/albums/k...psecd68791.jpg http://i276.photobucket.com/albums/k...ps3dd43b37.jpg http://i276.photobucket.com/albums/k...ps7b6e7cd6.jpg http://i276.photobucket.com/albums/k...psd6642194.jpg And off i went had a wicked day and showed my mates how it was done and much to there disappointment the ZR with 109k didnt had any HG faults :happy2: All tho the EBC pads were complete rubbish and after a few laps needed a slow lap to cool or i had a rock hard pedal and no brake fiction and even on a cool day the oil temp was way to high causing low pressure.... http://i276.photobucket.com/albums/k...psc93ebcc4.jpg http://i276.photobucket.com/albums/k...psa7596e30.jpg http://i276.photobucket.com/albums/k...ps13c9123f.jpg After stopping on for a beer on the way home with the boys and the Escort still out of use trying to find parts it was at this point the choice was made to move on to the ZR and cut my losses with the poor old Ford |
After this i went down the move power route and engine rebuild....
Late VHPD throttle bodies.... http://i276.photobucket.com/albums/k...psbe0e4206.jpg Before and after.... http://i276.photobucket.com/albums/k...ps760f9e10.jpg http://i276.photobucket.com/albums/k...psd446914f.jpg http://i276.photobucket.com/albums/k...ps0cde7467.jpg http://i276.photobucket.com/albums/k...ps27470111.jpg http://i276.photobucket.com/albums/k...ps7b14c32a.jpg http://i276.photobucket.com/albums/k...psb0e579c6.jpg Adapter made to link the 4mm vacuum hose to 10mm Map sensor.... http://i276.photobucket.com/albums/k...ps2c4c4cb6.jpg Used the IACV take off and put a t-piece in for servo.... http://i276.photobucket.com/albums/k...ps8406a7d7.jpg Fuel rail and wiring on.... http://i276.photobucket.com/albums/k...ps2d4c6207.jpg All on for a quick test run.... http://i276.photobucket.com/albums/k...psd0bc3392.jpg Now onto rebuild had injectors tested to make sure wouldn't need to run to much duty cycle all were ok but had new filter, best spray was at 5bar which made them flow 272cc so approx rating at 244bhp on a N/A engine.... http://i276.photobucket.com/albums/k...ps062f3bc1.jpg Engine out and on stand.... http://i276.photobucket.com/albums/k...ps2ee5d8db.jpg http://i276.photobucket.com/albums/k...psea320771.jpg http://i276.photobucket.com/albums/k...ps7cba5e7f.jpg http://i276.photobucket.com/albums/k...psd1d0a213.jpg http://i276.photobucket.com/albums/k...ps4fa3cc2e.jpg http://i276.photobucket.com/albums/k...ps3ee5b487.jpg http://i276.photobucket.com/albums/k...psd67d5333.jpg No real problems was a bit of pick-up on main bearing and liners were level so i put 4 thou shims in when rebuilt.... http://i276.photobucket.com/albums/k...ps326278e2.jpg All the parts were cleaned, measured etc to check tolerances etc.... http://i276.photobucket.com/albums/k...ps0f7d3cec.jpg http://i276.photobucket.com/albums/k...ps657cc216.jpg Now for rebuild using OE colour coded bearings, rings etc.... http://i276.photobucket.com/albums/k...ps09d4efe7.jpg http://i276.photobucket.com/albums/k...psc50f9dc8.jpg http://i276.photobucket.com/albums/k...ps5e5ba409.jpg http://i276.photobucket.com/albums/k...pscffd1ab8.jpg http://i276.photobucket.com/albums/k...ps46ed77d6.jpg http://i276.photobucket.com/albums/k...ps14cdee06.jpg "N" series gasket kit http://i276.photobucket.com/albums/k...psd6ebf5a1.jpg http://i276.photobucket.com/albums/k...psca80d9a5.jpg http://i276.photobucket.com/albums/k...ps21a3c848.jpg http://i276.photobucket.com/albums/k...ps572ef489.jpg http://i276.photobucket.com/albums/k...ps2dc06a20.jpg http://i276.photobucket.com/albums/k...ps1354f48b.jpg |
Next to get it back in with a new AP clutch....
http://i276.photobucket.com/albums/k...pswbelemjo.jpg http://i276.photobucket.com/albums/k...psnbyswpva.jpg Then a new Emerald K6 was ordered.... http://i276.photobucket.com/albums/k...psvihqbdl3.jpg Next was to make a new engine wiring loom so could put the new ecu in the passenger foot well.... http://i276.photobucket.com/albums/k...pszh2cgj2o.jpg All the multi-plugs needed.... http://i276.photobucket.com/albums/k...psisgyak7w.jpg Adding in the solder sleeves on the shielded cables for interference to ground on the cam and crankshaft sensors.... http://i276.photobucket.com/albums/k...ps7tebgb8h.jpg Test fit before all the plugs etc were added.... http://i276.photobucket.com/albums/k...psbk9pqqgd.jpg http://i276.photobucket.com/albums/k...ps8kgbqjnd.jpg Making of a plug, in this case 02 sensor.... http://i276.photobucket.com/albums/k...ps8k088arp.jpg http://i276.photobucket.com/albums/k...psjmskk92e.jpg http://i276.photobucket.com/albums/k...psbwuetfy5.jpg http://i276.photobucket.com/albums/k...pszags7ikw.jpg |
Been following this thread over on XPF :) cracking work mate :)
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Next was to remove the 6 pins i needed from the small MEMS ecu plugs (for fuel pump relay etc) i didnt want to cut up the factory part of loom in case it ever went back to standard etc so i added in 6-way male and female micro JPT plugs....
http://i276.photobucket.com/albums/k...psconec8og.jpg http://i276.photobucket.com/albums/k...psusaksrex.jpg And the finished job factory loom into my loom without any cutting or damage.... http://i276.photobucket.com/albums/k...psql83wqwt.jpg I also fitted flat switch :ohmy: Switch below.... http://i276.photobucket.com/albums/k...psclkggm5a.jpg http://i276.photobucket.com/albums/k...psfzhwoyny.jpg http://i276.photobucket.com/albums/k...pspccnelw4.jpg Quick test to make sure ecu seeing pedal postion.... http://i276.photobucket.com/albums/k...psencrlmfj.jpg http://i276.photobucket.com/albums/k...ps05ffgicc.jpg Repairing the worn out gear linkage and fiting a Dark ice quickshift kit, this was a real pain had to heat and bend in the gear rods as you couldn't get 5th hardly at all as they rubbed really bad.... http://i276.photobucket.com/albums/k...pswbbv30bg.jpg http://i276.photobucket.com/albums/k...ps2xrcljej.jpg http://i276.photobucket.com/albums/k...psowu6pa6u.jpg As so added a remote take off for oil pressure gauge to get it away from the sub-frame.... http://i276.photobucket.com/albums/k...psweyeikav.jpg http://i276.photobucket.com/albums/k...psqduxh9v7.jpg http://i276.photobucket.com/albums/k...ps4dkfjsxl.jpg Putting in the base maps.... http://i276.photobucket.com/albums/k...psazvgnf3r.jpghttp://i276.photobucket.com/albums/k...psi5iu8pfs.jpg I also wiring the in the MIL lamp to act as a shift light.... http://i276.photobucket.com/albums/k...psb0ttr1fw.mp4 And at last all back together for a quick test run.... http://i276.photobucket.com/albums/k...ps0n4ufdt3.jpg |
At this point run into a problem i had a oil leak from the rear of the headgasket, off again then.... :sick:
http://i276.photobucket.com/albums/k...psqcvk2zfc.jpg http://i276.photobucket.com/albums/k...pszb0geb6m.jpg Not sure what happened to gasket.... http://i276.photobucket.com/albums/k...ps0g3rv4h6.jpg And way on went a LR gasket with saver shim, no more leak.... http://i276.photobucket.com/albums/k...psk4a1oenh.jpg http://i276.photobucket.com/albums/k...pscn7ulzck.jpg Mapping next.... http://i276.photobucket.com/albums/k...psqgmedavv.jpg http://i276.photobucket.com/albums/k...pswfkkkfg7.jpg No problems here made stock power but with a fair bit more torque and the car pulled though the rev's a lot better on drive home.... http://i276.photobucket.com/albums/k...psuqclbzro.jpg Next was onto another test day at Bedford Autodrome to test it out as didnt want to go far in-case was a problem, that turnt out to be a wise choice. About 20mins in the engine lost power and was rattling so called it a day and a waste of £160 but there you go. Not 100% sure what happened but the front VVC unit was rattling like mad but after a compression and cylinder leakage test was done no damaged valves to piston ring troubles were found the engine was removed and a Piper 285H solid cam kit was ordered and thats were i am at this point. The plan was to use it with the VVC for a while to give me a bit of time to get the money together to get the full race Piper kit and the steel bottom end, forged pistons etc but there you go. I didnt think it was worth paying £600 odd for a new Rover cam and VVC unit as the Piper kit was £1020 nor did i want to risk using a second hand unit. |
So again engine out....
http://i276.photobucket.com/albums/k...psonbqbapc.jpg On stand.... http://i276.photobucket.com/albums/k...psftpqqly1.jpg Piper kit from DVA power.... http://i276.photobucket.com/albums/k...pssnyefmk3.jpg Head off again but trying another "N" series gasket all tho this one has the slickly glue coating as on the old LR head saver shim which the first gasket didnt have.... http://i276.photobucket.com/albums/k...psqdsdes0p.jpg Steel caps and uprated valve springs in.... http://i276.photobucket.com/albums/k...ps4y1ceg43.jpg Cams in.... http://i276.photobucket.com/albums/k...psxz8nbiuc.jpg All built back up again.... http://i276.photobucket.com/albums/k...ps218kctf2.jpg While it was out i thought i would paint the engine bay.... http://i276.photobucket.com/albums/k...pshfgfow6p.jpg http://i276.photobucket.com/albums/k...psyxom3er1.jpg http://i276.photobucket.com/albums/k...pschfeh7cm.jpg Changed the colour for next year too, the engine bay will match the bumper and wheels which are a red-orange colour called "Chevy Orange" http://i276.photobucket.com/albums/k...pskq08ji9d.jpg And for now that is it hope it didnt bore you to deaf :stupid: Heres a link to my youtube channel which has some trackday videos.... https://www.youtube.com/channel/UCNQ...FI2F_Tx5Vh41bQ Also got these to start the year off, a set of MGCC race slicks.... http://i276.photobucket.com/albums/k...psylting1e.jpg Just to end pictures of the ZR looking sorry for its self on last trackday :wave:.... http://i276.photobucket.com/albums/k...psjb5ckapr.jpg http://i276.photobucket.com/albums/k...psxga0zsu3.jpg And being recovered :rofl:... http://i276.photobucket.com/albums/k...psm3vsktkg.jpg |
Oh and plans to do over xmas....
1. ABS is gone 2. Uprated larger master cylinder 3. Race seat and harness (with weld in FIA floor tubes) 4. Lever type brake bias adjuster 5. Lightweight flywheel 6. Have it mapped again should be between 180-190bhp if goes to plan |
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How I miss working on small engines! My KV6 takes up too much room and is a pita to rotate on the stand! One day I'll get stuck in. Looking good so far.
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looks good, amazes me nowadays the money people spend on such old motors :) but all good fun.
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Track toys aren't cheap, but I'm totally with you in what they give you back in fun, and its always nice to be the 'underdog'! |
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Brilliant project!
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Great project , look forward to reading/seeing more of this
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For me its not just the monies spent but also the build. To take something back to the chassis then mod and build how you want it, to know every nut and bolt thats gone into it.
And well that moment it fires up for the first time well: :mbounce: |
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:rofl: |
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First update in while too cold and wet to do anything at the mo :mad:
Race seat here.... http://i276.photobucket.com/albums/k...psbk1sl0ig.jpg Race license application here to.... http://i276.photobucket.com/albums/k...pshx0377vz.jpg |
Are you planning on racing it?
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Cool, in which series?
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New 3.5kg flywheel came today so i'm almost read to start getting it back together now....
http://i276.photobucket.com/albums/k...psaqvxonw6.jpg http://i276.photobucket.com/albums/k...psmanbzfql.jpg |
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silverdreamracer on here can do your ards and sort medical etc |
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Quick update, been busy getting all the engine bay parts cleaned and painted, popped over to DVA and had the verniers and cam timing set up so im just about ready to get it all back together over xmas break cant wait. Finished gearbox today too :p....
http://i276.photobucket.com/albums/k...ps86rth1y1.jpg |
Gearbox looks great, what are the specs?
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Sorry guys nothing fancy inside just yet only had a open up to make sure wasn't anything that should cause a problem this year.
Of course the Starter got stripped and painted will need new bushes soon tho, brackets got some love to really happy with how it turned out. http://i276.photobucket.com/albums/k...psdwozfkqk.jpg http://i276.photobucket.com/albums/k...ps7vgzt13n.jpg http://i276.photobucket.com/albums/k...pslljyzp4a.jpg |
Looking good.
:thumbsup::thumbsup::thumbsup: |
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Got some time on the car today at last :)....
Getting some brackets painted.... http://i276.photobucket.com/albums/k...pstnujbnkz.jpg One of said brackets fitted with new bolts, dont worry i had new nuts as well but seemed to have mis-placed them :confused:.... http://i276.photobucket.com/albums/k...pstipfhdv0.jpg New 3.5kg flywheel on.... http://i276.photobucket.com/albums/k...psnoyxmax6.jpg Engine and gearbox meeting again.... http://i276.photobucket.com/albums/k...psfowcguzl.jpg http://i276.photobucket.com/albums/k...psiznl2rzb.jpg And where its meant to be at last.... http://i276.photobucket.com/albums/k...ps2hl4jhk2.jpg Still a fair way off but on the right track now hoping to get the cam cover painted tomorrow and the rest of the mounts on. |
Got the Cam/coil overs done at last....
http://i276.photobucket.com/albums/k...pstgqqdqhb.jpg http://i276.photobucket.com/albums/k...psxblo8c6l.jpg |
going for the concours look??
Will look good when its all back together. :thumbsup::thumbsup::thumbsup: |
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