well i`m still tinkering...

today has seen a job done that i`ve been putting off for a while..

blanking bungs for the secondary butterfly spindle holes in the bodies..



which get twatted in here...



and the protruding end can then be ground back flush...




theres 2 more sets of ally flanges being laser cut 1 will be welded onto the bodies (like i did to mount the jenvey trumpets) and the other set will go on the inlet manifold so they cn be bolted together rather than use silicone tube...

the satchshift gearstick has had a few tweeks on CAD and some big ass chunks of billet located still not 100% decided on the final design though...



also need to finalise a trigger wheel on the intermediate shaft and somehow mount a hall sensor to read wheel speed...

Hey !!!

Very cool car mate, but I'm surprised no one told you that you made it all wrong.

First, the car is not supposed to run like spider man : (upside down)


Second, man, you put the steering wheel the wrong side !!!






Sorry for the joke, that was too easy ^^


Do you plan to use it as a daily car, for track days or special races?
Nice car though.

T'es con tu m'as fais rire.

it has been a long while but i`ve started working on the car again!!

made a plate to block off the hole in the zorst tunnel:




made a bracket to mount me new horn:




got the tow strap mount tacked in place:




not sure if i`ve shown this before but the 205 washer bottle tank + pump is semi fited into the 3/4 recess:




then it was a job i`d been delaying for bleedin months as i wasnt quite sure how to approach it...

the strut-to-cage gussetting.. i decided the best bet was to refer to my pics of the black clio that resides at TDF occassionally and crack open the drinks:




so first job with stuff like this is some cadr templates:



clearance on the wiper mechnism is...er... bloody tight!!!




and after much swearing at the welder and a bit of cleaning up we had a semi-finished job:




midway thru i noticed a LOT of smoke coming up from under the dash and it appears i`d missed some seam sealer!! OOps:



then washed the girlfriends car and took some pics...

Hi there Stuart!

Very nice "one-O-six" you've got there!
Can't wait to see it finished

It's funny, because my name's Stewart (I'm Scottish but I live in France)
and i've got a blue 106 that's been "slightly modified" for trackdays too,
(but to be honest, I've not done half the work you've done on your's )

Good luck for the work left to do

turret/cage gusseting.. done!! tubes capped/welding done/job jobbed!



wheel speed sensor.. DONE.. might be fussy and lighten/neaten the bracket up but its on, fits and works...

drew some bits up in CAD...




made some tools to shape them..




which left me these..




which go like this!!..

Nice work !

It's very good work. Il love your Clio RS I too

thank you momo...

yeah the Clio was purchased for the girlfriend when she said she wanted something "fun"..

the previous owner spent a LOT developing it and went though Bilstein and AST coilovers before he settled on the KWv2`s.. it really does handle very nicely..

Quaife Quickrack!!

and like all things.. its been a headache!!

originally organised and paid for end of DECEMBER!! last year after a lot of stalling/excuses/bullshit they were eventually delivered earlier this month and early signs were good:



waiting was the easy bit.. once they turned up the real headaches began!!

a few people had mentioned there was an issue refitting the rack so rather than dive in and find out i stripped everything down and broke out the vernier!!

the flats that fit into the 106 UJ at the end of the colomn measured 13mm:



for some reason though Quaife decided to ignore this and made theirs 14mm!!:




a few phone calls and they admitted their balls up and the pinion was sent back and a modified 1 sent out super quick...


at this point i thought "here we fucking go...."

but no... more issues!!

the original bearing in the pug rack measured 32mm od:



and the 1 Quaife supplied measured............................................................................... 35mm!!:




fuckingwankingbloodycockarseballbagmotherfuckerwankstain!!!!!!!!!!!!!!!!


after a trip to my local bearing specialist it seems that SKF dont even list a bearing that size and peugeot are cunts... well.. not actual cunts.. but they had a bearing specially made for the racks..

the reason for Quaife supplying the 35mm unit was that a later model rack was sent to them and that uses a more common bearing size... so.....

a trip to my local scrappy today.. 15minutes climbing into wrecks resulted in this:



a S2 rack for a T plater.. this has literally JUST been stripped, rebuilt with the Quaife internals and refitted to the rattlebox..

the verdict is... WOOP!!!

OMG

That's a great work !

can you tel us about your engine an your gearbox ?

when did you start your project ? Maybe you spent a lot of time on it !

you are a boss !

the original 1600 engine was rebuilt by Shenpar back in 2004 to the following spec:

Yamaha R6 carburettors
Bogg Bros inlet manifold
ported + polished head
3 angle valve seats
piper 285 cam
balanced + lightened bottom end
custom engine loom
distributor conversion

new shells/main bearings/rings etc etc etc...

the clutch is an Alcon paddle item and i used to run a Compbrake quickshift boss and pug sport rose jointed linkages...

nothing has changed internally on the engine but it will now run on GSXR1000 throttle bodies and be controlled by TDF EC1 ecu.. the gear linkage has also been changed for the Colin Satchell design..

it has been evolving for MANY MANY years.. some of the parts were originally fitted to my 1400xsi back in 2002

some more progress...

for quite a while now i`ve wanted to get rid of the cross bulkhead braking system on my RHD car.. so ive been looking at bias pedal box solutions..

before spending any cash i made a mock up of the master cylinders to have a look for space....



ok... i dont like to be beaten.. and i really dont like the 106 brake linkage...


following on from Sandys comments about a overhung bias assembly being preferable i had a quick look to see what space was like above the steering colomn:



"the man from DelMonte.... he say YES!!"

so off with the rack.. off with the pedal assembly:



as you can (just about) see.. the clutch pedal (closest) pivots and the upper portion of the pedal pulls the clutch cable... the brake pedal pivots at the top and pushes a actuator through the bulkhead which in turn operates the cross link...

now... if the assembly could be modified so the clutch AND brake pedal shared a common pivot point and instead of using a "pull" motion like the clutch does the brake pedal "pushes" towards the back of the clocks area,, we may, in fact, have a winner!!

so thats what i did!!:



still need to fabricate a support for the pivot bolt as you can see but the idea seems to work...


ive also measured from the new pivot to the pedal pad and positioned the pushrod so it operates with a 6:1 pedal ratio...

a quick trial fit:



as you can see the steering knuckle is close to the pivot bolt but i can mod a few things and have a safe clearance easy enough....



as you can see the pivot point for the brake pedal has moved and a 3mm thick pickup made for the clutch and brake pedals to share.. a new 3mm outer plate has been made that not only supports the clutch pivot but also supports the master cylinders.. a piece now needs to be made to:

*support the brake pedal pivot
*clear the steering knuckle
*clear the throttle cable
*support the backplate that holds the master cylinders...

hmmm could be a tricky bastard!!!!



the big side plate needs a window cutting in to allow clearance for the bias bar...

an some geeky shit... feel free to ignore...

with the ideal pedal ratio of 6:1 acheived, due to the limited length of the peugeot pedal the short arm that operates the cylinders is quite short and that causes some issues..

1- suitable stroke.. pedal moves a lot but the arm only moves 1/6th of the distance..
2- the arc that the upper pivot is quite a tight radius that means as the arm moves towards the master cylinders it travels up and down (imagine 1 of those knobs on a steering wheel..)

1- according to the AP site the cylinders i plan to use have a 1" stroke.. 6" of foot travel?? meh.. should still be way off the floor i reckon...
2- also.. according to the AP site the maximum angle the pushrods can go through is 4degrees.. from a few more measurements i think theres about 40mm of travel before that angle is exceeded...

so... basically... it should work.....

http://www.apracing.com/info/products.asp?product=Vertical+Flange+Types+%3Cimg+border%3D%222%22+src%3D%22http%3A%2F%2Fwww%2Eapracing%2Ecom%2Fpics%2Fproductpics%2FFlange%2520Mount%2Ejpg%22%2F%3E%2DCP2623+Type_2386_2385

OK... a small step away from brakes at the minute..

some mods.. some re-work (nowt like spending ages on stuff only to find its not right!!!)

heater matrix bypass pipe...

so.. until the stat opens the water needs a way to get around the engine so rather than the push on rubber hose i went a bit OTT...

the stat housing was modified to accept a Goodridge fitting and the 45Degree fitting then goes onto a fitting i`ve welded onto the waterpipe i made for the back of the engine:



and the waterpipe:



and the rocker cover i modified the breather on, when theres a fitting on the cover and the catchtank i made the length of the pip is very short.. now.. he engine shouldn`t move too much due to the rose jointed bottom link and the GrpA mounts but it looked like a recipe for something breaking.. so its moved from the Cam end:



to the gearbox end:




should allow an amount of flex for engine movement and virbrations...

ok... update... and its a good `un..



attempted to try the box and 1 thing became apparent... it needed to go on a diet.. big time!!



so a lot of thin disc action, trimming and a revised mock up it was judgement time.....

















theres even clearance (just) for the std throttle cable grommet to pass...



needs a bit more clearance at the top but i can now make the final part in 1 piece and start working out master cylinder sizes once i finalise the front calipers....

i think that's the craziest guy on earth to modify a car as perfect as the way he think, and, he's from england! the crazy motorhood land.



i know mads english guys, because sister's in salisbury, the home town of the sxoc ( 200sx silvia ) forum.

hi folks... i hope things are all good overseas!!

i`ve been taking a break from the rattlebox recently, various reasons (family/work/money) all of which are far too trivial and boring to put here so i`ll skip to the interesting bits...

i`ve redesigned the pedal box so its a bit smaller now, and so the master cylinders sit closer to the colomn..






also after a few weeks of being outbid on various brakes i sent a few emails and got lucky!!!!







these are basically a direct replacement for the lotus elise and vauxhall VX220 front calipers except there machined to suit 300x26mm discs..