172 cup tarmac rally build

[richard1764]

After a number of years on the forum picking up lots of useful information and reading many impressive project threads I thought I would start a thread on our rally car build.
A bit of background to how we got here. I bought a cat D 172 cup about 5 years ago as a runabout and trackday toy but then bought a Leon Cupra R a couple of years later for our annual Nurburgring trips. As I already had a few other toys the Clio was a bit redundant so ended up going shares with my mate to keep it solely for some trackdays, hillclimbs and sprints.
We have had a lot of fun doing these as well as a couple of Ring trips but as we had rallied together for a number of years we found ourselves missing the atmosphere that rallying brings. We decided that as the Clio was so much fun in essentially standard spec, one with a few choice upgrades would be the way to go.
While looking at different cage options I stumbled across the advert that Tom Johnson had listed for a 172 cup shell with a fantastic cage already done. As it was only 15 minutes up the road, the decision was made. This was followed by the purchase of a MIG welder, a selection of Pure Motorsports upgrades and some sill stands. This brings us to today and rain meaning an early finish at work so into the garage to make a start.

We have got a PMS shifter and sump guard ready to fit and just waiting for our roll centre hubs from Mark. The rest of the spec isn't finalised but we think we know which way we are going engine wise and leaning towards a Samsonas dog box and Gripper diff.
Will update as we make progress, would like to think we might be ready to hit the stages next spring fingers crossed.

 

[richard1764]

Weather was much better today so had to put a full day's work in. Just managed a quick hour to finish off the sill stands tubes though

Much better for access and safety.

 

[Tomo3292]

Nice Progress mate, got a similar build going on. Love the sill stands

 

[celgt4]

I have a build on going. Mull this year is the target. Cage going in this week and then interior parts like.

1. Extinguishers
2. Nav foot rest
3. Everything else!

Good luck

 

[richard1764]

I have a build on going. Mull this year is the target. Cage going in this week and then interior parts like.

1. Extinguishers
2. Nav foot rest
3. Everything else!

Good luck

I have a build on going. Mull this year is the target. Cage going in this week and then interior parts like.

1. Extinguishers
2. Nav foot rest
3. Everything else!

Good luck

Great to see more Clios heading out onto the stages. Went to see Evogone a couple of months ago on a rally at Cadwell and he was mixing it up at the sharp end and has done really well in the Motoring News circuit championship. Might have a venture up to Mull for a watch, been meaning to do for a few years, will keep an eye out for you if you are there.

 

[massiveCoRbyn]

Those sill stands are monsters!

Nice to see someone else rallying a Clio. Would love to convert mine, think it would make a cracking little car for not a lot of money.

 

[richard1764]

The sill stands are the tallest I could find, 580mm to the centre of the pin. At just over £200 for the set thought they were pretty good value when you see the work involved. Much easier than having to kneel down to locate conventional stands in a suitable place especially in wet or muddy service area.
They do make a great little car out of the box, lot of fun can be had on a relatively modest budget. We are hoping with an aim of 220 to 230bhp, a decent box and diff plus well set up suspension we may be able to give some of the more common 2 litre class machinery a run for their money.

 

[Tomo3292]

Any news / updates on this mate? How you getting on with your project??

 

[trophy380]

Great work mate

 

[richard1764]

Any news / updates on this mate? How you getting on with your project??

Unfortunately work has been really busy so no real time on the car recently. However the upside of being busy is being able to do a little shopping. Was quite late when we got home so not a great picture I'm afraid. However, we now have a rather nice engine completely setup on a Gen90 ecu, PMS manifold and BTB stealth system and various other nice bits and pieces.
Plans for a Samsonas dog kit for the gearbox have gone up in smoke as they are not currently producing them due to high demand for their other products. So it is looking likely we will be biting the bullet and opting for a Sadev sequential.
Will try and get some more progress updates when we can get some garage time, the beers are in the fridge ready.

 

[eon172]

Subscribed, might go this route myself in the future.

Is that Mark's @NorthloopCup lump?

 

[NorthloopCup]

Subscribed, might go this route myself in the future.

Is that Mark's @NorthloopCup lump?

It is indeed my power plant. :wink:

 

[eon172]

Didn't see that advertised lol

 

[NorthloopCup]

Didn't see that advertised lol :smile:

That's because it wasn't! Lol! Everything has sold mate now apart from the turinis and the gearbox (for obvious reasons), but I have someone interested in it once it's been repaired.

I've been in conversation with Richard now for a good few months as he was keen for me to build them an engine. Mine obviously became available, so we struck a deal.

 

[eon172]

Good stuff, nice to see it put to good use ....I still have a gearbox and LSD to sort

 

[richard1764]

It is @NorthloopCup engine. As Mark said, we were very impressed with the way he had gone with his engine so were planning on him building us a similar spec for our project. After his unfortunate trip to the 'Ring and his decision to go down another path it was a no brainer to acquire his engine. It was a pleasure to deal with him and he has a fantastic knowledge of how to engineer a Clio, hopefully we can do justice to his engine and ruffle a few feathers amongst the fast guys.

 

[richard1764]

Finally managed to get back in the garage tonight to start putting a few bits back together.
Rear beam, subframe and wishbones have all been powder coated so fitted the PMS uprated rear stub axles to the beam, cleaned up the front hubs ready for new bearings and painting. The Reiger suspension has been paid for so should be here next month and just received the PMS top mounts to go with them.
Will hopefully have a few bits from CM Composites by the weekend too. Found ourselves in Wrexham last Friday so popped into Tweeks and picked up a steering wheel and quick release boss so we can finalise the position for the seat rails. Hopefully with the darker nights shortening our working days we can get things moving on a pace.

 

[Tom Johnson]

By heck that's a good looking cage :laughing:

Wish you had come to me to weld the Pms kit on the rear beam though :grin:

Good progress Rich

 

[richard1764]

It's a fantastic cage mate, will be painted shortly. Lad we had working for us was a welder so we got him to do the beam when we got rained off a job. Not as neat as you would have done but it's strong and won't be on show unless we stick it on its roof!

 

[richard1764]

 

[richard1764]

 

[richard1764]

Well, that has taken a while! A combination of work and a few complications stalled progress but the finish line is now in sight. The original idea of a dog box having gone up in smoke lead to a brand new Sadev box and a philosophy to try and incorporate the best of components. We have ended up with a Sadev ST75-14, 3 way Reiger dampers, a Cartek PDM to bin all of the fuses and relays, a Liteblox carbon battery, Ricambi carbon lamp pod with PIAA WRC spot lights etc. There are a number of very quick Clios out on the rally stages so hopefully we can compete.

 

[massiveCoRbyn]

Some seriously nice bits on this! Got a first event in mind?

 

[scullyg40]

The sill stands are the tallest I could find, 580mm to the centre of the pin.

I always wonder how you get the car that high in the air with these things?

 

[richard1764]

Thought it was time for an update as we are finally coming to the end of the build. I'll get some more pictures up tomorrow as these are a week or two out of date but give an idea of how it's looking. MSA scrutineer coming to log book it on Saturday, all we have left to do is put the navigators seat in, sideskirts, mudflaps and tow straps to fit and paint the bonnet and we are there. Booked in at Efi on the 15th June as he reckons there is a bit more to come from the engine now it's purely a competition car and also map the flatshift.

 

[richard1764]

Managed to get a bit more done after work today. Mostly finishing off jobs and fitting the MSA required tow straps and mudflaps. Passenger seat and both harnesses to go in and we should be about there for the MSA scrutineer to logbook on Saturday.

 

[AdamCup]

Can you reach the Cartek panel once you're strapped into the seat ?

 

[richard1764]

Can you reach the Cartek panel once you're strapped into the seat ?

Yes it's within reach, we still have stalks for wipers and lights so we shouldn't need to be pushing the Cartek buttons that often anyway.

 

[richard1764]

MSA logbook done today

 

[massiveCoRbyn]

Looking forward to seeing this in action. Got a first event in mind?

 

[richard1764]

Looking forward to seeing this in action. Got a first event in mind?

Not sure yet, definitely fancy Promenade Stages in September but will have to see what else is on before then.

 

[massiveCoRbyn]

I've always fancied a go at that as have been servicing on it for years. Clashes with a local event this year though, so will likely do that instead.

 

[richard1764]

I've always fancied a go at that as have been servicing on it for years. Clashes with a local event this year though, so will likely do that instead.

We've done it a couple of times, once in the bike engined Mini, and once in the Integrale.

 

[Nathan Evans]

Not sure yet, definitely fancy Promenade Stages in September but will have to see what else is on before then.

Proms going to be a good one. Jackson and the both Robs will be doing it too. I’m meant to be doing the closed road in Aberystwyth but if there’s going to be a load of clios the prom i might change my mind ?

 

[paul-h]

Lovely!! Serious spec here!

 

[richard1764]

Things all coming together now. Booked in @ Efi on the 15th, Tracktorque for suspension setup on the 19th and trackday booked at Blyton on the 23rd to give it a systems check. Fellow Clio rally pilot kindly lent us a 2118 to check caliper clearance worked so got to order a few of those tomorrow. Got the side skirts on yesterday over the sill stand tubes and fitted the kevlar protection to keep them tidy. Also got the tubular carbon cage protection cut and fitted and the lamp pod mounted on the bonnet. Bonnet and front bumper getting sprayed by the body shop tomorrow and the it's good to go.

 

[richard1764]

Had a nice delivery from Speedline today, got a set of Michelin p2g wets and some Hoosiers on order.

 

[richard1764]

Managed to get some tyres on one set of wheels temporarily so we can take it to Efi on Saturday. Refitted the bonnet and bumpers after a trip to the paint shop and labelled up the Cartek panel. Final inspection performed by Dave ? and he said he was happy ?

 

[richard1764]

First time out of captivity to load on the trailer ready for tomorrow's trip to Efi.

 

[NorthloopCup]

View attachment 1422244
First time out of captivity to load on the trailer ready for tomorrow's trip to Efi.

You should see some more hp out of the old girl tomorrow mate, as it was mapped on the hottest day of the year at the time! Still sounds fuckin epic too!