172 Cup Track Project

[AdamR]

I'm doing a bit of work on my 172 Cup to make it track-ready, so will post updates here as and when I've done anything. Won't be anything special compared with other cars like Chrispy's, but it'll keep everything in one place as reference for me...

Here's a thread I made when I first got the car a couple of weeks ago:

http://www.cliosport.net/forum/showthread.php?562772-My-new-%28to-me%29-172-Cup



Since then I've ripped a load of stuff out and saved approx 25kg, added a Skoda front splitter (will make a 'flat' carbon one when time allows) and had a go at making some door cards... Photos below!

1) Scarily big bit of carbon cloth, don't wanna feck this up!



2. Laid up, ready to cure. Took about 2 hours...



3. Bit of weight, and left for 36 hours... Possibly not enough as some of the resin pulled away with I released it



4. However, came out pretty well for a first go, reasonably happy. This is straight off the mould, no polishing.



5. Trimmed down.



6. Test fitted.



7. Checking fit.



8. Checking fit again.



9. New handle made on my lathe. Wanted to do away with the 'looks like your mums made it on her sewing machine' (nothing wrong with that mind!) pull cord and bin off the original door catches, so had to come up with something that would do both jobs...



10. Bicycle brake cable is exactly the same as the cable pull for the catch, fits into the new handle like so...



11. Other end - normally has a small bit of plastic to shim out the nipple, so had to come up with something to replace it since I would be cutting the OE cable and just using the outer from it.



12. New cable clamp with grub screw (filed a flat section to make it easier to start the cross drilled hole).



13. How it looks/fits in the catch.



14. Boss to fit the handle onto, bolts straight into the existing fixture for the OE handle.



15. Test fit, turn clockwise to open the door, pull to close it



16. All done!





Reasonably happy with it, not perfect by any means, but learned a lot for the next one and should be much quicker now I know what I'm doing. Don't think I'd bother making a pair again, the materials cost about £60 so a pair at £115 (performance trim) and not spending ~4 hours each making them is pretry good price! Anyone got any close up photos of the PT ones btw?

Any questions just ask!

Next job: Fit roll cage. Should be here this week if all goes well...

 

[Conlon]

Wanted to do away with the 'looks like your mums made it on her sewing machine' (nothing wrong with that mind!) pull cord and bin off the original door catches, so had to come up with something that would do both jobs...

Hey..... my mother made mine! lol

good progress, looks like you will be doing alot of the work yourself?

 

[Keith185]

Liking the handles, very nice work

 

[Cro]

Nice skills mate what cage you going for?

 

[AdamR]

Hey..... my mother made mine! lol

good progress, looks like you will be doing alot of the work yourself?

Haha, it's all good

Well, the previous owner(s) have done the hard stuff to be honest, I'm just gonna add a cage, RARB, pulled some stuff out, make a few carbon bits to tidy it up, then take it to the track!

Liking the handles, very nice work

Thanks man!

Nice skills mate what cage you going for?

Cheers - got a Safety Devices 6 point bolt-in on order, should be here next week if all goes to plan...


Another small update, rear wiper is off and carbon skinned the cap. Not a great job but was in a rush... may re-do it at some point!

 

[AdamR]

Cage arrives today! Got my ass to work half an hour early to pull stuff out...



Had both parts of the dash in and out a few times now so if there is anyone who wants a hand with it just shout... There is a guide for the top half but couldn't find one for the bottom bit. Was a bit tricky 'blind' but with some guidance I can see it being pretty straightforward!

 

[Matthew]

Good progess mate, looking good

 

[Curtis!]

Should have fibreglassed the whole first!

 

[AdamR]

Sorry man, not sure what you mean...?

 

[welshname]

SUBSCRIBED.

 

[AdamR]

Couple of updates...

Been prepping for cage - Safety Devices 6 point bolt in - just needs a bit more paint out around the towers, then ready for welding... Hammering the arches flat was scary, haha. Then the mammoth task of sanding and spraying the interior



Got wheels (15" Superturismos - thanks to beng-120!) and tyres (Federal 595 RS-R) sorted...



Then had a go at a brake duct today at lunch and after work. Seems to have come out ok for an hour's work, but might tweak the fixing method a bit. Needs building up a bit 'higher' at the very least I think, you'll see what I mean from the photos...

47p funnel from Asda



Chop chop...



Old Cod Liver Oil bottle - 48mm diameter, builds up to 50mm diameter when fibreglassed around, ready for 51mm ducting...



Moulded in in two parts (funnell first, then tube) but gives you the idea...





Added some tabs on the side...



For clipping into the fog light surround - makes a nice 'snap' when it goes in!







Quick blast of black spray paint to check how it looks. Not toooo bad considering it's cost about £2 and took about an hour. Considering trimming the excess off but it will obviously 'scoop' more air in as it is... Will probably re-make this one as it was a bit of a learning process.



Will update in a few days/a week once more stuff has been done

 

[AdamR]

View attachment 54238

Much better with the paint dry, hah.

 

[mx1_champ]

i like how your making your own bits, decent finish to.. ill keep an eye on this

 

[AdamR]

Thanks dude. Always like to get stuck in making bits, tis good fun

Done a bit more work over the last week or so...





Still to do:

- Tweak brake ducts (hoses a bit short at the mo, gonna make up some plates/tubes that sit right near the rotors to give the hoses a bit more effective length)
- Fit home made camera mount
- Fit RARB if/when it arrives...
- Tidy up wiring
- Buy some more bolts/cut down some bolts for the cage, a load of them are way too long!
- Turn up some spigot rings for track wheels (not paying £75 for official OZ ones!) - got the ali bar though the post today
- Fit TPMS for track wheels
- Probably some more stuff I forgot...
- Clean it (dirty as hell inside and out at the moment!)

 

[Fred@BTM]

how much was the cage fella? where from?

 

[mattsouthall]

like the progress. where did you get the federals from? I have read some good stuff about them and also want to give them a crack...

 

[jon_r]

Ditto that request.

Great thread.

 

[AdamR]

how much was the cage fella? where from?

It came to £810, from Mark Fish (probably about to tell me you could have supplied one about half the price that's twice as good? haha)

like the progress. where did you get the federals from? I have read some good stuff about them and also want to give them a crack...

Cheers man! It was... Tyre Traders: http://www.tyretraders.com/tyreInformation.aspx?ItemID=FED19550ZR1582W595RS-R - website is toss and they wouldn't let me order over the phone, but good service in the end from them.

I'd heard good things too and thought they were worth a pop for the price compared with R888s etc. Need to get them scrubbed in, get a heat cycle through them then will updated after next track day if you're interested? I don't have much experience for direct comparisons, but I used some Dunlop DJ01s (R-compound) on my last car which were night and day compared with road tyres.

 

[Fred@BTM]

na, just deciding on which cage to get for my race car!

 

[AdamR]

Ah cool - well it seems pretty decent. Had a few small alignment issues at the start (mainly down to the order I was doing stuff I think - it's my first go at a cage) but it's gone in really well now, no major modifications, no extending B-pillar hoop, towers were pretty close to the right shape from the start, etc. JUST clears the seats and about 10mm from the windscreen. Looks like it would clear roof lining too if that's of any help. If you want any close up pics of anything just shout dude

 

[Fred@BTM]

cool, cheers fella

its a toss up between that and the custom cages one (£425) but that's a bit of welding and a 6week wait, hum

 

[AdamR]

Yeah I had a similar choice... I'm impatient and not handy with welding kit so that sorted the decision out for me! lol

Think Mark had 2 left in stock (both black) when I got mine 2 weeks ago...

 

[Fred@BTM]

i was a welder/fabricator a few years ago, so welding is the fun part!

 

[AdamR]

Get amongst it :rasp:

http://cgi.ebay.co.uk/STEEL-CDS-TUBE-1-5-8-ROLLCAGE-ROLL-CAGE-2-0-mm-wall-/260753588427?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item3cb62000cb

 

[AdamR]

A little more progress...

Finished spigot rings and got track wheels fitted. Bought a solid bar originally, took fooking ages and ended up with a massive lump of swarf, haha. Same night I went online and bought some tube instead... Delivery was more than the bar (gits) but was much easier to make the others.

The spigot ring size for OZ Superturismo (Superturismos - search friendly ) seems to be 68.0mm from a bit of searching and measuring (got a roll of parcel tape and kept removing layers until it fitted, then measured it), which isn't standard so you normally have to buy official OZ ones at a silly price...

Luckily I didn't buy some because the wheels had deformed a little where the bolts go, so 67.90 fitted better. Made the bores 60.05 (officially the hub size is 60.1) so they are a very tight fit when cold (have to use the bolts to pull the wheel on the last few mm), but slide off nicely when hot

First one:



Full set done (one spare just in case I screw one up!):





I've got loads of spare bar so if anyone needs any give me a shout. Should be able to do up to around 69mm.

Probably nothing new to you guys but I thought this was pretty funny Certainly makes wheel changes easier! Gave the tyres (Federal 595 RS-R) a good scrubbing and a heat cycle last night, they seem really good so far. Nice and stable under braking, you can feel them gripping/squirming/feeling for grip where my Kumhos (Ecsta KU31s) would have started to lock up.





Black vinyl on the doors is because the previous owner had white ones on there, which I removed... but then realised they were there to cover up some horribly peeling lacquer. I'm not too bothered about the looks so they are staying on, I can probably put a 'This Way Up' arrow on them or something anyway :clown:

Also been playing with brake ducts and think I've settled on big scoops and deflectors: http://www.cliosport.net/forum/show...cts-Pipe-directly-to-rotor-or-deflector-plate





Can't wait to get RARB on and then book a track day, woohoo!

 

[Englebert]

Nice work, some commendable handywork there!

Now get it on track and stop fannying about...

 

[AdamR]

Nice work, some commendable handywork there!

Now get it on track and stop fannying about...

Thanks man.

Haha Half the fun is in making stuff! But I agree, needs a good thrashing now...

 

[AdamR]

Weeelllllll... I'm still faffing about with it :rasp:

Made some brake deflector plates:



More info: http://www.cliosport.net/forum/show...lector-plate&p=7646676&viewfull=1#post7646676

And fitted RARB. Need to pay with settings as it doesn't seem to have made all that much difference at the moment, the suspension is set up pretty firm though:



Also relocated switches from door card (wasn't going to go cutting loads of holes in it!) to dash.

Next up:

- Tidy up all the wires inside (bought some of these: http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=250778215542&ssPageName=STRK:MEWNX:IT)
- Finish padding the cage
- Make a blanking plate for where the radio was to mount switches/TPMS into/onto.

 

[mattsouthall]

I'd heard good things too and thought they were worth a pop for the price compared with R888s etc. Need to get them scrubbed in, get a heat cycle through them then will updated after next track day if you're interested? I don't have much experience for direct comparisons, but I used some Dunlop DJ01s (R-compound) on my last car which were night and day compared with road tyres.

yep, let me know how you get on with them!

Cheers, Matt

 

[AdamR]

Will do mate - got Cadwell on 12th May so full feedback after that.

For now, something I posted on a different forum:

I've only used them for a couple of heat cycles (10-15 mins in total maybe), but was going to put a few words up anyway - they feel free good so far. Once warm they are extremely sticky, they pick up all the crud off the road and fling it into your arches. Even under pretty hard cornering you don't seem to get any squirm/squealing (although obviously you could make them slide if you went silly), and the car feels really planted and stable at all times.

They are very predictable under braking and also seem to offer a lot of feel. With my road tyres (Kumho Ecsta SP31s) they kinda lock up without warning, but with the 595s there is a feeling through the brake pedal like they are 'gathering up' underneath themselves (if that makes any sense!) and you know exactly when they are going to start to skid.

If noise is a problem for you then I can't really comment, I haven't noticed a difference but then my car has zero sound deadening left, apart from a small patch on the bulk head...

No comments on wear yet, but hopefully can comment on that (well, lack of it if I'm lucky!) after next track day. The compound is very 'chewing gum-y' when warm though, you can really move it around with your fingers and it'll slowly squirm back into shape. Hoping they won't wear out too quick...

 

[Wests Renault]

Loving the progress so far. Like the fact you are making all your own parts and getting a good finish too! Keep up the good work.

 

[chrispy.clio]

Car is looking good now, really want seats like you have. I like the bits you have been making

 

[AdamR]

Thanks guys - much appreciated!


Latest update:

Dear Mr previous owner (who worked at a main Ford stealership and changed the rear discs while he owned the car),

I hope you use copper grease on customer's cars.



Oh, and don't fit the pads on the wrong side, so one of them sits at an angle and only contacts the very top edge of the disc, thus wearing at an angle.

Your sincerely,
The guy who had to buy an M12 x 1.5 helicoil kit cos the carrier bolts had cold welded in.

 

[Black Phoenix]

Thanks guys - much appreciated!


Latest update:

Dear Mr previous owner (who worked at a main Ford stealership and changed the rear discs while he owned the car),

I hope you use copper grease on customer's cars.

View attachment 55879

Oh, and don't fit the pads on the wrong side, so one of them sits at an angle and only contacts the very top edge of the disc, thus wearing at an angle.

Your sincerely,
The guy who had to buy an M12 x 1.5 helicoil kit cos the carrier bolts had cold welded in.

Using Cooper Grease on the back of the pads was the first time I had seen in this forum. In Portugal, at least in the Renault Dealerships I had visited for the maintenance of my car NEVER, but NEVER they used Cooper Grease when changing the pads. I had worked in the Metalworks role in Portugal and had a Degree in Industrial Electronics with speciality in Pneumatics, Hidraulics and Mechanics so I understand the reason why, but it's very rare to see that in use (I never had saw that) here in Portugal.

 

[AdamR]

Ah - maybe my post wasn't clear. There was no copper grease on the bolts, so they had cold-welded in and I had to helicoil the caliper...

 

[Black Phoenix]

Ah - maybe my post wasn't clear. There was no copper grease on the bolts, so they had cold-welded in and I had to helicoil the caliper...

Ha, OK, Sorry me!!!

 

[AdamR]

No problem at all, your English is a lot better than my Portugese

 

[Black Phoenix]

No problem at all, your English is a lot better than my Portugese

Temos pena!!!!

Hehehehehe

 

[Cup_Phil]

Awesome build so far - same cage I'm after

Am I right in thinking you've managed to remove the brackets the rear seats clip to? Around the rear suspension turrets?

I've been trying to find out if that's possible for ages

 

[AdamR]

Thanks mate. Cage went in well in the end

Anything is possible with one of these:



Took about 5 mins, then used a flapping disc to tidy up afterwards, can grab a photo if you like