ilya's 172 #BECAUSE_RACE_CAR

[RuskiWeldFab]

Feb 2019

First thing first.
AST5100 (110/90) fitted

Won’t be able to test for a little while as started with my weight loss program.
Phase 1 complete
Front crash bar completely removed and replaced with smaller support bar.
Also trimmed everything else that is not essential.
Material removed 7.25kg (-replacement support bar 2.05kg) total weight loss 5.2kg
This is what I started with

After the chop chop

New support bar

Just waiting for a bigger intercooler to arrive.
Now I have more space so why not. Hopefully won’t be much heavier than the original.
ED core size is 550x140x65
Will replace with 550x230x65

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[1985michael182]

Headlight blanks will save you a decent amount and if you changed your plywood splitter to a cmcomposites one you'd say weight again

 

[1985michael182]

Your always going to be heavier because of the turbo kit. Need more power to even it out. Power to weight

 

[RuskiWeldFab]

Headlight blanks will save you a decent amount and if you changed your plywood splitter to a cmcomposites one you'd say weight again

Yes and yes. Both valid points.


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[1985michael182]

Also the more you remove in weight from the front and not back to even it out you'll probably need corner weighting again.

 

[1985michael182]

Another option is to remove all stone chip protection from the underside, it's very dense and any excess seam sealer then just paint it. Obviously making sure water cannot ingress into any seams.

Used to do alot of Mk2 escort group 4 historic rally cars where they were blasted to a bare shell and once primed and flatted we would wipe into the seams the sealer and then wipe out any excess not required so as not to add unnecessary weight

 

[1985michael182]

Like these...
Sorry for the thread bomb

 

[Nafoff]

That new cross member gives you so much more room. Nice work.
Jealous of your ability to weld.... I need to get on that I think.

I got my shell rolled over on mattresses in my garage (bit pikey) and then stripped it all back. I then had a thin layer of protection added again. Not as much weight saved as removing it all, but I still want it to last.

 

[RuskiWeldFab]

New intercooler arrived.
Obviously it’s heavier than original.
So some of the weight I lost I immediately put back. But I’m my head benefits are greater than 1.5kg difference.
Made new brackets for it out of half box section. Lick of paint and we good to go.
Fits perfect!

I am happy and yes I know it’s overkill. Possibly won’t give me anything but tiny bit of extra turbo lag. Time will tell. At least it’s future prove for when I go high boost.

Moving on to phase 2. The rear.

I am actualy surprised how little it weighs. 7.15kg. Was expecting over 10kg.
Made a reinforcing lip on the inside so floor can sit on something. Not my best welding job as was spitting and blowing holes but will do.

Almost forgot. Decided to fit wire toe straps all round. 4 in total. I know I know. Losing weight and adding it back on. Makes no sense.
So made brackets of sorts out of 25mm box section. With high tensile m12 snug in the middle.

welded to the chassis

should be plenty strong. I hope will never get to use them.
Flat floor cut to shape.

will be fixed in place with panel sealant and rivets. Weight 2.05kg. So overall saving is 5.1kg on rear and 2.95kg at front. Total 8.05kg lighter. Some may ask, is it worth doing all that for 8kg? Probably not. But this will ofset the added weight of swirl pot and a diffuser. So far 3 solid days spent on it. 300g per hour roughly [emoji12].



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[1985michael182]

Galv makes it hard to weld and why it spits so much. We use scotch wheels on the grinder to take paint and galv off to get to bare metal without grinding metal away making it thinner. People don't realise how hard it is to weld 0.8mm body panels. Any monkey can weld 2mm+ so good effort m8

 

[RuskiWeldFab]

Galv makes it hard to weld and why it spits so much. We use scotch wheels on the grinder to take paint and galv off to get to bare metal without grinding metal away making it thinner. People don't realise how hard it is to weld 0.8mm body panels. Any monkey can weld 2mm+ so good effort m8

Yeah I used a wire wheel as well to clean as much as possible. 0.8mm welding sucks! At least I wasn’t upside down lol.


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[1985michael182]

Yeah I used a wire wheel as well to clean as much as possible. 0.8mm welding sucks! At least I wasn’t upside down lol.


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That's the worst!!!!
You have to be quick on the trigger so not to put too much heat into the steel.

I've been doing same as you today lol

 

[Usr117063]

Thought about something like this? Better weight distribution and still many ways to get air to it

 

[RuskiWeldFab]

Thought about something like this? Better weight distribution and still many ways to get air to it

View attachment 1405216

I have [emoji2957]. Not just yet. This is hardcore. Maybe when I ran 500+ awd haha


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[1985michael182]

By the time you finish it will be space framed with a removable shell

 

[Eddie555]

By the time you finish it will be space framed with a removable shell

Please don’t put those thoughts in his head.

 

[RuskiWeldFab]

Please don’t put those thoughts in his head.

[emoji23][emoji106]


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[RuskiWeldFab]

Last week wasn’t the most pleasant of weeks.
Had my house broken in to for keys. SQ5 tow vehicle gone. it has been recovered already. Some eagle eye seen them park it somewhere (in case it had GPS) and called the cops. but it is at the impound still with the forensics. Not seen it yet. So yeah not pleasant experience.

Anyways back to Clio.
Flat floor is complete. Sealed and riveted. Even tho there wasn’t much flex I still decided to introduce aluminium brace in the Center.

Next was to install fuel regulator and a return line.

Now for the swirl pot.
Struggled to find best position. There were some good contenders lol

decided over the axel as far left as possible probably best.
Here is the final (not quite) version

I couldn’t believe how noisy they are OMG!
But mine was sounding struggling. Decided to swap filter with pump. Remove restrictor. Turn filter around. Fit rubber bobbins and some neoprene cover.

Much better!

Adjusted to 3 bar. Should be good now. No more file starvation.



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[Nafoff]

Sh*tter on the break-in. Know exactly how this feels when my garage got broken into.
Hope you get it sorted chap.

Good progress too

 

[RuskiWeldFab]

Sh*tter on the break-in. Know exactly how this feels when my garage got broken into.
Hope you get it sorted chap.

Good progress too

Thanks mate. I was here as well. Tried to scare them of but not successful. Decided I like racing too much so called the cops instead.


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[RuskiWeldFab]

March 2019
Although most has been happening in feb.
First thing first.
My stolen SQ5 has been recovered. According to insurance it’s a write off. Ohh well at least got offered a semi-decent payout. So yesterday picked up this bad boy. Should work nicely as a tow vehicle.

Back to the Clio than.
After swirl pot was next stage. Rear diffuser.
Been reading a lot about aerodynamic, flow separation, vortex generators, lift, drag, ... list goes on. To say it’s an easy subject would be wrong.
Anyways. I had an idea of what I wanted.
Previously I bought this diffuser. Looks very very nice! But not as light as I wanted it to be. Especially after all the hard work trying to lose 15ish kg. Wasn’t gonna put it straight back.

Here is the one I bough. By the way, if anyone is interested, it’s for sale.!

So I measured it up to my car

and decided to make my own.
Used 4mm composite sheet.

Measures once cut twice haha
Than I folded the ends with my home made bender using drain pipe.

than cut the bumper. (Well I cut it before I bent the sheet lol.)

fits good!
I wanted it to be fully adjustable. Between 6-15deg (will test with tufts at the track)
So used rose joints front and back. At the rear it’s bolted to the floor and can be adjusted by the nuts underneath.
At the front it will be adjustable from inside the car. Again on rose joints and a pair of kart control arms. Made a simple bracket and 20mm rubber bushing. Plenty strong as I can lift myself from under the car

Next decision was how many fences.
Decide only 2 will be sufficient as I don’t have a flat floor.. yet

think it looks mean as hell [emoji41]

Some may ask where is you exhaust? Hmm good question.. here is the teaser if you can call it that

Like I said, will test with tufts for flow separation etc. Will adjust accordingly. I am not expecting 100kg of downforce. But being optimistic here.


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[scullyg40]

You are executing a lot of things that are going on in my head, including the exhaust.

 

[RuskiWeldFab]

You are executing a lot of things that are going on in my head, including the exhaust.

Well in that case I suggest wait a bit till I test hahaha especially on the exhaust.
Mind you, that’s another 11kg I am saving with new side exit. So total loss should be close to 25kg. I am really really aiming for less than 900 on a turbo car.


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[Nafoff]

Liking the look of the diffuser mate. You are a step ahead of me with that.
As Scully has said I think we are thinking down the same lines but I will have to wait as I don't even have the car here/running yet.

 

[1985michael182]

Same again, side exit is on the cards to free up the rear for diffuser. As long as its below track limits theres no dramas

 

[RuskiWeldFab]

Same again, side exit is on the cards to free up the rear for diffuser. As long as its below track limits theres no dramas

Yeah that’s my biggest worry! But mine is turbo so quieter than NA. I have sports cat as well and Fitting this Center silencer. The biggest one I could find that would fit. 625mm. In comparison, Ktec Center section I had was only 400mm. (And back box is 400mm as well. So effectively I am going down from 800mm to 625. If my man math is right haha should be under the limit. I know the diameter of the back box is bigger but mine was incredibly exhaust quite before.)

Fingers crossed. Measured db with Ktec Center section and no back box. Around 89db.



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[scullyg40]

Well in that case I suggest wait a bit till I test hahaha especially on the exhaust.
Mind you, that’s another 11kg I am saving with new side exit. So total loss should be close to 25kg. I am really really aiming for less than 900 on a turbo car.

Liking the look of the diffuser mate. You are a step ahead of me with that.
As Scully has said I think we are thinking down the same lines but I will have to wait as I don't even have the car here/running yet.

Same again, side exit is on the cards to free up the rear for diffuser. As long as its below track limits theres no dramas

I guess great minds think a like.

@pule333 The turbo must help a lot in the noise departement, but I think you can always place a small silencer in the side section.

 

[bloke]

Remember all those nice light titanium bits I showed you

 

[RuskiWeldFab]

Remember all those nice light titanium bits I showed you

Hahah yes I do! But don’t crap gold [emoji1787]


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[RuskiWeldFab]

Small ish update.
Exhaust is on. And, well I think might be a tad too loud lol. Didn’t even test it properly. Bouncing on the rev limiter at 3k while oil still under 60deg it maxed at 103db. My gauge could be lying. Or it amplifies the sound being close to the garage wall I don’t know. But not even gonna bother drop it in the ground and go for a test drive just yet. Ordered custom 3.5” silencer to go under fuel tank. And resonated tip. A bit more cutting, welding, head scratching and test again.
Looks good tho [emoji41] had to make a notch on the frame for clearance as well.

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[massiveCoRbyn]

Took quite a bit of work to get my side exit under 100dB, although I am NA rather than turbo. I run a big silencer and also some small half moon baffles before the tailpipe

 

[bloke]

Biggest oval box you can get in there.

 

[RuskiWeldFab]

First will try another silencer under the tank. If it doesn’t work, baffles and bigger Center silencer


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[bloke]

Need to go oval if you can.

 

[RuskiWeldFab]

Need to go oval if you can.

Why oval?


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[CZUCZU]

 

[CZUCZU]

5db less of loudness

 

[RuskiWeldFab]

Interesting. Where does this fit? Those aren’t the tips are they?


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[massiveCoRbyn]

Need to go oval if you can.

Would agree with that. I went from a round silencer to an oval (overall volume was similar) and dropped from 118dB to 102dB.

Two semi-circle baffle plates got me to 100ish, then another two and I was 97dB, so future proof for a while yet.

 

[RuskiWeldFab]

Would agree with that. I went from a round silencer to an oval (overall volume was similar) and dropped from 118dB to 102dB.

Two semi-circle baffle plates got me to 100ish, then another two and I was 97dB, so future proof for a while yet.

Do you have any pictures of yours mate? For comparison


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