The everlasting ph1 ITB Build **GREEN-BUILD STARTS AT PAGE 100**

[Nafoff]

UPDATE (cont):

The wiper motors loom needed a bit of fettling but was easily re-worked into the plug I already had. This was then clipped and tucked away.
A few attempts at alignment of the wiper but it is all good, sweeps really nicely and tucks away too, pretty happy with how tidy the result is.

I may look at a longer blade and a slightly different sweep (dependent on legalities) but seems pretty good.

Final job before I get it on the road is to sort the fuel sender into the dash2 wiring.
I am still having fun with the Dash2 but almost there I think... hopefully

 

[Chambers_RS]

Good work 👍🏻

Might look at this myself. Much weight save over the OE setup with passenger wiper arm on the drivers side you reckon?

 

[Nafoff]

Good work 👍🏻

Might look at this myself. Much weight save over the OE setup with passenger wiper arm on the drivers side you reckon?

I reckon for sure. I have the original linkage removed obviously, I think that alone weighs double the ally plate I have used

 

[Nafoff]

UPDATE:

In a push to get the car potentially MOT'd at/near the end of the month I am trying to get through jobs as and when time allows.

So, continuing on from the Dash/ECU fuel saga I think I am almost there. I have had to do/redo and redo again some of the wiring which takes a fair bit of time, especially if you have OCD like me. There were a few things to address with the wiring so I worked these out in order and set about it.

First up was adding in 2x 0.5a fuses to the Dash and Terminator wire circuits. This was on the advice of Race Technology to protect these items that little bit more. The best way to do this was to add them down at the wiring panel. They sit nicely here and are easily accessible.

When everything was wired back in, fuel in the tank and the car turned over I had all the information coming back to the dash, but the oil temp and pressure were still wrong. It turns out that the regulator had died too, so a new one of these was sent from Race Technology and this was changed out too (not an easy job when the wire gets shorter every time you cut into it). Yay, correct readings....

Next was to consider what I was doing with the fuel sender. I had done a lot of research on this and spoken to a lot of people as well as Race Technology. I managed to find a reference of the wiring diagrams for both the sender and dash ends so that helped a lot.

I initially started by running the wire from the sender to the dash. I was trying to keep it as stealth as possible as the loom was already wrapped and finished really nicely. I am happy with how it came out as its pretty hard to see.

Wiring wise the sender end of the wire needed an earth. so I needed to work out a nice way of doing this without running more wires into the car.
Previously the carbon fuel sender cover was riveted in (but not that well). I decided this could be the best place to earth to. I opened up the holes a little more, cleaned the paint off around them to bare metal and then looked at mounting a bolt through them.

Because of how I mounted the bolts I used some self adhesive foam padding strips to build up the height and to also stop the cover from rattling. I just need to touch the paint back in now (although it won't really be seen).

Next up was the dash end, however I didn't get any shots of that, its only wires, but I was concentrating a lot too.
The last part of sorting the fuel information is to measure the voltage from the sender unit each time you put in 5 litres. The car currently has 5/6 litres in it and I just wanted to see if I was getting any information.

In my long research before I set about working on this I was given information about what the empty and full voltages should be from the sender unit.
I took this information and divided it back by 10 giving me the 5 Litre increments I needed. This isn't the best way of doing it but its a start and allows some information to come through.

It plots the information on a graph and creates a formula within the Race Technology software. I was pleased to say that when the car was fired up that fuel information came through... pretty happy. I plan to run the 5 Litres down and then measure the voltage properly and re-input that for a truer reading.

With all the wiring working I set about making everything good again, re-attaching the loom to the dash bar, remounting the dash, etc etc. I have managed this time around to place the communication plugs for the loom (ECU) and the Dash to the right side of the steering column, this will make things significantly easier for any plugging in/problem solving in the future.

and, just to finish off tidying the interior back up I added the carbon roll cage protection strips. Really surprised with the quality carbon tape, round trimmed at either end of each pad they have come out really well..... getting there now.

 

[Nafoff]

UPDATE:

So more of a tarting up update as I think I am genuinely running out of things to do for the MOT, or might even be done.

Despite what I have just said above about an MOT I don't really want to run side repeaters. The loom was not made for them and I don't want to chop into it more again. I also don't want to just leave the holes empty so looked to make up some carbon blanks.

I am making this sound like a really quick process but the images below were taken in October 2019..... ha

I used tape to get the sizing and then transfered these to some carbon pieces which were then trimmed to size.
I added some super thin double sided tape and applied them to the car. (double sided tape for if I rally need to remove them and add side repeaters).

Next up was the window surrounds on the doors. I decided a little while ago that I wanted to paint these black so they looked more original. Obviously this is a little bit harder when the window is bonded to the door, but it wasn't to bad. I got the frame all masked up and then scotched it in prep, before applying a couple coats of primer and then satin black

It was only the curved corners that were a bit of a faff but they came out well.

Next I need to re-attach the mirror glasses to the housings and back to the car, but then I think I will basically be MOT ready.
Hopefully

 

[massiveCoRbyn]

Glad you're finally through the wiring issues. Car looks mega!

 

[Nafoff]

Glad you're finally through the wiring issues. Car looks mega!

Cheers mate, it is tough when stuff like that happens, but each time I try and take something from it, I learn more and I know the car that much better each time I have to sort it.

 

[Nafoff]

UPDATE: MOT IS BOOKED.

Genuinely already nervous.
From viewing the thread anyone got any suggestions on things I may need to worry about?

 

[EVO 4LEX]

Pretty sure no side repeaters is a failure.

 

[RSRowe]

One front indicator (Category 1, 1a or 1b), one rear indicator (Category 2, 2a or 2b) and one side repeater indicator (Category 5) or, in the case of a motor vehicle having a maximum speed not exceeding 25 mph, one front indicator (Category 1, 1a or 1b) and one rear indicator (Category 2, 2a or 2b).

 

[mace¬]

I read this thread, understand little of it but always wonder how many wars, pandemics, famines, royal weddings and general advancements in understanding the formation of the universe has happened since this project started.

 

[Chambers_RS]

Pretty sure no side repeaters is a failure.

Need a friendly mot tester 😉

 

[robzracing]

Definitely need a tester who understands the guidelines for track/race/rally vehicles.
Seatbelts and dash lights are the usual hurdles.

 

[Coops Mk1]

Great to see her so close Neil, it's gonna be so damn good to see her sideways down craners at Donington or skittering down the goose neck at Cadwell

 

[Nafoff]

Pretty sure no side repeaters is a failure.

One front indicator (Category 1, 1a or 1b), one rear indicator (Category 2, 2a or 2b) and one side repeater indicator (Category 5) or, in the case of a motor vehicle having a maximum speed not exceeding 25 mph, one front indicator (Category 1, 1a or 1b) and one rear indicator (Category 2, 2a or 2b).

Vehicles first used on or after 1 April 1986 must be fitted with one side repeater indicator on each side. Instead of a separate lamp, the side repeater might be part of the front direction indicator if it includes a wraparound lens.

Lamps incorporating a side repeater are marked either with an ‘E’ mark in a circle or an ‘e’ mark in a rectangle above which is a number 5. However, some vehicles are fitted with a wraparound lens with no European approval markings. These can be tested by standing approximately 1000mm to the side of the vehicle’s rear bumper with the indicator on. If amber light can be seen coming through the front lens (not a reflection) this is acceptable.

Sounds open to interpretation

 

[Nafoff]

Definitely need a tester who understands the guidelines for track/race/rally vehicles.
Seatbelts and dash lights are the usual hurdles.

Need a friendly mot tester 😉

Not sure how ‘friendly’ they are yet, but they do run a race team, hence me speaking to them in the first place. 👍

 

[RSRowe]

Wasn't trying to piss on your fire btw. I'm sure you'll be able to get it through if the tester doesn't do things exactly by the book.

 

[haimsey]

Good work with the window surround on the doors - finishes them off perfectly.
All the best with the MOT, as with everything else said aside from little niggly things. Side repeaters might be a down fall, but you might be able to get them to glance over it.

 

[Nafoff]

Wasn't trying to piss on your fire btw. I'm sure you'll be able to get it through if the tester doesn't do things exactly by the book.

Ah not at all mate, don’t worry

 

[Nafoff]

So on my list of concerns and things to address at the moment is:

Full size front plate (need to fit plates)
No visible Vin number (take v5 doc)
No Side repeaters
No Speedo (hopefully can use phone app and mount)

 

[Nafoff]

UPDATE:

The countdown begins to the MOT on Saturday with me being a little bit concerned about it but not with not much more I can do, it is in their hands.

There were some obvious things to do, like fit proper number plates. I had previously made up a carbon rear track number plate but I first sorted a carbon front number plate to match.

Using that as a template I knew where I needed to put the velcro on the main full size number plate (as there are holes in the bumper to feed the radiator).
This was sorted and both were applied, it is weird seeing the car with proper plates on again.

The window frame edging on the drivers side has now been completed to match the passenger side. So happy I did that, it looks so much better.
I then needed to re-fit the mirror glasses to the mirrors. When I removed them a long time ago I gutted the heavy electric internals so when re-fitting them I got them set in the correct positions when I was sat in the car, marked up the positions and then glued them in-place... Perfect.

Next up was the fuel level display. I needed to start of by draining the tank. I made a simple but perfect loom for the job that attached the battery one end and I could place on the fuel sender + and - the other end.

I started pumping it out from the fuel rail connection by myself initially then as it was getting to the dregs got the wife involved to let me know when it was running out. With around 10ltrs out I then had to set-up a new calibration on the dash to register the voltage put out by the fuel sender and start adding 5ltrs at a time and noting the voltage readouts.

This was done with not much trouble in fact (when it was a job i was initially dreading). You then put the readings you have back into the Race Technology software and it calculates an equation and displays the output. The car is now sat with a full tank of fuel and all the items I want working on the display.

There is not really much more to do now so I am doing little jobs here and there, just anticipating Saturday now really.

 

[JackJack]

Great progress 🤞 for the MOT

 

[Nafoff]

UPDATE:

The cars is also set to be insured in preparation for the MOT. I done a lot of research and found Reis Motorsport to be a good option.
This proved to be even better when I realised I could put our van on the insurance with them as a support vehicle too. Perfect.

The car will be fully covered with an agreed value set. I can change the spec throughout the year and not need to let Reis know too.
I have to send Reis a full spec of the vehicle which was interesting to sort as I have never written it up before, but this can be seen below:

Renault Sport Clio Phase 1 172

Body
Phase 1 172 shell
182 boot floor
Full bare metal strip down (including sealer and stone-chip) before full RAL6018 repaint
CCF Fiberglass doors
CCF Fiberglass phase 2 tailgate and cup spoiler with aero catches
Aluminium bonnet with aero catches
Stripped out front and rear bumper (rear bumper also cut down)
Fog light brake cooling feed with bespoke carbon deflectors
Early Renault fuel filler cap (no key needed)
Roof scoop feeding internal ventilation.
Front heated windscreen
ACW motorsport plastics door and ¼ panel polycarbonate windows with vents
Plastics for performance rear thermoformed polycarbonate screen
Phase 2 rear lights
Phase 1 front lights (split down and painted black)
Bespoke carbon indicator blanks
Radical carbon splitter
TRS tow straps front and rear
Oreca full weld-in roll cage with additional front suspension turret tie-in and dash bar. Tie-in to exhaust tunnel and rear tie-in to suspension turret with strut-brace/harness bar. Also tied in to A and B pillars.


Engine
Phase 1 172 engine
428 Catcams and group n cam timing
Jenvey 48mm Individual throttle bodies, Jenvey fuel rail
Bespoke RS Fabrications aluminium airbox direct feed to ITB’s
Bespoke RS Fabrications vertical aluminium radiator
Bespoke RS Fabrications slam panel bar
PMS ITB bracing plate
Bespoke manifold back centre exit centre exit exhaust
Magnecore HT leads
Bespoke coil pack bracket
Aluminium 2ltr Oil catch can
A/C and power steering delete
172 Cup alternator
Vibratechnics solid engine mounts (x3)
Samco yellow silicone coolant hoses
Phase 1 172 gearbox
PMS shifter
Specialist components Delta 400 ECU
Direct braided fuel feed line


Suspension
FK Konigsport Coilovers
Northloop roll centre kit
Powdercoated and Powerflex purple bushed subframe
PMS solid front top mounts
PMS solid mounted strut brace
Whiteline Rear Anti-roll bar
Powerflex black bushed rear arm
Solid top rear suspension mount bushes
Rear hub spacers and camber shims
Grayston stud and nut conversion


Interior
Recaro Profi SPG bucket seats (x2)
Schroth harnesses (x2)
Getflocked flocked MK1 dash top
Bespoke carbon dash panel with Race Technology Dash2 mounted within and race technology dash loom
Sparco dished suede steering wheel with Lifeline snap-off boss and (operations) button panel
PMS shifter central mounted (vehicle) button panel
Streamline carbon door and 1/4 panels
Bespoke pull straps
Bespoke carbon false floors (x2)
Longacre wide-angle rear view mirror
Lifeline rain/fog light on bespoke carbon mount
Bespoke passenger floor electronics mounted including Odessey battery, fuse/mini-fuse and relay panel and Armtech battery protector
Complete bespoke re-wire wiring loom


Brakes
EBC grooved front and rear discs
Carbon Lorraine RC6 brake pads
Proline full internal brake line kit with Titon bias valve
172 Cup master cylinder


Wheels
Black 15” OZ supplerleggra with Toyo R888 tyres

 

[Nafoff]

UPDATE: (all be it a very small one)

I had some Helitape that I bought a long time ago and as I have minty fresh paint why would I not add a little protection before it gets used.
I made up some masking tape templates and cut out the corresponding small helitape patches.

I only wanted to protect the area's that get effected by road rash, these were just behind the front wheel, the bottom rear corner of the door aperture and just in-front of the rear wheel (all shown below).

With that done I am pretty much sorted for the MOT tomorrow.

Next thing I wanted to do though was give the car a bit of a wipe over. We have just done some work on the driveway which now means the van doesn't block both garage doors so I rolled the clio out and gave it a bubble bath and wipe over....

Can't wait to drive it tomorrow....

 

[Nafoff]

UPDATE:

Saturday was MOT day, I was awake early and left the house at 7.30am to get the car to the garage for 8am.
I reached the garage bang on time to meet the garage owners who had just finished dropping a new engine into their race car that had got to them the night before from Kent.

They made me a coffee and we talked 'shop' for a while before pulling the car into the MOT bay.

The tester was impressed with the build as were a fair few passers by and dog walkers who seemed to know the workshop owners as they commented.
The build wasn't about that but it is certainly nice to hear...
A little bit later I was the very proud owner of one of these... 10 years after its last MOT in 2011

Absolutely made up...
With the pass I then taxed the car online and went for a little drive to see @Daniel at Ellani Cars just over the severn bridge, this would allow me to get it up to a decent temp and put some road miles on it.

It was brief before I had to return home but I am still buzzing now...
The wife and my son were waiting to congratulate me... ha

Needs some road miles put on it now as a 'shakedown' and also a trip to Cooksport for the geometry.

 

[Nafoff]

Not really an update as such...

I planned to go out for a drive over the weekend and by the time I got around to it it was raining. Now initially I will admit I didn't really want to take it out in the rain, stupid huh, but then I reconsidered it and thought it was a pretty good idea. I need to shakedown the car in the wet to see the niggles, to check where leaks may come from, to see how the wiper and the heated screen works.

I put about 40miles on it in the rain and it was brilliant. Not many leaks or drips (only really from the roof scoop a little). The wiper was great even though I haven't yet applied rain-x and the heated screen is brilliant, really happy with how they are were.

The car still needs geo set-up and where it is so stiff it is a bit of a handful on the road but she accelerates so so well and the noise is awesome. Steering wise I am not really noticing it much, I am surprised as people don't seem to like the straight up looped manual conversion but I am not having an issue at all yet.

Next journey will be to geo set-up I think, need to get that sorted and then a track evening booked.

 

[Bluebeard]

Have you got no PAS then?
I haven’t either but I’m going to fit it this winter.

 

[Andy P]

Looking great. Before I zoomed in I thought it was Bristol Airport.

Some nice drives over the Mendips not too far away.

I think @Daniel knows a good place in Bristol for geo set up.

 

[Nafoff]

I missed these replies, apologies i have had a lot on.

Have you got no PAS then?
I haven’t either but I’m going to fit it this winter.

Nope no PAS at all, and in all honesty I can't see what the fuss is all about...

Looking great. Before I zoomed in I thought it was Bristol Airport.

Some nice drives over the Mendips not too far away.

I think @Daniel knows a good place in Bristol for geo set up.

It is Bristol Airport, but not the main entrance. I have already been for several runs across the Mendips so certainly making use of the close proximity to them.

 

[Nafoff]

UPDATE:
Last week I got across to Cooksport for the geo/suspension set-up. It is a pretty good drive up across the mendips so would provide quite a good comparison journey out and back.

I had a good chat with the guys there regarding what I was using the car for and how I would like it set-up. I wanted the car to be quite progressive on oversteer, a long long time ago I had it snap on me and it wasn't nice. We talked about corner weighting it and they advised against it on a track-day car, I am more than happy to take there advice on that (although note the weight distribution further down)

They raised the front of the car slightly, they wanted to raise the rear but the adjuster rings were corroded to the thread so that wasn't happening, although it wasn't ideal this was not a major issue. I worked from the office there and by lunchtime I was sorted.

Set-up spec below:

I had previously had the car weighed at Northampton Motorsport but that was missing the front bumper and a couple other little bits, plus it was weighed with an un-kown amount of fuel so I was keen to get it weighed again, it was good to see the weight distribution too.

Pretty pleased with the weight. At Northampton Motorsport it came in at 830kgs.
The above was taken with 20lts of fuel and me sat in it so that is:

927.5kgs (20ltrs fuel + me)
853kgs (20ltrs fuel)

Now I need to use it....

 

[Nafoff]

UPDATE:

The summer seems to have been pretty much a write-off, lots of personal stuff going on which has been tough. It has meant the car has hardly come out which is quite a shame. Hopefully things are picking up now though and I am possibly looking at booking a trackday in October.

Back to now though I had several nights last week where I was stuck in the house of an evening so I decided to give the car its first proper clean since it was painted. I used the same procedure I have for years which is noted below, this is probably well out of date now with the detilers but it seemed to get good results, the Swisswax Carnuba is a b**ch to get off though.


Wash > Clay > Wash > AG Super Resin 1 > AG Super Resin 2 > AG Extra Gloss > Swisswax Carnuba

 

[Nafoff]

UPDATE:

I have been using the car for various 'out and about trips' recently just to keep it in use and for a prolonged shakedown I guess.
I decided to pop out this week in a lunchtime and decided on a loop that took in some twisties a short motorway run and then a dual carriageway home...

With 5ltr on the dash I thought it was probably ok but there were places I could fill up on the way if needed. All was going well until the dual carriageway about 4miles from home. The car slowed to a stop and wouldn't re-start.... with 5ltrs still displayed on the dash I concluded I was out of fuel.

I deliberated what to do, but first I felt I needed to get the car off the dual carriageway, I pushed the car 1/2 mile off the dual carriageway down the slip road and back under the dual carriageway where I could push it uphill no longer.... I called a mate who kindly came and towed me home.

I now need to relook at the fuel display and input some new readings as I am sure there wasn't 5ltrs left when the car stopped....
On a positive note though, it is super-light to push when it breaks down...

 

[gez 172]

That was my thoughts as I was reading it - it must be light to push 😂

 

[Nafoff]

That was my thoughts as I was reading it - it must be light to push 😂

It must have been hilarious to pass me, I was stood up pushing (not bent over straining) - basically I was taking my car for a walk....

 

[Nafoff]

UPDATE:

When I got home from the previous breakdown I put what little fuel I had at home in the car and it started up straight away - quite a relief.
New readings were inputted into the dash with the 5ltr reading now being used as the 0ltr reading (this also corresponded with some advice I got previous to setting up the dash the first time).

With the new readings input I went out for a drive with 'Jerry' last night with the intention (this time) to run out of fuel....
I did another 50ish miles last night and still didn't run out which was pretty frustrating.

The last 18miles of that was on -0.5ltrs to so that plan didn't work.
Could really do with the tank being empty again so I can see what the dash reading says - I may have to empty it again.

 

[R29TJR]

It must have been hilarious to pass me, I was stood up pushing (not bent over straining) - basically I was taking my car for a walk....

Maybe take a lead with you and attach it to the front towing eye for more comical effect!

 

[Nafoff]

UPDATE:

I wasn't particularly happy with just trying to use up fuel on my last drive, it seemed pretty irresponsible (this was pre the fuel 'crisis') so I decided I would rig up my fuel pump loom at pump the system dry... I must have got 0.2 of a litre out so I must have only just got home from my trying to break down drive previously.

With the tank drained down the dash was reading -0.5ltrs so I am happy the dash is displaying within the regions of correct, ultimately I will not be letting it go that low again so it shouldn't be a problem.

With the fueling pretty much there and the weather turning I was well aware that the car hasn't seen a track at all. I wanted to finish the year with a shakedown/trackday and had my eyes on the Cooksport day at Castle Combe. I held out until yesterday to keep an eye on weather forecasts - it seems good so I got it booked up. There are nerves and excitement about it but we will just have to go and see how we do.

I knew I needed a couple of things before the trackday, mainly a long sleeve t-shirt and a helmet so both were ordered a few weeks back.

The car now just needs a check over and I need to sort some simple spares to take with me... my next post will probably be post-trackday, hopefully all goes well.

 

[incy-spider]

Sent from my iPhone using Tapatalk

 

[Gray]

View attachment 1561836


Sent from my iPhone using Tapatalk

uhh ohh... Hopefully nothing serious, rear wheel bearing issue?

 

[gez 172]

Snapped stud?