Cadwell 24-07-2013 shakedown post re loom and rebuild of engine.
Booked an afternoon half day with Javelin to get us back in the driving seat and to test out\prove all the new bits added to the Cup over the last couple of months. We've been on a few Javelin TD's but found this one quite busy overall, though I guess £79 for an afternoon will always attract plenty of drivers. Been the first and only time that we've had to queue (15 mins) to get out straight after the sighting laps...
Noise test - blimey, don't think i'll be doing any 98 db days from now, forgot to ask the noise tester the actual reading but Sam said it was the nosiest car by far when she was listening and she was in the paddock a fair way back up the hill too. Glad I fitted an intercom!
On the sighting laps noticed a low down hesitancy in the low rev range, mid to high range, up to the moderate speeds of sighting laps fine, loads of power and plenty of grunt to play with, slowing for the right hand hairpin after the halls complex the car struggled to pick up from the low speed. Also noticed the brakes were getting worse, to the point of having to leave a very large gap to the car in front. Carried on as I'd swapped the pads around to even their wear - the piston side always wears more - so put the brake deficiency down to the pads bedding in. Using the intercom, warned Sam about the poor brakes and the low down hesitancy so she could complete her sighting laps - not actually required but completed more for her own piece of mind.
After the sighting laps brakes where as bad as ever, the car wouldn't idle below 2.5k revs and there was a hissing noise in the engine bay. A quick call to Dan 519, with something to try for the hesitancy and us now looking for an air leak we got to work. We found a split in the brake servo pipe, managed to cut the pipe shorter, leaving enough to still be able to connect it to the inlet. With the car now running and revving with no fault, tried the brake pedal - 1000 times better, never actually driven a non assisted braked car so didn't know what was happening to the brakes at all. I'd noticed after finding the split servo pipe that the heat behind the engine was immense, a lot more than before and the the bulk head heat shield went straight down. This was allowing the heat to radiate up and behind the heat shield to where the servo pipe was situated. Simply removed the heat shield and bent the bottom 1\3 back towards the bulkhead which would channel the heat up and in between the inlet and heat shield, it worked as the servo pipe didn't split again.
I drove for a short while to get a better feel for the car but the session was cut short, red flagged we saw far too many of these during the course of the afternoon, also the low down hesitancy was back again. I jumped out remedied the hesitancy and went out on track again, another red flag saw me park up and cool down. The cup was running a fair bit hotter too, both oil and water higher - so more cooling required - nothing too alarming but enough to warrant more cooling.
The short time I drove the car, apart from the slower corners or if you were in the wrong gear, the car flew! Having come out of barn with a blue scooby behind floored it and he just got past before the left turn up hill which is Coppice. I bet without Sam, the pax seat and rails (85kgs) I like to think may be a different story. Ultimately on a longer straight I'd been left standing for sure.
Sam drove the remainder of the last session, with me in the pax seat, giving pointers etc, found the cup hard to drive as the low down hesitancy returned part way through. Sam managed to get her lap time down 10 secs in the 30 mins but still a lot slower than a std Cup. Not driven since May, long time since we've been at Cadwell and very rusty overall. Coming back into the paddock, to swap over for the last 20 mins or so the Cup wouldn't start, a phone call to Dan saw me gently pulling, from the pax side on the starter solenoid wire. It kept on coming, vibrated off, attempted to put it back on but with limited access (heat shield) and roasting my hands even after a cool down wait, left it off and finished for the day there.
With the Mallory race (3rd August) in mind arranged to drop the car back off with Dan for the 27 July and got to work to add more cooling, drilled 6 holes through the bumper to the engine bay, still got some left to do - took a while, plus Tony said I was cutting too fast which saw me blunt a hole saw after 3 holes. Slower the better, thought i'd placed the rad as far back as I needed to but caught it with the hole pilot drill....didn't make a hole but going to get a bigger rad anyway.
Replaced the servo pipe with a solid alloy one, routed more or less the same way, just got to push the servo end on 5mm more. Not much access there. Also added a bit of heat shielding to the fuel pipe which comes from the floor pan to underneath the cams, for piece of mind more than anything else. It's made of the same plastic servo pipe that split with the heat and runs not far from the exhaust down pipes.
Re fitted the solenoid wire, though Dan is going to permanently attach this while he has the car so this won't come adrift again.
A day not without it's niggles but very happy with the overall performance of the "new" Cup. The loom work, switches all worked as it should and the forged engine absolutely on the mark.