Photobucket


+- +-

+-User

Author Topic: Tim's Mk1 Race Car build thread  (Read 3889 times)

0 Members and 1 Guest are viewing this topic.

Offline Tim Moll

  • Sr. Member
  • ****
  • Posts: 266
  • Welcome to the JMR forum.
  • Location: Ripley, Derbyshire
    • View Profile
Re: Tim's Mk1 Race Car build thread
« Reply #105 on: July 03, 2014, 10:00:13 pm »
Unfortunately I was still plagued by the misfire at Cadwell, however the good news is that thanks to the amazing technical backup from Karl at Emerald we have now found the cause of my woes  8)

And my initial thoughts of an ECU issue was kind of correct.....although the true cause is the injectors are the wrong impedance which is causing the ECU to go in to overload protection which is what is causing the misfire.  And the worst bit is that it is all my fault as I sourced the injectors based on their flow rate and didn't even think about impedance!  ::)

Offline Tim Moll

  • Sr. Member
  • ****
  • Posts: 266
  • Welcome to the JMR forum.
  • Location: Ripley, Derbyshire
    • View Profile
Re: Tim's Mk1 Race Car build thread
« Reply #106 on: July 18, 2014, 01:10:02 pm »
So a really quick update...more after the weekend hopefully!

Much to my families dismay I took the racecar on holiday with me down to Devon so that I could take it the extra 50miles down to Cornwall to see Jason and Alvin to get the new injectors fitted and get it re-mapped to suit.  While doing the new map Alvin said the car still didn't feel quite right....it turns out that the HT leads I had made for the car were arcing out to the head and inlet, as soon as these were changed everything was fine.....I have now ordered a set of custom Magnecor leads but unfortunately these aren't going to be ready for this weekends racing at Snetterton, so I will be using a borrowed set of leads to get me out of trouble  ;)

With 11 Class A cars and 20 Class B cars out this weekend the grid is going to be pretty full, but I am quietly confident that as the car is now performing as it should I will be able to get in to the top 1/3 of the field during qualy  8)

This weekend will be very much a learning curve for me as it'll be the first time the car has been performing to it's full power potential.....just hope I am able to stay on the grey stuff and do it justice.....looking forward to finishing somewhere else other than last  :-[

Offline JMR

  • Sr. Member
  • ****
  • Posts: 325
  • Welcome to the JMR forum.
  • Location: Plymouth / Saltash-Cornwall
    • View Profile
Re: Tim's Mk1 Race Car build thread
« Reply #107 on: August 06, 2014, 12:47:11 am »
Thought it about time I added my bit to Tim's build thread...

Tim and I hatched a plan a couple of years ago to build up an 8v he had been collecting parts for over a number of years. It was initially going to be a conventional 8v with throttle bodies at the rear based on a race head Tim had bought. To cut a long story short Tim got stitched up when he sent the head to be checked over by someone claiming to be a VW specialist, who claimed Tim's race head to be scrap, but in fairness he did Tim a "good" deal on an exchange head...so good I declared it junk when Tim dropped it down to me for flow testing, with valve seats that had done many thousand miles, a spark plug thread insert that pulled out when I took the plugs out and race buckets that had been shimmed by Stevie Wonder...thankfully they don't operate on here, but many have caught a cold in his hands.

Anyhow, I re-claimed the junk head for Tim but told him it wasn't up to scratch for what he wanted for a proper race engine and suggested the crossflow type head could be worth a look at. From there on in we embarked on a series of flow tests of the many variations...swirl...non swirl...German...Mexican...Tim sent so many I lost count, but a lot of the flow data can be found further back somewhere. We settled on a non swirl German casting in the end...I think!...Tim Know's them better than me...he's got less to think about than I have!...but we hatched a two tier plan which will eventually see a proper big valve head built up, but in the mean time, and based on all the flow data I had, we wondered just how close we could get to 200hp on basically std valve sizes as I've heard so many times that a big valve or big exhaust valve is needed to make power....read on to find out how close we get...

Tim supplied me the parts he had that he initially had planned to build up himself, but I fancied the challenge of seeing where we could take this so talked him into letting me build it for him. The block came in good nick but the blue had to go...didn't it Tim!...well it would have clashed with the car!









...looks much better in JMR orange!

In went a bladed crank secured with ARP main studs....



...along with steel H section rods and some Wiesco forged pistons. There were for a turbo 8v application with a deeper bowl, but I had them decked to reduce the bowl size and then the block skimmed down to match and bring the piston proud of the deck face to give my favoured squish...



It need a fair bit off....80 tho...yep..2mm!....but it took it ok much to the surprise of my machinist...



Some more ARP hardware is used to hold the head in place in the shape of their high quality stud & nut kit...



Nothing gets taken for granted in the JMR workshop, even new parts get stripped and checked...



...with the bottom end all closed off with a JMR baffled sump...



The head was built up with steel buckets & shims, along with some cam lobe clearance to stop the Kent GS6 cam we used clattering into the head!...



The internal hardware consists of Supertech valves, valve springs & top caps, and just to prove this is the "small valve" version...



It's difficult to know exactly how to describe it as it's running std valve sizes as per a GTi @ 40mm inlet & 33mm exhaust, but the crossflow comes with 39.5mm inlets in std form, so we use Supertech's 0.5mm oversize inlet which fits on the std seat ones cut to suit...so it's sort of a big inlet valve conversion but at the std GTi size we all know. The head flow's 94cfm on the inlet, which is around 8cfm more than I see from a std 40mm inlet in a conventional GTi head, and around the same as I see from a 40.5mm inlet in a conventional head...Jon Wool's & Tony B's original head both make/made 94-95cfm from a 40.5 inlet....so the crossflow head works better in that form.

Feeding the air into the head are a pair of Jenvey's finest in 45mm flavour, mounted on one of our JMR inlet manifolds which was prototyped on this engine...



...and the waste gasses exit via Tony B's old Ashley 4-1....nothing trick (yet!), but it works...



Tim supplied the trigger wheel already mounted on the front pulley so I made one of my sensor brackets to suit, and we gave it all a stir on the AP Motorsport dyno......but did we hit "our" 200hp target....



....not quite.....197hp @ 6,500 rpm, with a drop of to 194 @ 7000. Peak torque is very strong though with 162ib/ft @ 5000, which is 20-25ib/ft up on what I see from the top spec 1800 8v hillclimb engines...and they're far from slow!

When I say "our"...Tim had his fingers crossed for hitting 200 but I didn't calculate it as possible on the small valve head as I knew it would cap the torque back at the very top end and expected around 194-195, but it's still pretty good for a restricted 2ltr, and in all honesty as Tim has to run to a power to weight limit in the VAG trophy it gave a touch over what we needed for the cars weight so he'll need to carry a couple of kilo's ballast to start with to give the turbo boys a chance!....until we change to the proper big valve head over the winter that is!

After a few installation teething troubles Tim had a great run coming up through the field at Snetterton recently only for 5th gear to shred itself 2 laps into the first race of the weekend!....roll on Brands Hatch in a couple of weeks...I'll be watching from the sidelines so fingers crossed! ;)




Offline ces

  • Newbie
  • *
  • Posts: 43
  • Welcome to the JMR forum.
  • Location: france
    • View Profile
Re: Tim's Mk1 Race Car build thread
« Reply #108 on: August 06, 2014, 06:17:34 pm »
nice work  8)

Offline Tim Moll

  • Sr. Member
  • ****
  • Posts: 266
  • Welcome to the JMR forum.
  • Location: Ripley, Derbyshire
    • View Profile
Re: Tim's Mk1 Race Car build thread
« Reply #109 on: August 06, 2014, 10:41:09 pm »
Gearbox is currently being re-built ready for Brands Hatch GP circuit on 16th & 17th August, I was hoping to be able to get it back and in so I could do a test evening at Donington Park next Thurs....will have to see when Mart manages to get it finished as he's had to do a fair bit of work on it including new bearings all round, new springs and keys for all the synchronizing hubs, new 5th gear and 5th gear retaining ring, as well as a full strip down to clear out all the debris!

Here's  the broken spring on 2nd gear synchronizer hub which was why I was struggling to engage 2nd gear

and here are all the teeth that had disappeared off of 5th gear...

Offline Tim Moll

  • Sr. Member
  • ****
  • Posts: 266
  • Welcome to the JMR forum.
  • Location: Ripley, Derbyshire
    • View Profile
Re: Tim's Mk1 Race Car build thread
« Reply #110 on: August 15, 2014, 08:18:58 am »
So a quick update.....

Gearbox has been re-built and re-fitted, attended a track evening at Donington last night just to give the car a bit of a shakedown and make sure evrything is OK before heading down to Brands this afternoon for the next rounds of the Championship.

The good news is that she didn't miss a beat, but unfortunately I only managed to get three runs in before being black flagged and pulled from the circuit due to driveby noise....apparemtly I managed to record 102db  :o

I had fitted new silencers, courtesy of Milltek, while I was waiting for the gearbox to be re-built as the Jetex ones got a proper kicking due to the missfire I had at the start of the season caused by the incorrect impedance injectors I had supplied Jason  ::)  So I'm now starting to think that the noise may be induction road from the front facing ITBs!!

I guess I will find out for certain when I am noise tested at Brands this weekend........fingers and toes crossed!

I will update after the weekend, but if anyone is down that way and fancies coming along let me know  ;)

Offline ces

  • Newbie
  • *
  • Posts: 43
  • Welcome to the JMR forum.
  • Location: france
    • View Profile
Re: Tim's Mk1 Race Car build thread
« Reply #111 on: August 15, 2014, 11:22:38 am »
thanks for update  8)

Offline Tim Moll

  • Sr. Member
  • ****
  • Posts: 266
  • Welcome to the JMR forum.
  • Location: Ripley, Derbyshire
    • View Profile
Re: Tim's Mk1 Race Car build thread
« Reply #112 on: August 20, 2014, 10:44:56 am »
Well good news and some bad news......

Good news is that all my mechanical woes appear to be behind me and I managed to pedal round to qualify 10th out of 35.  I had a bit of a moment in qualifying when I completely ballsed up Surtees (I took the Indy circuit turn in point rather than GP) and ran VERY wide across the curb and through the kitty litter.....

Fast forward to race 1.....I got a reasonable start but heading down toward Paddock Hill bend one of the fast starting Class B cars tried to squeeze through a closing gap between myself and Ken Lark in his Corrado and hit me in my rear quarter putting me in to a spin and straight in to the side of Ken, opening the Corrado up with my towing eye like it hit been cut open my an axe all the way down the sill  :'(  I then tapped the tyre wall as well....how the rest of the field flooding through managed to avoid both Ken and I as we both spun across the circuit I'll never know, but thankfully they did!

A quick check of the temps and pressures showed nothing alarming so I spun her round and after a few twitches of the steering to make sure all four wheels were still pointing in the same direction I set off after the field like a man possessed....the rest of the race was as messy as that first lap with a couple of yellow flags and a race stoppage and re-start due to another accident.  By the end of the race I had managed to battle my way through to 11th overall, which considering the bump I'm pretty pleased with!

2nd race was uneventful by comparison, starting 11th and finishing 11th, I passed the two class B cars that started ahead of me but also got passed by a couple of the other Class A boys that started behind me, although checking car over thoroughly and straightening as best we could the car didn't feel a 100% and I struggled with selecting the right gear a couple of times, taking 5th instead of 3rd which actually cost me a couple of places as was battling with a couple of guys at the time and this allowed them to get past....we know the chassis legs have been pushed across in the shunt so suspect the gear linkage alignment is out as a result  >:(

Car is partially stripped already and the fibreglass panels are going back in the mould to repair them, this will add a little weight but cheaper than having to buy new panels  ;)

A new front panel was ordered from VW Heritage on Monday and should be being delivered today ready for the old front panel to be cut off and everything got ready for her to be put on a jig to get everything straight again ready for next round at Donny  ;D

I'll try and get some pics on later if I get a chance.

Offline smellyermaa

  • Jr. Member
  • **
  • Posts: 84
  • Welcome to the JMR forum.
    • View Profile
Re: Tim's Mk1 Race Car build thread
« Reply #113 on: September 07, 2014, 01:42:04 pm »
Good that you didn't let a wee bit of damage stop you from racing it - sounds like it must still be straight enough as you went well.

Offline GEL

  • Full Member
  • ***
  • Posts: 104
  • Welcome to the JMR forum.
  • Location: Doha
    • View Profile
Re: Tim's Mk1 Race Car build thread
« Reply #114 on: September 20, 2014, 07:52:44 am »
How`s things going Tim ?
Mk1 Golf GTI 16v
Alpina B10 V8 Touring
Audi S4 Avant V6 quattro

Offline Tim Moll

  • Sr. Member
  • ****
  • Posts: 266
  • Welcome to the JMR forum.
  • Location: Ripley, Derbyshire
    • View Profile
Re: Tim's Mk1 Race Car build thread
« Reply #115 on: September 21, 2014, 07:21:36 pm »
Well what an awesome weekends racing at Donny!

I qualified a respectable 8th yesterday and then bettered that in the race by finishing 7th......fast forward to today and starting from 7th I ended up 5th....absolutely buzzing and was really humbling to see our very own Jason Moyle choking back the tears  ;D

Offline GEL

  • Full Member
  • ***
  • Posts: 104
  • Welcome to the JMR forum.
  • Location: Doha
    • View Profile
Re: Tim's Mk1 Race Car build thread
« Reply #116 on: September 21, 2014, 10:25:34 pm »
Well done ...   :)

Any pictures of Jason then  ;D
Mk1 Golf GTI 16v
Alpina B10 V8 Touring
Audi S4 Avant V6 quattro

Offline Tim Moll

  • Sr. Member
  • ****
  • Posts: 266
  • Welcome to the JMR forum.
  • Location: Ripley, Derbyshire
    • View Profile
Re: Tim's Mk1 Race Car build thread
« Reply #117 on: September 24, 2014, 10:13:59 am »
No haven't got any pictures of him blubering ;-)

I'm sure he'll be along with his own take on things in due course....he will have had something in his eye or something lol


Offline Tim Moll

  • Sr. Member
  • ****
  • Posts: 266
  • Welcome to the JMR forum.
  • Location: Ripley, Derbyshire
    • View Profile
Re: Tim's Mk1 Race Car build thread
« Reply #118 on: November 02, 2014, 04:34:40 pm »
Unfortunately due to needing surgery to relieve severely trapped nerves in my wrists and elbows of both arms (left arm is being done in Dec) I missed the final round of the season at Oulton Park, which was really frustrating as I'm certain the track and weather conditions would have given me a chance to build on my recent performances and maybe even podium!

So with the 2014 season now at an end my attention has very much turned to planning for next season...so what do these plans include?

Well as previously stated Jase believes the reason for the dip seen mid range in the torque curve is the 4-1 exhaust manifold currently fitted, so later this week this is being removed and the car taken up to Tony Law exhausts in Leeds for a bespoke 4-2-1 JMR manifold to be designed and fabricated using primary and secondary runner lengths as specified by Mr Moyle. 

The new manifold will also help with the increased hot gases which will need getting rid of as a result of the Big Valve crossflow head that Jase is in the process of doing for me.  This head will again be treated to Supertech valve gear, but this time it'll have 42mm Inlet and 35mm Exhaust valves fitted which should allow the 2ltr bottom end to breath a lot better throughout the rev range, but especially at the top end where it's currently being strangled by the std size valves!

At the same time as the engine is being upgraded the gearbox will be heading down to Mart (aka Hotgolf) to be stripped and checked over and while it's with him I'm contemplating getting a different diff fitted, as while the Quaiffe is good I feel a plated diff will be better suited to the type of abuse and use the car is being subjected to.

The next thing planned for the winter is an upgrade to the suspension setup.  'Dolly', as the car has come to be affectionately known over the season, is currently sitting on Gaz Gold coilovers.  Again these are great bits of kit, but I can't help but feel that if I was running proper motorsport 3-way adjustable dampers like the rest of the Class A cars I would see a huge improvement in the handling characteristics!

The final piece of the puzzle will be a lot of aero development, in the form of a front splitter, rear diffuser and flat floor, this will the hardest of all to get right and will require a significant amount of back to back testing, however this will also allow me to get more 'seat time' in Dolly which I haven't really managed to do this season unfortunately.

I will keep this thread updated over the winter and let you know how we're getting on.  My team manager and best friend Ben is currently trying to secure us some much needed sponsorship for next season, so if anyone knows of anyone or any company that may be interested please get in touch  ;)

« Last Edit: November 02, 2014, 04:36:52 pm by Tim Moll »

Offline GEL

  • Full Member
  • ***
  • Posts: 104
  • Welcome to the JMR forum.
  • Location: Doha
    • View Profile
Re: Tim's Mk1 Race Car build thread
« Reply #119 on: November 03, 2014, 05:22:39 pm »
Hi Tim,

Good to hear that you are `on the mend` and thanks for the update, look forward to the execution !

Diffs ... I too have considered `where to` after the Quaife ?

Full plate appears to be too harsh for my use so perhaps a Wavetrac or Kazz ?
Mk1 Golf GTI 16v
Alpina B10 V8 Touring
Audi S4 Avant V6 quattro

 

+-Recent Topics

JMR – Customer Cars