Corsa Maxi rally car

[azzmi]

yes mate, thank you for reply,
I have a number of pics of the cars progress. I don't want to mess Rob's area but if he execuses me here some of my clutch pics.
I have three of used clutch disc to be choosen and restored. With the tought of six pad disc is more lasting.
http://www.elk.itu.edu.tr/~azzmi/pics/DSC00002.JPG
After new friction pads riveted, complete clutch,
http://www.elk.itu.edu.tr/~azzmi/pics/SANY1279.JPG
Flywheel surface conditioned and bolted,
http://www.elk.itu.edu.tr/~azzmi/pics/SANY1288.JPG
positioning clutch disc by a "specially broken" tool
http://www.elk.itu.edu.tr/~azzmi/pics/SANY1290.JPG
finally clutch is in-place
http://www.elk.itu.edu.tr/~azzmi/pics/SANY1295.JPG
my new and ex grN corsas

cheers,

Azmi

[azzmi]

I use a sprung Helix plate as its less shock on the transmisson, i assume thats why Rob has too.

Azmi have you any pics of your rebuild?

I am afraid you are indeed right about the shock on the transmission. But in short term I don't have the time enough to order and change the disc. I also think as "there must be something positive about solid hub that because of it is produced." Unfortunately there was so many problems with the car and sometimes I had to ignore some drawbacks to get the car ready at the time. So I believe a second evolution is necessary after a test drive in coming rally.

[robertkassner]

Hi azzmi,

Yeah Kev is right about the clutch. Plus i was also told that the sprung clutch gives you a bit of slip on the clutch rather than it being like 'on or off'.
Which for me was a bit of a plus as ive never driven a car with a paddle clutch before.

Nice looking corsa you have. You have any more pictures?


Rob

[lee303]

Hi azzmi,

Yeah Kev is right about the clutch. Plus i was also told that the sprung clutch gives you a bit of slip on the clutch rather than it being like 'on or off'.
Which for me was a bit of a plus as ive never driven a car with a paddle clutch before.

Nice looking corsa you have. You have any more pictures?


Rob

hmm, have to disagree with the 'slip' comments, having driven both now i didnt notice any difference pulling away tbh and find a solid clutch to be no grief at all

[azzmi]

Hi Rob,

I have been driving in rallies for a while, My first car was a Renault 11 TXE GrN with three pads cerametalic clutch disc with spring hub. Then I made some machining and adapted it to my GrN Corsa. When I brought this kit car, the solid hub discs came with it as an "used spares" - the guy who sold the car call them like this-. I agreed with lee about clutch feeling of engagement practically there is no difference, both engagement and disengagement are very sudden for both types of hubs. Since there is no need to soft engagement in rallies,that is improving gear chenge speed and of course heat resistance of clutch disc. I think the weight of spring type hub is a bit more heavy. But the difference is not so dramatic. I was hoping an answer like "there is something this type hub which gives you extra horses .

I have many pictures and also some videos about rebuild of the car I will be happy to share them. But unfortunately there is no pics in the super special. If you like to watch my other GrN corsa (totally standard) in the forrest action you can click the link. http://www.elk.itu.edu.tr/~azzmi/clip00.wmv

Here is the last picture of her


I can upload here a few more if it is not a problem.

Cheers,

Azmi

[robertkassner]

No problem mate, get them on here!

[azzmi]

Eh, the car was not so mint condition when arrived. Me and my wife (also my navigator) started to dismantle everything we touch.

Firstly I liked to check gearbox (6 speed dog quaife with plate LSD). Unfortunately 1-2, 3-4 dogs and selectors heavily worn.

But the real drama was inside of the LSD unit. two of the friction plates was fractuated eight pieces.


Since there is no time to get originals I have drawn it by auto cad then laser cutted and surface grinded them.

Then got LSD together.




I hope to make a full rebuild to the gearbox with original parts to next coming spring.

Hope you'll like them,

Cheers,

Azmi

[azzmi]

By the way,

As you can see I like to work at home

[robertkassner]

Great work, its good to see you can do most of the stuff youself.

What kind of suspension setup do you have on the front? Do you have pictures?
Wanting to see what the struts are like as using standard suspension strut gives you too much camber.

rob

[azzmi]

Thank you Rob,

Front and rear suspensions are proflex two way adjustables, front with 40kg/cm progressive, rear with 33 kg/cm springs.
I will put the pictures as soon as resized them. Much camber is a result of wide track kit. if you use proper strut, camber will stay reasonable limits. The mounting holes of standard struts are very close to the strut body, that is resulting very much negative camber. Maybe to drill new holes or widen the standard holes can help.

[azzmi]

Here they are,

[rc]

you rally guys have some pretty dam impressive bits if kit

[azzmi]

side effects of working at home.

[mattyd81]

hi guys putting the turret onto my quaife 6 speed dog box as above tomorrow. do you know the bolt thread size??? As i dont have any until i but some tomorrow

[robertkassner]

hi mate, just use the standard ones.

rob

[mattyd81]

hi rob i dont know what the standard ones are in size as i havent got any lol

[mattyd81]

oh by the way is there any torque settings for attaching the turret? not sure if there were. thanks again

[azzmi]

I think ( I will check them tomorrow) they are metric type M6X1mm bolts approx 20mm long, 8.8 grade, 1kg.m tightening torque will be enough. Do not over tighten them otherwise you will destroy the aluminium threads of the gearbox.

[mattyd81]

guys sorry for all the posts, can you tell me how you put the gearbox into neutral before you started setting up the gear linkage??

[azzmi]

sorry mate,

I think you better consult a local mechanic about this gearbox installation process.

[lee303]

to put the box in to neutral, align the three selectors you can see through the turret opening so they are central and there is a gap in the middle of them for the finger on the turret to fit through, and the bolt size for the turret is actually M7, if you dont have any then you can use clutch plate bolts as they are the same thread

[donlop]

my car

www.opelmotorsport.dk

[robertkassner]

looking good Donlop, Is that the one at Protec at the moment?

Rob

[donlop]

hey
my car at Protec at the moment? i can not see it make a link
I have many pictures i cant get them on here!

[robertkassner]

You could email them to me and ill put some up?

There is a white Corsa Kit car that looks like yours at protec motorsport in the north west - i thought it was yours.
Or did you get some parts from them as im sure they have shown me pictures of it.
Im sure it was from Denmark to.

rob