Corsa Rally Car

[am2050]

The mounts off the old car fit fine Kenny but the new ones are probably getting on for 2inch bigger in diameter and are nowhere near fitting.

Anyone got any pictures of some polybushes fitted in the later style corsa (and I'm guessing tigra) tie bar mounts. Mine seem to have loads of lateral play in the mount, spoken to the manfacturer and they can't offer any explanation, perhaps I'm missing something obvious??

mattyd81

Re: Corsa Rally Car
Have a look at my for sale thread if you need anything for your car. Plenty of rally parts I'm selling!

Nothing I need I'm afraid, service crew might like the gazebo but they've got a ground sheet and waterproofs already!

[am2050]

Rubber hose and duct arrived to finish off connecting heater up.
It's smaller and lighter than the standard setup and has made loads of room under the dash. Hopefully do the trick of keeping the windscreen demisted.




The dash has come back from flocking. Pleased with it.




Cleaned up a gearbox casing and took some material off the inside so the diff goes in and out easier when it's built up. Did it at both sides but you can't take much off the other side as you're soon to where the bearing shell sits.
Fitted new bearings, oil seals and the crown wheel and then put it back on the car. Still need to fit the cluster but will do that when it's on the car.




Whilst the box was off fitted the new thrust bearing to match the Superclutch (on the RHS, standard on the LHS) which is a fair bit different to the standard one.




Sorted the hinge mounts out for the fibreglass boot. It came with nuts moulded into it but no hinges so cut some out of an old boot and fitted them. They are spot welded onto the original boot so ground them off and had to drill them which was a right tw*t as the hole location was where the spot welds had been which was hard as hell. Several drill bits later and a bit of filing and it all lined up. The outline of the hinge was visible in the moulding of the GRP which made it easier to get the position right.




Also welded the threaded boss into the front gearbox mount rather than using one of the existing holes.




A couple more jobs out of the way, still a few to go.

[DrewyCoupe]

good work mate well done

[kennybarbour]

does that mount use a bolt thru the bushing on the chassis and then just a nut on the other end normally? im just waiting on mine coming from hocklys now, hopefully i'll get them this coming week so i can make some progress.

that little heater looks good, are you using a heated screen too?

[Rallycorsa]

Good idea that heater wonder where you got that idea ;-) (works a treat)

[am2050]

Kenny, yes, there is a cap head bolt that pushes through the bush and then can be bolted through one of the 2 holes in the mount with a nut. The kit comes with a threaded boss to weld into the mount (as the picture) if you prefer. We've welded the boss in on this car but on another one we just ran it with the bolt through the top hole with no problems.
Hopefully the heater will do the job and a screen won't be needed.

Rallycorsa

Good idea that heater wonder where you got that idea ;-) (works a treat)

Glad to hear it works well, it's tiny compared to the standard heater and frees up so much room under the dash.
Got a few ideas from your car Kev, they're costing a fortune.

[Rallycorsa]

Hopefully the heater will do the job and a screen won't be needed (It wont be needed)



Glad to hear it works well, it's tiny compared to the standard heater and frees up so much room under the dash.
Got a few ideas from your car Kev, they're costing a fortune.[/QUOTE]

Tell me about it lmao it is so small compared to the standard heater

[kennybarbour]

what colour is your interior?? im about to order my paint and that colour looks perfect. i take it its a flat non metallic grey? i wanted audi nimbus grey but the painter reckons its metallic... an answer asap would be brilliant if possible

p.s. we want an update!

[am2050]

We wanted Iron Grey (GM colour) which is a dark metalic colour but was discouraged away from metalic for both applying it and being able to satisfactorily touch it up.
The colour used is a flat grey, it looks light when it goes on and we thought it was too light but does darken off and does look good.
I'll check what the colour is tomorrow morning and let you know.

Not that much evidence of progress to show, just doing little jobs that seem to take ages. Like putting the engine loom back in; a fairly small, pre made loom that came from the other car and follows a similar route but still took an evening to put it in and be happy with it. Making little bits and peices, routing and connecting stuff up takes time but it's worth putting a bit of thought into it. The other cars we've had (both bought and built) all had stuff that we weren't happy with so putting the effort in with this.

Seat mounts have been made and both seats fitted, fuel lines are in (cheers Kev), rest of looms have been made and are in the car ready to terminate, roof vent fitted, steering stops machined and fitted, air vent covers made. Don't know what we've been messing about at!

Some photos taken over last week or so:

[Rallycorsa]

Looks great brings back memories lol

[big e]

Top work mate..

[kennybarbour]

any updates? she must be done by now, even mine is haha

[GaryVaux]

hadnt seen this thread before! Really nice car, and there was me thinking all these neat wee ideas were kennys own
The shaped centre pannel on the dash looks so much better that most of the efforts ive seen, will it be painted/covered in vinal?

[redtopnutta]

absolutley loving this!

[Rallycorsa]

hadnt seen this thread before! Really nice car, and there was me thinking all these neat wee ideas were kennys own
The shaped centre pannel on the dash looks so much better that most of the efforts ive seen, will it be painted/covered in vinal?

What do you mean Kenny's ideas both of the buggers knicked mine lmao

[FranXu]

I do not speak English as I do not as posting.
But I wanted to ask you a question about the pipes of extinction
Are you used are metal pipes? Is it "tecalan"?

In Spain, the competition rules mandating the use of metal pipe, the copper and aluminum are the most used for its ease of modeling
The problem with the fire that melts the plastic.

Very good job on the corsa, taking notes for my other car racing

[DTV Racing]

Thats definately a wellsorted out car, great attenetion to detail. will be watching this closely, your interior colour is similar to mine great colour. looking forward to seeing this done. great job so far

[am2050]

Been a while for various reasons but the cars just completed it's first event.
Pics of the car:



















and one for the sponsor...

[am2050]

We're doing the BTRDA Gravel Championship again and the first event was the Wydean Forest Rally last week.
Unusualy we were loaded up and away in good time and got to scruiteneering when it opened.



Unfortunately we lost 4th gear going from noise check and had to take out the cluster. It turned out that a peice of the 3rd gear baulk ring had broken off and wedged into 4th gear baulk ring. We found the peice and could get all the gears.
The stages were sheet ice and snow and after speaking to Pirelli we ended up using a snow road tyre.
We weren't looking forward to the event at the start with the combination of the weather conditions, nursing a gearbox and not having driven the car much.
However, Dave soon got to grips with the car and the tyres worked really well. We did suffer a puncture though but that was a result of the soft sidewall tyres and a rock we hit. We also had a couple of spins where the engine stalled and was then difficult to start and some massive moments with a couple of tank slappers in 5th gear on the ice.
Other than the initial gearbox problems the car was great.
Despite the conditions and new car we did amazingly well. We finished 2nd in class behind Julian Wilkes and an unbelievable 7th overall!







Next event is the Malcolm Wilson rally at the start of March.
This is how it ended for us last time:




Got a few jobs to do before then, including sorting out the gearbox.

[mr04rpm]

wow all i can say is wow ! im doin n xe corsa project but id love to have the time money tools to do this awsome !!!

[big e]

Looks awesome mate well done..

[rc]

great pics

[Rallycorsa]

Cracking result on the Wyedean, Mr Wilkes can drive the ass off that Nova, keep the updates coming.

[am2050]

Cluster removed and stripped.



1st/2nd and 3rd/4th sycro rings worn, 3rd and 4th gear worn and showing signs of stress to some of the teeth.
The 3rd and 4th baulk rings were worn and starting to fracture plus the chunk missing from the 3rd ring:



The box is an F15 but the quaife kit uses the syncro assemblies from the F13. Vauxhall wanted over £600+vat for the syncro bits and there's none in the UK so we got an F13 from our local breakers for £80 and stripped the bits we needed.
Got it built up along with the new gears from quaife and it's all back together.
Rest of the jobs done so we're ready for next Saturday.

Thinking of going to 15" wheels if someones got some Compomotive MO's they want rid of?

[kennybarbour]

car has come out looking brilliant! well done

excellent result on the wyedean too, seen some pics of the event and figured the white and orange one must be this car.

keep us updated with the rest of the seasons performances please!!