displaying posts 276 to 300 of 516

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Author Subject: DemonDriverDan's Race Rallye Project
demondriverdan

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Location: Londinium

Registered: 29 Nov 2010

Posts: 2,665

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Post #276
So, windscreen looks ok. No marks or anything on it so I think I've got away with it again Smile

No pictures but I test fitted the wheel studs to a hub and they worked ok. Took a few attempts to find a good enough drill bit but got there in the end! Will get the local garage to press the studs in properly when they refit the flange and bearings to the hub.

Took the car outside for the first time to pressure wash and gunk the engine bay:







Then gave it a couple of coats of etch primer:





Followed by some red:



Needs another coat of red in the engine bay and a couple more in the footwells as it rubs off during the year.

Also painted the slam panel, subframe mount cups and brake servo:



Nearly time to start fitting things back on again!

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Rallye Race Car
Posted 7th Dec 2015 at 13:34
eddy_gti6

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Location: Durham

Registered: 20 Oct 2008

Posts: 8,716

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Post #277
Coming on well now. Be back together before Christmas will it?

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Posted 7th Dec 2015 at 14:39
demondriverdan

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Location: Londinium

Registered: 29 Nov 2010

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Post #278
Probably not. I've got to create the new wiring loom which is going to take some time. Also want to get a Satchshift before putting the engine back in to make it easier to cut the holes

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Rallye Race Car
Posted 8th Dec 2015 at 19:49
6waysforward

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Location: Benfleet essex

Registered: 30 Oct 2005

Posts: 3,168

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Post #279
Nice work dan Thumbs up

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***Breaking*** Ph3 Silver GTI 6 High Boost Superman




Posted 9th Dec 2015 at 21:43
demondriverdan

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Location: Londinium

Registered: 29 Nov 2010

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Post #280
Cheers. Progress is going well, hopefully should be able to start putting things back in it soon although need to get a new steering rack sorted first!

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Rallye Race Car
Posted 10th Dec 2015 at 23:27
pug_306

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Location: Great Hockham

Registered: 28 May 2013

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Post #281
demondriverdan wrote:
Cheers. Progress is going well, hopefully should be able to start putting things back in it soon although need to get a new steering rack sorted first!


Did you still want to come up at the weekend buddy for the parts ?

________________________________________

1998 Supercharged White Rallye
1992 205 GTi6
205 Turbo 340bhp
Posted 11th Dec 2015 at 08:27
demondriverdan

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Location: Londinium

Registered: 29 Nov 2010

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Post #282
Is Monday ok? Will definitely take the rack and most probably the wings Smile

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Rallye Race Car
Posted 11th Dec 2015 at 09:05
pug_306

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Location: Great Hockham

Registered: 28 May 2013

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Post #283
Yes buddy monday will be fine ;-)

________________________________________

1998 Supercharged White Rallye
1992 205 GTi6
205 Turbo 340bhp
Posted 11th Dec 2015 at 09:22
demondriverdan

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Location: Londinium

Registered: 29 Nov 2010

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Post #284
Since the last update I've finished painting the engine bay and refit most of the front end so it can be a rolling shell again. Thanks to pug_306 for the new steering rack to replace the bent one and the new wings!

There are some stuff I forgot to photograph like the dash being finished and plates I've made to fill holes in the bulkhead, not that any of them are very exciting Smile

Engine bay looks quite nice now:



Hubs with the stud conversion, I need to drill out the brake discs a bit to make them fit but not the end of the world:



Steering column also fitted. You can just about make out the template for where the digital dash will sit, should be nice when it's finished!

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Rallye Race Car
Posted 29th Dec 2015 at 17:16
aaron6

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Location: On the sofa in maidstone

Registered: 16 May 2006

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Post #285
Looking good matey. Be nice to see her getting put back together. When's the body shop getting the old girl?

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Posted 29th Dec 2015 at 18:29
demondriverdan

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Location: Londinium

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Post #286
Good question! Needs to go in ASAP but there's plenty of other stuff I can do first, they don't need it running.

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Rallye Race Car
Posted 29th Dec 2015 at 19:04
demondriverdan

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Location: Londinium

Registered: 29 Nov 2010

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Post #287
Fair bit has happened since the last update. It now has an engine, brakes, dashboard, and wiring! Satchshift is all fitted as well and feels great.



I'm creating a new wiring loom for the car as the standard one is massively overkill for what I need now. It's a huge amount of work and is taking far longer than I expected but should be nice and simple when done. Most of the engine wiring is in place but I haven't got everything for the bulkhead connector yet so still more to do. Some photos of the progress:







Lots of spare wire!



Trusty heater that kept me warm all weekend



Car now runs although the map seems to have changed slightly with the firmware update as it's running a bit lumpy. It goes in to the bodyshop next weekend for a few weeks which will cause some delays but has to be done.

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Rallye Race Car
Posted 19th Jan 2016 at 13:17
demondriverdan

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Location: Londinium

Registered: 29 Nov 2010

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Post #288
Car's back from the bodyshop now, good turnaround considering the amount of work that was needed! Also trial fitted the splitter. Front of the car is going to be lowered a bit to help it but a reasonable start.

Less dents:









Spoiler was also painted and put together:

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Rallye Race Car
Posted 2nd Feb 2016 at 18:14
superchargedblack1997gti6

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Location: guildford

Registered: 15 Aug 2009

Posts: 2,376

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Post #289
Looking good mate Smile

________________________________________

Super high boost Completed, destroyer of gearboxes and 160mph club
Posted 2nd Feb 2016 at 18:38
pugheaven

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Location: Fareham

Registered: 17 Dec 2006

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Post #290
Looks awesome!
Posted 6th Feb 2016 at 06:49
Day666

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Location: Bristol

Registered: 20 Apr 2013

Posts: 5,209

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Post #291
Great Job Dan Thumbs up

What else you planning ?
Posted 6th Feb 2016 at 07:48
demondriverdan

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Location: Londinium

Registered: 29 Nov 2010

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Post #292
Cheers guys, getting there!

In terms of plans, not much else really. Lots of finishing off to do but hoping to make it driveable this weekend. Need to finish the wiring and bleed the brakes to do that which I'm hoping I can do in a day then spend the rest of the weekend doing other stuff like fitting perspex windows.

________________________________________

Rallye Race Car
Posted 6th Feb 2016 at 09:41
Day666

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Location: Bristol

Registered: 20 Apr 2013

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Post #293
demondriverdan wrote:
Cheers guys, getting there!

In terms of plans, not much else really. Lots of finishing off to do but hoping to make it driveable this weekend. Need to finish the wiring and bleed the brakes to do that which I'm hoping I can do in a day then spend the rest of the weekend doing other stuff like fitting perspex windows.


Just keep the updates coming Dan ...
Wish I'd done a thread at the start of mine 3yrs ago LOL
Posted 6th Feb 2016 at 12:38
demondriverdan

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Location: Londinium

Registered: 29 Nov 2010

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Post #294
I like to keep a log of all the work done and when I did it. It needs to go in for remap, power test and tracking before I can test it. Getting close though

________________________________________

Rallye Race Car
Posted 6th Feb 2016 at 14:17
demondriverdan

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Location: Londinium

Registered: 29 Nov 2010

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Post #295
So after a long and frustrating week I've finally had the car on track. Took it to the dyno company on Tuesday to get my power run done for the championship and what I thought would be a quick remap after changing to the standard manifold. Turned in to a full remap with the bill to prove it! Only lost 0.3hp at the wheels going from a Maniflow 4-2-1 to the standard manifold though. It also decided to throw oil on the floor from the rear main seal. Refitted that and it was still dropping oil which turned out to be the hockey stick seals, spot the problem:



With that fixed I finished off the wiring and got the fuel gauge to work with the digital dash which took a bit of messing around with resistors. Finally I fitted the rear spoiler and put it all back together again.





Yesterday we went off to Brands for the first run. As you might have seen from the thread I posted there were some pretty frustrating issues with brakes jamming on but we eventually sorted those and could put some laps in. It's fast, very fast. Between me and my brother we only had 2 clear laps and beat our fastest ever lap round there with a 55.7. The aero is definitely limiting us in a straight line but really works through the corners, the grip it has is incredible.

Quick drive-by video:

https://www.youtube.com/watch?v=fPUWdcnpo9M

Ended the day with my brother going a little wide through Surtees and cutting the grass (literally!), also managed to knock the fan off:



Day ended well. Engine survived although it's weeping a little bit of oil from the other side now, nothing to worry about. Hopefully doing a test day at Snetterton next week where I can test with and without the aero package to see how much of a difference it's making to speed.

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Rallye Race Car
Posted 23rd Feb 2016 at 14:43
welshpug!

Capt Pedantic

Location: Bigend, Wales.

Registered: 27 Mar 2007

Posts: 25,817

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Post #296
who cares about the 0.3 drop, what did the curve look like? Wink

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Posted 23rd Feb 2016 at 14:50
demondriverdan

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Location: Londinium

Registered: 29 Nov 2010

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Post #297
Gained some mid range torque, curve is a bit bouncy at that point though. I'll upload the graph next weekend Smile

________________________________________

Rallye Race Car
Posted 23rd Feb 2016 at 14:52
blandy

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Location: Bucks

Registered: 25 Feb 2007

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Post #298
Looking fantastic dan you must be chuffed. What did the headline figures make in the end?

Also will have a look at the championship wouldn't mind popping along to watch a race or 2 if there localish looks a good little series
Posted 23rd Feb 2016 at 15:11
demondriverdan

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Location: Londinium

Registered: 29 Nov 2010

Posts: 2,665

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Post #299
It's a bit different, not many 306s have a ridiculous splitter and wing fitted!

Power was 180.3hp at the hubs, torque 145 I think. It's Trackday Championship, we're racing at most of the larger circuits in the UK, should be a good year.

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Rallye Race Car
Posted 23rd Feb 2016 at 15:12
99rallye

Regular

Location: Hitchin

Registered: 26 Aug 2009

Posts: 348

Status: Offline

Post #300
Great work. Looks so good now its put back together. How did the Sachshift perform?
Posted 23rd Feb 2016 at 15:43

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