My E30/R5Turbo track car - Gearbox MkIII

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GeoffBob
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Fri Aug 07, 2009 5:47 pm

mt1104 wrote:could install the lotus style variable traction control to ease yourself into it, would be interesting to try to setup too.
No worries there, has both traction control and ABS. She'll still do silly things though if I'm not careful.
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GeoffBob
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Wed Aug 12, 2009 9:52 pm

New Compomotive rims arrived today so am very excited. 2 off 8Jx17ET11 shod with Dunlop DZ03G 245/40/17 semislicks on the rear, and two off 6Jx15ET25 with Dunlop DZ03G 195/50/15 semislicks on the front. Aint they just the bees-knees! :D :D :D

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I am soooo chuffed with they way these fit around my Alcon four-pots! And no wheel spacers required, no bumping into the wheel-arches and no rubbing against the cut-down coil-overs!
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"It is amazing how many drivers, even at the Formula-1 level, think that brakes are for slowing the car down." - Mario Andretti
rix313
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Wed Aug 12, 2009 10:13 pm

I still don't like you for having them but they look brill
GeoffBob
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Wed Aug 12, 2009 10:18 pm

rix313 wrote:I still don't like you for having them but they look brill
Thanks :D
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"It is amazing how many drivers, even at the Formula-1 level, think that brakes are for slowing the car down." - Mario Andretti
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harry_p
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Wed Aug 12, 2009 11:46 pm

words cannot describe how much i love the low offset 8x17 MOs :mad:
cheers,

harry
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b4gga83
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Wed Aug 12, 2009 11:50 pm

Beautiful - absolutely amazing i've got a tear of joy leaking from the corner of my eye!!!! :cool:
GeoffBob
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Sat Aug 15, 2009 1:39 pm

Ta very much gents. Wasn't just a tear of joy that leaked out of me when I first laid hands on them :D Definitely something quite erotic about smooth black rubber 8O

I was pleasantly surprised to find, after test fitting the 195/50/15's that I still had sufficient clearance to go wider. Thus, at my request, ATS Motorsport very kindly took back the 195's and supplied me with a set of 205/50/15 semi-slicks in their place, which fit very nicely indeed. It's R1 rubber compound all round. I have yet to see how this performs compared to the more endurance orientated H1 compound. Anyone ever objectively compared these two compounds from Dunlop?

If I could just get my new GRP bonnet out of customs I would be able to fit the front fenders and put my colours down the side. All in good time I guess.

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"It is amazing how many drivers, even at the Formula-1 level, think that brakes are for slowing the car down." - Mario Andretti
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baptie0
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Sat Aug 15, 2009 6:23 pm

one cracking car you have built there, looks brilliant.
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Sun Aug 30, 2009 11:49 pm

realy does look great geoff, love the stance to, be you cant wait to get it on the road again!

What sort of inspections do you have to have over there for a "kit car" type build. SVA style thing or engineers report? :D
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GrindCulture
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Mon Aug 31, 2009 12:09 am

If someone told me they were building an E30 chassis based R5 powered by a turbo Toyota 4pot I'd recommend they go see a doctor, but this is truly brilliant! Huge respect dude! :thumb:
Not in E30s any more :(
GeoffBob
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Mon Aug 31, 2009 2:55 pm

Too true Appletree, can't wait indeed :D But not long now, if I could just find out where the new bonnet has got too. I thought it was in customs already, but they claim it's not yet in the country. I suspect the bloke who made it sent it by surface mail instead of air mail, which would explain the painfully long wait.

Grindculture, I've been off to the head-doctor a few times on this build already. Gettin' everything to fit has been a huge source of frustration for me, but she'll be worth it in the end :D . Ta!

Appletree, if I want her road legal I'll have to have her inspected by our local bureau of standards, and then issued with a VIN number. Similar rules over here as apply to kit-cars in the UK - so long as I don't plan on mass producing her. For mass production (even kit cars) she'd need to be tested to failure in almost every respect. But she's a once-off for myself only, so no worries there. I'll have her road certified if I think its worth it, but ultimately I am building her for the track only.

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'Was thinking I would separate the blue from the yellow with a white pinstripe. I also need to add the obligatory white square on the door for her number, and there is still the white running board below the door (that joins the front and rear fenders) to fit.

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"It is amazing how many drivers, even at the Formula-1 level, think that brakes are for slowing the car down." - Mario Andretti
ross_jsy
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Mon Aug 31, 2009 9:35 pm

amazing project, first car was a r5 turbo and love em to bits.

didnt fancy going down the maxi colour scheme route?
Jim78
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Wed Sep 02, 2009 7:00 pm

That colour scheme suits the 5 down to the ground. Did you do the spray job yourself? If so, is there anything you can't do?!........

V.excited about seeing this finished - sure a few magazines would like to do a feature on this beast! :D
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initial_g
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Wed Sep 02, 2009 8:41 pm

brilliant project dude cant help but feel all yellow would surely look better?
GeoffBob
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Thu Sep 03, 2009 9:20 am

Thanks gents for the comments.

Ross, the Maxi5 look didn't appeal to me. Using E30 suspension components meant that my front track width was substantially wider than the standard R5turbo, but comparable to the Maxi5 (which was technically an evolution version of the narrower track R5Turbo specifically for Group-B rally). I therefore had to use the maxi front fenders and bumper to match my wider front track. While the Maxi5 was a stunning looking rally car, the six jumbo spotlights (which were built into the bumper and bonnet, as opposed to mounted on the bumper and bonnet, like the Tour de Course car) have no place on a track car. I thus shaved the light mounts/enclosures to produce a bumper more in line with the yellow, white and black R5Turbo LeCar, campaigned rather unsuccessfully in the IMSA GTU series in the US in the mid 1980's. I therefore felt that a Maxi5 paintjob would be inappropriate.

Thanks Jim. Yip, busy doing the spray work in the back garden. Not the ideal location, but our winter down here comes complete with minimal humidity, which makes doing a decent job all the more easier. I’ll be sure to post more pics as I go along.

Agreed Initial_g, but I did my last R5 in all yellow and eventually became bored with it. Traditionally, the track and rally R5Turbos had multicolour paintjobs, plus it will improve my visibility on the track. Personally I think she’ll make more sense once she has her white pin-stripe (between the blue and yellow) and her jumbo size white running-boards down the side.

Watch this space gents,

Regards
Geoff
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"It is amazing how many drivers, even at the Formula-1 level, think that brakes are for slowing the car down." - Mario Andretti
Jim78
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Thu Sep 03, 2009 3:41 pm

Looking at the pics reminds me of a Corgi toy R5 Maxi that I had when I was a kid in a similar colour scheme... :cool:
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GrindCulture
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Fri Sep 04, 2009 8:56 pm

Jim78 wrote:V.excited about seeing this finished - sure a few magazines would like to do a feature on this beast! :D
Definitely front-cover-worthy :cool:
Not in E30s any more :(
GeoffBob
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Tue Sep 15, 2009 9:20 am

Jim78 wrote:Looking at the pics reminds me of a Corgi toy R5 Maxi that I had when I was a kid in a similar colour scheme... :cool:
R5's always looked like toys, no scaling down required :D
GrindCulture wrote:
Jim78 wrote:V.excited about seeing this finished - sure a few magazines would like to do a feature on this beast! :D
Definitely front-cover-worthy :cool:
I am honoured by your comments sirs!

'Have put myself into training for Kyalami using the fairly realistic simulation software GTR2. No, don't laugh, it's a great way to learn a new track and I already have every straight and turn memorised. I figure this should help reduce the amount of time I spend learning the real track when I finally get there, enabling me to concentrate on more important things. Of course if the simulation differs from the actual track then I could be in for a nasty surprise!

For those who aren’t aware, it is possible to edit the suspension, engine, gearbox, tyre and point-mass setup files for each of the GTR2 cars. I selected a Z3M due to its similar mass distribution to my own car, and then set about editing these files (including redefining the torque curve) to match the details of my own car. Of course, it still looks like a Z3M in the simulation, but that's not really the point. The GT and GTR simulation model is known for its accuracy and the resultant simulated vehicle performance is a very real function of changes made to the above mentioned setup files. Hence, you really need to know a fair bit about how to set up a real car in order to be able to fiddle with these files, else all simulated hell can break out on the simulated track.

If anyone is interested in using software like this as a training aid I would honestly recommend buying a steering wheel with separate "H"gate manual gear selector and clutch pedal. I have a Logitec Momo wheel with "flappy paddle" gear change and no clutch pedal and I am already finding this to be too unrealistic. I hope to upgrade at some point.

In conclusion, obviously not the real thing, but probably a very useful tool for someone located a long way from a track that they plan to visit in the future. I doubt I will ever have the opportunity to visit the Nurburgring, but it's nice to know that I can at least learn (to a reasonable degree of accuracy) the layout of the ring ahead of time if I ever did plan to visit.
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GeoffBob
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Fri Sep 18, 2009 1:43 pm

Yee Haa. Bonnet finally arrived! By the looks of whats left of the packaging it was transported down through Africa on the back of a camel - but the bonnet is, luckily, still intact. Will require the usual preparation work to remove some rough edges, as with all the other GRP bits I have fitted.

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"It is amazing how many drivers, even at the Formula-1 level, think that brakes are for slowing the car down." - Mario Andretti
GeoffBob
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Wed Sep 30, 2009 11:15 am

The fun begins.

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"It is amazing how many drivers, even at the Formula-1 level, think that brakes are for slowing the car down." - Mario Andretti
Nobby_N
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Wed Sep 30, 2009 12:35 pm

Amazing! :D
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Rik178m
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Wed Sep 30, 2009 7:07 pm

More pics of how you're doing the carbon fibre are deffo needed! Awesome! :cool:
GeoffBob
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Mon Oct 05, 2009 6:19 pm

Rik178m wrote:More pics of how you're doing the carbon fibre are deffo needed! Awesome! :cool:
Ta, will do.

Placed the GRP bonnet over two trestles and began by sanding down the gel coat with 60 grit paper to provide a rough surface for the epoxy resin to bond to. I then lay the cut CF fabric over the bonnet and began applying the epoxy resin with a 75mm brush, working from the middle outwards. I shaped the CF over the ridges around the hole in the centre, but found it more difficult to shape and form than the usual GF cloth I am used to. The CF seems to have a mind of its own, wanting to curl up and bubble wherever possible. With perseverance, however, it all came right in the end. I used packing tape to secure the CF around edges of the bonnet. I found it necessary to watch over the bonnet for the first hour of curing vigilantly smoothing out bubbles and blisters that formed wherever the CF decided it wanted to lift off the GRP underneath. I am convinced that during the curing process the epoxy resin releases some or other gas which can cause bubbles to occur. I found a heat-gun set to warm useful for "de-gassing" the bubbles from the resin while curing.

After curing over night I have begun with the arduous task of sanding the resin down by hand to expose the smooth CF weave underneath. Where the resin is thin this is quite easy, where it is thick it is a pain in the arse. If I could do anything differently I would apply less resin next time so as to require less elbow grease during sanding.

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"It is amazing how many drivers, even at the Formula-1 level, think that brakes are for slowing the car down." - Mario Andretti
appletree
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Tue Oct 06, 2009 8:18 am

Are you going to keep the CF visible or paint it when you paint the rest of thre car?

Would be nice to see it :D
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GeoffBob
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Tue Oct 06, 2009 9:49 am

appletree wrote:Are you going to keep the CF visible or paint it when you paint the rest of thre car?

Would be nice to see it :D
Matt, would you believe, of all the idiot things to do, I am going to paint over it! I need the CF for its strength (the GRP bonnet from France is a bit flimsy) but the black colour of the CF just doesn't fit with the yellow and blue colour scheme of the car. I have been scratching my head trying to come up with an idea as to how I can at least leave a portion of the CF visible.
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Jon_Bmw
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Tue Oct 06, 2009 12:46 pm

I think a light paint session and PLENTY of lacquer would allow the weave to still show through. This is what demlotcrew did I think. That is the best option IMO.
GeoffBob
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Tue Oct 06, 2009 3:15 pm

Hmm, I like that idea, thanks Jon. I'll experiment with some yellow or blue added to clear coat (to make what the Americans call a "candy" colour).
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"It is amazing how many drivers, even at the Formula-1 level, think that brakes are for slowing the car down." - Mario Andretti
GeoffBob
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Mon Oct 19, 2009 10:26 pm

Right, time for an update.

'Did a fair bit of experimenting with the CF and ultimately decided to paint it with a solid colour. Regardless of whether I apply a candy-yellow or a candy-blue, the black of the CF just makes the colour too darn dark. The CF has made the GRP bonnet a lot more rigid, and thus its objective achieved so far as I am concerned.

Other news is my Z1 rear discs and ALCON 2-pot calipers have arrived. I plan to do another write up on how to fit these. Will be similar to the 4-pot how-to guide I did on the front brakes.

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And finally, this is the Quaife ATB diff I have been banging on about in some of the other track-day threads. I am in the process of fitting this to a spare medium-case final drive. I am taking photo's of this process as I go along and will do a write up on this too when I get a chance. May be of interest to anyone contemplating a similar operation.

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"It is amazing how many drivers, even at the Formula-1 level, think that brakes are for slowing the car down." - Mario Andretti
Jon_Bmw
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Mon Oct 19, 2009 10:40 pm

I love new slippers. They are always heavier than I expect as well!

:cool: update. Looking forward to reading the brake article.
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Mon Oct 26, 2009 7:21 am

Jon_Bmw wrote:I love new slippers. They are always heavier than I expect as well!

:cool: update. Looking forward to reading the brake article.
Agreed, this one caught me by surprise. I always thought most of the final drive weight was in the cast-iron housing. By the feel of this one I'd say its about 50/50.

Will be a while before I type up a rear brake upgrade article - am busy frying bigger fish at present.

Air intake is now installed in the front bumper. I've run a 3-1/2" thin-walled stainless tube from the air filter straight back to the 2-3/4" mouth of the turbo. Almost a direct path (slight kink required to route the tube around the radiator). 'Am seriously running out of space under the bonnet so there really was nowhere else to put the air filter. The turbo should breath fairly well.

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GeoffBob
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Fri Nov 06, 2009 10:33 am

This is how I get air into my Garrett GT3267 turbo. The first part of the 3-1/2" pipe is welded into the body, the second half is removable to allow access to the tubo.

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"It is amazing how many drivers, even at the Formula-1 level, think that brakes are for slowing the car down." - Mario Andretti
Theo
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Fri Nov 06, 2009 5:59 pm

That looks superb 8)
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Gunni
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Sat Nov 07, 2009 6:26 pm

Your car is by far the best vehicle on this website.

In saying so I mean how you have allowed yourself to cut away compromises to achieve way higher level of vehicle competence.

interested to know why you didn´t go with a celica 4wd system?
What is your profession? Somewhere you mentioned that you did something race related for a living.

Any videos of it in action?
With great challenges comes great engineering.

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Sat Nov 07, 2009 8:43 pm

Gunni wrote: interested to know why you didn´t go with a celica 4wd system?
I would guess/assume it's for two reasons, 1 that the Celica has a heavy torque bias to the front wheels (possible not in the daft/rarer ST205 version though?) and 2 because the Celica uses a transverse engine/box?
WMS E30 brake kits! (4-pot 280mm & 300mm front / 2-pot 290mm rear)

www.wms-brakes.co.uk / http://www.e30zone.net/modules.php?name ... c&t=209737
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Gunni
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Sun Nov 08, 2009 1:49 am

Alright,

Even so, why not a 4wd over a 2wd setup,

as I´m assuming the engine is quite powerfull and should be able to break traction easily.
That leads to the chance that a 4wd system "could" provide more traction for most occasions
With great challenges comes great engineering.

Gunni
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