Track car project - including diary of a track n00b

16th Feb

The plan for this weekend was to change the gearbox. As already discovered, Humphrey popped out of 5th gear, which wouldn’t be so bad for the actual sprints but might get rather annoying on the long drives to and from the tracks.

As you can see, we had plenty to choose from:

gearboxes.jpg


The two in the picture were the most easily accessible, although if the worst came to it, we also had one in Mister-Two. One of the ones in the picture were out of The Red One, and the other was an absolute bargain. Phil got it on eBay for 99p, although ended up paying a fiver for it in the end as the guy he bought it off gave him loads of other MR2 bits too. Obviously it’s a bit of a risk as it’s a complete unknown. Watch this space…

The plan to get the gearboxes changed was to raise and lower one side of the engine, using a rather lovely engine hoist.

hoist.jpg


This plan worked rather well, although it was difficult to get the bolt back in to the engine mount at the end of the day. It took ages! Phil tried all kinds of methods including getting into the engine bay himself:

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However, in the end, perseverance and hammers did the trick.

I caught a sly pic of Phil working under the car:

philunder.jpg


Whilst Phil was doing the gearbox, I was stripping the interior. I’ve got a bad back again today for a change so took quite a long break, but I’ve got to the point where there is just carpets left in there:

interiorstripped.jpg


It is just a case of unscrewing every screw you can see, and then finding a few you can’t!! Tomorrow, the carpets will come out and then the seats and centre console will go back in. We aren’t sure which seats yet as we think we have someone interested in Humphrey’s, but we do have two other sets to choose from! There is also the option to put in a proper race seat, although we are currently trying to think of a way to make one adjustable as my legs are slightly shorter than Phil’s!!!

The exhaust will be going on tomorrow so I thought I’d attack those tailpipes with Autosol.

tailpipes.jpg


It’s a bit battered anyway but much shinier now!

We need to pay the final part of our entry fees this week and have also been told that we can buy spectator tickets at £3.50 rather than the £7 they will be on the day. Does anyone want to come? The first sprint is at Waterbeach (Cambs) on the 16th March. It would be great to have some support!
 
Sun 17th Feb…

Phil started fitting the exhaust manifold and I carried on stripping the interior. Once the carpets were out, I also removed the glovebox and radio! It all adds to the weight saving! Once this was done, Phil gave me the bad news.

carpetsout.jpg


Where there is a funny red bit on the side of the fuel tank, the floors and also the back wall, is covered in a soundproofing material that needs to be removed in order to save weight. This is horrible stuff, like glued foam, which chips off in small amounts. I protested loudly as I wasn’t getting anywhere, and eventually with Phil’s help, we discovered I was using the wrong tools. If anyone is thinking of doing this, you need a small sharp screwdriver and a small hammer, unlike the blunt screwdriver and large hammer I was originally using! Once I had the correct tools, I was well away, and it’s a rather therapeutic activity.

Here is the result of todays chippings, and next week I have just the floors to do!

soundproofoff.jpg


soundproofoff2.jpg


Whilst I was doing this, Phil had finished fitting the exhaust. The cat can do the next one for us as she expressed great interest in the whole thing.

zorston.jpg


Phil also managed to sort out the rats nest of wires discovered upon removal of the carpets. The car had two alarms fitted, both of which were coming out. It was a slight worry that they may immobilise the car, but we managed to sort that, despite a worrying moment when the engine turned over but then died. We realised that we had no fuel, as we’d been running him about on the fuel light more or less since we got him, and coupled with the fact that he was on ramps at the back when we tried to start him, no fuel was getting through. Once he was wheeled off the ramps, he started, although fuel is now needed!

Total costs so far amount as follows:

Getting Humphrey through MOT £500 approx – includes welding and windscreen.

Uprated suspension £160

Entry fees £200 (£100 each driver)

We have also gained about £3 from what we have found in Humphrey when stripping the interior! I found another 56 pence today.!

Plans for next week are: suspension, stripping floor of soundproofing, and hopefully a bit of time for polishing and fitting nice race parts like steering wheels!
 
24th Feb

I returned home from work on Friday to find that Phil had managed to do three corners of suspension already! Cue some quick pics before he gets done:

The new suspension waiting to go on, currently sat in the front boot!

newsuspension.jpg


Suspension on the car:

suspensionon.jpg


Undoing the droplinks to get the old suspension off:

droplink.jpg


And Phil finally putting the last wheel back on. All done!

suspensiondone.jpg

Well, that’s now the end of all the really technical stuff, and we now have a car that is road and trackworthy. We’re well ahead of schedule so we can now do all the niggly bits such as polishing, and trying to save as much weight as possible. However, first I had to clean my own car as she looked like this:

dirtysakura.jpg


She’s been neglected lately so I gave her a quick wipe.

cleansakura.jpg


OK, now on with Humphrey! I carried on shipping away at the soundproofing whilst Phil got started on the dash and heater. We had originally decided to keep these items in, but as we had time to kill, we may as well remove them.

One big pile of stuff later:

pile.jpg


And we have a much more stripped out car:

partstripped.jpg


We had to be in Chelmsford on Saturday night for a friend’s surprise party, so work was finished early. More stripping (!) will ensure next weekend. On the way back from seeing our friends on Sunday, we picked up some Sparco race seats and harnesses, which are a lot lighter than the standard MR2 seats. Have you ever seen an MR2 with four seats before? Now you have:

seats.jpg


Unfortunately it rained on the way home so they are now drying off in the living room!
 
Soundproofing is always fun to remove, some of the guys on Cliosport who are stripping the interiors out found a hetgun to be the best way to remove the tar like stuff Renault use.

Also have you removed the whole heater/blower assembly? Not quite hardcore but it's worth thinking about leaving just the windscreen blower bits in place to help things if the screen mists up :)
 
One seat is dry, the other just finishing drying out :) It's like an oven in the living room though!!!

We decided not to use heat on the soundproofing as it makes it all tar-like and sticky. Both of us now have dodgy hands though from holding screwdriver and hammer!!

I'm not sure if you can leave in part of the heater/ blower assembly, but that's a very good point. Maybe we can get some ventiliation in there instead!
 
Everyone on one of the AE86 forums I read swears by dry ice - pour it over the soundproofing and it chips off really easily.

One way of doing it I suppose!
 
We decided not to use heat on the soundproofing as it makes it all tar-like and sticky. Both of us now have dodgy hands though from holding screwdriver and hammer!!

Yup goes very tar like, looks horrible stuff!
 
There are 2 very distinct approaches to getting soundproofing off. Either heat to soften it, then deal with the sticky residue or cold to make it nice and brittle then chip it off.

Given the time of year we went with the cold approach and it's worked ok.

The decision to remove the heater was helped by the fact the thermostat in my road car is knackered and I've had no heater all winter anyway. It's not been too much of an inconvenience so I thought I may as well junk it all from the track car.

There's actually a lot more missing then the pic shows. The center console and the passenger side of the dash are now history and the heater is nearly out. The ducting for the screen vent is staying because it's a pita to get out and doesn't really weigh anything anyway. Might rig up a removable blower which I can attach to that vent for emergency screen clearing :p
 
Hi guys, glad to see this is going well.

Would come and support you if the events were a little closer. If you ever travel to castle combe with it then drop me an email as it would be good to catch up too.

All the best, Chris.
 
I'm sure that we'll at least be tracking it at CC one day :)

Have you seen the Silverstone thread Chris?
 
Great to see the progress!!! Keeping tabs to see how things are going, much quicker than me at the mo :( My 2 has gone to see the old duffer who does the welding. Took the arch kit and thought things would be fine, however he has found an endless ea of bodge and was complaining bitterly about it earlier and how it was taking up his garage :D I'm more concerned he's going to die before it is finished!!!:eek:

At least my nice mintex pads and official bleed pipes arrived today, not that I have a car to fit them too....
 
Oh dear.

Today I realised how cheaply I can get Toyo R888s. Unfortunately this cheapness is offset by the fact that I'll have to buy some 15" wheels to put them on.

I sense an impending budget blowing exercise once I've been paid later in the week.
 
Have you seen the Silverstone thread Chris?
Yes, unfortunately I already have a trip away with some friends that weekend.

This will be the first time I have missed the camping.

Hopefully something can happen later in the summer?
 
Oh dear.

Today I realised how cheaply I can get Toyo R888s. Unfortunately this cheapness is offset by the fact that I'll have to buy some 15" wheels to put them on.

I sense an impending budget blowing exercise once I've been paid later in the week.

£100 should see a set of Mk3 wheels, ok, they will probably need a refurb but they look nice on the Mk1. Alternatively, my set of Hydragrips on the standard 14's kept me alive right around the ring - the performance for £ was top draw.
 
We've got hydragrips on vix's car which will be at the events as a support vehicle so if it's wet I'll be stealing those for the sprint car.

Unless I buy something else in the meantime our dry tyres will probably be my set of A539s but one pair of those hasn't got a huge amount of life in them and may not last the season. Probably looking to get a set of Rotas (Either Grids or JSPL's) with R888s for just over £600. JSPLs are slightly lighter but I wanted Grids for my road car anyway so if I get them now for sprinting I can always put them on my road car a later date.
 
The big garage could work in your favour. Ours is barely big enough to keep all the spare bits in and is useless for actually doing any work.
 
Latest discovery is that Toyo actually make R888s in the standard mk1 size so I might just get a set put on some spare rims (Got a few sets lying about :p)
 
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