Track Car Project

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Joined
21 Jan 2006
Posts
2,171
Location
Seaham, Co. Durham
Hi everyone,

Me and a friend have recently purchased a 1999 Melina Blue 1.7 Puma, with the intention of turning it in to a dedicated track weapon. We bought the car from a friend with 70k miles on it with 6 months MOT and 4 months tax for £350.

It is generally in good nick, the only issue when we bought it was a broken starter motor, so we fixed that and it is running nice.

I should mention we have no formal training in mechanics, just learning as we go along and also seem to be accumulating new tools at an alarming rate!

The first job was to strip it out, we went to the extremes on this, removing everything that isn't needed. This included removing the heater matrix, blower motor, carpets and soundproofing, spare wheel, rear wiper motor, airbag, etc. There really isn't a lot left in there now and the suspension has raised about 10cm haha.

We then removed the old seats and put some buckets seats in, they weigh around 8kg each which is a hell of a lot lighter than the standard seats which seem to weigh a tonne.

We have also fitted an induction kit and are going to install a heatshield around it to keep intake temps low, I work at an insulation company making heatshields for cars and aircraft so I have access to high quality insulation. We decided on the induction kit over a FRP airbox as we knew once we got it insulated properly it would perform just as well as, if not better than a FRP airbox.

The engine bay received a tidy up and the cam cover was painted green, we also changed the oil, oil filter, spark plugs and fuel filter.

The next big purchase was a full Milltek 4-2-1 system with sports cat for MOT time. We spent all of yesterday fitting it in the pouring rain, but now it is on and sounds awesome, should free up some more power too as the standard manifold and cat looks like a pretty rubbish design to me.

We have had the car for about 3 months now and are just buying parts as funds allow.

Future plans include:

Harnesses
Roll Cage
Coilovers
Re-profiled cams
Bonnet Pins
Mondeo Throttle Body
Fiesta ST front and rear disc brakes
Cambelt needs changing
Momo wheel
Trackday tyres + lightweight alloys
Possibly remove the ABS.
Replace window glass with polycarbonate if we can find a good deal

After the engine mods are done we plan on getting it mapped to run on 98 RON and to take advantage of the new cams we will be putting in.

It's a long term project and we are in no rush, just taking our time to do things properly. Initial targets are to run somewhere around 150bhp and see if we can get the weight to around 850kg. It should be ready for a track day in a few months.

Long term plans include LSD and throttle bodies, but thats a long way off.

I will get some pics up when I'm next working on the car, oh yer, the colour scheme is fluorescent green and Melina blue :D
 
Will be following this with interest, sounds like a bit of a larf.

Yep not taking ourselves too seriously with it, trying to make a good job of the mechanics but the styling will definitely be a bit lairy.

Pictures... include pictures dammit!!! :D

Ahh you're at Seaham. When it's ready.. give Tim at www.thetrackdayclub.com a call as he runs a very good track day at Teesside Autodrome.

(And I want to have a go! ;))

Sounds good, I have a lot of karting experience at Teesside autodrome so should be fun to go around in a car.
 
Sounds good to me, I'm pretty local (Ok very local) If you guys want a extra pair of hands some time give me a shout I'd love to take a look. Think you could be interested in my cousins 205 track car build also :)
 
Yep I'm in Seaham but the car is actually in Washington at my friends girlfriends house as it's the only place we could get some space for it. Will no doubt be turning up to some local meets once we get it all sorted and insured.

It just needs some harnesses and new suspension before it is ready for it's first track day, although the brakes seem quite rubbish so may do those before going on track.
 
I have same year Puma and mine is my work transport part time track car!
I would not go for the induction kit - the home made FRP conversion to airbox gives better gains as it keeps the cai

I have mine on eibach lowering springs but standard shocks - tried one with cheapo coilovers and it didnt set my world on fire - cost more going the way i did and ideally i would have gone with bilstein dampers.

I have part poly bushed it, only rear beam left std powerflex elsewhere with FRP lower arms if i recall - my car has a harsh ride and with rear polybushes its harsher (not as much of an issue for you) The bushes make a huge difference to handling esp if like mine its on originals!

Can i ask how much you paid for the full milltek - 900 seems going rate and not sure i can justify it?

Love mine, cracking car to chuck around but could do with a bit more power at times - would like to see pics of yours too.
 
I will get some pics up ASAP. Next chance I get to see it will probably be Wednesday.

The Milltek I got 2nd hand for £400. This included the 4-2-1 manifold, sports cat, cat bypass pipe, center section and backbox. It's in very good condition, since it's all stainless it polished up great.

Will definitely be looking at polybushing, looking at AP coilovers, possible some KW's, going to require saving up though.
 
According to various sources a Milltek, cams, remap and better intake should get you close to FRP spec of 150 odd bhp, which will cost us around £1000 if we wait for parts to appear at the right price.

With the weigh loss that should be plenty to be fun on track. I'm very interested in keeping a nice balance and improving the handling rather than out and out power.

I don't really know what weight it will go down to. Standard is 1049kg, but ill get it to a weigh bridge when its insured.
 
Yep only so much you can do to the engine.. might be worth just putting a different lump in there to begin with?

Making it lighter though could help a lot I guess.
 
Id poly the windows, Strip the loom back to basics, 140-150 bhp with a car weighing say 900kg will be plenty quick enough for the tracks up here.
 
Id poly the windows, Strip the loom back to basics, 140-150 bhp with a car weighing say 900kg will be plenty quick enough for the tracks up here.

Yep that's pretty much the plan. I need to develop my skills as a driver more than anything since I don't have car racing experience, only karts. Once I feel confident in my ability I can start looking at more power and engine swaps.
 
Some photos I took this evening, sorry about the quality I only had my blackberry.

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Priorities at the moment are suspension and brakes, one they are upgraded we will be looking at a FRP gearbox and roll cage.
 
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