172 Cup Track Project

[AdamR]

I'm doing a bit of work on my 172 Cup to make it track-ready, so will post updates here as and when I've done anything. Won't be anything special compared with other cars like Chrispy's, but it'll keep everything in one place as reference for me...

Here's a thread I made when I first got the car a couple of weeks ago:

http://www.cliosport.net/forum/showt...-me%29-172-Cup

clio1.jpg

Since then I've ripped a load of stuff out and saved approx 25kg, added a Skoda front splitter (will make a 'flat' carbon one when time allows) and had a go at making some door cards... Photos below!

1) Scarily big bit of carbon cloth, don't wanna feck this up!

carda.jpg

2. Laid up, ready to cure. Took about 2 hours...

cardb.jpg

3. Bit of weight, and left for 36 hours... Possibly not enough as some of the resin pulled away with I released it

cardc.jpg

4. However, came out pretty well for a first go, reasonably happy. This is straight off the mould, no polishing.

card1.jpg

5. Trimmed down.

card2.jpg

6. Test fitted.

card3.jpg

7. Checking fit.

card5.jpg

8. Checking fit again.

card4.jpg

9. New handle made on my lathe. Wanted to do away with the 'looks like your mums made it on her sewing machine' (nothing wrong with that mind!) pull cord and bin off the original door catches, so had to come up with something that would do both jobs...

card6.jpg

10. Bicycle brake cable is exactly the same as the cable pull for the catch, fits into the new handle like so...

card7.jpg

11. Other end - normally has a small bit of plastic to shim out the nipple, so had to come up with something to replace it since I would be cutting the OE cable and just using the outer from it.

card9.jpg

12. New cable clamp with grub screw (filed a flat section to make it easier to start the cross drilled hole).

card10.jpg

13. How it looks/fits in the catch.

card11.jpg

14. Boss to fit the handle onto, bolts straight into the existing fixture for the OE handle.

card8.jpg

15. Test fit, turn clockwise to open the door, pull to close it

card12.jpg

16. All done!

card13.jpg

card14.jpg

Reasonably happy with it, not perfect by any means, but learned a lot for the next one and should be much quicker now I know what I'm doing. Don't think I'd bother making a pair again, the materials cost about £60 so a pair at £115 (performance trim) and not spending ~4 hours each making them is pretry good price! Anyone got any close up photos of the PT ones btw?

Any questions just ask!

Next job: Fit roll cage. Should be here this week if all goes well...

[Conlon]

Wanted to do away with the 'looks like your mums made it on her sewing machine' (nothing wrong with that mind!) pull cord and bin off the original door catches, so had to come up with something that would do both jobs...

Hey..... my mother made mine! lol

good progress, looks like you will be doing alot of the work yourself?

[Keith185]

Liking the handles, very nice work

[Cro-Clio]

Nice skills mate what cage you going for?

[AdamR]

Hey..... my mother made mine! lol

good progress, looks like you will be doing alot of the work yourself?

Haha, it's all good

Well, the previous owner(s) have done the hard stuff to be honest, I'm just gonna add a cage, RARB, pulled some stuff out, make a few carbon bits to tidy it up, then take it to the track!

Liking the handles, very nice work

Thanks man!

Nice skills mate what cage you going for?

Cheers - got a Safety Devices 6 point bolt-in on order, should be here next week if all goes to plan...


Another small update, rear wiper is off and carbon skinned the cap. Not a great job but was in a rush... may re-do it at some point!

cap1.jpg

cap2.jpg

cap3.jpg

[AdamR]

Cage arrives today! Got my ass to work half an hour early to pull stuff out...

stripped.jpg

Had both parts of the dash in and out a few times now so if there is anyone who wants a hand with it just shout... There is a guide for the top half but couldn't find one for the bottom bit. Was a bit tricky 'blind' but with some guidance I can see it being pretty straightforward!

[Matthew.]

Good progess mate, looking good

[Curtis!]

Should have fibreglassed the whole first!

[AdamR]

Sorry man, not sure what you mean...?

[welshname]

SUBSCRIBED.

[AdamR]

Couple of updates...

Been prepping for cage - Safety Devices 6 point bolt in - just needs a bit more paint out around the towers, then ready for welding... Hammering the arches flat was scary, haha. Then the mammoth task of sanding and spraying the interior

cage.jpg

Got wheels (15" Superturismos - thanks to beng-120!) and tyres (Federal 595 RS-R) sorted...

wheels.jpg

Then had a go at a brake duct today at lunch and after work. Seems to have come out ok for an hour's work, but might tweak the fixing method a bit. Needs building up a bit 'higher' at the very least I think, you'll see what I mean from the photos...

47p funnel from Asda

duct2.jpg

Chop chop...

duct3.jpg

Old Cod Liver Oil bottle - 48mm diameter, builds up to 50mm diameter when fibreglassed around, ready for 51mm ducting...

duct4.jpg

Moulded in in two parts (funnell first, then tube) but gives you the idea...

duct5.jpg

duct7.jpg

Added some tabs on the side...

duct6.jpg

For clipping into the fog light surround - makes a nice 'snap' when it goes in!

duct8.jpg

duct10.jpg

duct9.jpg

Quick blast of black spray paint to check how it looks. Not toooo bad considering it's cost about £2 and took about an hour. Considering trimming the excess off but it will obviously 'scoop' more air in as it is... Will probably re-make this one as it was a bit of a learning process.

duct11.jpg

Will update in a few days/a week once more stuff has been done

[AdamR]

duct11.jpg

Much better with the paint dry, hah.

duct11.jpg

[mx1_champ]

i like how your making your own bits, decent finish to.. ill keep an eye on this

[AdamR]

Thanks dude. Always like to get stuck in making bits, tis good fun

Done a bit more work over the last week or so...

nearlythere1.jpg

nearlythere2.jpg

Still to do:

- Tweak brake ducts (hoses a bit short at the mo, gonna make up some plates/tubes that sit right near the rotors to give the hoses a bit more effective length)
- Fit home made camera mount
- Fit RARB if/when it arrives...
- Tidy up wiring
- Buy some more bolts/cut down some bolts for the cage, a load of them are way too long!
- Turn up some spigot rings for track wheels (not paying £75 for official OZ ones!) - got the ali bar though the post today
- Fit TPMS for track wheels
- Probably some more stuff I forgot...
- Clean it (dirty as hell inside and out at the moment!)

[Fred@BTM]

how much was the cage fella? where from?

[mattsouthall]

like the progress. where did you get the federals from? I have read some good stuff about them and also want to give them a crack...

[jon_r]

Ditto that request.

Great thread.

[AdamR]

how much was the cage fella? where from?

It came to £810, from Mark Fish (probably about to tell me you could have supplied one about half the price that's twice as good? haha)

like the progress. where did you get the federals from? I have read some good stuff about them and also want to give them a crack...

Cheers man! It was... Tyre Traders: http://www.tyretraders.com/tyreInfor...ZR1582W595RS-R - website is toss and they wouldn't let me order over the phone, but good service in the end from them.

I'd heard good things too and thought they were worth a pop for the price compared with R888s etc. Need to get them scrubbed in, get a heat cycle through them then will updated after next track day if you're interested? I don't have much experience for direct comparisons, but I used some Dunlop DJ01s (R-compound) on my last car which were night and day compared with road tyres.

[Fred@BTM]

na, just deciding on which cage to get for my race car!

[AdamR]

Ah cool - well it seems pretty decent. Had a few small alignment issues at the start (mainly down to the order I was doing stuff I think - it's my first go at a cage) but it's gone in really well now, no major modifications, no extending B-pillar hoop, towers were pretty close to the right shape from the start, etc. JUST clears the seats and about 10mm from the windscreen. Looks like it would clear roof lining too if that's of any help. If you want any close up pics of anything just shout dude