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172 Cup Stage Rally Car



Pauleds

ClioSport Club Member
  Merc Dueliner sport
I may as well try and start a bit of a build thread for my Clio stage rally car.

A few of you know that I was competing in Sprints and hillclimbs in my original cup car and had some pretty good results in 2014. I had a lot of fun with quite a few class wins, 1 track record (Wigan), 2nd overall in the Chester and Liverpool speed championship (div 2 - less rounds than div 1), and 3rd overall in the Longton and District sprint and hillclimb championship but I fancy a go at stage rallying again, this time in a Clio.

Last year I started to strip my Clio down and sold the suspension and other bits I didn't need to reshell into a black 172 clio that I had bought with a knackered engine. I also started to stock pile other parts and a better engine which led me to @Ph1 Tom house to buy his engine, but also ended up buying a load of other bits including the 172 Cup shell. This was just the time my neighbour binned his Cup at Oulton park so he ended up buying my original shell from me to reshell his car.
So for the last 6 months or more, I have had a shell, a cage which I bought in the group buy last year and a garage full of bits which require building together. Working away and family stuff when I was home meant a lack of time to do anything so I really have to pull my finger out now and get it sorted.
As @sam JFM was breaking his clio rally car, I also bought a load of bits off him too to save me some time and hassle.
Over Christmas I took the cup shell to my mates unit and finally managed to get the cage in (worst cage I have ever fitted and ive done a fair few over the years) and get it back into the garage. I just need to finish welding the seat rails, mounting the extinguisher brackets etc before I chuck a bit of paint in there before refitting everything. I have also been cleaning up the engine parts etc and spraying them silver to tidy things up a bit. The engine and gearbox will hopefully get fitted in this weekend.

Spec of the car will be.........
Engine - 172 engine with head work, supatech valves, piper cams, arp bolts, PAS delete, k+n panel filter, cable throttle, 182 manifold, sport cat, ktec stealth supersport exhaust, Alloy rad, braided fuel line

Gearbox - JC129 gearbox rebuilt with Gripper diff and lower CWP

Suspension - Bilstein B14, PMS solid topmounts and strut brace, PMS reinforced rear beam

Brakes - Front are AP3307 calipers on 300mm rotors with alloy bells, rears are standard discs pads and calipers. Also has a vertical hydraulic handbrake and bios valve. (mechanical handbrake still there for emergencies!)

Wheels - 15" TD Pro Race 1.2 in anthracite

Interior - fully stripped out with unused brackets etc removed, SD full cage with cross door bars and tunnel brace etc, flocked dash (when I send it off), new HRX racer seats and side mounts and HRX hans 6 point belts (from www.torq-racewear.com ), deep dish pop off steering wheel, FG door cards, 4.25ltr plumbed in extinguisher, 2.25 hand held extinguisher, carbon drivers plate, carbon codrivers footrest, modded scenic gearshift, EPAS column, fuel and brake lines inside, autolec cutoff and hopefully a lightweight battery.

Other - moulded fibreglass tank guard, 10mm alloy sumpguard, aerocatches

I will try to keep it updated with the odd pic from time to time

Cheers
 

Pauleds

ClioSport Club Member
  Merc Dueliner sport
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Pauleds

ClioSport Club Member
  Merc Dueliner sport
Tonight's job - finish wrapping the 182 manifold
100ft of 1" wide exhaust wrap and about 4 hours in total (whilst watching TV at the same time)
Crappy job but it's done now and should reduce a fair bit of heat from the engine bay.
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Pauleds

ClioSport Club Member
  Merc Dueliner sport
have you got gearbox and diff yet?
Yes, it's the one I was using in my old sprint car. You had the original box that I replaced with the gripper box.
Paul have you stopped Sprinting now???
Yeah, I want to concentrate on trying to do some rallies this year, although I will probably still go to a few sprints and hillclimbs to watch my brother in his Mazda
 
  dan's cast offs.
Yes, it's the one I was using in my old sprint car. You had the original box that I replaced with the gripper box.

thought you said you did have one but wasn't sure. got fresh built box coming in over next week or two.
 
  Mazda mps
The more Clios in rallying the better. I think they make an excellent tarmac car. Single venue events are more suitable than the forests for the car I would have thought, so it's airfields and hill climbs for mepPlus Mull
 

massiveCoRbyn

ClioSport Club Member
  Several
Looks good, be interesting to see how it goes in that spec. Been thinking about doing something similar with mine as my Escort is a money pit.

Not sure on the brown cardboard windows though. You might be able to see better through white card?
 

Pauleds

ClioSport Club Member
  Merc Dueliner sport
Looks good, be interesting to see how it goes in that spec. Been thinking about doing something similar with mine as my Escort is a money pit.

Not sure on the brown cardboard windows though. You might be able to see better through white card?

Card and tank tape is the new MSA ruling, bit of extra protection to go with the window film. I am finding the brown a bit dark so may switch to white to brighten it up
 

Pauleds

ClioSport Club Member
  Merc Dueliner sport
The more Clios in rallying the better. I think they make an excellent tarmac car. Single venue events are more suitable than the forests for the car I would have thought, so it's airfields and hill climbs for mepPlus Mull

The big bucket list rally for me is the Manx in September, but hopefully use at Wigan and possibly rally of the midlands too
 
  225 powered mk2
@Pauleds that alternator mount looks nice and tidy now, I need to do this to mine when I put my EPAS on, what belt have you used for it?

Cheers
 

Pauleds

ClioSport Club Member
  Merc Dueliner sport
Had a sort out of a load of stuff and tidied up my garage so I can assemble some more bits in there and store my seats etc safely.
Also moved the engine and gearbox to the car so once I have swopped the pedal box to the one with cable throttle and fitted the new braided line from the m/c to the bulkhead I can finally get the engine in.
Hopefully have a few evenings on it this week.
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Pauleds

ClioSport Club Member
  Merc Dueliner sport
Had a couple of hours in the garage earlier and got a few jobs done.
Did the rear brake lines from the master cylinder to the bulkhead fitting and fitted the throttle cable as it's a lot easier to do before fitting the engine
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Then I have dropped the engine and gearbox back in as my brother needs the engine crane tomorrow
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Getting there slowly!
 

Tomo3292

ClioSport Club Member
  Clio 1.6 K4m
Happy days cheers for that.

I'm in the process of building a 172 Tarmac rally car too. However it's a non cup so looking to swap where possible to cup parts.

Am I right in thinking that if I use a 172 cup subframe, hubs, wishbones etc.. That it gives a wider track?
 

mikekean

ClioSport Club Member
  996 C4S, 135i, E30x2
Track rods are different as well, personally I wouldn't bother converting to cup parts other than the wishbones for extra castor. If at a later date you bend a sub frame then yeah replace it with a cup one as why not but for the gains currently I would save your time/money.
 

Pauleds

ClioSport Club Member
  Merc Dueliner sport
Had a few hours in the garage again today.
Engine wiring loom pretty much all in, exhaust manifold bolted up and alloy rad and slam panel trial fitted
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I then moved inside to see about trying to get rid of the airbag wiring crap.
That's not a lot of fun and any advice welcome!!
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Getting there slowly!!!
 

Pauleds

ClioSport Club Member
  Merc Dueliner sport
Been at it again today, alloy radiator, slam panel, lights, bumper and wings on now.
Plugs, coil pack and leads on.
New ph1 upper and lower inlet and throttle body now fitted, just need to work out the wiring. Just working out the positions for the extinguisher nozzles and fuel line route.
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Pauleds

ClioSport Club Member
  Merc Dueliner sport
Spent the afternoon spraying a bit of the inside today so I can get the dash back in.
I have sprayed the metal dash bar thingy gloss black, the front pillars, front edge of the roof and upper front bulkhead in satin black, and the front footwells are now anthracite (the rest of the interior will eventually be anthracite too)
Pics are a bit crap. Sorry.
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Pauleds

ClioSport Club Member
  Merc Dueliner sport
Having to work all weekend so not getting to the garage to work on the car but I have managed to skim my rotors in my dinner hour. Will hopefully do my spigot rings, sort the hubs and fit the longer studs tomorrow.
Can't rebuild my AP calipers yet as I'm still waiting for the correct size seals and link pipe from AP.
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Pauleds

ClioSport Club Member
  Merc Dueliner sport
Finally managed to get the rest of the interior painted, should have finished it yesterday but ran out of paint. Not a perfect job but looks a lot better than blue and primer.
Before
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After
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Whilst that was drying I fitted the driveshafts, hubs and new bilstein suspension.
Still no brakes though as I am still waiting for new seal kits and link pipe from AP.
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Getting there slowly
 

Pauleds

ClioSport Club Member
  Merc Dueliner sport
Todays update.......I have decided it needs sorting a bit quicker so to motivate myself I have set a target of 6 weeks to get it finished as I am going to enter a rally!
 

markmcgivern

ClioSport Club Member
  RB 182 Cup
Todays update.......I have decided it needs sorting a bit quicker so to motivate myself I have set a target of 6 weeks to get it finished as I am going to enter a rally!
Great to hear! I've followed your build. What event you think going to be your first? Hoping to hear you embarrassing some bigger motors
 

Pauleds

ClioSport Club Member
  Merc Dueliner sport
Great to hear! I've followed your build. What event you think going to be your first? Hoping to hear you embarrassing some bigger motors

Cetus stages at Wigan.
As I've been sprinting on there the last 2 years and previously codriven on there I thought it would be the best event for me to start on with the new car.
Might need a codriver yet Mark if my mates misses can't swop her work shift!!
 

markmcgivern

ClioSport Club Member
  RB 182 Cup
I'd snap at the chance in a clio but I've hung my helmet up this year with a baby due in 5 weeks. Let me know if you struggle as I can ask a few lads
 

Pauleds

ClioSport Club Member
  Merc Dueliner sport
I'd snap at the chance in a clio but I've hung my helmet up this year with a baby due in 5 weeks. Let me know if you struggle as I can ask a few lads

That's a shame, but family comes first!!
What helmet and hans device have you got.........??!!! Lol
 

markmcgivern

ClioSport Club Member
  RB 182 Cup
Most helmets went out of date this year. didn't need hans last year, one of the reasons I didn't continue
 

Pauleds

ClioSport Club Member
  Merc Dueliner sport
Yeah, my 2 year old V2 is no longer legal as it doesn't have hans posts. Havnt decided whether to hire or buy a new helmet (I can borrow a hans) as I doubt I will do many this year
 

Pauleds

ClioSport Club Member
  Merc Dueliner sport
Back on it again today.
Rear bilsteins are fitted, as are the rear lights, boot catch, boot seal, black spoiler (not a cup one but doubt I will ever notice any difference). Positioned the wiring to the rear lights, just need to sort some clips or something. Started to position and mount the hydraulic handbrake so tweaked that a bit then gave it a lick of paint as well as the handbrake. Hopefully get back in there again tomorrow.
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Also tried to put the window film on the rear windows but it was a nightmare and I saw my arse and ripped it off.
Anyone near Wrexham good at fitting msa window film??!!!
 


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