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I gave the car a test and do feel its made things more smooth and 'on path'. The car has loads of feedback with its current setup its really nice to drive, just gotta do the column which I think will give me the confidence to push things for when on track, currently just put in the old oem column and wheel and its about a foot too far away.
Many months later, the door card is finished! The last thing too do was cut out the holes for the handle, strap and switches, I also drilled a couple more holes, in the door though It could do with a couple more at the bottom but its very secure and doesnt rattle..
Iphone struggles with light real bad
Been collecting cleaning products for a bit now, also have some dodo juice sour power
So far have gave it a few basic washes with an iron x wash between, dressed the tyres and started to give some of the ares between the doors and boot a clean. Havnt polished or waxed yet which Im looking forward to being able to do as it looks quite good as is!
Column fabrication started today! Well more just prep work and seeing what things will have to be done that I cant do myself.
With a spare column, I cut back the rear mounts and what joins the front to the rears off. This allows the rear to go as high as possible, for now.
Just to see where to drill the hole. If it was going to be done this way Id put a support arm across the original holes. Dont know how strong it would be without. And of course some type of spacer
Light saber picture I just took. I used some paper rolled up to get the distance. There is quite a lot of adjustment to be had, though Im trying to consider the pedal box which needs space near the column to get as far left as possible (from original pedal position) With this in mind, If I had the column bolted closer to me and extended the lower shaft It would give more room.
Im thinking about moving the seat back around an inch, as the further back Ill get the angle of the wheel will get closer to perpendicular but wont change height, all pending the pedal box will be the right distance for me. And 100% Ill need a scenic shifter bent back loads if I want to do that, as I dont want to cut up the chassis. Also weight distribution ?
Just a few weeks back I drove the car 7 or so hours in one day to pick up a gearbox. The car was faultless and didnt skip a beat, I couldn't of asked for more and it really brought back the enjoyment that I was questioning the car could offer! I also drove another 3 hours yesterday to visit a mate and it was even better, though it went into limp mode when we were driving back for a bit, hadnt happened to me before but possibly its the white connector under the fuse box which I read. Needless to say I had a look, it cooled down and later on the way back home it was fine.
Also very exciting, the gear stick gaiter clips have all snapped so bought another one ?
Seat and pedals out today, drilled a couple more holes in the seat base mount and started to eye up the tilton. I elongated the front mount holes of the column to bring it more forward to try and make more space, though theres still hardly any room there. The box will mount happily but it will be to far to the right, just like the standard pedal positions, which is one of the reasons I want to go custom!
The best I could 1 hand. It can go higher than this.
If you put the clutch pedal as far left as possible, the mcs dont have room. I think the column would have to come way more forward to allow room.
I picked up the tilton for a great deal but its looking like Ill have to go to a normal mounted one to get the position I want
Also everything is back together now. Before I put the dash on I taped foam around everything I could think that was making rattles and a lot have gone but still a few, will tackle those in a bit. Tilton box sold though am very excited to have something on order which will allow to have as far left as needed and much easier access to Mcs. Will be good to get rid of the servo and bulky oem brake stuff as well. Will be a worthwhile weight reduction doing this
Seating position will be quite a lot further back soon ? Hopefully the scenic shifter bent back will be enough and for the stalks Im sticking to my idea of extending the column with an alloy sleeve and bearing, then I can run ducting along as well
Sorted the bleed screws now, will order up some new inner seals for when I put the knockback springs in. Also will order a couple of fittings to make up the lines. They could do with a paint!
New pedal box arrived so had a quick mock up, it will be able to go lower and further back when there's no carpet (will only be trimming around the pedals!) And Ill do my best to make sure it wont look like its been cut if you were to put it back in.
It seems a pretty good piece of kit, not amazing but solid enough. Though the throttle pedal linkage is a tiny bit loose but the pedal action is fine, also the bolts that hold the mcs seems to be too big so the mcs dont fit, nothing that cant be sorted. For the price you get a lot in comparison to other makes.
Took it apart to inspect everything and the thread on the bolts that holds the pedals on wasnt great, ran a die over them and they are all good now.
I a few things now to finish this off
-Front brake mc (have clutch and rear brakes)
-clutch slave + reservoir
-fittings and lines
-mounting for pedals
-column fabrication, or just use a larger spacer to get going
The great thing about the floor mounted is theres tons of room for the column, you can go as far left as you want without the column interfering and plumbing or servicing the mcs is super easy.
Yeah the pedals come forward a bit and you have to move back but I think that there are benefits to be had, cgs move back and the weight of this compared to the standard with servo is much lighter.
Also it can be taken in and out to check things while the standard pedals dont have to come out! Especially efficient when I take it to get the mount made
Made up new lines and bled the brakes in the last couple days. I couldnt wait to try them out so just went out and gave them some heat, I forgot how good they were and how much feedback you get with the ds1.11, you can really feel them biting but its easily manageable. Although Id forgotten what no abs and good brakes are like so I got a couple surprises but its no problem, easy to get used to
I didnt do a proper run so will go out again and properly get some heat into them
Slow progress but Its starting to form how I wanted.
I have now moved the seat back about 60mm, it could go back much further (it will need to) but Ill just wait until my sliders arrive as I had already drilled new holes in the mounts so no need to do any extra work for now. Also made up a dirty spacer for the wheel for now to get the measurements for when the other column gets fab'd.
I have an alloy sheet coming which Ill bolt the pedals too and will allow to me get the overall posititioning of everything as they just slide about right now. Nothing has cropped up major that will need doing, only thing is the twingo lower uj I got will need to be cut for a different uj to bolt to the splines. After a look a round a land rover uj might be exact thing I need.
Scenic shifter will be bought soon as you need an 8ft wing span for 1st gear
Regarding the stalks I want to have a switch panel ideally but Im not sure how to go about it and dont have any experience with electronics.
I saw this which @neil a has used but if the interior loom has to be completly re done then it will be just further to reach and take a lot longer, Id like to have this all done by august time and to be tracked this year at least once
Also want to add that the the full interior will be staying, the only thing Ill do is cut around the carpet for the pedals and removed all the foam undearneath around the foot rest, as theres still space to rest my foot. Im thinking about trimming some of the lower dash but really trying to keep the 50/50 track and road style, more so the looks is the road part because its very strung and far from a road car, but I tell my self its more safe than 95% of road cars at how capable and predicatable it is! Hasnt stopped me driving for hours in it, as its such a joy to drive
Great project @ZachB , really impressed with the way you are designing and fabricating as much as you can yourself, it's so much more satisfying when it works, and if it doesn't you can always tweek the design!
Love the door cards. I can't lose any more weight for my class at the moment, but I will get to replacing all the glass with lexan, losing the winder motors etc. At that point I'll be looking to copy your design.
Pedal box looks a great idea, but also quite a lot of work. Totally agree with moving the driver back to help weight distribution, and to give some flexibility in steering wheel and seat position, not to mention decent pedals, heel and toe friendly.
I'm really short, and even worse my legs are short in relation to the rest of me, which means to reach the pedals comfortably the steering wheel is so close to the stalks my knuckles tend to set the wipers and indicators off when things get exciting on track!
I think a pedal box would be a good solution, or the maybe the instrument panel and delete the stalks? But then you don't get the rear shift of the seat......Damn I shouldn't read other people's builds.....mentally spending money again!
@banhama Thanks for checking the thread out. Yes it can give ideas reading what other people have done and ones that are a bit on the £££ side as well!
Thats interesting what you did using the oem wheel, perhaps you could move the whole stalk assembly back a bit, it would mean removing the small tab on the column that kinda holds it in place but you can do up the bolt underneath to make them solid enough. Not 100% if it would work though!
I hope to have the current jobs finished by july in time for august (my birthday) to be tracked. I just need a clutch slave, the fittings and the necessary fab work done on the column and pedal mounting and its good to go.
Have all the necessary brake and clutch fittings, Ap racing R3 brake fluid on order and have spoken to pms about the clutch slave mount.
It needs an mot and to be tax'd, just gotta put fresh tyres on the front and have a quick check over everything, but I know it needs nothing else.
Then I can get the fab work done for the pedal mounting and the column, after that Ill plumb the system and hope for the best! Think Ill get the garage that do the fab work to do the bleeding and set the brake bias and clutch, might not be much to do but Its best someone does it that knows about it, and its easy to test there than from my narrow one way road.