TomoTek - 182 Track Build here we come!...

[f0xy]

Excited to announce @Jenbo and I have now registered for the 2019 Trackday Championship (TDC) .. here’s a summary we’ve put together about the championship!

Now to get prepared and smash next season!.. might have to do a few other races too to make sure we can get enough signatures to upgrade to a Nat A licence in time to compete at Zandvoort

Reliability is the key too...! In 9 races this year only managed 5 signatures due to mechanical issues, and a cancelled round. Luckily only need the one now for Spa in 2019. Good luck with it, you've built the car well.

What fuse/relay board are you using in the 205? I've been through a number of different types over the years but never found one that fits certain requirements

 

[Tomotek]

Reliability is the key too...! In 9 races this year only managed 5 signatures due to mechanical issues, and a cancelled round. Luckily only need the one now for Spa in 2019. Good luck with it, you've built the car well.

What fuse/relay board are you using in the 205? I've been through a number of different types over the years but never found one that fits certain requirements

Yeah exactly!, you never know what can happen; contact is the other risk too!.. We have a few options in case we need to get a couple more signatures though. Have fun at Spa!, another track I need to tick off

We’ve just used a simple modular fuse/relay box from auto electric supplies.
https://www.autoelectricsupplies.co.uk/mobile/product/181/category/37

We did look at some PCM’s and membrane switch panels, but for speed and cost reasons we just went for the modular system.

 

[Tomotek]

Zandvoort is a cool track, nice underlations to it. I'll try and get to Brands to have a watch

Yeah it is cool!. just had a go on the simulator, like you said the undulations are amazing, proper 'park' type circuit. cant wait now!... that would be good, defo pop over for a brew and a chat

 

[Tomotek]

We’ve bought ourselves an early Christmas present. a nice TTV lightweight flywheel came up at a great price so couldn’t say no!

TTV weight 3.2kg
Std weight 5.3kg

Not to pull the box out again to fit it!

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[JamesBryan]

New flywheel bolts don't forget ?

 

[Tomotek]

New flywheel bolts don't forget ?

haha, yeah 100%.. also fitting a new clutch and release bearing at the same time

 

[ClioManDan]

Been reading through this build for the last couple of days when I've had a sec or two to spare. Great build with good workmanship, wish i had the facilities to do what you've done! Keep up the good work!

 

[scullyg40]

Zandvoort is a cool track

It is indeed, been there twice now. Watch out at Scheivlak though. ?

 

[Ricardos]

It is indeed, been there twice now. Watch out at Scheivlak though. ?

I drove it for the first time 3 weeks ago on a public sessions day. I'm unfamiliar with corner names but what I do know is it was ridiculously over busy! Sending out 50 cars in one session, far too crowded and with people giving it the big one from the off. A shame really as yeah it's a decent track but my experience tainted by overcrowding, I came in after 3 laps as I had a car spin in from of me and one behind nearly drive into me. I spent more time looking in my mirrors at cars overtaking either side than enjoying just getting on with it.

I'd love to go back, better structured trackdays there are bloody expensive though.

 

[Tomotek]

Been reading through this build for the last couple of days when I've had a sec or two to spare. Great build with good workmanship, wish i had the facilities to do what you've done! Keep up the good work!

Thanks Dan .. been a bit quiet as I’ve been mad busy with work and organising everything for the racing this year.. hoping to keep up the updates

 

[Tomotek]

I drove it for the first time 3 weeks ago on a public sessions day. I'm unfamiliar with corner names but what I do know is it was ridiculously over busy! Sending out 50 cars in one session, far too crowded and with people giving it the big one from the off. A shame really as yeah it's a decent track but my experience tainted by overcrowding, I came in after 3 laps as I had a car spin in from of me and one behind nearly drive into me. I spent more time looking in my mirrors at cars overtaking either side than enjoying just getting on with it.

I'd love to go back, better structured trackdays there are bloody expensive though.

Nothing worse than an over crowded track day.. far to many organises these days try to get as many people as they can on track, it just ruins it really.. that’s why I like the open track events.. ran well and they keep the numbers down

 

[Tomotek]

I’ve been a bit quiet over the past few weeks/months.. it’s been crazy busy organising everything for the racing, managing my full time job and planning a wedding at the same time.. it’s all coming together now though..

Here’s a bit of an update as to what I’ve been up to.. more to follow

I’ve been working on mapping out all our costs for this year and finalising the budget.. including all races, upgrades, consumables etc.. then writing the to do list!!.. over 100 jobs to get done.. luckily I’m more than half way through those already.

The whole front end was stripped down ready for a clean and check over.. obviously with the new flywheel the gearbox had to come out again!.. took the opportunity to replace the clutch for a new one and got a new sump seal as the old one was sealing slightly.

Oil looked good, filled prior to all our testing last year.

New seal and quick inspection inside the cylinders

I then fit the TTV lightweight flywheel and clutch kit.. lovely piece of kit the TTV .. so light over the original, and the quality is great... out with the old and in with the new

Gearbox going back in

I also finally got round to sealing off the bulkhead fully with a non AC blanking plate.. holes put in for the fuel line bulkhead fittings

I then set about putting a fresh set of spark plugs in.. and then keeping the set that came out as a good spare set.. they looked like they were getting good combustion which was nice.

Quick mark up of the leads so they go back on the right way round

Old ones out

I also gave the filter a good clean out to, was full of dirt and debris from all our testing, defo did its job!

I then turned my attention to cleaning up all the AST dampers and the engine bay.. looks as good as the day we finished the car build

More to follow!...

 

[Usr117063]

All the best for this year, the cars looking real clean and in order! Is that a drivers cold air feed going into the bulkhead? I was thinking of doing this but undecided on where to route it, I was thinking around the pedal area could work but I have to think if its purely for fun or will it actually work.

 

[Tomotek]

All the best for this year, the cars looking real clean and in order! Is that a drivers cold air feed going into the bulkhead? I was thinking of doing this but undecided on where to route it, I was thinking around the pedal area could work but I have to think if its purely for fun or will it actually work.

Thanks, fingers crossed we can get some results [emoji1694] .. yeah we have the duct being fed from the front bumper.. it goes into the scuttle area, then down into the cockpit through the hole where the heater used to sit.. then attached to the gearshift frame and points at the drivers.. blows nice cold air at my chest.. worked well at Snet in the summer heat last year

 

[Nafoff]

Looks great mate. Good to stay on-top of things. All the best for racing this year.

 

[Touring_Rob]

Have you had the engine running since fitting the flywheel? impressions?

Looking too clean to go racing in!

 

[Tomotek]

Have you had the engine running since fitting the flywheel? impressions?

Looking too clean to go racing in!

Not yet, just fitting some sensors to the engine then filling it back up with oil before we get it running again., will report back when we do

 

[Touring_Rob]

I think the 'filling it back up with oil' bit is a smart move

 

[Tomotek]

I think the 'filling it back up with oil' bit is a smart move

Haha.. it’s on order! Should be running shortly

 

[Tomotek]

For Racing this year we were really keen to get rid of the std dash, as it was only useful to see RPM, Fuel level and rough water temp.. it was always our plan to fit a digital display and mount it to the column as per an old post I did.

We really want to make sure we have all the data we need to be able to monitor the car parameters and analyse any changes we make in the future. We also want to be able to log our driver inputs to help @Jenbo and I improve and learn from each other during our test sessions.

With that in mind we started to spec up some sensors and dash options.

Main sensors we want to log
- engine rpm
- water temp
- engine oil temp
- engine oil pressure
- gearbox oil temp
- air temp
- manifold pressure
- fuel level
- fuel pressure
- brake pressure
- throttle position
- steering angle
- lat / long g force
- distance / time splits

Obviously a few of those are already fitted and read by the ECU so we could tap into the CAN bus feed and pull those out.

Engine / gearbox oil temp and pressure were the main ones to sort out.

I ordered some sensors from RRR Engineering who are now the ECU Master UK distributors. They are top quality products and a great bunch of guys

I then set about trying to find a decent oil sandwich plate to position the sensors on the engine.. I ended up finding a D1 Spec plate which was perfect.

This then simply screwed onto the block, and a new oil filter to match

I then decided to use the old reverse switch port on the gearbox for the temp sensor.. I’d blanked this off during the rebuild so I sourced a M14 x 1.5 to 1/8 NPT adaptor to put in its place and fitted another temp sensor... not necessary really but I’m interested to see how hot it gets

More news on the dash and other sensors later [emoji1360]

 

[RuskiWeldFab]

That is very neat idea about gearbox temp! I been wondering how hot it gets and even used infrared gun on the casing. Not sure how this info would help in anyway unless you (or me) were planning to have gearbox oil cooler fitted. But very interesting nevertheless. Infrared gun was showing around 90deg. But I would assume it’s not very acurate. Might borrow you idea ( again) hehe!
Ps. As others said before, your car is too nice and clean to race haha! Throw some dirt or grease over it common!


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[Tom Johnson]

Ran a gearbox temp sensor for last 3 years for racing. Runs about 98°c

 

[RuskiWeldFab]

Ran a gearbox temp sensor for last 3 years for racing. Runs about 98°c

I guess infrared gun isn’t too far off than! [emoji106]


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[Tomotek]

Ran a gearbox temp sensor for last 3 years for racing. Runs about 98°c

Nice one thanks, that will be a good reference.. where did you mount your sensor?

Might borrow you idea ( again) hehe!
Ps. As others said before, your car is too nice and clean to race haha! Throw some dirt or grease over it common!

It should be a good indicator if there is a potential problem with the box, excess friction on the gears / diff etc.

No worries, I’m used to you borrowing them now [emoji6] ..

I’m sure it will get dirty once we’ve thrown it through the gravel trap a few times pushing too hard! Haha

 

[Tom Johnson]

Nice one thanks, that will be a good reference.. where did you mount your sensor?

Same place as you, reverse light switch

 

[Usr117063]

Have you ever thought about finding the centre of gravity? I was looking at the method to do so the other day, kinda haulted by having to lift each axle up with only home tools. Would like to know though!

 

[Tomotek]

Have you ever thought about finding the centre of gravity? I was looking at the method to do so the other day, kinda haulted by having to lift each axle up with only home tools. Would like to know though!

It would be interesting to see, I’m making a gantry to help engine removal (more transportable than an engine crane) so could use that to raise the back of the car up... I’ll add it to the list haha

 

[FrogJam Motorsport]

Have you seen the Pro Tune TDL dashes?

Just started looking into digital dashes myself. Want something that will work with the original ECU until I switch to a stand alone one.

 

[Tomotek]

Have you seen the Pro Tune TDL dashes?

Just started looking into digital dashes myself. Want something that will work with the original ECU until I switch to a stand alone one.

Yeah I saw that one at the autosport show, I had a good look around all of them, Bosch, AET, Motec etc.. I weighed up all the options and we’ve gone for the ECU Master ADU 5 .. the functionality and levels of customisation sold it for me, and the guys at ECU Master UK were by far the most knowledgable and helpful!.. I ended up spending a day down at their workshop learning all about the products and getting a walk through of all the dash features

ECU Master and RRR Engineering have decided to partner up with my race team Pro-Am Racing for this season to develop their systems for Clio cars, which I’m happy to announce!

They offer both a 5” or a 7” ADU (Advanced Display Unit) with in built data logging

These can be purchased through RRR Engineering (if you quote our race team you can get a good deal)

https://rrrshop.co.uk/ecumaster-adu-1254-p.asp

I also decided to get the GPS kit to enable vehicle speed and predictive lap timing and lap delta and the USB to CAN to connect the dash to he laptop so I can load the custom screens

We are also working with RRR Engineering on a plug and play kit for their stand alone EMU Black ECUs.. they will be developing an adapter loom that plugs directly into the standard clio ecu connector loom and allows full use of the EMU features. (This way you don’t need to make custom looms to run an aftermarket ECU and also unlock more features over the standard unit)

https://www.ecumaster.com/products/emu-black/

They will be using our Clio to do all the dyno testing and tuning to get a base map to issue with the kit..

Exciting times!, should be a good partnership and can’t wait to see the end result!

 

[FrogJam Motorsport]

They look great!!

Going to have a good read up on them but will be very interested to hear about how you get on with them.

Worth a trip to the workshop to have a look at them do you think?

 

[Tomotek]

They look great!!

Going to have a good read up on them but will be very interested to hear about how you get on with them.

Worth a trip to the workshop to have a look at them do you think?

Yeah the quality and even the base templates are really impressive.. have a look at the manual on their website, u can see all the features..

I’ll do a post with the fire up.. just in the middle of wiring everything into the car now.

They also do have a test dash which they can turn on and demo quite a lot of the features on... I can put you in contact with one of the guys if you wanted to visit.

I had all our parts arrive last week!.. better than Christmas haha [emoji23]

 

[scotiamr2t]

I priced up the ecu, dash, GPS module etc last year an was over 2k! Not cheap but the features are awesome

 

[Tomotek]

I priced up the ecu, dash, GPS module etc last year an was over 2k! Not cheap but the features are awesome

Yeah the full set isn’t cheap is it!.. but they’re well priced compared to most of the other options out there I thought, with a lot more functionality too. A good balance I’d say

 

[Tomotek]

Bit more work done on getting the dash fitted over the past week.. I designed a dash shroud to both mount the display to the car and also prevent some glare at the same time.. Ive decided to sandwich the mount inbetween the steering column clamp and supports. This way I can easily adjust the angle of the screen and it will follow the steering wheel if we adjust the column height

Quick CAD model designed to enable me to print out some flat patterns to start making it.. fabricated TIG welded aluminium was the chosen manufacturing method




I then set off making the shroud.. here are a few pics of the process

 

[Tomotek]

Final shroud assembly in all its glory...

Now just to get it flocked to give it that finishing touch, which will match the current dash top we have installed

 

[RuskiWeldFab]

That is some clean fabricating mate! Love it! Quite interesting how you going to mount it. Is it going to be same as mine on the column itself?


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[Tomotek]

That is some clean fabricating mate! Love it! Quite interesting how you going to mount it. Is it going to be same as mine on the column itself?


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It is sandwiched between the column clamp I made and the support bars.. this way I can adjust the angle of it before tightening up the joint

I got the shroud back from the flockers last week and fitted the dash and the GPS unit

 

[Tomotek]

I also managed last week to make the dash loom and connect it all up.

You get a connector and pin out to start with. I started the wire the main wires required.

I also made a wiring diagram to understand all the additional wires I’d need for the extra sensors etc

Then set about finalising the loom and splitting it into the sub sections for connectors

Then it was just a case of heat shrinking it all and labelling it before connectors were put on.

 

[Mbeau]

Such a cool build. Real attention to detail as well. Very impressive.

 

[JamesBryan]

If you were to put a price on this car if you were to sell it, what would you put it for?

Just out of interest.