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Thread: GavinR's Mk2 Stage Car - DVY

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    Re: GavinR's Mk2 Stage Car - DVY

    West Cork Rally - 18/19th March 2017

    This year there were 141 cars entered with myself and George at 113. David and Richard were servicing - Carrie couldn't make it this year, having recently moved house and in between jobs. Due to ongoing insurance issues, the entry fee had gone up again and there were less overseas crews making the journey.

    George and I completed the recce in plenty of time and after bleeding the brakes on DVY, we headed off to scrutineering.
    This went smoothly, the only comment from the scrutineer was that they prefer the buckles on the shoulder straps (which hold the straps round the cage / harness bar) to be as close as possible to the bar to prevent any slack in an accident. We sorted this out after signing on and parked up in Parc Ferme for the night.

    Saturday was dry but overcast and was a late start to allow it to get dark for the night stage. We went out on the slicks for the first loop, Ring followed by Dunworley.
    Apart from the windscreen starting to steam up at the end of the stages, everything went well and we were up to speed quickly. A quick check in service and out for the second loop on the same stages - 26s quicker on Ring and 15s on Dunworley, setting times just outside the top 50 National crews.

    Back to service for a late lunch, everything checked, even the tyres were lasting well! The afternoon stages were Ardfield and Hayes Cross, both run twice. There was a big delay at Ardfield but the stage was still running so we waited patiently and completed it and the following one. Another service and a few cars were putting spotlights on, even though the night stage was later. I thought we'd get through these 2 again without it getting too dark, but there was another delay on Ardfield and by the end of Hayes Cross it was pretty dim - I was having trouble seeing the end of the straights and George was looking hard at the notes. We were slower on both these, and so were a lot of crews around us, the front of the field obviously having a better run in daylight.

    At the final service of the day, it was time to fit the spotlights and head off into the dark for Sams Cross, a good 10 mile stage. We left service a bit early (as we were allowed to) but parked up near the start of the stage to allow a few cars past so we were in the right order. As we queued up getting closer to the start, the temperature was creeping up, but with only a few cars to go I knew it would come down as soon as we left the start line. We were given a start time and realised they had switched to minute starts so it was 5 more minutes, the temperature now off the scale. I should have switched off, let the engine cool down and gone a bit later, but neither George nor I thought of doing that (years of starting problems always make me reluctant to turn off in the queue!)

    Anyway, we pulled up to the line, lights on, heated screen on, pace note light working, 3-2-1-Go - and we expired in a cloud of steam
    The marshals pushed us away from the line and over to the side. She started up again so I asked if we could head into the stage, but the scrutineer (who was there to check everyone was ready for the night stage) said he thought a hose had gone and suggested I had a look. He had a decent torch so we looked under the bonnet and found the radiator overflow pipe (which is pressurised and blocked with a bolt) had split near the radiator. This was good as it was the only hose I had a chance of repairing and I had my Swiss Army knife in my pocket A few minutes later, I had shortened the hose and refitted it. The scrutineer got me some water from the Rescue people and we were ready to go.

    Cars were still leaving the line just beside us and the marshals weren't sure about allowing us to go into the stage from where we were parked. As we had left the line, I think we could have gone anyway, but a better plan was to ask them to give us a new start time and do it properly. The stage commander and start marshals had a chat and decided they might as well let us restart, so we got organised, manoeuvred back over the line and started the night stage 15 minutes after we'd first attempted it!

    So we got going, but I couldn't see much - there was so much steam inside the car, and water on the floor being turned into more steam by the exhaust, the heated screen couldn't keep up. I drove as fast as I dared but didn't want to throw it off after having got away with the problem, and George did a great job reading the notes slower than she had been all day. We got caught near the end by 2 cars, but it was a great relief to make it out in one piece, although we dropped over 2 minutes on this stage. David and Richard collected us from Parc Ferme and we just made it to the Italian to pick up a takeaway before they shut at 10pm.

    After a good nights rest, we headed back to Parc Ferme on Sunday morning. DVY started up fine and I added some water and dried the floors as well as I could. We had a short service before heading out on the stages and took the opportunity to fit the X22 wets as it had rained overnight and was still damp in the air.

    There were 3 stages run twice, Clogagh, Ballinascarthy and Rossmore, all familiar stages but run slightly differently this year. We started well, despite cocking up the first hairpin and nearly ending up in the bank! It was slippery but not too bad, although we passed quite a few cars who had gone off, and set times in the top 50.

    Back in service, Richard did a final spanner check and I checked the water again, before David and Richard went off to watch the final stage, and we went to the start of the loop. Clogagh had dried out quite a lot so we were 30s quicker here, and I got the hairpin right! Ballinascarthy and Rossmore were still damp so we werenít much faster, being sensible we got to the end in one piece to collect our finishers mugs.

    When the results came out we were 36th in the National section and got a special award for 1st English crew

    This picture is from the very first stage, when DVY looked clean!



    Not sure when Iíll be out next Ė I need to sort out a decent demisting system first...
    GavinR

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  2. #482
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    Re: GavinR's Mk2 Stage Car - DVY

    http://www.turbosport.co.uk/showthre...ghlight=heater


    The heater motor in post number 260 might be helpful for your demisting issues. Though Im a little surprised the heated screen cant keep it clear. I used to have a heated screen in an mk6 escort van and it was nothing short of bloody excellent...

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    Re: GavinR's Mk2 Stage Car - DVY

    It's more that the heated screen has a 12" section directly in front of me that doesn't work - the screen's only a few years old but they don't seem to last very well.
    So I want to go back to a traditional demister / blower, but cannot fit a std Escort heater as the bulkhead's been cut.
    Thanks for the link - I've been looking at something from T7Design as well
    GavinR

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  4. #484
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    Re: GavinR's Mk2 Stage Car - DVY

    Oh ok, funny you say that as although I said the screen in my van worked brilliantly I also had a 2.0ltr sierra sapphire that had a heated screen, an that seemed to be dead on the passenger side, I never worked out what was wrong with it although I suspected it had a wiring issue on that side as they had a power feed to each side of the screen if remember correctly. The heated element was in 2 separate sections within the screen if I correctly...

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    Re: GavinR's Mk2 Stage Car - DVY

    Gav. I have a heater box from a caterham 7 that's spare if you're interested. Came out of my mk2 but I don't need it

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    Re: GavinR's Mk2 Stage Car - DVY

    Quote Originally Posted by rallyrob View Post
    Oh ok, funny you say that as although I said the screen in my van worked brilliantly I also had a 2.0ltr sierra sapphire that had a heated screen, an that seemed to be dead on the passenger side, I never worked out what was wrong with it although I suspected it had a wiring issue on that side as they had a power feed to each side of the screen if remember correctly. The heated element was in 2 separate sections within the screen if I correctly...
    Bit's of it work, probably about half of it on my side and most of it on the passenger side, so it's the individual element wires which have failed

    Quote Originally Posted by clarky205 View Post
    Gav. I have a heater box from a caterham 7 that's spare if you're interested. Came out of my mk2 but I don't need it
    Thanks for the offer, I'll get back to you when I've looked at a few options
    GavinR

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    Re: GavinR's Mk2 Stage Car - DVY

    They were also wired to a timer relay so they weren't on permanently, about 10 minutes I think the van one ran for before it switched itself off.

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    Re: GavinR's Mk2 Stage Car - DVY

    Did some investigation over the weekend as I was curious how something had been done...

    When I first owned DVY and had removed the heater, we never had any problems with the screen misting up, even on very wet events. No heated screen and no blowers either. I always assumed there was enough airflow into the car to keep everything clear.

    The chap who I sold her to and did some forest events and Barbados, initially ran a Vauxhall engine and recessed the centre of the bulkhead / heater bubble a couple of inches. This was done very neatly so I didn't bother putting it back to original.
    After the problems in Ireland this year, it got me thinking about where any water going into the grill below the windscreen went. Looking inside the car, there is a flat sheet welded over the blower motor recess, and in the engine bay there is a vertical flat sheet slicing through the heater bubble.
    So I got a watering can and poured it into the grill, looked underneath and there was no water coming out, or inside the car.
    So I got another watering can and poured more water into the grill and managed to fill it up

    The two plates join creating a V shape and without any drain holes, the water cannot drain out!

    Eventually the water dribbled out of some bolt holes and I poked a drill through at the bottom of where the 2 plates join and let some more out. As much dribbled into the car as outside so I think this is a large part of the problem - whenever it rains there will be water in the heater bubble, which can easily get into the car and turn into steam from the hot floor.

    Next step is to cut a slot / drill a large drain hole at the back of the engine bay to allow it to drain out.
    I still plan to fit a blower to help the screen
    GavinR

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    Re: GavinR's Mk2 Stage Car - DVY

    What heater are you going to use? I have a large tunnel in mine and I don't know whether to cut the mk2 heater, use a mini one or something else.

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    Re: GavinR's Mk2 Stage Car - DVY

    I'm still trying to figure that out!

    When I first bought the car, it had a std Mk2 heater unit with the bottom vents cut down slightly to make it fit with the big tunnel
    But with the bulkhead mods it's not possible to fit one back in - the previous owner was using a Mini unit
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    Re: GavinR's Mk2 Stage Car - DVY

    Will be interested to see what you come up with.

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    Re: GavinR's Mk2 Stage Car - DVY

    As I'm rebuilding Fly this summer, I decided to get out in Dvy again, so I entered the Mewla this weekend.

    So I've spent the last 2 weeks sorting out the minor issues that happened in Ireland, including fitting some new bushes in the alternator mount. This simple job turned into a few evenings work as the new bushes moved the alternator forwards by 6mm so the pulleys didn't line up I resolved this by making a new mounting plate - the alternator is spaced forwards anyway due to the dry sump system. I also fitted a slightly longer Poly-V belt as the old one was so tight it made it very hard to fit.

    Back to the heater / blower - after taking measurements from Fly and looking at an old Mk2 plastic heater box, I decided if I cut 40 mm off the front I could make it fit...
    I drilled a hole in the engine bay and cut a slot to let any water out - this is now covered with an ally plate to keep the scrutineers happy, but before I covered it I fished out various washers, old rivets and rust!
    Inside, I drilled into the middle of where I thought the original blower motor circle would be, and snipped round the circle to recreate the hole with a flat on one side.
    When I'd found the heater box, I also found a Mk1 (or early Mk2) metal heater and fan - the fan being mounted in a sort of alloy casting with 3 legs. This fitted into the hole I had created, but not all the way. After a few hours cutting the heater box, I ended up with this
    The fan is recessed to allow for the smaller heater bowl, and the top 2 legs fit on the flat side of the circle I had cut out





    The tie-wraps are temporary so I could offer it up in the car and make sure it fitted. It did fit, so I cut an ally plate and glued it over the hole with some sealant. I also sealed the freah air vents and cut away some of the floor vents so it sat better on the tunnel, locking the lower flap in position so the air always goes to the screen. A bit of foam round the top and I screwed it into place using to of the original mounting points. The other 2 had been removed when the bulkhead was cut, so I added some ally brackets to the tunnel to stop it moving around. A fuse, switch and a bit of wiring later and I have a working demister.





    I'm hoping after all this that it will be a lovely sunny day on Sunday!
    All loaded up and ready for scrutineering tomorrow

    GavinR

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    Re: GavinR's Mk2 Stage Car - DVY

    Good luck Gavin
    Mind the sheep
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    Re: GavinR's Mk2 Stage Car - DVY

    A good day on Epynt, but the 3 stages at Builth Wells showground were not so good - the 50% tarmac was fine, but the 50% gravel was very dusty so I had to slow down to see where I was going, most people were complaining about these stages.

    Final Result was 19th Overall and 6th in Class, so pleased with that, although it was a smaller entry than usual, with around 60 cars
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    Re: GavinR's Mk2 Stage Car - DVY

    Good result Gavin well done
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    Re: GavinR's Mk2 Stage Car - DVY

    Southdowns Stages - Goodwood - Saturday 10th February 2018

    This year I'm not going to West Cork for various reasons, mainly financial (after spending too much on Fly last year!)

    So I'll be doing a few in this country and started with the Southdowns Stages at Goodwood a few weeks ago with Carrie codriving
    Richard came over from Essex with another friend Stuart who usually marshals

    I'd given DVY a good check over - fitted the tarmac springs, new rear coilovers, lowered all round and a new centre box as the noise regs are quite tight at Goodwood

    There were 9 stages, most were 2 laps of the circuit with a couple only one lap. We were seeded car 9 out of a full entry of 55 cars - I thought we were a bit high but was hoping for a top ten at the end of the day.

    We started very slowly on the first stage, trying to remember to use the whole circuit and brake late enough into the chicanes. The second stage was not any better as it started drizzling and we were still on the slicks. We fitted the wets for the 3rd stage, but nearly slid into a chicane and had to reverse a few yards to get through. By the 4th stage we were up to speed - the circuit was now properly wet and my wet tyres were working better. The 5th stage was a short one and at the lunch break we were down in 19th...

    So 4 more stages after lunch and these were the correct way round - the corners seem to flow better this way.
    Stages 6 and 7 went well and we moved up to 15th.
    Stage 8 was at dusk and here we benefited from a good seeding. My friend Chris (DrDub) was at 29 in his new Escort and being 20 minutes behind it was dark by the time he went round.
    We only gained one place but were a lot closer to those in front.
    The final stage in the dark went well, until I out braked myself into a chicane, managing to avoid all the cones we made up our own route (to keep the marshals happy) and our time was 10s slower, but this was enough to move us up to 12th overall and 6th in class.

    We had an enjoyable day, DVY was running well and we managed not to hit anything! Thanks to Carrie for co-driving and Richard and Stuart for looking after the car.

    A few pics from Andy Manston







    And some in car (when I'd remembered how to work the camera!)

    SS5
    https://youtu.be/kOxTHMlazHM

    SS8
    https://youtu.be/TzhPgmNJv68

    Next event should be the Corbeau Seats Rally Tendring & Clacton in April - the first Closed Road event in mainland England...
    GavinR

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    Re: GavinR's Mk2 Stage Car - DVY

    So how did clacton go then Gavin?
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    Re: GavinR's Mk2 Stage Car - DVY

    Clacton was great fun, well organised and everything ran on time

    Very enjoyable until the engine went on SS9

    This was us on SS7
    GavinR

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    Re: GavinR's Mk2 Stage Car - DVY

    Any updates Gavin?

    What went wrong with the engine?
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    Re: GavinR's Mk2 Stage Car - DVY

    Hi

    Exhaust cam snapped in 2 places - between 3 & 4 and just behind the cam pulley
    Not sure why, maybe a valve got stuck down then the piston hit it hard and the shock was enough to break the cam - always difficult to tell when 12 out of the 16 valves are bent!

    Anyway, everything in the head has been replaced, new bearings in the bottom end, head skimmed a few thou and pistons skimmed to match and she's up and running again

    Rolling Road booked for Thursday morning, then Wethersfield Stages on Sunday with Carrie
    I'm hoping for a good run without any problems
    GavinR

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    Re: GavinR's Mk2 Stage Car - DVY

    Wethersfield Stages - Sunday 9th September 2018

    The rolling road session went well, we just added some fuel at part throttle to improve the pick up and lowered the rev limit to 8k - power was 220bhp but still climbing at the this limit

    Carrie was codriving - we'd competed here twice before, in 1997 and 1999, and helped Chelmsford MC set up their other stage rallies there. More recently I've done Targa events so I was looking forward to the tricky bomb dump section - apart from this, the rest of the stages were very open without a chicane anywhere
    There were 6 stages each over 10 miles long (it's a large airfield) and we were seeded car 11 out of the 50 entries.

    It was a nice dry day but not that warm so I started with soft Hankooks all round and there was plenty of grip on the concrete and tarmac. Chelmsford had also laid a couple of sections of concrete in the bomb dump where the surface had deteriorated over the years. We made a sensible start, 15th quickest, but got going on stage 2, 30s quicker - it's amazing how much speed you can carry round a 90 degree corner on the perimeter track when it's 30-40ft wide

    Stages 3 and 4 were in the opposite direction - the tyres were working well so we left them on. Going into the bomb dump on the second lap we were catching an Escort WRC and were on his bumper by the time we exited, but had to wait a couple of corners before going past as he hadn't seen us... Another couple of good times brought us up to 9th

    Onto the last 2 stages, really going well now, hitting the limiter in 5th in a couple of places (108mph on the slicks), 7th quickest on the last stage

    We finished 10th overall and picked up a pot for 3rd in class - it was a very enjoyable day, DVY was running well, we finished on the same 4 tyres we started on and just added fuel during the day!
    There's a couple of things to do over the winter such as fit a bigger electric fan, reseal the rocker cover and rebuild the gearbox which was whining a bit, but she can go away in the garage for a few months while I concentrate on other events in Fly
    GavinR

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