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Thread: My mk2 Rally car - Duratec power

  1. #121
    Pit Crew Decade Plus User PaulAlex's Avatar

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    Re: My mk2 Rally car - Duratec power

    Hi Jon,

    I'm in Shenzhen, just over the water from Hong Kong, doing some IT infrastructure work at our office there. Slight problem is that some of the kit has been held back in customs, so I'll be scrabbling around for stuff to do after tomorrow I'd say.

    If no parcels arrive, then I'll be coming back home earlier and then another trip out in January Airmiles!!!

    BTW If you ever want to borrow some 15s to try the car, just say the word...

    Cheers,

    Paul

  2. #122
    Mechanic JonSegger's Avatar
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    Re: My mk2 Rally car - Duratec power

    Quote Originally Posted by PaulAlex View Post
    Hi Jon,

    I'm in Shenzhen, just over the water from Hong Kong, doing some IT infrastructure work at our office there. Slight problem is that some of the kit has been held back in customs, so I'll be scrabbling around for stuff to do after tomorrow I'd say.

    If no parcels arrive, then I'll be coming back home earlier and then another trip out in January Airmiles!!!

    BTW If you ever want to borrow some 15s to try the car, just say the word...

    Cheers,

    Paul
    Ah OK. Yes I know it, I've been to HK quite a few times - also for IT infrastructure work. We have a data centre in HK.

    Cheers for the offer of borrowing the wheels. I'm thinking it would be worth buying a set of 15s if some come along at the right price to use on the road or for track days where there are longer straights to help gear it up a little. But I might give you a shout if a track day comes up before I've got some.

  3. #123
    Mechanic JonSegger's Avatar
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    Re: My mk2 Rally car - Duratec power

    So final preparation before Brands Hatch this weekend...

    All the jobs have been completed, including fitting these bad boys:


    We also made some new over sized mud flaps to meet the new regulations. Off with the old:


    ..and on with the new:



  4. #124
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    Re: My mk2 Rally car - Duratec power

    Love the slightly tatty, ridden hard put away wet look Jon, suitably pukka

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  5. #125
    Mechanic JonSegger's Avatar
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    Re: My mk2 Rally car - Duratec power

    Quote Originally Posted by dobuy View Post
    Love the slightly tatty, ridden hard put away wet look Jon, suitably pukka
    I prefer to think of it as the 'pre-loved' look...

    The bodywork will get a tidy-up at some point soon. We've pushed out the dent in the rear quarter to a reasonable shape, but I'll get the next couple of events out of the way before going any further with it.

  6. #126
    Pit Crew Decade Plus User cossie matt's Avatar
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    Re: My mk2 Rally car - Duratec power

    Good luck Tomorrow Jon

    I'm coming down to watch and make sure you are suitably sideways so I'll come say hello anyway.

  7. #127
    Mechanic JonSegger's Avatar
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    Re: My mk2 Rally car - Duratec power

    Quote Originally Posted by cossie matt View Post
    Good luck Tomorrow Jon

    I'm coming down to watch and make sure you are suitably sideways so I'll come say hello anyway.
    Cheers fingers crossed it's dry, not too cold, and holds together OK.

    See you tomorrow.

  8. #128
    Racer mervhill's Avatar
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    Re: My mk2 Rally car - Duratec power

    You may get the dry bit at least I would have liked to have come to watch myself, but my rugby team have a match tomorrow so I have refereeing duty.

    Good luck though mate, hope it goes well for you!

  9. #129
    Mechanic JonSegger's Avatar
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    Re: My mk2 Rally car - Duratec power

    Well, unfortunately it didn't go entirely according to plan. All was going well and I was getting used to the new brakes until the 4th stage when we had gearbox problems. We lost 4th gear - just couldn't select it. Then I managed to get 4th, but it jumped out of gear, so at that point it was time to call it a day as I didn't want to wreck the gearbox.

    We took the box out last night and had the lid off. We can't see anything obviously wrong, so its now going to go to someone who knows what they're looking at.... I wish I had the cash for a 60G...

  10. #130
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    Re: My mk2 Rally car - Duratec power

    bugger, the joys of Motorsport

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  11. #131
    Mechanic JonSegger's Avatar
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    Re: My mk2 Rally car - Duratec power

    So, the gearbox is now with Competition Transmission Systems for repair. It seems that they have the exclusive rights for selling and repairing the older style Type9 sequential boxes now. The 3rd/4th dog gear was knackered, which is what was causing my problems, but the 1st gear was apparently also worn.

    They're repairing it and at the same time upgrading the maincase to an alloy one. The original cast cases are a known weak point as they are prone to cracking.

    Here's a few videos from Brands. I was braking far too early on almost every corner as I was still getting used to the brakes.

    Stage 1. We went straight on at the first corner of the first stage as it was incredibly slippery:


    Stage 2:


    Stage 3:


    Stage 4. The gearbox fails at about 2 and a half minutes in:

  12. #132
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    Re: My mk2 Rally car - Duratec power

    pretty slippery at the start, engine sounds very crisp

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  13. #133
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    Re: My mk2 Rally car - Duratec power

    Quote Originally Posted by JonSegger View Post
    So, the gearbox is now with Competition Transmission Systems for repair. It seems that they have the exclusive rights for selling and repairing the older style Type9 sequential boxes now. The 3rd/4th dog gear was knackered, which is what was causing my problems, but the 1st gear was apparently also worn.

    They're repairing it and at the same time upgrading the maincase to an alloy one. The original cast cases are a known weak point as they are prone to cracking.
    Hi Jon,

    I'm sure they'll do a good job at a sensible price, my 6 speed came from them

    You'll save some weight with the alloy maincase as well

    Good videos, I think a lot of people nearly went straight on at the first corner, I know we did
    GavinR

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  14. #134
    Mechanic JonSegger's Avatar
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    Re: My mk2 Rally car - Duratec power

    Sorry... I haven't updated in ages. Its been a busy few months.

    The gearbox went to CTS for repair & rebuild. At the same time, the case was upgraded to an alloy one.


    So I got that back and took it for a test on a track evening at Snetterton. It went very well, gears all working perfectly.

    Then, I had a call from Mr Dunnell. One of his customers in the FIA European Rallycross Championship was in a tight spot with their engine. They'd had a problem and damaged one, but they'd left it too late to get to him for a rebuild. Their engine spec was pretty similar to mine, so, long story short, they borrowed mine on the basis that they'd foot the bill for a rebuild when returning it a few weeks later. As it turned out I ended up with their old one once it was rebuilt - but with a new oil pump and all new induction system and throttle bodies:


    The overall induction length with these throttle bodies is shorter than my old ones, which means that there is more clearance to the inner wing and I can get a 'proper' filter on instead of having to make an air-box which just about touched the end of the trumpets on the old set-up.

    So then it was on to the Richard Burns Memorial Rally in August. I hadn't had an opportunity to test it since fitting the new engine. And, I was using a throttle linkage which I had made myself - so it was also untested. I was expecting teething problems of some sort.

    Scrutineering went OK on the Friday evening. Saturday morning was wet, but it was warm and muggy. We lined up for the first stage and the engine was getting quite hot. Once we got off the line though, it soon returned to normal operating temperature.

    About half way round the first stage though, the oil pressure warning light came on and the gauge read zero. I killed the engine and we parked it on the grass to take a look. The belt was still on the pump. There was still oil in the dry sump tank. There were no obvious leaks. So, we started the engine again and made sure that oil was returning to the tank. It was a faulty oil pressure sender! The warning light was driven from the SPA oil pressure gauge, so I had no way of confirming whether there was a problem.

    We carried on to finish the stage. Looking back at the in-car video, we were parked for 7 and a half minutes. We carried on the rest of the day without an oil-pressure indicator, which is not a nice feeling. After stage 1 we were in 102nd place.

    Overnight, I found an oil pressure switch in my bucket of spares, so we rigged up a bulb on the end of a piece of speaker wire. For day two we had an oil pressure warning light

    On the sunday we started in the order of our current position, so we were down at 60-something, which meant we were starting behind some slower cars. It was good fun catching and passing them though - especially knowing that being held up wasn't costing us a trophy because we were well down anyway.

    We finished the rally 39th overall and 15th in class - which, considering the time we had lost on the first stage was OK I think.

    Here's a few photos:
















    And a video:


    Since then, I have replaced the oil pressure sender and also fitted a separate oil pressure switch which operates the warning light on the dash.

    I then did a track day at Woodbridge last weekend for a bit of fun. I was using some very knackered slicks on the rear which gave very little grip, but made it a lot of fun. Here's an in-car video:


    We couldn't make the Woodbridge rally this weekend, but we hope to be at the Lynn Stages in October - although that depends on whether or not my second child, who is due on the 18th October, arrives at a suitable time and not during the weekend of the rally. Fingers crossed

  15. #135
    Racer Decade Plus User DarthVader's Avatar

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    Re: My mk2 Rally car - Duratec power

    Sounds mint! So smooth.

  16. #136
    Mechanic JonSegger's Avatar
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    Re: My mk2 Rally car - Duratec power

    I haven't updated this thread for ages - mostly because we haven't spent much time on/in the car. We didn't get to do the Lynn Stages in October as the event was cancelled. Although, as it turned out, we wouldn't have got to do it anyway as my second daughter was born on the day the rally would have taken place. The new baby has taken up quite a bit of time since then and that, in conjunction with not having as much 'spare' cash nowadays, has meant things have been a bit quiet car-wise.

    Anyway, 11th Feb 2012 saw Mark and I competing in the South Downs Stages at Goodwood. Just like every time we've done it before, it was a very cold day. The oil temp gauge read -7.4 degrees centigrade when I started the car!

    We got through scrutineering without any issues and then it was time for the first stage. I felt pretty rusty if I'm honest - not having driven the car for a while, so I was pleasantly surprised that we were 12th fastest on the first stage. The second stage felt better and we were 7th quickest.

    It all went wrong on the third stage though. Some of the chicances were marked out with lorry tyres and as I went through one of them it I just clipped one of the tyres with my right front wheel. It whipped the steering wheel out of my hands and as I grabbed it again to re-join the circuit, I could see that I'd done some damage as my steering wheel was now perfectly upside-down. The yellow tape marker was now at the bottom. The car would still going in a straight-ish line, although I could feel that something wasn't right. We finished the stage taking it a little easier through the rest of the chicanes and then inspected the damage when we got back to the service area.

    The wheels were now toe-ing out somewhat and upon closer inspection we could see that the brackets on the crossmember that hold the steering rack were bent up and partly torn. There was nothing we could do to fix them, so we carried on for the rest of the day as it was, checking the rack mounts after each stage to make sure that the damage wasn't getting any worse. I had to be a bit more cautious for the rest of the day though as we couldn't afford to hit it again in case it pulled the rack off completely.

    The last two stages were in the dark, which was great fun. We finished the day 13th overall and 6th in class. Not brilliant, but better than a DNF which it could have so easily been.

    Here's a couple of photos:






    So, this weekend I got round to repairing the damage to the steering. I had to cut one of the brackets off the crossmember and make a new one. I also had to repair the locating bracket that is welded onto the tube of the rack itself. I think the pictures show what I mean better than words:















  17. #137
    Pit Crew Decade Plus User cossie matt's Avatar
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    Re: My mk2 Rally car - Duratec power

    Sounds like it was a cold cold day at Goodwood mate, I bet you didn't have any oil temp probs there like some of the events we have done together!!!

    You must have given the rack a fair old clout, that's a fairly bent mount there!!! When I got my cross member, before I got it powdercoated I boxed them all in with extra bracing. Mind you with a knock like that it'd probably just bend a steering arm instead Glad you got to carry on and finish anyway. Cross member looks good as new again

    Laura and I have got our first baby due in 10 days so I think I will just have to be happy with polishing mine for a little while At least she's all ready to go in the garage.

    Hope to see you around soon mate.

    Matt

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    Mechanic JonSegger's Avatar
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    Re: My mk2 Rally car - Duratec power

    Hi Matt,

    Yes, oil temp was fine, but water temp was a bit of a worry. I'm running a thermostat in the water system now because I was concerned that the water temp wouldn't get high enough (which happened once before at Goodwood in the freezing cold). With the thermostat it was fine when we were moving, although it was getting too hot whilst we were queueing for ages waiting for the starts. I couldn't turn the engine off whilst we were waiting as the battery was knackered and wouldn't start again without a jump start. I have a new battery to fit now though.

    Good luck with the impending parenthood! It's hard work, but very rewarding at the same time. The months just fly by and before you know it they're not a baby any more, so enjoy it while you can. The car will still be there in a few months time

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    Re: My mk2 Rally car - Duratec power

    So 'time flies' and all that... about 6 years in this case!

    I still have the Escort. We've not done much in the way of rallying for a few years though. One reason for this was that the MSA introduced rules regarding seats and belts having expiry dates. These went out of date for my car, meaning I needed to replace them if I wanted to continue competing. I just couldn't justify the cost at the time, given that we were only doing one or two rallies a year. It seems wrong to spend all that money and then only use them maybe 10 times if I'm lucky. The MSA then introduced a requirement for HANS devices, which also means new crash helmets. It was all too much, so we just used it for a few track days instead. A lot cheaper and still lots of fun.

    As the car has seen a bit of action, it was showing its age a bit. It's a very solid shell, but there was a rust patch on both of the door posts (the only bits I didn't cut out and do properly when I built the car) along with some damage to the rear quarter. I also had fitted a roof vent which just didn't work properly because it sat too far back and the airflow skipped over the top of it. I couldn't sit it any further forward because the internals hit the roll cage. I'd added a dodgy extension to the front of the air scoop, which worked better, but looked a bit crap.

    So it was time for a freshen up. The main objectives were to give it a fresh coat of paint, fix the rust/damage and fit a better roof vent. So about a year ago the mini-rebuild began...

    First job, getting the stickers off (which took ages) and then sorting the door posts:
















    New roof vent fitted:








    Off for the respray at Scole Engineering:










    Back home, looking fresh:
















    It's taking shape now. Hoping to crack on some more over the next week or two.

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  21. #140
    Racer mexicotait's Avatar

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    Re: My mk2 Rally car - Duratec power

    Looks very nice Jon

    I’m in the same boat as you although I built mine so I could still use is for road rallying glad I did now as I will never see the stages with how much it costs now although most of the targas etc I have done have been just as much fun at a fraction of the cost
    Last edited by mexicotait; 12-02-2018 at 18:32.
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  23. #141
    Mechanic JonSegger's Avatar
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    Re: My mk2 Rally car - Duratec power

    Quote Originally Posted by mexicotait View Post
    Looks very nice Jon

    I’m in the same boat as you although I built mine so I could still use is for road rallying glad I did now as I will never see the stages with how much it costs now although most of the targas etc I have done have been just as much fun at a fraction of the cost
    Cheers. Yes, it is a shame, but as you say, targas and road rallies, along with track days and sprints etc. are all good fun too. Less regulation and cost can't be a bad thing...

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    Re: My mk2 Rally car - Duratec power

    Hi Jon,

    Good to see you've still got the Escort and she's getting some attention
    I'm sure there are a lot of people in the same position - with a good car but needing to spend thousands on updating to new safety regs

    Gavin
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  25. #143
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    I cannot believe anyone using EBC pads on rally car .or quick road car come to think. Just asking for trouble

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  26. #144
    Mechanic JonSegger's Avatar
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    Re: My mk2 Rally car - Duratec power

    Quote Originally Posted by GavinR View Post
    Hi Jon,

    Good to see you've still got the Escort and she's getting some attention
    I'm sure there are a lot of people in the same position - with a good car but needing to spend thousands on updating to new safety regs

    Gavin
    Hi Gavin,

    Yes, I'm sure there must have been a drop in the number of clubman level competitors, which is a shame. Good to see you're still competing and doing well though!

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