User Tag List

+ Reply to Thread
Results 1 to 25 of 25

Thread: Sierra cosworth lightning rod budget build

  1. #1
    Pit Crew

    Join Date
    May 2010
    Location
    london
    Age
    60
    Posts
    1,139
    Thanks
    48
    Thanked 110 Times in 99 Posts

    Sierra cosworth lightning rod budget build

    This is my Cossy lightning rod built on a budget of 500 pounds
    its not pretty but it works

    it was once a proud cossy before an argument with a brick wall,: rescued from the scrap mans crusher and lives again.



    The engine 205 block
    2 ltre bored +1mm
    Lightened and balanced
    Lightened 1600 flywheel and cluch
    injection head skimmed for11.1 compresion
    stnd valves with 3 angle seats
    oil cooler
    alloy breather catch tank
    baffled sump
    high pressure oil pump


    Thats how it started
    Decided to improve the exhauste system try to get some more power...
    Car up on ramps ..

    Old system out new power tuned system fitting
    Silencer box needs to go in the footwell behind driver so remove floor and new tunnel welded in

    Top hat to keep everything square and provide extra heat protection..

    New seat mounts /cross brace fitted


    Re-locate batterys (everything is fitted on the drivers side to keep the weight on that side because i only turn right being an oval racer)
    24 volt starting with 2 seperate 12volt feeds from each battery 1 feed for ignition and the other for every thingelse(electric power steering brake lights ect)

    Old seat gone (they burn realy well)(top tip dont weld brackets on seats bolt them on)

    New seat with arse protector fitted on base (i think black seats go faster than old blue ones ...? could be wrong)

    New seat fitted(new to car) batterys insulated and covered ready to go

    all it needs is a coat of paint (not good at pretty ill do it later)

  2. #2
    Pit Crew Decade Plus User Group4_Mark2's Avatar

    Join Date
    Dec 2004
    Location
    Ireland
    Age
    53
    Posts
    1,781
    Thanks
    31
    Thanked 72 Times in 58 Posts

    Re: Sierra cosworth lightning rod budget build

    Like the car.

    Great to see a cosworth saved from the scrappers and put to good use. Lightening rod is something I would like to do some day. What racing licence do you need to compete?.

    Rgds
    Tom

  3. #3
    Pit Crew

    Join Date
    May 2010
    Location
    london
    Age
    60
    Posts
    1,139
    Thanks
    48
    Thanked 110 Times in 99 Posts

    Re: Sierra cosworth lightning rod budget build

    Your local track will have there own licence ...speedworth/r.t.s/o.r.c.i. or ect..... all you need is 60 pounds and you have your licence for the year...
    Most tracks have electronic timing and use A.M.B 260 dp (direct wired 12v) they cost a bloody fortune over 200 pounds secondhand....

    But it is an afordable way of racing and gives people the chance to build and experiment with there own cars..

    Cheers mark

  4. #4
    Way too much free time Decade Plus User Retromotorsport's Avatar
    My Race Car
    Join Date
    Mar 2004
    Location
    Harlow, Essex
    Age
    55
    Posts
    14,285
    Thanks
    318
    Thanked 173 Times in 164 Posts

    Re: Sierra cosworth lightning rod budget build

    Its good to see something different ... you'll have to keep us updated with your results

  5. #5
    Racer Decade Plus User NRspeed's Avatar

    My 1st Project
    Join Date
    Jul 2002
    Location
    In the middle
    Posts
    1,762
    Thanks
    27
    Thanked 16 Times in 15 Posts

    Re: Sierra cosworth lightning rod budget build

    hi
    I like the doors (lack of), I take it, it is non contact rule sport (generally).
    CheeRS Nat

    Various parts for sale! Just ask.
    Now where's that Lotto ticket!!
    PS3 gametag: NR_Speed

  6. #6
    Pit Crew

    Join Date
    May 2010
    Location
    london
    Age
    60
    Posts
    1,139
    Thanks
    48
    Thanked 110 Times in 99 Posts

    Re: Sierra cosworth lightning rod budget build

    Hi yes its meant to be non contact...but it never happens...

    I didnt have any doors ...so i made a couple of door pannels out of a bit of tin and welded them on... Dukes of Hazzard style...

    And thanks NRspeed for the wheels ..will be using a pair on sun ....

  7. #7
    Racer Decade Plus User

    My 1st Project
    Join Date
    Feb 2006
    Location
    romford essex
    Posts
    2,613
    Thanks
    86
    Thanked 191 Times in 186 Posts

    Re: Sierra cosworth lightning rod budget build

    Looks good on a budget gotta start somewhere good luck with it keep us updated

  8. #8
    Tyre Kicker

    Join Date
    Nov 2009
    Location
    donegal ireland
    Posts
    19
    Thanks
    0
    Thanked 0 Times in 0 Posts

    Re: Sierra cosworth lightning rod budget build

    looks really good, lightening rods are a great class and can put on some great racing. just noticed the 2 battery's always ran 2 myself until i put my car on a diet to keep up. i now run a automatic starter with an odysey race battery save myself 30 kgs. keepin the weight down will make her far more competitive on the straight and in the corners. have you had her on the scales yet?

  9. #9
    Pit Crew

    Join Date
    May 2010
    Location
    london
    Age
    60
    Posts
    1,139
    Thanks
    48
    Thanked 110 Times in 99 Posts

    Re: Sierra cosworth lightning rod budget build

    Not yet.. i think shes well over weight.. now ive got her running well..i will have to get her turning better..loose some weight and some spring poundage at the rear...

    we have a min weight of 1000 kg from memory...

    Have you raced over here.. i remember about 10 lightning rods made the trip from ireland for the championship a couple years back.. long way.. nice to see every one..

    have you posted a pic of your car?

    Cheers mark

  10. #10
    Pit Crew

    Join Date
    May 2010
    Location
    london
    Age
    60
    Posts
    1,139
    Thanks
    48
    Thanked 110 Times in 99 Posts

    Re: Sierra cosworth lightning rod budget build

    Raced on sunday... Car was spot on pace big grins all round...
    Need to sort out cornering now... will go softer on rear springs i think..

    I managed to clip the wall with the rear wheel on lap 3 ... finished the other 17 laps pushing as hard as i could...
    Returned to the pits and noticed id ripped a chunk of the rim off ...tyre stayed up...





    Put my spare on finished the second race ...slipppppery.. went to lower the air pressure and the valve fell apart in my hands...
    No more spare tyres ..and i bottled using the broken wheel..so couldnt make the final..
    But had a Great day ...loved the car..

    I think i could loose easy 100kg and still be heavy!!!!!!!
    Will look at car set up now..get that better..then look at engine again...got 3 weeks before next race..(=3 days off!!!!!!)

    and get 2 spare wheels now..and might buy a pair of new tyres( all my tyres are old cast offs from other racers...Free...helped the budget to get started)
    Cheers mark

  11. #11
    Pit Crew

    Join Date
    May 2010
    Location
    london
    Age
    60
    Posts
    1,139
    Thanks
    48
    Thanked 110 Times in 99 Posts

    Re: Sierra cosworth lightning rod budget build

    Just checked the min weight is 845 kg....... will weigh car and loose some weight........

  12. #12
    Pit Crew

    Join Date
    May 2010
    Location
    london
    Age
    60
    Posts
    1,139
    Thanks
    48
    Thanked 110 Times in 99 Posts

    Re: Sierra cosworth lightning rod budget build

    Had a think about loosing some weight...not easy on a car with nothing left on it.......

    So decided to make a new roll cage to exact spec for my formula....my old cage was made using 43mm tube (because i had it) i only need to use 32mm i will loose the extra door bar ect ..i calculate i should be able to loose about 40kg
    Next remove the inner roof tilt and slide sunroof panel ..about 10 kg
    Petrol tank mounts 5 kg
    inner bonnet stiffners 5 kg
    rear hatch inner 5kg...
    About 65 kg in total......

    This is the plan will post pics after removal.......
    Mark

  13. #13
    I used to be: steely dan Decade Plus User
    Turbosport Subscriber
    Turbosport Moderator
    Dan's Avatar

    My 1st Project
    My 2nd Project
    Join Date
    Aug 2006
    Location
    north london
    Age
    42
    Posts
    4,378
    Thanks
    115
    Thanked 116 Times in 110 Posts

    Re: Sierra cosworth lightning rod budget build

    looks like a good laugh. defo need some action shots though

  14. #14
    Pit Crew Decade Plus User Group4_Mark2's Avatar

    Join Date
    Dec 2004
    Location
    Ireland
    Age
    53
    Posts
    1,781
    Thanks
    31
    Thanked 72 Times in 58 Posts

    Re: Sierra cosworth lightning rod budget build

    How is the work progressing on the car?

    Tom

  15. #15
    Pit Crew

    Join Date
    May 2010
    Location
    london
    Age
    60
    Posts
    1,139
    Thanks
    48
    Thanked 110 Times in 99 Posts

    Re: Sierra cosworth lightning rod budget build

    Spent a day with the angle grinder...Removing weight...

    REMOVED
    Complete roll cage
    Sill bars x 2
    Cross brace(floor)
    Petrol tank steel platform
    Steel sunroof panel
    Inner tilt and slide roof
    Steel name sunvisor
    Inner bonnet skin
    steel rear light skins
    20 brackets of every shape and size
    exhauste hangers
    steel battery box


    I weighed each part as i removed it and the total weight removed 148 kg

    Some of the larger parts removed








    I then spent a day cutting ...bending...and welding my new cage...built to minimum spec(with my new pipe bender)
    Even managed to paint half the cage..







    I Replaced the sunroof cover with ally

    The Name sunvisor is now Ally

    The rear light covers are ally

    The petrol tank has moved to the floor with an ally splash tray

    Ally battery tray

    The harness now locates on the roll cage crossmember..

    Total weight of all items replaced 24 kg (including roll cage)

    A TOTAL WEIGHTB SAVING OF 124 KG


    While the car was stripped inside i took the opertunity to re wire the system with proper cable in shorter runs

    I also modified the exhauste system again....After testing.. an extra 5" on the first section felt better and proved a fraction quicker...

    This moved the exhauste box 5 " further back ...so i could remove 5" of exhauste tunnel(save some more weight) and move my driving position 4" further back and get an exact upright seat...

    The old position was a compromise and felt very awkward (arms good/legs bad or legs good /arms bad..)

    Now arms and legs in good position................

    Next race is the 28 th August...

    That gives me 1 whole days to finish.. (sunday my day of)

    All ive left to do is to change all the suspension spring rates and heights ...ive decided to go softer at the rear?
    Bit of paint
    New fuel lines..
    Reconnect batters and wires...
    and fit a new tyre...

    If theres time !!!... remove the inner skin of the rear hach and reweld the skin back in position.....

  16. #16
    Pit Crew Decade Plus User Group4_Mark2's Avatar

    Join Date
    Dec 2004
    Location
    Ireland
    Age
    53
    Posts
    1,781
    Thanks
    31
    Thanked 72 Times in 58 Posts

    Re: Sierra cosworth lightning rod budget build

    Considering all you have done in such as short time, that jobs left for the final day should be no problem to you...

    124Kg is a huge weight saving. Should definitely be worth some time on the track. Will be looking forward to the 28th to see how you get on.


    Tom

  17. #17
    World Champion Decade Plus User exboyracer's Avatar

    Join Date
    Nov 2003
    Location
    Wirral UK
    Age
    50
    Posts
    6,740
    Thanks
    257
    Thanked 523 Times in 511 Posts

    Re: Sierra cosworth lightning rod budget build

    124kg! Fook me that's massive!

    Good luck with the next event
    http://escort.accelerator.org
    1968 MK1 Escort 1300GT
    1969 'Big Wing' MK1 Escort
    1972 MK3 Cortina 1600XL
    1984 Sierra XR4i
    And other junk I don't like to talk about!

  18. #18
    Pit Crew

    Join Date
    May 2010
    Location
    london
    Age
    60
    Posts
    1,139
    Thanks
    48
    Thanked 110 Times in 99 Posts

    Re: Sierra cosworth lightning rod budget build

    I was a bit surprised myself... my old cage was built using 43mm x 3.5 mm weighed a ton!!!!

    I calculate im 10% lighter...... Does that mean i can go 10% faster...!!!!!???????

    Looking forward to next race...cheers

  19. #19
    Racer Decade Plus User RWD fords rule's Avatar

    Join Date
    Feb 2006
    Location
    Ireland
    Age
    39
    Posts
    3,579
    Thanks
    173
    Thanked 374 Times in 312 Posts

    Re: Sierra cosworth lightning rod budget build

    124kg! that is more or less the weight of your pinto engine!

    Good to see something defferent on here, I am a fan of cheap and cheerful racing, when it gets too expensive the fun stops, give it some stick at the next event

  20. #20
    Pole Position Decade Plus User Pushrod King's Avatar
    My Race Car
    Join Date
    Feb 2006
    Location
    East Sussex
    Age
    58
    Posts
    5,023
    Thanks
    6
    Thanked 171 Times in 159 Posts

    Re: Sierra cosworth lightning rod budget build

    Is there a minimum weight for lightning rods?

  21. #21
    Pole Position Decade Plus User Pushrod King's Avatar
    My Race Car
    Join Date
    Feb 2006
    Location
    East Sussex
    Age
    58
    Posts
    5,023
    Thanks
    6
    Thanked 171 Times in 159 Posts

    Re: Sierra cosworth lightning rod budget build

    Quote Originally Posted by Pushrod King View Post
    Is there a minimum weight for lightning rods?
    Just checked the ORCI rules and yep there is : 845kgs..... You may find that the car's now underweight!

    Also Sierra shells are reknowned for flexing, you may find that the car was stiffer before you removed the cage and replaced it with less bars!

  22. #22
    Pit Crew

    Join Date
    May 2010
    Location
    london
    Age
    60
    Posts
    1,139
    Thanks
    48
    Thanked 110 Times in 99 Posts

    Re: Sierra cosworth lightning rod budget build

    YES minimum weight is 845kgs.... According to my bathroom scales im still in the 900+kg.....
    The new cage is a 6 point weld.. and its also fixed to the body in about 12 other points...my door panels are welded in place.. and the rear hatch is welded in place.........Fingers crossed..

    I Jacked up the rear of the car on the wheel rear suspension point and i can still get both rear and 1 front of the ground.......


    I think its a compromise between weight and strength.....

    They also changed the rules i used to run my lower door bar along the sill welded to it ...but this no longer counts as a door bar...

  23. #23
    Pit Crew

    Join Date
    May 2010
    Location
    london
    Age
    60
    Posts
    1,139
    Thanks
    48
    Thanked 110 Times in 99 Posts

    Re: Sierra cosworth lightning rod budget build

    Well after 7 years this is back in my life...to be honest it never went any where...i sold it 5 times got paid 5 times and no one ever came and collected it...i think the dream becomes a reality.then you relise you have to build it, store it, mend it and afford to race it and then tell the wife....

    So i stripped the dead engine out and measured the front lower suspension points...and as expected they were 50mm out on the lower fixings...(its had a hard life)

    i plan to get it straight and then fit the new engine im building(bv variable stack shed build ) and get it to the rolling road) then put another engine and race it next year (march)....lol...

    So we take a measurement from one point to another point...the same on both sides...and the measurement should be the same...i dont care if its wrong ,,i just want them the same....

    One side



    other side



    As you can see they are well out so the front end is bent...the top mounts are protected by a brace so they havnt moved ..just the chassis legs and the cross member...if they had moved the opposite way i would have left them because racing oval it would give me more camber...

    but its the wrong way so makes the car handle shit..(and i thought it was my driving...blame the tools syndrome)

    so using all the wrong equipment...i starrted to push one leg...and also to pull the other leg(using a brace instead of the cross member)



    Its about equal now...but im going to go to far and gain a bit more camber by offsetting the crossmember in relation to the top mounts...

    cheers mark

  24. #24
    Pit Crew Decade Plus User Group4_Mark2's Avatar

    Join Date
    Dec 2004
    Location
    Ireland
    Age
    53
    Posts
    1,781
    Thanks
    31
    Thanked 72 Times in 58 Posts

    Re: Sierra cosworth lightning rod budget build

    great to hear you are back working on the Sierra. It has been quite a while since I think it spun a bearing on the oval
    To finish first, you must first finish

  25. #25
    Pit Crew

    Join Date
    May 2010
    Location
    london
    Age
    60
    Posts
    1,139
    Thanks
    48
    Thanked 110 Times in 99 Posts

    Re: Sierra cosworth lightning rod budget build

    Quote Originally Posted by Group4_Mark2 View Post
    great to hear you are back working on the Sierra. It has been quite a while since I think it spun a bearing on the oval
    Hi tom...good to here from you...

    yea time just flies......how long ago did i send you half the head...scary hey....

    hope to be out next year before im forced to retire...lol...
    what you up to now days...
    cheers mark

+ Reply to Thread

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts