GavinR's Mk2 Rally Car - FLY

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  • GavinR
    Pit Crew
    Decade Plus User
    • Jun 2004
    • 1494

    Re: GavinR's Mk2 Rally Car - FLY

    Wethersfield Targa Rally - Sunday 13th July 2014

    After a few hours work Sat morning, the calipers brackets were welded on, the axle refitted and I went for a test drive - Fly was going well but the handbrake was not so good, reaching the top of it's travel before enough pressure was applied

    I didn't have any time left, so I loaded up and headed to my brother's in Essex. Saturday night there were big thunderstorms and heavy rain so when we arrived at the airfield, there were large puddles everywhere although it wasn't actually raining. We spent a while bleeding the rear brakes which helped but I still couldn't lock the rear wheels at speed

    The event was run by Chelmsford and had a good entry of 60 cars with various quick crews out - I was hoping for a top 5 but knew the rain would help us so fitted some worn 21r's all round. Derek was down to drive Fly as well but had bought a Clio 182 off eBay on Sat morning very cheaply so decided to use that instead

    There were 3 tests done 3 times in one direction and twice in other direction with minor changes in between. I was 1s off the top 2 on the first test but quickest on the next 2 and was leading by 5s after the first loop. Derek started off slowly in his new car

    On the second loop, Derek was driving first and drowned out in one of the deeper puddles despite going very slowly into it. After 5 minutes she fired up and we drove back to the start as the organiser generously said we could have another go. We looked under the bonnet and there was an induction with an extra hose routing the air intake to just under the front bumper, so water had been sucked up to the filter and blocked the inlet. We disconnected most of this and drained the water out of the pipes before setting off again, this time taking to the grass to avoid the puddle. A few hundred yards later we stopped at a marshal for a signature and when Derek pulled away, something broke and we lost all drive. So not a very good day for Derek - we pushed his car out of the way and left it there until we could load it on my trailer later

    Back in Fly I pulled out a few more seconds and the same again on the 3rd loop up to lunch to be leading by 30s from a double driven Clio Williams and Aron Rayner and David Lobb double driving a 1400 Corsa

    We had a couple of showers in the afternoon but apart from adding petrol and swapping the tyres front to back, Fly was going well. Derek was good on the maps all day and by the finish I'd extended our lead to 48s. So another 1st Overall on a Targa Rally.
    Derek was pleased to be the winning navigator but would have been happier if he'd finished in his car
    The Clio Williams was 2nd and 5th, with Aron 3rd and David 4th, they were all very close


    I think the handbrake problem is down to one of the brackets being not quite square, but I'm not happy with the caliper positioning (going over a small bump the bleed nipple hit the chassis rail, snapping the end off, luckily just the bit where you'd attach the bleed hose, so not a problem), do this needs sorting before my next event which is the Neath Valley Stages on 9th August...
    Last edited by GavinR; 28-07-2014, 14:17. Reason: .
    GavinR

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    • GavinR
      Pit Crew
      Decade Plus User
      • Jun 2004
      • 1494

      Re: GavinR's Mk2 Rally Car - FLY

      Neath Valley Stages - Saturday 9th August 2014

      I had big plans for this event, after competing last year with George and finding the long straights quite boring, I came up with a cheap way of having more power in Fly...
      After 3 weeks of working many hours in the workshop including 3 full days leading up to the event, I got everything done and had a successful test drive at 7pm Friday evening, before loading up and catching a few hours sleep before George came over for 4:15am and we set off to Resolven

      George had no idea what I'd been up to, in fact there was only one friend in the motor club who knew and he'd been helping me, but when I started Fly for scrutineering she knew something was different - I'd fitted DVY's n/a cossie into Fly to give us an extra 90-100bhp

      Scrutineering was fine and around 10am we headed to the first stage in Rheola forest. Going off the line I was having trouble getting the power down, I found it difficult to feel when the wheels were spinning so I was changing up too early, it was definitely going to take a few stages to get used to, and George was having to read the notes out quicker. Even if I wasn't cornering any quicker, the straights were a lot more interesting, just a few inches off line into the loose and the rear started fishtailing and up the hills it was even better!

      So everything was going well and we'd done about 7 miles of the 8.1 mile stage when there was a death rattle from the engine and I looked down to see the oil light come on, so I switched everything off. We'd got far enough through the stage that the final mile was downhill so I carried on coasting and we reached the finish just as the car behind caught us. We continued coasting to a safe place, parked up and I got out to see what had gone wrong...

      I opened the bonnet to see the cam belt just lying there, not fitted around the cams, the dry sump belt nowhere to be seen and this pulley lying on the sumpguard...



      It's the jack shaft pulley and you can see in this pic where the shaft has snapped...



      So it was great fun while it lasted, but turned into an expensive experiment. It would have been good to get through one stage if nothing else, to see what our times were like, and of all the things that could go wrong on a rally, I never expected to have the engine let go
      Although I've started taking the engine out, it's difficult to know what failed first...
      1. Did the jackshaft seize, get snapped by the cambelt which then flew off and took the dry sump belt with it?
      2. Did the dry sump belt come off first, causing the jackshaft to seize?
      If it was an oil problem, I'd expect the bottom end to seize first, rather than the jackshaft

      Anyway, I took a few bits off last night and found the dry sump pump was very hard to turn - usually I can turn it by hand, but had to use a spanner to get it going
      I also put a spanner on the crank pulley and this was even harder, but I went backwards a little and the bottom end is not seized up, so maybe something will be salvageable - the noise we heard would be the pistons hitting the valves when the cams stopped. I'll get it down to HT next month and they can let me know how bad it is

      Meanwhile, I'm doing the Mewla on Epynt in just over a week, so this weekend I'll be refitting the Pinto and I've changed class to the Road Rally class
      George is on holiday but she found me a replacement co-driver in Ross Whittock from Bath Motor Club - he's been navigating on Road Rallies for a few years now and has done a couple of forest events earlier this year but has never been over Epynt. His dad, Dave Whittock, won the Mewla in 1982 with Bob Fowden, so I've a lot to live up to
      GavinR

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      • MCURZON
        Mechanic
        • Nov 2006
        • 743

        Re: GavinR's Mk2 Rally Car - FLY

        See you on the Mewla then Gavin, first time we've had entries in for the same event!
        Come over and grab a cuppa if you have time, my service crew have an amazing tea urn! I'm in car 100
        Cheers
        Matt

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        • lee edwards
          Mechanic
          • Oct 2011
          • 792

          Re: GavinR's Mk2 Rally Car - FLY

          Fair play mate your threads always make a good read! Your keen il give you that

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          • freddy686868
            Pole Position
            Decade Plus User
            • Jul 2010
            • 4689

            Re: GavinR's Mk2 Rally Car - FLY

            seen you towing the car in on the neath valley stages i was a marshal on the main service gate as the i'm in the three counties car club that run the rally. Really gutted for you i thought you had done more than one stage as you got towed into service quite late in the day.

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            • GavinR
              Pit Crew
              Decade Plus User
              • Jun 2004
              • 1494

              Re: GavinR's Mk2 Rally Car - FLY

              Thanks for all your comments, got the engine out on Sat and found a small split in the sump below no 1 cylinder. Haven't had time to investigate further but maybe the rod let go first and hit the jack shaft causing it to seize up...

              Our service crew were servicing for another crew as well, so we had to wait a bit to be towed in

              Anyway the Pinto's back in now so just a few jobs left and I'll be ready to go. I'm car 71 and there's 6 of us in the Road Rally class, if we get into the top 3 I'll be pleased

              I'll try and get over to see you Matt, and I think Arwel is competing as well so a few TS people out
              GavinR

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              • Arwel
                Spanner Monkey
                • Jun 2009
                • 292

                Re: GavinR's Mk2 Rally Car - FLY

                You seemed to be going very well yesterday Gavin. Literally flying from the photos I have seen. Not a good day for me and Abi, electrical fault stopped us on the road section on route to SS4. Matt also had a bad day with engine failure on SS1. I think we need an Escort
                sigpic Instagram: A86_Motorsport Facebook: A86Motorsport

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                • para144
                  Pit Crew
                  Decade Plus User
                  • Jan 2006
                  • 1075

                  Re: GavinR's Mk2 Rally Car - FLY

                  http:// https://www.facebook.com/ral...399523/?type=1

                  Great shot of FLY on Epynt

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                  • para144
                    Pit Crew
                    Decade Plus User
                    • Jan 2006
                    • 1075

                    Re: GavinR's Mk2 Rally Car - FLY





                    Great shot of FLY on Epynt

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                    • mexicotait
                      Racer
                      Decade Plus User
                      • Oct 2008
                      • 2437

                      GavinR's Mk2 Rally Car - FLY

                      Hexham and District Motorclub

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                      • marchy
                        Bodger
                        • Sep 2008
                        • 105

                        Re: GavinR's Mk2 Rally Car - FLY

                        My photos from Epynt the number plate made us laugh

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                        Full set from the day here: https://flic.kr/s/aHsk1NNSPD

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                        • GavinR
                          Pit Crew
                          Decade Plus User
                          • Jun 2004
                          • 1494

                          Re: GavinR's Mk2 Rally Car - FLY

                          Mewla Rally - 24th August 2014

                          We had a very enjoyable day on Epynt, a bit slow up the hills but flat out down them
                          I think we got overtaken on every long stage, just didn't have the power of the cossie to get us going, so it was a day of trying to keep the speed through the corners. The road rally tyres (21R's) gave plenty of grip and I was very glad I was running the big AP brakes on the front, there was no brake fade at all

                          Ross did a great job on the notes, he only got lost on the Burma Road when he got too far ahead but was quickly back on track. I didn't have any service crew, so Dave Whittock took the van to service and then went out spectating with his wife before coming back for the final service and brought the van back to Builth which was very helpful

                          I hadn't had a chance for a road test before the event and on the first road section the steering was wobbling quite a bit which turned out to be play in the front wheel bearing so I tightened that up in service, then on the forest link sections there was a rattling also from the front, this was traced to a knackered rosejoint on the comp strut. I left this to the lunchtime service when we had an hour which gave me time to swap the joint for a new one

                          There are some great pics over the jump by the black hut

                          We'd gone over it 3 times up hill in the morning, which normally gives a heavier landing, but I couldn't get up much speed from the start so it wasn't bad. Each time I went over I was thinking about the line to take in the afternoon...
                          Downhill to the jump, I was flat from the hairpin, I'm not sure what speed we were going, but I lined Fly up where I thought I should, we took off and landed heavily with 2 wheels on the grass
                          Luckily the grass is smooth and level with the tarmac so I just held her straight and kept my foot down
                          The hill then goes steeper down with a slight left - I dabbed the brakes and the pedal went a long way and then the front tyres locked up and I realised the rear brake pipe must have been damaged when we landed, so no rear brakes. A bit of on and off the brakes and we just made it round the hairpin to the flying finish

                          The next stage was 4 miles so I took it steadily and we got back to service where we had 20mins to try and make a repair before the final loop - I expected the pipe had gone near to one of the calipers and hoped I'd be able to fit a new union and carry on

                          Dave was back from spectating by now, so he and Ross put the last jerry can in while I checked underneath to see which side had gone. It was the driver's side, the brake pipe union on the caliper had hit the chassis rail which had fractured it and let all the fluid out instantly. Worse still, part of the union was still in the caliper so not repairable in a hurry
                          The obvious solution was to block off the pipe so at least I'd have one working rear caliper, but I don't have any blocked unions. Then I remembered the rear caliper bleed nipple is M10 fine thread which is the same as a standard metric union. In my bag of spare aeroquip parts I found a suitable union, screwed it into the end of the braided hose on Fly, got Dave to pour in the brake fluid while Ross pumped the pedal gently and when the fluid was coming out steadily, screwed in the bleed nipple to block it off. To complete the bodge, I tie-wrapped the loose pipe to the panhard rod to keep it out of the way, put the wheel back on and we made service out with about a minute to spare

                          The final loop went well, the brakes were surprisingly good, with a nice firm pedal and I assume braking one wheel on an axle effectively brakes the other wheel as well, I couldn't tell much difference. We took the jump flat out again, this time landing on the tarmac with the brakes still working

                          Back at the finish in Builth, we were 47th out of the 51 finishers and 5th (last) in class. I was surprised how far down we were but we did finish when about 50% retired

                          Many thanks to Ross, Dave and Diane

                          I'm sure I'll be back on Epynt next year, but it will be in DVY with a rebuilt cossie engine...
                          GavinR

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                          • GavinR
                            Pit Crew
                            Decade Plus User
                            • Jun 2004
                            • 1494

                            Re: GavinR's Mk2 Rally Car - FLY

                            Some great pics there Marchy, thanks for posting them up
                            GavinR

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                            • mexicotait
                              Racer
                              Decade Plus User
                              • Oct 2008
                              • 2437

                              Re: GavinR's Mk2 Rally Car - FLY

                              Have you sold the princess callipers yet

                              Could i have first refusal if you havent ?
                              Hexham and District Motorclub

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                              • GavinR
                                Pit Crew
                                Decade Plus User
                                • Jun 2004
                                • 1494

                                Re: GavinR's Mk2 Rally Car - FLY

                                Originally posted by mexicotait
                                Have you sold the princess callipers yet

                                Could i have first refusal if you havent ?
                                Hi Luke,

                                I tried to reply to your last PM but your mailbox is full

                                Thanks
                                GavinR

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