GavinR's Mk2 Stage Car - DVY

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

    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 weren’t 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 I’ll be out next – I need to sort out a decent demisting system first...
    GavinR

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    • rallyrob
      Racer
      Decade Plus User
      Turbosport Subscriber
      • Apr 2010
      • 2726

      Re: GavinR's Mk2 Stage Car - DVY




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

        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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        • rallyrob
          Racer
          Decade Plus User
          Turbosport Subscriber
          • Apr 2010
          • 2726

          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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          • clarky205
            Spanner Monkey
            • Dec 2013
            • 236

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

              Re: GavinR's Mk2 Stage Car - DVY

              Originally posted by rallyrob
              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

              Originally posted by clarky205
              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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              • rallyrob
                Racer
                Decade Plus User
                Turbosport Subscriber
                • Apr 2010
                • 2726

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

                  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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                  • tom_escort_mk2
                    Bodger
                    • May 2013
                    • 193

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

                      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
                      GavinR

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                      • tom_escort_mk2
                        Bodger
                        • May 2013
                        • 193

                        Re: GavinR's Mk2 Stage Car - DVY

                        Will be interested to see what you come up with.

                        Comment

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

                          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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                          • mexicotait
                            Racer
                            Decade Plus User
                            • Oct 2008
                            • 2437

                            Re: GavinR's Mk2 Stage Car - DVY

                            Good luck Gavin
                            Mind the sheep
                            Hexham and District Motorclub

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

                              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
                              GavinR

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                              • mexicotait
                                Racer
                                Decade Plus User
                                • Oct 2008
                                • 2437

                                Re: GavinR's Mk2 Stage Car - DVY

                                Good result Gavin well done
                                Hexham and District Motorclub

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