Sierra cosworth lightning rod budget build

[madragon199]

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)

[Group4_Mark2]

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

[madragon199]

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

[Retromotorsport]

Re: Sierra cosworth lightning rod budget build

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

[NRspeed]

Re: Sierra cosworth lightning rod budget build

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

[madragon199]

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 ....

[joe GSM]

Re: Sierra cosworth lightning rod budget build

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

[spaceframe]

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?

[madragon199]

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

[madragon199]

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

[madragon199]

Re: Sierra cosworth lightning rod budget build

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

[madragon199]

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

[Dan]

Re: Sierra cosworth lightning rod budget build

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

[Group4_Mark2]

Re: Sierra cosworth lightning rod budget build

How is the work progressing on the car?

Tom

[madragon199]

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.....