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Robbie C's Ibiza Cupra

Jan 8, 2007
2,958
1
Wiltshire
Earlier in the week I collected some new manifold to turbo bolts from Badger5 (thanks Bill) along with accompanying Nordloc locking washers and a new gasket which should hopefully keep things in place a little better (excuse poor quality phone pics):

DSC00570.jpg


And so began the soul crushing process of trying to replace these manifold bolts in-situ...

In order to replace the bolts it's necessary to undo all the head -> manifold bolts to slacken off the manifold and give enough leverage to access the bolt closest to the head due to the angle at which the engine sits relative to the manifold, making this a royal pain in the ass.

To add to the fun, it's turning out near impossible to properly access the bolts that sit closest to the collector, as you can make out here:

DSC00572-1.jpg


To give you an idea of how awkward this really is, none of these spanners could quite get the reach we needed:

DSC00575.jpg


We need something with a deeper reach that avoids fouling the head when trying to loosen them off, so without bending an ordinary spanner which I know a few people have opted for before now I need to get hold of a deep offset ring spanner to get the job done...

Failing this we'd need to remove the turbo out of the way, which involves removing the whole exhaust (the downpipe is sleeved) as well as the oil and coolant lines - all of which is asking for trouble with an upcoming track day just over a week away :blink:

All this hassle for three bolts that shouldn't even have come loose in the first place... thanks JBS.

Hopefully if I can get hold of said spanners today we'll make some more headway tonight. Watch this space.
 

Prebs

Full Member
Dec 28, 2004
662
0
Norway, Bergen
All this hassle for three bolts that shouldn't even have come loose in the first place... thanks JBS.

Hopefully if I can get hold of said spanners today we'll make some more headway tonight. Watch this space.

Good luck mate. When I fitted my k03s and hi flow mani I also forgot the inner bolt closest to the head before fitting the mani so it had to come all the way off again and refitted. 6 hours thrown away but I did learn from it:)

There was no way the bolts would fit on mine without the heashield witch was one of the first things I got rid during the session.
 

ibizacupra

Jack-RIP my little Friend
Jul 25, 2001
31,333
19
glos.uk
yep, heatshield good point.. needs to be removed..
I fitted MtsB's on the car, and it was a pig in situ.. but we do have a selection of "bastid" spanners accrued over the years of fitting various manifolds..
 
Jan 8, 2007
2,958
1
Wiltshire
The heatshield was binned ages ago as it fouled on something, though I forget what specifically - possibly the charge pipe. It's the large collector on this particular manifold that's getting in the way of those last couple of nuts as you can justabout make out in the above pic.

All this is just to get the old ones out first Prebs, nightmare :)

I've been out and bought that set of deep offset spanners I linked to in my last post so hopefully that will allow enough access to get to the little buggers tonight.

I've come to the conclusion I either completely love this car or hate it depending on what it's doing at any particular point in time, no in-between. C'est la vie
 
Last edited:

Damoegan

Sir Bob,a geordy legend..
Oct 15, 2007
8,993
3
Newcastle
Cheers, Rob.

I had some 10.9's to fit to mine before I sold it, just couldn't face doing the mani again.....
 
Jan 8, 2007
2,958
1
Wiltshire
So... after another few hours of battling with the manifold bolts with my new deep offset spanner set we found it still wouldn't budge and even ended up bending and grinding a couple of spanners to try and get a better fitment.

Down to one final nut by the collector there just wasn't quite enough leverage to crack it loose without the risk of rounding it. It seems the only way to get proper access to these nuts by the collector is to either remove the turbo, which in my case involves removing the entire exhaust and lines, or removing the head... neither of which was too appealing with a track day booked for Monday.

With time not on my side we eventually had to admit defeat and ended up replacing just the gasket and two of the three manifold to turbo bolts with accompanying Nordloc locking washers, leaving the one closest to the head which was re-torqued. Given that I've covered 6,000 miles since this has become an issue I'm hoping it may hold out for at least a while - if not then I may be looking at removing the head.

Once everything was back in place and running again it was time to re-new the MOT before swapping my wheels over to a set of black Compomotive MOs I've had sitting around for a while which I'm now going to use as summer/track rims. These are Jabbasport's old demo car wheels and I'm really happy with how they look on the Cupra - pics to follow soon :)

I've also now replaced my wheel bolts with studs and nuts for ease of fitment; especially when trying to line up spacers too; though I've decided to ditch the 5mm fronts, leaving just the 20mm's on the rear. Once that was done I also had to re-align one of the rear ARB brackets that clamps to the rear beam, which had worked it's way several inches out of line. This is the second time it's done that now, annoyingly scuffing my fuel tank too which I'll need to keep an eye on... :blink:

One oil change later and I'm now finally ready for my track day at Castle Combe tomorrow. This is the first time driving this circuit so I'm really looking forward to it :D

I've borrowed a friend's pencil cam to get some videos if possible so I'll see if I can get some decent footage to upload.
 
Mar 20, 2009
1,707
0
Largs Scotland
These manifolds are such pigs to get a spanner into! Im having my INA mani replaced with the OEM mani which gets sent to Bill for porting tomorrow just need to find someone who is up for the job of fitting it :cry: i also have those nord-lock washers to go on mine hopefully once its done this time thats it all sorted :)
 
Jan 8, 2007
2,958
1
Wiltshire
These manifolds are such pigs to get a spanner into! Im having my INA mani replaced with the OEM mani which gets sent to Bill for porting tomorrow just need to find someone who is up for the job of fitting it :cry: i also have those nord-lock washers to go on mine hopefully once its done this time thats it all sorted :)

Good decision. Based on Bill's logging comparing the INA and JBS manifolds to a ported OE one then it looks like a fair contender with these turbos, not to mention the unfortunate reliabilty and erratic quality issues of the INA manifold.

Where did you get your stud conversion from Rob? I have the same annoyance with spacers and what not...

I got them straight off the shelf from Bill, he keeps a fair few in stock so best to give him a shout. Definitely the way to go.

Neuspeed ARB? Jonzy's does that all the time, pain in the ass innit.


Good luck with the track day, let me know how it goes.

Neuspeed yeah and very annoying, just one more thing to keep an eye on. I wonder if it's from when I visit the 'rents and park on their driveway which normally involves getting on three wheels and I can hear the chassis creaking which may be a sign of things moving under a twisting motion.

Cheers, it's a good little circuit and nice and local to me for a change. Should be good fun :)
 
Jan 8, 2007
2,958
1
Wiltshire
Castle Combe write-up

So, yesterday I headed over to Combe for an open pit track day organised through Javelin - which would be my first time actually driving this circuit. As a local circuit to me I've spectated at many events and been round as a passenger, but never driven it in my own car before.

I pulled up at 08:20, just in time to sign-in and get sound tested before the safety briefing. Static noise at 4,500 RPM was a whopping 80 db :lol: I nearly got laughed out of the testing area... though little did they know :)

Parking back in the paddock I was surrounded by various exotica, including a GT3, this tasty '74 RS Replica by Nur Motorsport, several caterhams of various flavours including a GSXR 1000, an M3 CSL, an M3 powered E30 coupe, Exige, Monaro VXR, 300ZX and a MINE's R34 Skyline, amongst others.

After the safety briefing where we were pre-warned, warned and warned again about the sheer number of accidents involving Quarry corner we headed out for the sighting laps before we were allowed to let rip. Having witnessed a fair number of crashes on Quarry corner myself I knew how it could easily catch you out and chose to approach with due caution all day.

After checking my tyres, levels, wheel nuts etc I headed out for the first session to get things warmed up and get settled into the track. Promising myself that I'd take it steady for at least the first session I took the first 3-4 laps nice and slow before temptation and a sense of inflated confidence got the better of me and I stamped that pedal - hard :whistle:

An occasional glance at the speedo showed just shy of 140 MPH coming into Avon Rise after Folly which was a real adrenalin rush holding it flat through from Camp before stamping the brakes and down into fourth into Avon Rise, moving over the left on the brow and then down into third before entering Quarry. I tried a variety of lines in Quarry varying from taking it wide and late to hugging it really tight through to the apex, eventually settling for a middle ground somewhere in-between. It's a toughie to get exactly "right". The torque steer coming out of Quarry was a bundle of laughs as you have so much tarmac to play with, allowing me to come right over to the curb and move up into fourth before the first chicane that is the Esses.

This is a really fun part of the circuit with plenty of space for forgiveness allowing me to push into it hard, dropping into third and throwing it over both curbs as tight as I dared. This was the once place I did end up in a spin in one of the afternoon sessions after pushing my luck just a tad too much, braking too late and forcing me to enter with way too much momentum, unbalancing the car as I tried to flick it over to the second curb coming out of the chicane. Feeling the car twitch I did the stupid instinctive thing and touched the brakes... sending me round in a not-so-elegant pirouette in the middle of the track, thankfully with nothing in close proximity. With my pride slightly dented but having learned a valuable lesson, it was back into first and back on it.

Next up was Old Paddock bend, which was indisputably my favourite part of the track. Coming out of the Esses in third I'd go out slightly wide to miss the first apex, allowing me to bring it back in tight for the following curb as I feathered the throttle high in the revs and fought with the steering wheel to get it over to the correct line. On the Hammerdown it was then held flat up into fourth where I could gain some good momentum and a perfect overtaking opportunity, before it's back on the brakes quite hard for Tower corner - a deceptively steep right-hander with a later apex than you might first anticipate.

Down into third and round I then kept it in gear towards the next chicane; Bobbies - almost redlining but not enough of a run to justify changing into fourth and then back down again. A sharp stamp of the brakes before entry and it was back over the curbs, with plenty of tarmac to run out nice and wide on the exit before coming out on Westway on the approach to Camp.

This was a particularly difficult corner for me to get what I would consider perfectly correct as I found it difficult to accurately judge when exactly to finish braking and turn in for the apex. For the first few laps I was even dropping down into third though it was soon very obvious how it could be taken at higher speed and much more smoothly in fourth - allowing the car to flow much better out past the start/finish line.

After a few laps round in the morning I was surprised at just how many things I was overtaking without much effort - the car was pulling like a train and with all the uprated suspension, brakes and transmission it all came together and really felt like a nice complete package that was perfectly at home on track. Suddenly every penny spent on the car was completely justified in every sense ;)

Keeping an eye on oil temps and mindful of my water/meth levels I would see temperatures peak at 130 Deg C with ambients of ~20°C after ~12-15 fast laps before I'd have a cool-down lap and bring it back into the paddock to cool down. An oil cooler would probably be a wise investment, though Guy at Opie Oils assures me that the Fuchs/Silkolene Pro-S is stable to 150°C :blink:

During the lunch break I left the bonnet open to let things cool down while topping up the race battery with my trickle charger and was surprised at just how much intrigue and interest it received from those that walked by, with plenty of nice compliments which made it all the more worthwhile. The Porsche owners clearly weren't used to the concept of building your own hot hatch but were very receptive to the idea after seeing it come past a few of them :D

The photographer also took a shining to the bonnet which apparently gave some great shots with it shimmering in the sunlight as it came past, he referred to as aliasing. I'm going to try and get hold of a few of these if I can - I forgot to catch him before I left, having far too much fun out on track.

During lunch I also had an amusing conversation with one of the organisers who asked me

"You're the driver of that blue SEAT aren't you" ...

"yes... *gulp*"

"Have you driven this track before then?"

"No, first time, why?"

"Oh.. well you certainly drive it with enthusiasm then. We've all commented how you're very ambitious out there and really going for it"

While I'm farily sure that was a friendly warning I'll take it as a back-handed compliment :D

Unfortunately the latter part of the day wasn't met with quite so much fun when I began noticing an all-too-familiar rasping noise near the turbo and peak boost drop by 5-6 PSI... yeap you guessed it - loose manifold bolts again!

Annoyingly it was in fact the two new 10:8 bolts we'd fitted with Nordloc washers that had worked their way loose, proving impossible to touch until the car was left to cool down. This meant that I had to tighten them as best I could without burning myself silly before each session and then go out on track sounding like a tractor on boost. Each ~10-15 laps out on track and they'd work their way loose again, joy.

So, what do you do when waiting for your Cupra to cool down, simples - take your daily 1.0 4-speed 106 out on track! :D Much to the amusement/slight disbelief of the marshalls over it went for sound check before hitting the tarmac with it's 50 BHP of *ahem* raw power. Well, it had to be done... landing sub 1:50 lap times and a whopping 85 MPH into Avon Rise. Pics to follow!

Once the Cupra had been mended again it was back out on track for a couple more sessions where I battled it out with the MINE's Skyline, not knowing what power it was running. After three fast laps with it in my rear view mirror it became obvious that I couldn't keep him behind me any longer with him gradually gaining on my tail and I indicated over to let him roar past. Once back in the pits he asked a friend what the Ibiza was running and made the comment that he had to really work to get past it which I was more than happy with when I learned it's running 600+ BHP :blink:

Not so surprisingly, the only other car out there the same time as me that did come flying past almost as if I was stood still was the GSXR 1000cc Caterham - and he really knew how to drive it too. A very nice weapon of choice.

Towards the end of the afternoon things unfortunately went from bad to much worse. On the last lap of the day - chequered flag in sight I came through the last chicane at Bobbies and put my toe down in third only to hear a nasty crunch of metal and a sudden lack of drive. Oh, that'll be third gear rattling around in the bottom of my box then. D'oh!

Fortunately I could still engage every other gear so I limped it round for a relief lap before retiring it to the pits, with a noise closely resembling spanners in washing machine - not to mention the additional tractor-like rasp of the blowing manifold gasket. All in all a very poorly Cupra that was now in need of some TLC. Going very careful, the car was limped back to my parents house some 15 miles away where it's now sat in the garage awaiting repair. I've decided to SORN it over the winter so I can weigh up my best options to get it back to it's former glory without any time pressures. Just as well the 106 held out lol, sat there with a somewhat smug look on it's face.

So, if anyone knows of a 02J Cupra gearbox up for grabs, I'd appreciate you letting me know!

Just goes to show how things like this can and will happen when you push them hard, though for the abuse it's withstanded to date I can't exactly complain. These things happen. All in all though it really was a fantastic day and I had a massive amount of fun out there, making me feel all the work on the car really has paid off. There's no doubt I still have much to learn in the driver's seat and the car is capable of more than I can deliver but that comes with experience :)

With all the issues I ended up having with the car, particularly the manifold bolts I decided against getting any video footage in the end but there are a few pics floating around on different cameras that I'll try to get hold of and upload this week. I have got a couple of randoms which I'll post up in a few mins.

That's about it for now, hope you enjoyed the write-up and as always I welcome everyones comments.
 
Nov 2, 2004
9,335
0
South Wales
Awesome write up, sounds like fun apart from the obvious. Its a good track and must be awesome on a track day without any idiots like you get on the sessions at a show.

I always find Camp really tricky, its where the diff loves it, 3rd gear for me on my few laps there but i think if i had more time i'd be taking it in 4th as well as its really top end of 3rd.
 
Jan 8, 2007
2,958
1
Wiltshire
Few pics :)

First thing in the morning, pulling up before sound test, sat on my Comp MOs:
P1010014.jpg


Cooling down over lunch:
DSC00579.jpg


DSC00580.jpg


Quarry, just in shot:
P1010015.jpg


The mighty 106, just before it's debut on track :D

10601041010.jpg


...and a couple of randoms:

P1000977.jpg


P1000976.jpg


More to follow
 
Last edited:
Nov 2, 2004
9,335
0
South Wales
Just realised you have standard seats!!! Dear god you're a braver man than me. I got fed up of driving on track with one hand on the passenger seat!

You really need some seats and harnesses now.

Great pics as always! I'll keep an eye out on the photography photos of your car.
 
Jan 8, 2007
2,958
1
Wiltshire
Awesome write up, sounds like fun apart from the obvious. Its a good track and must be awesome on a track day without any idiots like you get on the sessions at a show.

I always find Camp really tricky, its where the diff loves it, 3rd gear for me on my few laps there but i think if i had more time i'd be taking it in 4th as well as its really top end of 3rd.

Cheers Phil - yeah I wouldn't ever take mine on track on an Action Day tbh, far too many idiots and just begging for trouble in my eyes. I was surprised how quiet it was out there too, I had the track to myself a lot of the time, with no more than 12 cars on at once.

The diff was working overtime, great piece of kit :)

Just realised you have standard seats!!! Dear god you're a braver man than me. I got fed up of driving on track with one hand on the passenger seat!

You really need some seats and harnesses now.

Great pics as always! I'll keep an eye out on the photography photos of your car.

Yeah they're pretty shite even as road seats tbh, so uncomfortable and a really crap driving position but I've always liked the look of them.

I've never really decided what to do with my interior as if I start putting in seats and harnesses it'll only end up completely stripped and caged through the bulkhead. Must resist... ;) I also don't like to give the game away too much on the road, but it comes at a cost.
 

ibizacupra

Jack-RIP my little Friend
Jul 25, 2001
31,333
19
glos.uk
One thing occurs to me re those 10:8 bolts
torque is 45-47lbft for these.
when I have fitted them I torque them cold, get it hot and re-torque them again

what did you torque them to?
 
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