iTB Ibiza Cupra 16v Track Toy - Engine Rebuild, Aero & More Page 73+

[keefr22]

Few little updates, I missed the post man yesterday so I got to

I don't have a grinder or grinding disc so a trip to B&Q tomorrow.

If it's not too late go to Argos instead - got a nice Black & Decker one from there a couple of weeks back for a few quid less than B&Q, & they had a special offer of a half price set of metal cutting & grinding discs if bought at the same time as the grinder.

That bush removal tool looks very good - any chance of a quick explanation of how you made it?

keith

 

[Dave_R]

Here's a photo of the ridge I need to grind back to allow room for the lower arm

A new angle grinder and grinding disc later

And the offside before

After (mind the yellow line, used it to help me)

They now give enough clearness for the vertical movement of the front mount of the lower arm.

Missed the post man Friday morning so popped up to get my package and it was these lovely bushes

Used old OEM bush vs Powerflex Black Series bush

This gave me the chance to use my home made tool again

Going in

New bush in its new home

Built the rear beam back up, arb on and the clips for the brakes hoses riveted so its ready to go back on the car. Painted the grinded bits of the subframe so once they are dry I can get them on and then fit the uprights so I'm coming to the point that I'm just wanting for the coilovers, which I'm sending off this week.

Also forgot to add a photo of my powder coated strut brace

 

[Dave_R]

That bush removal tool looks very good - any chance of a quick explanation of how you made it?

keith

M10 Stud Bar 200mm
2 off M10 nuts
Choice of washers in different sizes
Then a sleeve bigger in diameter & length than the bush. In this case 65mm in diameter & 60mm in length
Then a plate bigger than the sleeve with a hole drilled in the centre to act like a massive washer lol

 

[keefr22]

M10 Stud Bar 200mm
2 off M10 nuts
Choice of washers in different sizes
Then a sleeve bigger in diameter & length than the bush. In this case 65mm in diameter & 60mm in length
Then a plate bigger than the sleeve with a hole drilled in the centre to act like a massive washer lol

Thanks! I want to re-bush mine at some stage so that's really helpful.

cheers

 

[Dave_R]

Last bit of work on the car Friday before I go to see Mickey Mouse!

Fitted my rear beam & brakes

And fit the lower arms, they weren't the easiest things to fit.... Very tight fit but that is what you want really!

Made the template for a carbon fibre panel on the boot lid, going to send this off to Andrew @ LWS Design to get it made up.

Also collected my radiator from AH Fabrications on Thursday was hoping to get a chance to fit it but time got on and ordered some Powerflex Black Series, Rear Top Mount & front sub frame bushes this afternoon.

 

[benoit62]

hi dave
I do not know if you have already run the fiber hood, but I have a problem uh ...
I put four home like you, but medium and high speed, it vibrates and deforms downward ... the air rushes from below and the fact is "swell" ... I'll add a fifth central fastener to avoid it, hoping that it works ....

 

[Dave_R]

No I haven't yet, I would have guessed it will flex a bit! Don't mind that as long as it doesn't crack or break off lol.


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[Dave_R]

A few little updates, firstly had a passenger ride in this while I was in Flordia

Got back and fitted the front wheel bearings, uprights, new ball joints & the brakes

Today I fitted the rad & oil cooler back on and then removed the rear crash bar, since the car is sorn I won't need to worry about someone driving into the rear of me. So a bit more weight saving and it's weight removed from outside of the wheel base.

 

[m0rk]

Good weight saving - they do naff all in a crash apart from pull the chassis legs in anyway

 

[Dave_R]

No major update (yet)

Since I'm waiting for bits and in between work & sleep been doing little tidy up jobs, painted my rear towing eye to match the front.

And went to clean up my oil catch tank but had enough of getting it clean then having a dirty finger paint on it so rubbed it down and finished off a can of Matt Black paint I had there.

Photo of it in primer and half painted

And not really a car update hopefully get a sunny track day and the sun setting at the end of the day I can use this,

Had an email from Dave Pook (Spires ST) tonight, my suspension is to be sent out so everything is finally coming together and LWS have sent my rear carbon panel for the boot.

 

[Dave_R]

I'm in the middle of fitting my solid top mounts, I had to grind off 0.9mm on the turret to allow room for the lip on the mount.

When I did this and go place the bottom half of the mount up into the turret it just slightly not right.

This is where it's going to get confusing, below the photo shows the offside turret. This is untouched at the moment and you see that the lip is larger towards the front of the car

The next photo shows the near side that I have been working on and again the lip towards the front of the car is much larger

(Sorry missed out the 't')

The lip on the face of the top mount now fits perfect if I place it upside down and fit to the turret hole it fits perfect and measurement with the vernier shows I'm +50 microns max to the top mount BUT when I place the top mount into the turret it just slightly doesn't sit right!! As you can see below

I'm thinking that the shoulder of the top mount is following the turret and because the hole is offset the lip on the top face isn't lining up. Now I'm not sure to keep enlarging the hole or to start working on the side that as the larger lip.

These mounts were for a Mk3 Golf, the Ibiza uses the same top mounts so these were the closest I could find lol. Here's a photo of them taken apart so you can see

 

[Dave_R]

Problem solved! Ended up taking measurements of the oem mount and compared to the solid mount. Only difference was this diameter of the lip, placed the oem mount into the turret and it sat the same as the solid mount was.

So used a line on the oem mount that was the same diameter as the face of the solid mount and ground the hole to the line, placing the solid mount into the turret checking time to time. That's one side sorted, just need to do it all again now

 

[Dave_R]

And the oil catch tank all sprayed up now, gave it a second coat

 

[James23Parkin]

Great work as always Dave. The new top mounts look like a good bit of kit. The milling down will be more than worth the effort. When's your next track day planned for?

 

[Dave_R]

Thanks James, be honest I think it's well off a track day. Hopefully get the suspension on a week tomorrow then it will need setting up & then going to have more engine work

So hopefully July or August time.

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[benoit62]

hi dave
you made ​​a good job! congratulation!
for fiber hood, I add support to the middle and it's okay now
I always admired your project!
if one day you just drive in France, Belgium or Germany, tell me, I come to see you!

 

[Dave_R]

Thanks, I was hoping to do a load of track days here this year but this work as got on a bit now. Would love to do Spa one day. What sort of tracks do you have in France?

 

[benoit62]

I mainly ride a "circuit de croix en ternois"
many English rolls on this racetrack. it is not very far from the Channel Tunnel
if spa is a our wonderful circuit. I was there for the assistance of FunCup is really nice! but I never ride. there is also the racetrack zolder (Belgium), and of course the Nurbergring in Germany!

 

[unsimple]

What a thread!

 

[Dave_R]

I mainly ride a "circuit de croix en ternois"
many English rolls on this racetrack. it is not very far from the Channel Tunnel
if spa is a our wonderful circuit. I was there for the assistance of FunCup is really nice! but I never ride. there is also the racetrack zolder (Belgium), and of course the Nurbergring in Germany!

Been to Nurburgring twice, Spa is on my must list to do and I think I will be in touch with you about track day dates for Circuit de Croix En Ternois over the next year.

What a thread!

Thanks