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

[Dave_R]

The top mounts are now a perfect fit, have given them a coat with some paint to prevent any rust.

Fitted the oil catch tank

May note the attempt of a filter on top, this is because I can't find a filter to fit with the gap above the tank. Wasn't a problem before because it would spit oil onto the bonnet but now with the fibre glass bonnet it won't wipe off so easily so found a old induction kit from my old Cavalier and cut it up.

Bought these a while ago,

Rear Top Mount (New vs Old)

Subframe Mounts

 

[Dave_R]

Purchased a new oil cooler, I'm going to go for solid lifters and due to the engine being able to rev more the 16 row cooler I have now wont be up to the job so I new have this 19 row cooler.

Had a delivery from LWS Design, you may remember the paper template I made a while ago. Well this is what it turned into!

Fitted it this evening

Fitted the top mounts

And the strut brace I had powder coated a while ago

Had my coilovers back from Dave Pook @ Spires ST, the front springs are 110Nm/mm & rears are 50Nm/mm. The dampers have then been sent to Bilstein UK to be re-valved to match the spring rates.

Cleaned the threads and un-seized the adjustment plates

New Front Spring (Eibach ERS 110Nm) vs Original Bilstein Spring

New Rear Spring (Eibach ERS 50Nm) vs Original Bilstein Spring

Front Coilover built up

Rear Coilover built up

Noticed a problem with the top mounts, again! This part sits on top of the coilover and then goes into the bearing BUT it doesn't leave any thread to place the nut on top.

You can see how little thread is left.

Looking at the oem top mount bearing you can see there's a countersunk bore

Looking at the part for the solid mounts it looks like the sleeve can be removed, have tried to knock it out but didn't work. Thinking of getting the blow torch out and give it another go, if I can remove that sleeve then it will be a perfect fit.

The rear coilovers are on, just need to sort this problem now.

 

[Damoegan]

If it wont knock out then you could always put it in a lathe and open up the ID..

If you cant find anyone local I will do them for you

 

[Dave_R]

If it wont knock out then you could always put it in a lathe and open up the ID..

If you cant find anyone local I will do them for you

Thanks, couldn't knock it out so tried a dremel but that wasn't much better.

The sleeve I thought to knock out wouldn't have left enough diameter anyway, so I have now dropped it off to my mate at Godspeed Brakes to machine it on the lathe.

Thanks for the offer

 

[Dave_R]

Had my mate sort out the mount

Now fits the suspension perfectly

And the car finally coming together, shame that I have got work tonight so can't carry on until the middle of the week

 

[Dave_R]

Done a few more jobs this afternoon. Managed to adjust the coilovers but found a problem with the rear top mounts.... It's the same problem that I had when fitting the Bilstein coilovers before but this time because the Powerflex black series are so much stiffer I can't compress the bush enough to get them top nut on.

Photo of the ride height before adjusting

After

Can see the amount of castor that these lower arms give to

Here's my problem, its more due to the Bilstein collies. The threaded shaft isn't long enough, this is with the Powerflex Black Series attempted to fit.

Then I found the nknown make red bushes in my workshop, which are better but not good enough.

These red bushes though has given me an idea to get the Powerflex ones machined down and then get a new top washer made to have a larger diameter to match the machined bush. Trip down to Godspeed Brakes tomorrow!

So I could get on with adjusting the suspension, I cut down the original bush and did this

All that's left to do tomorrow is reconnect the front ARB & bleed the coolant.

 

[Dave_R]

My front sub frame is down Gripz to have the new bushes pressed in. In the meanwhile I popped up to Aqua Graphix, where they do this water transfer stuff!!

Had my centre caps on the Compo's done in carbon fibre and had a set of steelies for my misses Arosa (that I bought years ago) done in a flower finish.

And for the missus Arosa

Wanted to do the outer rim too but I know she WILL curb them!

 

[James23Parkin]

Great updates Dave. Can't be long until it's ready for some track action? The dipping is pretty clever stuff isn't it. The caps look great!

 

[Dave_R]

Great updates Dave. Can't be long until it's ready for some track action? The dipping is pretty clever stuff isn't it. The caps look great!

It's booking into Saxon Motorsport for 8th July, I'll be taking the car down there on the weekend. Going to be having solid lifters fitted and bigger cams, they've developed some cams with Kent Cams that are a cross between the 304 & 314 race cams so will be having them fitted. I'll be looking at 230-240bhp and a rev limit of 9500 rpm

Also my manifold is cracked so that will get sorted by Powerspeed down there, going to make me solid rear engine & gearbox mounts and sorting the suspension set up (corner weighting and geometry).

I'm looking at Castle Combe track day on the 19th July if all goes to plan.... looking forward to it but nevous at the same time, very interested to see how the suspension upgrades will go.

 

[Chambers_CUPRA]

All sounds good Dave.

Be good to hear how your spring etc go. Especially after being corner weighted etc.

A mate of mine had his civic corner waited and they moved his seat about to get it spot on.

 

[Dave_R]

My cars been corner weighted a few time. First time was before I went to the ring by Centre Gravity and then another time by Aviva Autos.

But since my car is down at Saxon I might as well get it done there.

It does make such a difference to the cars handling! Brings all the handling mods together. I'm looking forward in seeing what -3.5 degrees camber is going to look on the front lol.


Sent from my iPhone using Tapatalk

 

[cupra.al]

do you think your get any more problems on track with the level of exhaust noise with a higher rev limit?

 

[Dave_R]

No, because most tracks just do a static test which is 1.5 metres at 45 degrees (I think) and 4500rpm.

 

[Chambers_CUPRA]

Dave have you had your car weighed yet? Or remember how heavy it was last time?

 

[Dave_R]

Before it was 978kgs it's been on a diet since so should be less than that. I'm hoping for 960ish next


Sent from my iPhone using Tapatalk

 

[Neil82]

Is the mk2 lighter than a mk3 standard?

 

[Dave_R]

Is the mk2 lighter than a mk3 standard?

Probably is, since the Mk3 will have extra bits bolted to the engine, turbo, intercooler, air con. Put it on a diet won't be far off tho.

 

[Dave_R]

Well the car went into Powerspeed for the manifold to be repaired but Alex (AjVR from Club GTi) wanted to help design the primaries which ideally need to be extended due to the higher rev's.

Wasn't sure if it was happening due to a bit of confusion but then I see these photos lol.

Ideally I would have preferred this sort of design to extend the primaries. (Ian's Golf)

Mainly because it keeps the engine looking empty and its away from the Brake Fluid Reservoir, brake pipe, vacuum & coolant hoses.

But the workmanship and skill gone into it is amazing and it is a bit of automotive **** lol.

Saxon Motorsport are adding a bit of heat shielding and I will be getting it ceramic coated over the Christmas period.

 

[cupra.al]

i love looking at the craftmanship that goes in to some manifolds and that looks pretty awesome too.

 

[Dave_R]

The effort gone into it is amazing! Look even better when its ceramic coated in white!