Mods & Drives

2006 Diary

Jan  -  Feb  -  Mar  -  Apr  -  May  -  Jun  -  Jul  -  Aug  -  Sep  -  Oct  -  Nov  -  Dec

Maintenance and modifications are in grey and drive outs are in dark blue.

Ho hum, weather's yuk, so no work on the car... Still got a bit to do, finish off the sidepods, make the boot lid mould and then pull a carbon jobbie off and fit and bed in the new rotors and pads. May well give the brake system a bit of a bleed as well, as the pedal feels very different (with the very small amount of driving I've done this year). The brakes also make a very odd (but pleasing) noise when applied, guess it's the holes, but they don't judder any more, at all in fact.

Part of the reason in changing them was that the grooved disks would be fine for a while, then get progressively more juddery in a couple of hundred miles or so - not 'really bad' but somewhat annoying. They were juddery when new, but CAT assured me this would clear up as the bedded in, but the time between them being 'OK' (after a heavy braking session) and starting to get nasty again was getting shorter and shorter - not good, (I've an unfounded but sneaking suspision that these were EBC rotors made by Hi-Spec, but I may be wrong, however it would help explain things).

Having had a bit of a read it seems that not all disks are made equal (as it were), and suffer from having the braking faces not parallel to one another, leading to 'problems' or have a nasty high spot that over heats, (and changes its chemical composition to one that is harder than the surrounding metal). This leads to the softer metal wearing and the high spot/s getting higher, so making the problem worse... wait a moment, that sounds familiar :-) I think that the way the disk were made meant that the leading and trailing edges of the 'grooves' were higher than the surrounding material, so causing a 'hot spot' and leading to the effect discribed above, also the width of the grooves probably didn't help (maybe?).

The odd thing is the rears seem fine, unless the fronts have masked them, but then again they really aren't working anywhere near as hard as the fronts... we'll see.

Gave the system a bleed - may or may not have got air out, probably just the air in the bleed hose being expelled. Quick blatt and the pedal feels more 'solid' but all this just may have been my paranoia at fiddling with the brake system.

Left the car  for a day then tried the brake pedal and it's fine, so no air in there.

First club meeting of 2006 and Harvey K. actually turned up in his rather spiffing Westy - in the belting rain - Stunt man! Pretty good turn out concidering the ghastly weather and we got to drive home in climate controlled heaven - whimps or what?

Test sprayed one of the carbon side pods with clear lacquer and I must say it turned out rather well, then feeling bold I did the top sides of the diffuser - also pretty good. This has solved the "how to I match the the very shiney Factory items" problem I was facing. On the side pod front... this is turning into a job and a half! I have to try and match weave across four items, join the O/S set together and joint the N/S set AND make the Gurney flap moulds. Still, it will look rather good when the job is done and be somewhat more effecient than the current items (not to say conciderably lighter and stronger as well) at removing stagnent hot air within the bay.

Started the engine for the first time in a while and thought that as it was running and the weather was fine, why not go for a quick blatt? On the way to fill the tank up the engine kept misfiring, so back home for a look. Checked all the obvious things and popped the plugs out which all looked fine. Restarted the engine and it was back to its normal fast purr, quick spirited blatt and indeed we're back to normal. Either a plug lead/connection was loose/dirty or there may have been some condensation in a carb... either way, looks like its fixed.

The weather was rather nice so off to LH for some "chip shop chips". The roads were pretty clear and apart from the usual Arun Valley fog bank not actually freezing cold. The car went very well (as usual now it seems) and we had the W/I LED flashing away happily to itself at every opportunity. The water pump/controller are work well, with the temps staying just under 80°C no matter what we're doing. As I was keeping an eye on the temps clock I noticed that the boost will go way past 0.6bar now (and this with a certain amount of parallax error), I suppose it always has since fitting the W/I and it's just not registered.

On the way home at a certain point the road changes from single lane to dual carriageway, so I pulled out to overtake the car in front. This time however the revs were much higher than they usually are when applying a healthy amount of throttle (in third at 6 - 7000.... maybe). The net result was the rears let go at around 50mph and scrabbled along until a quick gear change or two got them to bite again. To be honest, since the resolving all the clutch slip issues I've only let the car fully unwind a few times, so when it's given its head... wow! Anyway, this is of course the turbo's fault, as normally (or the revs are under 3000) I don't often change down the gearbox as the torque is pretty impressive from very low down.

Designed some half door moulds... Daaaaaaad :-)

366 Hours modification/maintenance time  -  (558)924 Hours total work time  -  144 Hours design time  -  (95)239 Hours total Design time

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Fitted a 1KΩ pot in series with the shunt variable resistor. This gives a value of 9.3KΩ ± 500Ω, just got to test it and reset the 'on' value. Should give me a useful hot/cold weather sweep for the pump. Mounted the pot in the centre console carbon panel between the immobiliser LED and the choke lever - easy to get at, but tucked away from inquisitive little fingers.

Weather has been rather nasty, so no blatts and no mods to the car... I have been playing with my CAD software and have done the front suspension of my car, (but only using a 'jig'), and converted it to pushrod. Rather clever even if I say so myself... It means I can now remodel for wide track and get the geometry set on the computer, then give the data to the suspension setup chaps. I have yet to model an accurate upright, so the geometry isn't quite there yet, but it's too bad.

The video file is rather large, so only attempt to download it is you have a dsl connection.

Since doing the one shown I've done another using rod ends, ball joints and ball races that end, joint and race... gosh :-) And as a bonus, the shock doesn't foul any components now. So, my next project is to accurately model the front end of the car and see what wide track will do when compared to the standard width setup. It should show less movement of the wheel (in camber) Vs deflection of the suspension.

I've just re-read the above.... you can tell I'm fed up with the winter and bored can't you. What a load of tosh, even if the wide track only gives me a usable turning circle - I'll be ahead of the game :-)

Boat's out of the water, so I've got a couple of weekends scrubbing, polishing and painting it with antifoul.... Hmmmmm tin. Was quite fun on the day, Dad™ and I took it round to the yard... very breezy (that's bloody gale force to the non-yachting majority) with twin rudders and a folding prop... no risk too small - stopping definitely was happening to someone else - 'cause we didn't see much, but Dad™ seemed to enjoy it... and got us into the lock and moored up with consummate ease, the big show off :-) 

Should have it back in the water for Easter, so the weather had better behave. Looks like the Solent, Poole and maybe the Channel Islands for the summer... It's going to be tough, but I'm sure I'm upto the task :-)

370 Hours modification/maintenance time  -  (558)928 Hours total work time  -  144 Hours design time  -  (95)239 Hours total Design time

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Third time this year I've gone the the monthly club meeting in the tin-top... Roll on Global warming! The weather has mitigated against finishing off the carbon side pods (they're all done, just need cutting, fitting and coating), but we did get the boat lifted, cleaned off, hull polished and waxed and two coats of rather nasty anti-fouling paint done. So she's back in the water and waiting for some nice weather.

I 'built' a single cylinder engine using my CAD software... The piston goes up and down, the crank turns (and the cams are geared correctly) and even the valves work!

First RBFYB™ run of the year... Not too bad but the roads were wet. I was very impressed with how the car coped with the conditions, the A048s do seem much better than the A032s.

Next month we have some rather nice blatts planned, the European Kit-Car show, a Goodwood brekkie run and may be a sail to Littlehampton if the weather plays fair.

Video of CAD Engine (2MB)

371 Hours modification/maintenance time  -  (558)929 Hours total work time  -  144 Hours design time  -  (95)239 Hours total Design time

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Very nice RBFYB™ with Steve & Adam R... Run out to the Henfield greasy spoon (for a toasted bacon snarnie - which was sublime), then a blatt to the Goodwood Sunday Breakfast club which had an Italian sports car theme. The Ferraris and Lamborginies were very pretty... but curiously 'unmoving' and homogenised. It seemed that the latest Milan fashion for engines is a  'sneeze guard' to stop anyone actually seeing what was in the bay (and tell the truth they really were all a bit samey), but then if someone threw one at me they'd have a job getting it back :-)

A couple of cars where rather nice.. an Alfa rally car circa 1970 and a couple of Fiat 500s with fat tyres and 'odd' bulges in the body work. The atmosphere was great and we also had fun having a look at the cars that weren't part of the theme... couple of Astons, a Noble, various other kits... jolly good fun. My car got probably more than it's fair share of interest... makes me smile... take the bonnet off and you have an instant crowd, complete with still and video cameras :-)

As part of my Area Organizer duties for the SWSCC I sorted out the run to the Detling Kit-Car show... 15 cars turned up at the meeting point! Given that I tend to get lost  - a lot and really easily - I was a tad worried at leading this rather large string of Westies... However, GPS to the rescue! And to top it all off, we only lost one car - but someone hared after him to bring him back... not too bad, (mind you, I did get lost on the way home - some blighter had nicked the A26).

The show was OK... some very pretty cars and some stunningly ugly or "WHY!!!?" type cars, even sat in one of the latter, sort of a four seater 'Seven'... hmm, while Val™ sat in one of the former - a rather nice Ginetta/Fury hybrid thingy (sorry, I've lost the info on the car). The Toniq bodied Stuart Taylor was pretty good (except for the fish pond lights they had bolted on - boy did they look wrong). The overall finish on the car, the body quality and styling were appealing... several nice design touches too - hope it sells.

The Pilgrim Minator, (twitch twitch... just remember, Mr T is no longer involved... twitch twitch... Long story that involves Dad™'s first Kit-Car, a really big hammer and needing a shower after it was all sorted out.... brrrrrrrrrr). Anyway, the car is rather imposing and the show item was finished very well, but the Ultima GTR is still waaaay better.

I did like the Land Ranger thingy, it was flippin huge! I could park the Turboblade under it! The wheels! It was 8 feet high for goodness sake! You'd get a nose bleed just climbing into the cab, Sir Edmund would have probably thought twice! I want one... not too sure why though, as there aren't many shear rock faces on any of the 'approved' blatt routes where I live. I tell you, if the Himalayas Sherpa Union find out about this thing, well vexed will not cover the half of it.

Something that I didn't catch onto while I was there but found out later was a company offering a body kit that turned an old Range Rover into a 'New' Range Rover... or at least that's what I think was happening... What they really want to do of course is to turn their old Range Rover into a Land Ranger!!! Oh yes indeedy, with big, big wheels!

The Aeon was there in the centre seat Canam guise... Can't help it, but I quite like the look of it, not an 'Ultima' but a shed load cheaper and put together pretty well. However, not keen on the 'lidded' version, odd really.

Some very nice cars in the show parking area... an RS200 which looked the part, some very pretty Furys, a dribble inducing GT40 (in fact two a dribble inducing GT40s) and of course 15+ Westies in all their glory - easily the best bit really.

The drive home was fun - yes I know, I got lost, but hey, only two cars following me this time, so what do I care :-) - but with too many dead head drivers out and about to be really fun... Only got to let the engine off the lead a couple of times, but when we did, it didn't muck about. Even had three shift lights up in three gears on one stretch of country lane, (which, when you think about it didn't even graze the full power output of the engine - he he he).

Decided that the quality of the carbon side pods is not good enough, so I'm going to redo the mould to make producing these items with a consistently high finish easier... Double damn, that's £150 I won't see again :-(

The odd thing was, the first item we pulled off the mould was perfect, the next three however... All is not lost, as I can use the flat plane parts of the items in other areas of the car and indeed as re-enforcements for the final, final versions... Nope, that doesn't work, still cross with m'self - oh well.

What we'll do is fillet and pull off two GRP items then fill, re-enforce and finish them. Then we'll join 'em and pull a mould off to use with the carbon. The mould will now be doubled ended and incorporate the Gurney flaps - and the finished items will fit with standard track suspension - ah, the beauty of CAD.

We had to cancel the regular SWSCC meeting due to a tad too much rain... So another was organised for the following week! We had planed a run up to see some relatives then pop over to the pub early for some food and await the rest of the chaps... While at said relatives it started to rain, so we thought: "Shower, no problem, we'll head over to the pub as it was on our way home... but the rain will stop.

It didn't, in fact it got much much worse, so we started back home with an eye out for Steve R as our route home was the same as his one to the Pub. We found him, and after a Keystone Cops'esque turn around we chased after him, (by this time it had in fact stopped belting down and was rather pleasant)... Went by him with a 50mph speed advantage... One minute he was a small yellow dot, the next was "where'd he go?". Later, he said the huge flames coming out of our exhaust on over run where "Very hot looking" and "Just like plasma" and "Jolly entertaining"...

I really love this car  :-)

The club meeting was very well attended and rather a hoot... It rained on the way home.

Started the process of filleting and pulling off plugs for a new side pod mould... Smelly but all is going well - and I also get to play with Plasticine, result!

Not going to go to the Stoneleigh Kit Car Show... Haven't got a really good reason to attend and as only two other club members showed an interest..., ho hum. Shame really as I was really looking forward to having a sit in a..... Land Ranger!!! No step ladder too big! A guaranteed groin strain with every climb up into the cab! Oxygen masks provided! Buy one now and be the envy of ladder owners everywhere!

The "new mould for the pods" is coming on a pace, got both the plugs off and they look very good indeed - Harrah for Plasticine! Even was very very brave and jointed them: Cut them with the Rotorzip (even better than Mr. Sparky) and malleted them back into the pre-filleted mould then clamped them down. Gelcoat and layed up four sheets of CSM across the join, (and waited....)

The item popped out of the mould with little fuss and is fan-flippin-tastic. Just got to clean up the joint and it's polish, polish, polish! The current item is 1.6Mtrs long, so once I taken the mould off of it, I'll remove the re-enforcement, cut it in half and put it up for sale.

Decided to use the rubbish carbon pods to make some fins for the diffuser. The flats of the items are very good it was just the "oh so too tight" radiuses on the bends that leave a bit to be desired. Managed to get three fins out of one pod, one that ended up the template and two to use. Clamped my belt sander in the workbench and shaped them all up to fit then had a bit of a think as to how to attach 'em.

Used a couple of beads of hot glue to hold them in place, then mixed up a batch of PE resin and industrial talc to make a very high build filler. Masked up the fins and the diffuser and filleted the filler in. Removed the tape once the fillets were smooth and there they were - it worked! Rather saucy if I say so m'self.

385 Hours modification/maintenance time  -  (558)943 Hours total work time  -  155 Hours design time  -  (95)250 Hours total Design time

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Started on the side pod plug again... Cut off all the excess fibre with the Rotozip and began the delightful process of removing the joint flashing and smoothing the 'bend' radii. It actually went pretty quickly and looks very good, just got to fair in some bits and bobs - but other than that... Well, that's 'Pass One' - probably end up taking the same amount of time as the diffuser mould (I.E. 20+ hours later...).

Rather good run with Steve R. to the Goodwood Breakfast Club this month, it was the turn of Pre 1939 cars... Very nice and gooey bacon'n'egg sarnie, also some great cars on show... the odd thing with these events is the 'car park' is just as interesting as the show cars. Great atmosphere as usual and the sun was out with a vengeance, also the blatt there and back was rather fun. Teased an R1 on the A281/A27 slip road at Shoreham, I know it's not clever... but it was very funny from our point of view..., even more so when he didn't drop us (until the speeds got silly) once he got onto the dual carriageway.

I'd noticed that the car has been blowing a small amount of white smoke when cold, it disappears pretty quickly as the engine heats up, I.E. inside of a few minutes. Doesn't do it always but I've seen it a couple of times in the last six months (and have ignored it). Given the 'Blade engine is pretty bullet proof I thought I'd better get the turbo looked at.

Finally found a company that were very helpful/knowlegable and prepared to take the time to discuss options (and believe me, there are some VERY odd companies that 'say' they service turbos out there). So, unbolted the unit, packed it up and off it went... Turns out the shaft, bearing and seals were damaged by 'oil contamination' (and I know what from, damn it... all down to a certain supplier who shall remain nameless, mutter mutter mutter). The turbo refurb' company involved fitted/made up the parts needed and the unit was back with me inside eight days, not bad at all.

Looks like all the nasty clutch material, five damn clutches would you believe (and countless Plasticine 'heavy duty' spring sets!), that got dumped into the oil when the engine was burning them at the beginning did for the turbo bearings... The oil filter caught the 'engine damaging' big bits but the small particles seem to have been lethal to the turbo. As the current clutch has been in the car for more than a year (and is still way within specs) I think this is a past problem rather than an on going issue and was due to lack of 'customer support, general know how and "I really don't care as I have your money"' on the part of the original UK kit supplier - little did they know :-O 

Also replaced the heat tape on the link pipe from the turbo and added some to the first six inches of the exhaust pipe and held it in place with safety wire, a whole lot better than metal ties or jubilee clips.

Drilled all the nuts and bolt heads that hold the turbo to the car so the process of wiring them is much stronger/easier... Went through two 2mm drills, which for me really is not that bad. Also drilled the sump nut and the alloy blade on the sump, (been meaning to do this for ages) and safety wired it up.

Took the time to pop the exhaust manifold off and replace the crush washers (David Silver Spares rule OK!), as the number one cylinder had started blowing when the engine was cold, no big thing as it stopped after a minute or two... but it 'bothered' me.

Have fitted softer springs (but still 'slightly' better than the Plasticine 'heavy duty' rubbish on the market) and added a washer to the lock-up pawls to have a play with standing starts. I think at the moment the clutch locks up too soon, bloody fantastic in the 6 - 10200rpm range though :-) but the car will spin the wheels far too easily if you try for a drag. So I thought I'd have a bit of an experiment by (perversely) allowing the clutch to slip in the initial pull away and let the lock-up to do it's thing once the engine is in its stride. I tell you, the difference in engine torque between my 'old' Megablade and this car is quite astonishing.

It's been rather nice having a fiddle with the car... I'd been getting a tad bored of late what with it working perfectly for so long :-)

Finally started some sailing (the start of the year has been 'not good' weather wise)... Bottle of red and a greasy take-out Pizza while drifting with the tide... The sun blazing away, not a breath of wind and not another person within three miles. Goodness me it was hell, I really don't know how we survived. Even went to the rescue of a floundering Seagul..., he really wasn't keen and in the end stopped mucking around and flew off... How were we to know he was just drying/washing his wings (or doing that weird 'Racoon Thing' when they're fishing)? Looked very odd anyway :-)

Had some rather good F4 breeze at the W/End... So got several hours out sailing - very nice.

Fitted the turbo system back on the car... straightforward enough, just fiddly and cramped. Cleaned out the air inlet and turbo side pipe work with white spirits and acetone, then had a fight refitting it (it really wanted to stay off the car let me tell you). Also, as I was never particularly happy with the way the turbo oil outlet pipe feed back into the sump, Dad™ and myself made up an 'oil rail' that provides a straighter run for the pipe work. Cut some 25mm box steel to length, then cut off three sides 25mm on each end to provide a flap of metal we could bend up to create the ends. Drilled/ground out two 15mm holes for the pipe ends and welded it all up.

Once that was done we pressure tested it with water... amazing the size hole that shows up! To our credit we only found two pin prick ones to re-weld. Once that was done I shoved it in the oven for a couple of hours to bake off water residue at 150°C then let it cool so I could paint it up.

Fitting it to the car was a right pain, but after a mere two hours it was on... with the car full of oil and ready to fire up. Pulled all the plug leads and turned it over to get pressure - which happened in the usual fast manner, popped the leads back on and the beasty fired up first turn of the key - and was remarkably quiet. No white smoke, no blowing number one exhaust port and even better - no oil leaks from anywhere!

Let the engine oil settle back into the sump for a couple of hours and topped it up to the upper limit of the dipper, checked again for leaks and found none, so time for a test drive:

The engine really is much quieter, so much so you can hear the location of the exhaust tail pipe now, rather than just an exciting bellow of noise from the front/side of the car. The turbo spools up at lower throttle weights and hits the water injection point seemingly much quicker than it did. All in all pretty good, got back and checked again for leaks and found none. Check the oil level after an hour or so and was were it should be.

RBFYB™ this morning to LH... Bacon & egg toasted sarnie and a very nice blatt with clear roads there and back, jolly chilly though, but good fun. I've noticed that the turbo doesn't make the odd (but it was rather nice) chattering noise when I change gear now, most odd. The car really is quicker than it was before, with the acceleration being a touch more savage and hitting the W/I point more frequently...

Given the that the original turbo kit UK supplier was, errm how can I put this delicately: "not the best in the World by a long chalk", I now wonder in my idle moments if the 'new' turbo that was supplied  originally was in fact either (1) a poorly reconned item or (2) an old used one that had been cleaned up. Just a thought and I guess I'll never know, but the performance of the car is markedly different than before (in a good way), also that the hardware currently on the car now bears little to no resemblance to the original turbo kit as supplied is a real comfort to me :-)

Just totted up the total hours working on the car... works out at about an hour a day since the beginning, way back in March 2003!

403 Hours modification/maintenance time  -  (558)960 Hours total work time  -  160 Hours design time  -  (95)255 Hours total Design time

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Got some excellent sailing in today, five hours of sunny F3 from the SW... Ah, bliss. Dad™ got some images of a skimming dish with surface piercing props - which did look rather good, it also had dual 'V gawd knows what' engines which were unsilenced and sounded sublime (from a distance anyway, hate to be on board for any length of time with those beasties blairing away.

Checked the diff oil level (boy is that stuff smelly or what!) and it turned out it needed about a 1/4 of a cup full, also the magnetic bolt didn't have any nasty lumps of metal attached to it... So pretty good indeed. Took the car for a petrol fill up blatt to check I'd done the filler bolt up properly and had some fun around my 2^nd favourite round about. The diff didn't leak so I put the diffuser back on ready for tomorrows blatt to Goodwood.

The Sunday RBFYB™ to Goodwood was very well attended by the Surrey WSCC group... Great blatt to the meeting point on warm dry empty roads and thanks to Steve R doing an excellent job leading us to the event, a rather nice blatt all around.

However, the psychology of some tintop drivers amazes me, it truly does.

I feel a bit of a rant coming up...

Picture it, a stick of 14 Westys pulling away from a set of lights and getting sorted out, I take the tail end position and a complete 'spanner' in an old Nissan swerves out, lumbers past and cuts me off so he can get between me and the next car, (and I really do mean "cuts me off", there was very little room and I had to brake heavily)... Where did he think he was going? He's now got 13 Westys in front of him instead of 14...PROGRESS! Nipped by him on the first clear straight to resume my original position and neatly slotted into the 200 yard gap between him and the next, fast disappearing car... What was going on in his testosterone soaked tiny mind?

What am I saying, what mind?

Then we get to within a 1/4 mile of Goodwood on a country lane, all us Westys and everyone else in a 40 mph que and... a 'hair dresser' in an MX-5 decides that he really 'must' get in front of everybody... My oh my oh my, I mean, a boggo MX flippin 5!!! Hells bells. He drove on the wrong side of the road for 500 yards to perform the staggering display of "my willies really small, but I've got an open top car" - where's oncoming farm traffic when you need it?

I didn't see it but apparently he mucked up the next roundabout and made an even bigger tit of himself. Dear oh dear oh dear.

We had this same thing several years ago (in MB919) coming back from the Detling Kitcar Show, 'last man' again... At a T-Junction and a "Very Strange Chap" in a Cavalier got between me and the next Westy (in a stick of six). We hit an empty stretch of curvy lane and the Westys in front are away... We're stuck watching this "Very Strange Chap" in his tintop trying to keep up with them, which was very very scary, to the point where I eased way off, checked we had the first aid kit on-board and waited for the crash...

I think that the sight of a group of sports cars (rather than a mass produced pretend tintop'esque ones) brings out the Dish Mop Terrier in a 'certain aged bald headed/max power wanna be under endowed' tit... you can just hear it thinking: "I know if that really huge dog takes it seriously, I'm his dinner - but I can't help m'self and I'm gonna bite his leg"... What do they think they are going to prove, apart from obviously: "look at me! I'm a spanner!"?

... Aaaaah, that's better.

Anyway, the show was great and they even had an Enzo (Mmmmmm, carbon fibre) which had an engine note like no other - wow! The usual crop of Italian, German and some American cars, which was quite refreshing... and even some Ultimas, though they're kit-cars aren't they? On that front the show critierior was quite odd, said Ultimas were in and what I could have sworn was a kit Cobra or two, (didn't the originals have the bonnet scoop riveted on? And were LH drive?), but a spanking couple of new TVRs out - odd. They did let in a Monaro which I could do damage with, so not all bad :-)

Great atmosphere and strolling around in the sunshine (armed with a bacon and egg bap) made for an enjoyable morning - blatt home was pretty good too. The car is performing rather well and the water temp mod' I did a while ago is working better than I expected... Even on hot days the coolant temp never goes above 85°C when your on the move, no matter how much weight goes on the engine, pretty dang good.

Did you see the Italian MotoGP!!!? By five laps from the end we were reduced to yelling incoherently at the TV. I loved Rossi's comment at the interviews on going wide when in the lead: "I closed the throttle for half a second... and then I was fifth!" absolutely fan-flippin-tastic, what a great example of how motor racing should be - and they do this every single race!

Went for my first week day blatt as the weather was so good, did the Levels road twice! It really is a corker, swooping long curves mixed in with some esses with 180° bits and you can see the oncoming traffic from miles away. On the way home on a long straight road decided to try out the new clutch settings...Slowed and dropped down into second at around 40mph/6000rpm then applied a generous measure of throttle - Hells bells! I swear I had the front wheels off the floor, as the steering went every so light :-)

The tyres and road were hot and the grip was pretty good so just got the rears chirping rather than just spinning them. The front just lifted... and lifted as the car catapulted down the road, changed gear on the red lamp and found m'self at fair positive percentage of the national speed limit in less than a blink of the eye. The clutch worked well and did it's job nicely, so the mods seem to be just the job.

We went for another blatt this afternoon, again down the Levels road then onto Beachy Head for a couple of 99s. The plan being that 'Ingerland' were playing their first match so the roads would be empty (given the number of cars with flags...) Only half right damn it.

The roads weren't too bad (and the Levels one was indeed empty) but a surprising number of be-flagged cars were still out and about - What were they thinking!? Have they no feelings of patriotism!? Not supporting 'Our Brave Lads' in their time of need - and by the sound of it, they need all the help they can get!? Shock!!! Horror!!!

The questions I can't help asking are: "Where are all these flags made?" bet it's not in the UK... and so: "Who gets all that money?" Apparently it's set to be over £1B! And finally "Boy, are people gullible, England winning the World Cup?" MWWWAAAAHAHAHAHAHAHA!!!!!

Gosh, two rants in one month... I really need to get out more :-)

Met Trev of Duratech Westy fame at BH and, while we were there a very pretty Tiger X-Flow joined us - Odd isn't it that we all had the same idea... England playing = Empty roads :-)

Cracking full days sailing today with F3/4 from the South once it settled down, glorious sunshine beer and sausage sarnies. The boat performed well, slipping along faster than most bigger boats off the wind and pointing as high as some of the racing boats that were out there - a really great days sailing.

Heard two rather scary MayDays on the VHF, (one involving a diver, which lets face it is double scary), which were resolved happily and four PanPans, one of which gave us pause for thought...

The poor chap couldn't get his main engine to start and then the aux. one wouldn't play either, so he calls up Solent CG. The Coast Guard, once they were happy that the chap and his boat were fine and in no danger, were trying to get him to tell them were he was with no luck - kind of:

CG: "Can you give me your current position please"

Casualty: "Erm, well I'm about 3 miles East of the pipe (a known land mark) and 2 miles off...., I think".

He wasn't anywhere near.

Then a very helpful chap in another power boat calls up and says that he's pretty close to that area so he'll go and give the 'casualty' a tow back to the marina - all fine and good.

The next hour and a half involved the very very paitient and kind volunteer trying to find the stricken boat with the help of SCG while the chap on the conked out boat was jumping up and down waving his arms at all and sundry (as we were in the general area we were also looking out for the boat, but his given position was over an hour away from ours, so seeing a small power boat from seven plus NMiles was a slim chance).

The chap in the broken boat had a GPS on board, but as it was 'new' he didn't know how to work it... these things are automatic for goodness sake, switch 'em on and they find themselves! The positional data he was reading out bore no relationship to Lat/Long and his best guess as to were he was ended up being 3 miles 'West of' NOT 'East of' and about 3 miles further offshore than he thought. So only seven'ish NMiles out then.

By the end we were lost in admiration for the kind rescuer... How he kept from going completely Tourettes on Channel 67 we'll never know. It all ended happily for the casualty with a tow back (and a stern talking to from the CG I suspect - and hope - as they were going to meet him at the dock). On that note, if the broken boat had had a more serious problem, not knowing the first thing about basic navigation, (both paper and electronic), or indeed geography could have had some what more serious consequences for the poor chap. Two hours to find him from first call is a lot of time for something nasty to happen.

Made the big mistake of watching the GB Grand Prix when we got back... Why do we waste tape space on this crap? The 'race' such as it was, was over at the end of the first corner, [irony alert] Button did really well again [/irony alert] and Mr Allen really needs to be a victim of a sensless, gratuitous and bloody mugging asap (this is an idle day dream not a request by the way - I am of course completely against cruelty to dumb animals - if only he were in fact dumb..., sigh). Roll on the next MotoGP!

Another England world cup event... So out for an evening blatt and this time the roads were empty! Ran the country lane route at a very fast pace and was blipping up and down the gearbox like a good'un... Very relaxing. Even had the MP3 plumbed in, all rather pleasant in the evening sunshine. So now can't wait for the next match.

Yet another blatt in the sunshine.

Impromtue blatt as Val™ was at her summer fete... Met up with Trev and had a great run out to a new club member who is building an Sport 2000 Westy. Then another blatt so Trev could show him what to expect when the build is all finished. The run home was pretty good as well - don't know where all the traffic went, but hope it stays there.

London to Brighton bike ride tomorrow, so up early and spend the whole day on the boat after a RBFYB™ at one of the marina restaurants. Mind you, they're all pretty 'up market' now... no more Fishermans Cafe in a Portacabin..., damn it I really miss the bacon & egg butties they used to serve up - dribble dribble... Just have to see if one of 'em serves a brekkie that doesn't include latte (what ever that is) and whole wheat cibattas with goats cheese glaze on a bed of rocket with juuust a drizzle of extra virgin olive oil :-)

After much research, decided to fit a dump valve... Went for a 0.5 - 1.2 Bar jobbie with adjustable actuation. Fitting was very straight forward with just a bit of a juggle with the style of Samco 90° elbows and ali pipe. the vacuum pipe was lead to the No1 cylinder fitting and it was done. Tried it out and found that the actuation point was too low - sounded like a Max Powermobile! Every time the throttle was even eased back the valve was whoooshing away to itself. After a trial or two the valve seems set pretty well... It will whoosh but only when the engine is actually making boost and has some weight on it :-)

Had a nasty thought: "What if, when the valve is open a high velocity insect zooms into the induction system?" Might not be very probable, however I made up an aliuminium guard for the dump valve.

410 Hours modification/maintenance time  -  (558)967 Hours total work time  -  161 Hours design time  -  (95)256 Hours total Design time

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England out of the cup! Oh no no NOOOOO! Please tell me this cannot be!!?

Now all the traffic will be back out and about, shedding flags like a Porcupine with galloping alopecia :-)

Goodwood RBFYB™ blatt was rather good this time around... We split the group in two so Steve and myself only had a stick of six cars each. The odd thing was, given we started each group five minutes apart and went different routes - we ended up at GW at the same time... odd stuff. The route we took was full of smooth sweeping A roads with some very twisty up hill stuff. The show was pretty fair (as was the B&E buns), we even ended up parking out of the sun in the paddock shelters - result! The theme this time around was 'Classic British Cars", so there was a Radical in the show... yep very classic... Spot the envelope stuffed with fivers changing hands, oh, hang on, this is Goodwood, make that tenners :-) Run back was good with Trev and ourselves dropping in on Adams new build, which is progressing rather well. He's done a very nice job of the tub/scuttle & nose fitting and the trobble bodies do look spif.

Noticed when out blatting as you come off the throttle from hi boost, you have the bracing smell of screen wash wafting over you... dump valve AND the W/I  doing their thing :-)) On the dump valve front... Have a look at this: "Duck call" dump valve video... Ooooo, so tempting, (link opens a new window, just close it to return here).

Took Steve R sailing... Had a job prising the tiller off him :-) Mind you, you could tell he'd done some sailing before - did a grand job. Great weather too with a top end 4, a reef in the main and the headsail rolled out to No3... No weight on the helm and zipping along like a good'un. A bit of a chop (he got the decks wet - shock, horror) but jolly good fun.

Trackday booked, at flippin last! They've either been when I'm working, miles away, bloody expensive or sub 98dBa noise limits (though I'd probably squeak that with the big can). Two day affair on an RAF base... The day/s are only open to car clubs rather than Max power Novas, so should be good especially with a number of the SWSCC chaps going.

So, now I've a number of little jobs to do before the day.

RBFYB™ to LH with just Val™ and me... Very nice, with empty roads and a warm breeze (and this at 0800!)... Got back and watched the German MotoGP... Hells bells! It almost got to the point were we really couldn't look at the last lap :-) Exciting or what.

Slipped off for a couple of hours sailing after the MotoGP... Fantastic weather again, probably a top end 4 low 5 with a reef in the main and No3 rollout again.. The fully battened main is very powerful, so you have to take it in early or you're on your ear upwind - flippin quick on anything more than close reaching though :-)

Got back and watched the French F1, luckily on HDD so we could fast forward - or Val™ did when I.... Fell asleep. really, that must be the ultimate comment on the 'racing'... Just couldn't keep my eyes open it was sooo dull. So, we've made a decision... No more will we watch this crap, that was the last F1 'race' we'll see until they sack Allen and then actually design cars that can overtake each other on the track for goodness sake.

As we're doing a trackday I don't want the W/I pump to run dry (read expensive)... Not a problem on the road, as if you managed to use 2.6L of screen wash on a blatt you'd probably find an armed responce team waiting for you once you got home. However, on a TD the tank was designed to last for one 20 minute session'ish, plus or minus... So, I decided to fit a float switch in the tank...

So, trackday job number one:

First thoughts were to fit one in the lid, as this would mean no holes in the tank. Found some devices that would probably do the job, but I'd have to make some logic CCts up to handle the switching. They were rather swish with twin vertical floats and four reed switches - but in the end looked a tad complicated to sort out and didn't give me the options I was after.

Had a look on the WWW and found a float switch that, while it needed a BIG hole in the side of the tank, it could be wired in series with the pump on/off switch (that provides power to the pump power relay and the ON LED) for a simple install.

Before I belted a rather large (and irreparable) hole in the side of the tank I thought it would be a good idea to ignore the data sheet that came with the pump and do an Experiment. This would determine the 'Contacts open' point as a fluid level dropped and so as a centre point for the flippin big hole.

Have I mentioned how big the hole in the side of a perfectly good  non leaking tank would be... at all?

After playing with some containers and a lot of water - it was a sunny day after all - I worked out that the huge hole centre point needed to be 35mm from the bottom of the outside of the tank. This would give 15mm of fluid in the tank on 'switch off' which just covers the top of the outlet pipe.

Marked up the 16.5mm hole (16 point flippin 5 mm!!) and drilled a 5mm hole, then 8, then 10mm... Resorted to a file to get the hole out to around 14mm, then could get the big Dremel sanding drum in, (which is just the right size by the way).

Made sure the switch fitted then carefully washed the tank out.

Fitted the switch and connected up the Multimeter to check... and had a fit. The flippin thing was showing closed circuit (I.E. the pump will run) with no fluid in the tank, Oh do come on!

Then realised that the datasheet is incorrect... It says the little arrow on the thread shank of the switch should point down... When it should in fact point up..., be still my beating flippin heart! Once I'd re-orientated the switch it worked fine. Wired it in series with the manual On/Off switch, gave it a test and job well done.

Trackday job number two:

Finally go around to fitting a baffle plate to fill the rather large gap between the top of the rad and the nosecone. Marked and cut a cardboard template and duct taped in place to make sure my mark ups were correct, then used one of the 'nasty' scrap carbon side pods (see, I told you they would come in handy) to make the baffle. Blocked in place and used some fine cloth to bond it to the nose. Once that had gone of, did the same to the reverse and it was done.

Also stuck some ali/fibre heat shield to the engine side of the water pump... It was an idle thought: "Wait a moment! The pump face is 30mm away from a sump full of oil at 100'ish °C!" But then again, it is also pumping water at -/+80°C... Oh well, better safe than running up my credit card bill.

Went out for a blatt with the thermocouple on the hot 'engine out' water pipe with another one measuring ambient air temp... (all this was done on a closed private track - of course)... 27°C ambient at 120mph with the W/I running the water temp climbed to a needle's width past 80°C on the VDO and showed 75°C on the thermocouple - so call it a discrepancy of around 7°C.

At 110mph with the same ambient, the VDO showed 80°C and 75°C on the thermocouple. At 80mph the VDO showed just under 80° C and the thermocouple was at 74°C. What I feel is happening here is a hysterisis effect with the VDO, as over time (minutes rather than seconds) it will indeed read the same as the thermocouple - eventually.

Both runs were for more than 4 miles at the stated speeds and were back to back, so giving the engine no chance to cool down.

The noise was really great... You can hear the turbo's high pitched whistle now, plus the induction sound and the dump valve, as well as the exhaust note change when the W/I activates - a real challenge to the senses - Oooh oooh, which one sounds the best...  :-)))

Anyway, what does this all mean? Gawd knows, but it was jolly good fun, plus very pleased the cooling system works so well.

A bit more temperature data:

RBFYB™ run to Cowfold this morning so left home at 0630 in warm sunshine and had a great blatt up to the BH meeting point - no traffic, dry roads and a warm breeze. Ten cars made the meet and we set off for another rather good blatt to the greasy spoon, where we had a RBFYB™, oh yes indeedy. After a chat and a tyre kicking session we got home and went for a 'mellow out' on the boat... The holidays are looming and we needed to get some jobs done.

Trackday job number three:

Had to design a new video mount... The one I'd done previously was a bit of a lash-up and it really did need re-doing. CAD to the rescue, designed it up then made a wood trial version to check it will fit, which it does... So now just got to cut the metal and weld it up.

Use the CAD software to provide a cutting list, chopped up the 12x12mm box and welded it up... Just need to weld the 2mm strap for the bolt mounts and the top bar clamp, spray it up and it's done.

Bit of a rant here... As the weather has been so nice and I've had a couple of afternoons off, the blatt/week average is at a healthy high. Unfortunately this 'extra blatting time' has meant that the car has been exposed to some very strange motoring behaviour by my fellow road users.

We'll pass over the spanners that use their mobile phones whilst driving down twisty county lanes, like wise the inordinate amount of over weight Lycra™ clad imbeciles that think Sussex is a good second venue for the Tour de France and, assume that no one will mind if they travel two abreast at 15mph along a two lane road that has a 60mph limit - both ways mind you, so you cannot overtake safely.

(Also  just how can you fall off a bicycle when traveling in a straight line? Nearly stopped and asked the gentleman when I saw this happen - really, he was traveling at less than 10mph and just... fell off -  high level of skill there).

Nope, the ones that really get me are the strange, strange people that drive along a dry country road in good viability that has a 60mph limit at... 40mph (or less in some sad cases) with the off side wheels drumming along the cats eyes on the straights.

OK, if they had any concept of 'The Here and Now' they could pull the safety card and say: "Ah ha, what about the horse riders just around the next bend" (see below) or even: "Yes, but, if a rogue rambler armed with an OS map and a thermos jumped over that extremely high hedge and leapt out at me, by traveling at 35 instead of 60mph they would be OK when I.... ran over them with my tonne and a half car..., ah, yes well now you come to think about it, maybe not 'OK' then..."

All well and good you say.

Why then do they not slow down to 30mph (as I do) when we come to a town or village with prominent 30 signs, but blithely carry on at 40?

Why do they drift out to the centre of both lanes when you do manage to find a stretch of road that is suspiciously clear of buffoons on push bikes to overtake?

Why do they ignore people (who should know better, lets face it that's a whole other rant on it's own) on horse back and treat them as though they don't exist?

But the really big question is: Why do they always, (and I do mean always), brake when an oncoming vehicle appears - even when the bit of road they are on is straight. Why? I mean, it's not as though it was a shock or anything. Realistically, they must realise that 'Vehicles coming the other way' is a possibility.

They also seem to apply braking in direct proportion to the size of the oncoming vehicle as well, so a small car = a tentative dab of the brakes while drifting over to the curb then taking 2 miles to slooowly regain the heady delights of 40mph. While something like a tractor = a near lock-up with a bit of a swerve followed by a total loss of confidence and any spatial awareness exhibited so far - OK, no real loss I know.

And, they can't seem to hold a conversation with their in-car co-conspirators without slowing down, swerving and/or braking when they just have to look at them to reply... What is going on?

The staggering lack or awareness that they have of the environment they are passing though is very scary. They seem to think that because they are crawling along at a speed less that the stated limit (if they are even aware of one) that this absolves them of any cognitive thought or responsibility and therefore, anything that happens is nothing to do with them. And heaven forfend that they actually look in any of the three rear view mirrors at their disposal and use some common sense/courtesy.

Age isn't the predominator here either, Dad™ just had a birthday that had a seven in it and he still drives like a maniac... so why can't they :-)

424 Hours modification/maintenance time  -  (558)982 Hours total work time  -  168 Hours design time  -  (95)263 Hours total Design time

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Went for a quick blatt to test the video mount and camera... all worked fine. Just got to cut some perspex and cable tie it to the roll bar to protect the lens.

Sailing holiday to the Solent, so not much done on the car this month... The holiday was pretty damn good though - Only nearly died once this time, so big improvement on last year :-)

It was jolly good fun - got into places we either hadn't been to for a long time or had never been to, did some exciting sailing, met some fun fellow yachties, had some del-lish' food and drank some great beer, you can tell it was hell, can't you.

The weather was fun too, ranged from an offshore F3 in glorious sun to NW F7 in Southampton Water (so, blowing straight down it), wind against tide and a two meter confused and very short chop, nasty nasty nasty. It was worth it though, as there is a very fine Chinese restaurant in Swanick :-) The last time we were there was ten years ago on Val™'s birthday, the night before we did a "Round the Island Race" and it was just as good as we remembered.

Run home was great, nearly 9 Knots over the ground through the Looe Channel and 6.5 hours berth to berth (and for an 8M sailing boat, that's pretty quick), kind of "Don't blink or you'll miss the marks". Turned out to be the fastest we've ever done Gosport to Brighton, by 1.5 hours no less!

Home for a few days before we're off again to the bits we missed last time out, so...

Trackday job number four:

Made a camber gauge (DT wanted £90 for the same kind of thing - obviously not as 'polished and refined' as mine)... Used 12mm box to make a rigid frame, riveted some 1mm ali over it for the scale plate, drilled the pivot hole, made up the pendulum and scale then glued some bubble levels in place and it was done. Reset the front & rear camber settings to the 'recommended' values from my tame tuner... pretty easy once you get your head around what you need to measure/get flat, so got the job done in less than two hours.

Fixed the odd readings my speedo had started giving, the speed would be fine at say, 30mph then jump around to 140mph before settling back to normal... Turns out the sensor had come slightly loose and it was just enough for the trigger plate to say 'hello'...at +4000rpm. It had only just clipped the sensor and still managed to peel back the first 0.5mm of steel off the end of the sensor. The trigger was slightly wonky but easily bent back to shape and once the new sensor was in place we were back to normal. Westfield spares department were the best on this one... Many thanks chaps.

Went out for a blatt to test, well, everything... It all works well and the car seems to me to be more settled in the corners and under braking.

Val™ had her first drive of the car this morning... Said it was very smooth and easy to drive and "went very fast ever so easily". She did very well, mastering clutchless up changing first try and only stalling it once. It was great fun sitting in the passenger seat as well. The noises you get are totally different from the drivers seat and it feels much more open to the elements for some reason.

Trackday job number five:

As the Factory don't seem keen on making Carbon nose cones any more, I was a tad concerned about the looming Trackday and the propensity of rouge cones to leap out and savage innocent passers-by. So, I found a chap that was selling a damaged nose (good) and bonnet (OK, but not needed)... Collected the bits and had a bit of a think on how to attach a 1993 SEiW nose with the flat flange type bonnet fitting and teeny tiny radiator hole (it really is very small) to a 2003/4 tub and bonnet.

It involved lots of chopping up of the under side of the cone for the oil cooler, grinding out the super thick layup to clear the big rad I've got and mending re-wiring the indicators... Not complicated but a nasty, dusty and fiddly job. HOWEVER, I now have a nose that will do for Trackday use, so saving the lovely carbon one from cone harm.

Over the winter I'll redo the ali bits on the nose with a faired in glass chin and repair the damage to the O/S, I'll also repair the bonnet (not that it needs much) and sell it to someone who's forgotten to clip the bonnet down and gone for a blatt in a 1993/4 SEiW with a VX installed :-) OK, so I may have to give it loft space for a while.

Did the RAF Coltishall Trackday... Fantastic! ...'Report' next month:

432 Hours modification/maintenance time  -  (558)990 Hours total work time  -  170 Hours design time  -  (95)265 Hours total Design time

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And so to the 'normal' stuff for this month, though probably best to read the trackday report first:

Once we'd got the car back home from the Trackday (and returned the trailer) it was time to give it a jolly good clean before anything else - it was filthy! Then due to the gear change issues I'd decided to remove the engine (as at the time I thought I have a gearbox problem and didn't know what was causing the issues) and pull the sump off to see what was what.

Getting the engine out is a pretty simple task and only takes an hour or so with Dad™ helping... While we were doing this I had a chat with Andy of AB Performance WRT either repairing the gearbox, replacing it or just bunging in a new engine. A very nice and knowledgeable chap that really knows his stuff, so got that sorted out and it was just a case of identifying what the damage was.

Once we had the engine out of the car we moved it to our hi-tech clean room type workshop (more commonly known as "The Conservatory" Back to November - Dr Who or WHAT!) flipped it upside down and popped off the sump, expecting to find big splinters of metal everywhere... In fact, the engine was completely clear of metal shavings/splinters and the selector drum, rods and gear sets all looked in remarkably good condition... Hmmm, now what, I'd been expecting to be able to say "Ah ha! that's broken, can I have a new one please?" and this was not the case.

We then popped the clutch cover off and removed the lock-up and plates AND THEN IT ALL BECAME CLEAR... I'd forgotten to put the gear selector shaft extension on, (which is needed with the lock-up clutch cover extension), so the shaft assembly was moving 'forwards' in the engine when you changed from 3rd to 4th and jumping off the selector wheel, so dropping you back into 3rd!

Five seconds later the engine was fixed!

Next task was to get the water injection pump checked and as Aquamist is half a mile away, I wandered round and had a chat with Justin. Another very helpful and knowledgeable chap who found that the pump was fine and it was probably (and it was) a blocked jet, he nevertheless stripped the pump and redid the seals for me "just in case" - service plus again. Got home and cleaned the installed jet and yes indeed it all works again - swapped it for the 0.5mm jet though.

I then checked the clutch for wear and apart from a small amount of bluing on about 50% of the plains, (which came off with the gentle application of 800grit W&D) it looked pretty damn good. Next job was the Turbo oil feed pipe and crappy fitting. Spoke to Matthew at Think Automotive and Ian at AET (the chaps that redid my turbo) but ended up driving up to Think... Matthew identified the thread, commented that the original pipe was "going to be hard to seal", (no, really? A Holeshot product that was 'less than good' - Shock! Horror!), and had a new pipe/fitting done for me there and then - fan-flippin-tastic!

Found that the Honda carb/engine rubber 'tubes' were leaking..., had a thin varnish of fuel/air mix over the carbs/head. Replaced them with some 45mm Samco silicone hose, so we'll see how we go.

Went to the Donington Kit-Car show - in the TinTop... Blimey it's a long flippin way. They were having a 750MC race meeting the next day, so we wandered along to the 'paddock' area to have a look at the BECs... and met Andy of AB Performance fame, great chap with a rather nice looking blade Striker. You could also take your own car out on the track (in 20 minute sessions), so we munched a burger and watch the cars through the twisty bits. All rather good fun.

We then had a look at the Kit Cars in their area (plenty of Westys) and then the stands in the hall. Not much that was interesting TBH, Ultima where there as was GD with a couple of very nice 70s. Other than that... there were several other manufacturers with stands who's cars seem to have been hit very very hard with an ugly stick.... The only car that did make me grin was a very interesting R1 Powered (?) single seater from MK Engineering, not bad, not bad at all :-)

So, the engine is back together, the turbo is attached and after four goes, the engine bay is actually clean again! Just got to reconnect all the bits & bobs and get my new Yoko 48Ms put on and the car is back on the road.

Well, six and a half hours later... It started with no fuss. Pretty easy, just fiddly, (and the number of times we put on/took off the induction pipework, well!), got it all connected up, used the J&R™ patented method of recharging the coolant system... and lo and behold, no air locks and the pump going like a good'un. On startup we left the plug leads off and turned it over until we had oil pressure, put the leads back and it started within a couple of seconds. The engine took four litres of fully syth oil and kept it all on the inside, no oil/water/air leaks... and it changes gear :-)))

Jobs to finish up are:

1. Polish up the O/S rear wing CF guard or re-lacquer it
2. Refit the rad
3. Get the Yoko 48Ms changed over
4. Clean the underside of the car
5. Hoover all the stones out from the cockpit
6. Repaint the wing mirror extensions
7. Refit the carbon nose
8. Make the flippin carbon side pods - see November, honestly.

Re-seated the radiator and fitted the carbon end can system on while I was re-lacquering the O/S rear wing protector, (which had got rather badly pitted and T-Cut was not doing the trick)...  Just got to run the car up to temps to double check all the fluid joints... and the nose/bonnet can go back on.

Booked in with Worthing Discount Tyre Warehouse to have the new Yoko tyres put on - don't trust anyone else with these rims - so come Tuesday the car will be done.

Ran the engine up to temps this afternoon and it stayed coolant/oil tight, so re-fitted the carbon nose and bonnet - it's a car again!

Out to DTW for the tyre swap... The first drive of the car since the Trackday and finding the GB 'problem'. Took it easy'ish on the way there and had the usual excellent service from DTW, popped the old tyres in the back of Dad™s car and we were done. Pushed it a bit on the way back, and all was better than fine! It changes gear very smoothly now and stays in whatever gear you choose :-) Pulls like a train and I again have the invigorating smell of screen wash when the dump valve goes "swooosh"! One odd thing though is that the brakes seem better than they were before the Trackday, (and they were pretty damn good then!), most odd.

Re-torqued the wheel nuts and re-set the tyre pressures, next job is to raise the rear ride hight by around 10mm, as looking at the images of the Trackday one-up the rake angle looks OK, but two-up it looks a tad flat and, as mostly the car is two-up....

Winter upgrade list is:

1. Wide track front wishbones
2. Front & rear ARBs
3. Full cage
4. 13x6" ET15'ish Steel/Cheap rims

463 Hours modification/maintenance time  -  (558)1021 Hours total work time  -  172 Hours design time  -  (95)267 Hours total Design time

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A very quiet month on the car front, but a busy, (and sad - kind of), one on the boat front... Bullfrog³ has been sold! We decided to sell her and buy a bigger boat once we'd got back from our summer holidays... Just didn't think she would go so quickly. The new owner phone on a Wednesday, saw the boat on Saturday AM, made an offer that evening, sea tested her the following Tuesday and she was his that Sunday.

The hunt is on for the next boat...

We did several blatts this month... The usual Goodwood RBFYB™ run with my colleague shamelessly tuning up in his (admittedly rather saucy) tintop, because it was "spitting with rain"... a bit :-) This, the last one of the year, was 'Americana', which meant a car park full of either completely barking barges with acres of chrome and lazy but huge V8s, (and I'd take any one of them home with me, total madness - and 'Bad' but in a good way), or a look-a-like contest of 'modern' Chevys/Pontiacs - I think, they really do look too similar, (and dull ... and bad in a bad way).

Tried to do the Brands Kit Car Live thingy and was really looking forward to it... Paul A. volunteered to do the route and lead - what a trooper. We had 10'ish cars, the weather was good but ten minutes into the blatt... my clutch cable snapped. Oh well.

Got the car home, (and only had to stop once), which 'aint bad. Two hours later the car was fixed, but as the chap that was buying our boat was due in a few short hours we decided not to join the chaps at the show. Bit of luck really as everyone I spoke to was under whelmed with the content, shame as it was my idea :-)

Next day met up with Steve R and Jane for an 'Area Organisers' RBFYB™ to LH... And very nice it was too, Steve  had an interesting route sorted out and the weather was pleasant, as was the brekkie. The car performed well after yesterdays panic.

Half term was pretty good... Three days away looking at boats/holiday ports with junk food/drink, bit of a hoot. We REALLY need to buy an up to date Pilot book, 20 years and the current one is well past its sell by date :-)

Also did, probably, the last RBFYB™ run of the year. A well attended, (10 Westys and an Elise), run from BH to the Cowfold greasy spoon. Which was populated, or so it seemed, by most of the West Sussex Police Force :-) Guaranteed to put a crimp in your style.

The roads were a bit damp, but the Yokos performed well... The weather was great and the blatt home was fun fun fun. 

News is, after the trackday ate his Yokos, Trev went down the Toyo 888 route, so that'll be an interesting comparison. On that front, I'm going to try for a 'mob handed' Goodwood trackday - expensive but a non (car) stressful hoot - as the circuit really only has three corners at the speed a Westy can hit :-) Or the same but (slightly, and I do mean 'slightly') less expensive bit of buffoonery at Brands (thanks for the idea Paul)... we'll see.

Going to 'lay up' the car for the winter now... Jobs to do and things to design/make.

Heard from my namesake in the USA with the F28 TurboBIRD... Winter, we just don't know we're born :-) This, he tells me is 'normal' for the time of year... It's just not fair, just look at the scope for low speed rear wheel drive buffoonery here :-) The lucky lad.

So, jobs for the winter are... Widetrack front end, a Quaiffe close ratio box, (if I can mug enough helpless little old ladies), although having just put the ratios into my rpm/speed spreadsheet it would actually drop the top speed conciderable - so maybe not. CF full length side pods - and, yes I know I've been put that particular job off for a while. Model up the trackday nosecone and produce some moulds to finish it off some what better than it is, oh, and spray it black. Have a go at the bonnet... I may well do a trackday bonnet affair with an intercooler intake and ducted air to the air filter, (bunging in the Ford intercooler is a pretty simple job... Just got no room with the 'standard layout', would have to make some mounts for it so it was high up in the bay... but that would be pretty easy to do. Bootbox vent/exhaust panel... Dad™ started that, so should be the work of but a minute :-)

So, the coming months should be a tad busy...

No images this month I'm afraid.

465 Hours modification/maintenance time  -  (558)1023 Hours total work time  -  172 Hours design time  -  (95)267 Hours total Design time

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I'm Finding m'self waiting to get the November SWSCC meeting 'out of the way' so I can start on the winter projects...

Mean while, had yet another go at the side pod plug and got it pretty much there, the radiuses should much improve the finished items and, as of today, there are just a couple of pin holes to fill and fair... Just got to polish, (for hours and hours), so its ready to take the mould.

Had to run up to my MinL 'on the way to' the SWSCC meet to collect Val's ski jacket that she let there the day before... and ripped the carbon end can completely off the car on a flippin speed bump, (and I was only going very slowly). After a lot of swearing, (mostly at town and road planners everywhere, idiots every flippin one of them, mutter mutter mutter), the can was bodged back on and we made the club meeting. Fifteen cars tuned up, which can't be bad, but boy was I in a foul mood :-)

Started to get the engine out today - rain, rain, rain, so all done inside the garage... Five hours and it's ready to lift out of the car, pretty easy as usual, just fiddly and cramped.

Next day: Rain again... So sorted Dad™'s computer out - removed Norton and installed some rather nice replacements that shouldn't slooooooow the PC down so much.

Next, next day: Sun... 10 minutes and the engine is out of the car and in our 'clean room' (see above). Before we start stripping the engine down I thought we'd have another go at the oil drain pipework from the bottom of the turbo, (Why strip the engine? Because we can :-) That and the air management stuff I want to do requires an empty bay, so why not?). Really not happy with the rubber oil return hose as I feel/think that it will 'close up' and restrict the oil flow.

Tried to make a full steel oil rail that went from the turbo to the sump, but couldn't get a tight enough bend in the down section of the pipe. Next plan was to use the rubber hose for the first 'bend' then use a metal pipe for the near 180° bend to the sump - success! Blinking nasty job that was, but then again, it 'only' scrapped two slinkies - so not that bad. The 'lumpy' appearance of the pipe is due to a coating of Liquid Metal - It's a harsh environment in the bay... So every little helps!

Took the top mount off the engine so I can start making up a plug, (then mould), for the engine bay air management idea I've had... Cut some hardboard for the frame to drop through, marked it up so just go the get some 40mm placcy pipe, cut some Conti-board, apply the Plasticine fillets and job done... Well, I expect after about 30 hours 'job done' going on previous experience :-) Also measured up where the prop is in relation to the trans tunnel so I can make up a two piece blanking plate - in carbon, of course.

Started making up the plug for the engine cover using 40mm placcy plumbing tube, cut to rough length and then cut all the joints in using the Dremel with a sanding drum. Messy but pretty easy and I've ended up with a pretty good start. Also faired off some pin holes in the side pod plug with some poly resin, so need that to harden off over night before W&D'ing it off.

Next jobs on the composite projects front are:

1. Hot glue the placcy pipes to my engine top from template
2. Cut the Conti-board to fit
3. Fair everything using Plasticine
4. Gel coat the plug and fair off
5. W&D the side pod mould then s
6. Start polishing it
7. Make up the engine cover mould
8. Make up the side pod mould

Stripped the bottom end of the engine... Getting the crankcase split was pretty easy once we'd undone all the flippin bolts - there seems to be hundreds of them! Had a look at the gearbox and decided to replace several of the gears and one selector fork, (they looked 'a bit dodgy' - The dogs on some of the gears have a bit of wear and the right selector fork is a tad shy.)... Phoned Andy at AB Performance and he is going to sort me out replacements - probably for next month.

The down side to all of this is it costs £90 'above and beyond' for all the oil seals, sealing washers and gaskets, however, it will save some 'pain & anguish' later on. The rest of the engine, (that we could see), looks pretty damn good, the crank looks as new, the bores look fine and there is no nasty bits of metal sloshing around. The odd thing that keeps rushing to my forebrain is, given how much BHP it produces and how high the engine revs to... It really is pretty simple to fiddle around with - Mechano^® for Men type of thing - thank goodness :-)

Adam R. got his Zetec Westy through its SVA after some exhaust quietening effort (with a welder - the lucky devil) - Got to be a good result, well done him.

Cut and fitted the Conti-board inserts for the engine cover, then started to fair in the pipes to the new level with Plasticine... Looks good but going to take some time I think :-) The upside is, the plug doesn't have to be 'perfect' as all the 'nasty' bits will be positive curves on the mould, so pretty easy to W&D / fair off once I've gelcoated and laid up - I hope, anyway that's what the CAD says.

More work on the engine cover plug... Nearly finished it, well finished fairing in the bottom and tube joints, (looks a bit of a mess at the moment, as the excess Plasticine smears haven't been cleaned off). So this W/E Dad™ and m'self should be making up the top cover, fairing it in, cleaning up the plug, THEN... waxing/polishing both it and the side pod mould up ready for some Gelcoat. Easy :-)

Had a phone call from Steve R. ref Adams registration forms... Was asked "did I have copies of the V55/5 and build-up forms," two sets of uncontrolled giggling later... What do you think.

Cut and glued the top cover to the engine cover and then used roll-on anti-deodorant lids cut in half and trimmed to make the tube end caps so we could fair them in - pretty dang good. The shape is done, now all we've got to do is neaten it up some and get it smooth. Put one layer of glass tissue over the shape and then give it one coat of black gel/resin in a 50/50 mix, next one will be a white 100% gel coat. Then we can start W&Ding, oh joy!

Actually looking forward to fitting all this kit, as I'm sure it will make a significant difference in engine bay air flow and air intake temps, that and it will look rather stunning, (if I do it right!) Probably make a GRP item first as the cut-outs will be a tad complex.

Had a go with Mr Staniforths suspension book and MS Excel™ today... It turns out that with my current setup I have a 10Kg weight transfer front to back, (and back again), if I bung on widetrack front wishbones this drops to 9Kg, a 1Kg drop! Must say it sounds pretty damn impressive, a 10% improvement! 

The big questions are however:

1. "Will I really really notice?"

and...

2. "So flippin what! If it was a 50Kg difference well then you'd be talkin...'"

and...

3. "What else is happening to justify £300 worth of something I've already got?" and therefore refer back to 1.

Hmmmmm, think I've 'unconvinced' m'self about widetrack for the moment, at least until I can do some more calculations on the suspension. No argument that it will 'improve' the handling.... The issue really is: To what extent and so, am I that good a driver that I'll feel the benifit - Probably not.

Still, I have a while to go on this as I'm taking all the suspension component dimensions and fixed points and designing a spreadsheet to do all the sums for me. Then I'll bung it all into the CAD and see what's what... I tell you, I could 'Anorak' for my country if it was even instigated as an Olympic sport :-)

W&D'd the side pod plug and I think all the pin holes and imperfections are sorted out (December note: No they flippin weren't!)... Just got to polish it to a glass finish and take the mould from it. Think we'll do a one layer CSM glass item first, cut and fit it to the tub then do the Carbon versions. This will mean we get the leading edge shape done and dusted using an 'inexpensive' item rather than £150's worth of Carbon/epoxy, which I do feel is 'rather a good plan'.

Made up a plywood mockup of the transmission tunnel blocking panel and worked out how many and where to put the brackets. Got them done and then came the hard part... marking up, placing and riveting the flippin things to the chassis, why oh why didn't I realise I'd be doing this when I was building the thing? Still, a scrapped slinky drill extension, and bent - yes bent a 4.1mm bit. So, numerous cuts and abrasions later all the brackets are in place.

I will cut the two carbon panels 'long' and without the prop hole, (just in case I did the original measurements wrong), but I will drill the bolt holes and make sure each fits correctly.

So now I'm just waiting on the gearbox bits/gaskets to get the engine back together and the fab jobs of fairing off the engine cover plug and polishing up the side pod plug to get both ready to take a mould from. Once that's all done (ha!) We'll start on the boot lid vent and I might revisit the diffuser.

500 Hours modification/maintenance time  -  (558)1058 Hours total work time  -  185 Hours design time  -  (95)280 Hours total Design time

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Trimmed and fitted the two transmission tunnel panel parts, fitted and marked up both them used the belt sander, (upside down in a vice), to fit to size. Used Plasticine to mark the position of the rivnuts then drilled the panels, riveted 20x20mm plastic angle on the top edge of the upper panel and the bottom edge of the lower panel to take Velcro strips. Just got to trial fit the engine back in the bay to get the exact position of the prop and this bit is done.

Got the boot vent from Dad™ so I can fair it off and take a mould from it... Looks OK at the moment but a bit too angular, this will change as the item is finished off.

Spoke with Andy of AB Performance today... My new gearbox should be with me tomorrow and, by the sound of it, it's an "as new" item. The man has checked and replaced any items that looked even slightly worn and is supplying all the bits and bobs to effectively replace all the moving parts of my current gearbox with one that has done less than 10,000 miles. All this for a very reasonable cost and way more than I thought was needed. However, Andy took a 'long term view' given the engine output and did a very nice deal for me... So, if you want Fireblade parts I would unreservedly recommend AB Performance.

More W&D of both the side pod and engine cover plugs... What fun.

Bought some high build primer/filler 'paint' for either/or both the plugs... This stuff reckons it lays down 0.2mm per coat... Flame'in 'ell, that's a lot of paint! There are still pin holes in the side pod plug, so I think I'll spray that up and see..., if it's as good as it says on the tin then I'll do the engine cover as well.

So, instead of the widetrack suspension what about an up/down flat/trick shifter system? Only using the clutch for pull away then slipping up and down the gearbox effortlessly does sound rather a hoot, plus I'll see more of an effect... Shame it's three times the flippin cost, damn it :-)

Found this site... Odd how physics can be both obscene and strangely beautiful all in one instant - weirdly I used to work at the UK agent for the camera maker. Another is here, not as 'wondrous', but fascinating nonetheless.

Moved the fuel regulator and catch tank up by 25mm so the pipes to/from them clear the engine cover panel..., makes it much easier to fit.

Degeased the side pod plug, took the plunge... and sprayed it up with the undercoat/filler stuff. Weirdest painting I've ever done, it goes on like dry sand on a windy beach and kind of 'melts' onto the surface, looked OK though. Just got to W&D/Tee Cut it then 'several' coats of wax and it's ready.

Right, lets start on the plug... 600 grit W&D took all the over spray/dust off the coat, 800 grit got most of the tiny imperfections out, 1200 improved matters and 1500 grit was the finishing touch. Several Tee-Cut sessions later and the plug is 'rather shiny'... and both arms are killing me, I am knackered! Used one of those garden weed killer spray thingys when W&D'ing, rather than a bucket of water... Makes a big difference in speed of work, quality and paper life.

The primer/filler stuff is a hit, took all of the pin holes out and helped with the hollows as well, most pleased. I've since found I can buy the stuff at 1/3^rd the cost from my local car shop, (of all places), and it's in a prettier colour :-)

Took all the lumps and bumps out of the engine cover plug with 120 grit W&D, just got to give it another coat of resin then four'ish coats of primer/filler, W&D/Tee-Cut and it should be pretty much there.

SWSCC Christmas din dins... And very pleasant it was too, lots of the chaps turned up - even an honorary club member attended, (he's a Caterham owner, poor lamb :-D )... And he cycled four hours to make the do... dedication or what... Well actually "insanity or what", but I was entering into the Christmas spirit - also, is it me or does "own a Caterham and push bike miles and miles instead of using the car" make you grin rather a lot as well? Oh, hang on, I think he knows where I live... I take it all back :-)

Got all the gaskets/washers etc... Really doesn't look a lot for £90!

Adam R. also braved the rather suspect weather, (as did Steve and Jane.. Jane what were you thinking!!!), to show off his very nice newly SVA'd/registered jet black and saucy Westy. A consummate job, well done that man.

Phoned Andy of AB Performance... Well you do after five days and the box hasn't turned up, (plus Dad AND Mum™ were going batty waiting for the damn thing)... Turned out the carrier had carefully, and with great precision, removed the flippin delivery address... You really can't make this stuff up can you :-) So Andy is resending it, ho hum.

Had a blinder of an idea... I was a tad concerned about how I was going to 'break' the engine cover panel so you could get to all the bits under it - brake fluid, clutch adjuster etc. Also the thought of fairing off yet another flippin huge plug was not one that cheered me up much :-) So, the plan is to just fair off the tube/plateau (+15mm) parts and take the mould from that, this means all the fiddly bits that needed to be cut out now are discrete panels, (and so easier to manage), and creating them is pretty easy by just using Conti-board as the 'mould' as they are just flat panels... as I said, blinder!

Just got the relatively easy job of fairing/spraying the tube/plateau are of the plug, score a parting line and wax the thing up... Five maybe six hours work..., see I told you it was much faster :-)

Finally finished waxing the side pod plug... Wax, let it haze (10 minutes all told), rub dry and leave for fifteen minutes then polish up, (25 minutes for this)... Repeat ten times... Well, that's six hours I won't see again. The result is rather swish though, all liquid glossiness and gleam. Then you have to go and ruin it by painting two thick and gloopy coats of flowcoat, (same as gelcoat except it isn't 'tacky' when it goes of), and covering the lot with three layers of 380gsm CSM. Just got to wait a couple of hours for it to set off to see if all my hard work has paid off, or do I have to start again. Ooooh the tension! Will it, won't it ?

Made the mould support frame... Amazing how long this type of thing takes: Three hours to design, cut, screw & glue and lay up, should do the job though.

Another big decision to make about the side pods and boot lit vent is: "Vortex generators or Gurney flaps?" Having had a bit of a read up, they both have advantages/disadvantages and they both really do work - pretty well... So much so, that it was very nearly a serious question.

I suspect at 180+ mph in an LMP you'd worry if you'd made the correct choice... at 130'ish flat out in a Westy, (or any other sevenesque kit come to that), you should be more worried about "will the damn thing take off". Hang on, what about that Mercedes car. If a factory team can get it that wrong....It's been said that Sevensies type cars have all the aerodynamics of a brick... All fine and good, except that given enough velocity/air flow you can indeed make bricks fly. So 130mph plus a 'breezy' head wind and you're well and truly in the "Wendy, I can fly!" zone..., I really should tuff up the car shouldn't I :-D

Finally got the gearbox from AB Performance and all looks fine - I'll give everything the once over on Monday and then just got to drop it into the engine and bolt everything back up again. Mind you it'll be the Friday before Christmas before I'll get a chance to do the deed, what with all the lovely mould making that needs to be done. Then we get to play 'musical engines' as the poor old lump looks like it's going to be put in/removed around six times... What with the trans tunnel blanking plate and the engine cover.

Spent the day W&D'ing the side pod mould, boot vent and engine cover plugs - I'm soaked and frozen, shed loads of fun.

And again and, even Tee-cutted the damn thing, this really is fun..., was it my bright idea to do it the flippin winter? Don't half shine though... So just got to wax it up and take a couple of thin GRP trial items off of it :-)

When giving the mould a final Tee-Cut I noticed that the base support was no longer attached, this was causing the mould's main flat plane to arch inwards - not good. So, unscrewed the long base board from the three cross supports and malleted it out. Then cut in back to 100mm wide, heavily scored the mating face and mixed up some resin/talc jollop. Bonded this long stringer to the GRP mould then used CSM to glass it - belt and braces. Then screwed this new long stringer to the three cross supports and hey presto... three hours work and I'm back where I was yesterday! :-)))

Three coats of wax on, so seven more to go and we can take the first items off the mould. Going to use clear gelcoat and glass woven cloth to simulate the epoxy/carbon 2x2 twill... On a brighter note, Dad™ and m'self are going to start putting the engine back together tomorrow.

Cleaned up the crankcase mating faces, (very very carefully), the 'new' gear box and the clutch baskets, then installed the selector drum, drum cam pawl and the gear selector rod. I hate torquing up bolts in ali... I really really hate it, you're just waiting for the bolt to go soft and so ruin a perfectly good day, luckily I had a very good day!

Sounds good that, don't it... Line and a half to describe three hours work :-) Next job is to put the gear box back and rejoin the crankcase.

Final coats of wax on the side pod mould, so it's ready to take some pieces off it - tomorrow.

Masked up the centre 1000mm with 60mm on the verticals and painted up one coat of black gel. An hour later it was dry, so layed up two sheets of CSM with around 500ml of PE... two and a bit hours later it popped off the mould like a good'un, all glossy and slick. Cleaned the mould with some white spirits/acetone and re-waxed it ready for the next one. It all looks rather good at the moment, there are some very small flaws in the mould which I'll remove for the carbon jobbies but I am very pleased with the results.

I'll cut the GRP pods to shape/size and use them for working out the mounting hardware but I don't think I'll attach these ones to the car... Also put the current item back in the mould and will run the heater for a couple of hours just to 'make sure'.

The air temperature in the mould reaches 68°C using our custom/hi-tech temperature controlled... erm, fan heater. Nevertheless, not bad, not bad at all and it really does make a difference to the epoxy resin items, (but not so much to the PE jobbies, but hey, it can't hurt).

The next one was just as simple to do and turned out just as good! Two for two - unheard of :-) Re-waxed the mould ready for the next item, which will probably be the carbon pods.

Nope... Next time:

Designed up the Gurney flap mould... Just got to tidy up the original plug, make/fix the 'upright' sections and pull the new mould off. Been there, done that... Just got to:

1. Re-enforce the plug
2. Cut it to shape
3. Bond on the end plates
4. Fillet the joint between the plug and the end plates

and finally...

5. Take a mould off it.

Gosh, that was a busy afternoon! Finished up the plug, (the fillet taking ages to get acceptable), took a risk with three coats of wax and layed it up with three layers of CSM. Couple of hours later I took the end plates off and the dang thing popped of the plug like a good'un :-) Just got to smooth out the bumps and ridges that the Plasticine leaves behind and we are in business!

While the Gurney flap mould was curing I cut the first full length side pod to size and shape... I know, I know, came as a bit of a shock to me too, only taken two years to do. As a bonus, the wheel does indeed clear the pod on full lock, however I need to modify the front where the brake line is to stop it fouling - not a big issue though. Got to cut the near side one then sort out the mounting hardware and I can start on the carbon items.

Cut the N/S pod and duct taped them to the car... not bad at all, I may spray the leading edge of the tub black - or indeed, cut it off - we'll see.

Decided to make the Gurney flaps out of GRP... The fillet radius is very small and I feel that black gelcoat will give a better stress free finish.

So, a final word or two:

Happy New Year!

542 Hours modification/maintenance time  -  (558)1110 Hours total work time  -  197 Hours design time  -  (95)292 Hours total Design time

:: 1402 Total Hours ::

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© Copyright 2000 - 2007 - J.B.Cobb

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