July 14, 2016

Some additional photos from Imola.

Look at that body-roll! Needs to be addressed.

After finally completing (sort of) the Great Danton I was finally able to attend a round of the Time Attack Italian Championship, my first one this year and round 3 of the championship. This was always going to be a shakedown event to actually make sure the car runs ok and to ensure that all the new components are fitted and working correctly.

The day before the event I had quite a few things to sort out, most importantly a large water leak from the left side of the engine which ended up being one of the water heater coolant lines. I also had to drive the car down from Bergamo all the way to Imola so I was quite careful as it was all unknown, and I stopped a couple of times during the 3 hour trip to check fluids and so on.

This first image sums up my day quite nicely; a lot of time waiting for a session after fixing the car. I had some sort of problem during every session which meant that my actual running time on track was very limited. I would usually go out for about 2-3 laps and then find out I needed to come back in to fix it, by which point it was too late to reenter the session.

The first session I went out for about 5 laps and came back in thinking everything was ok but I had lost a nut from the power-steering pump and the belt was slipping.
In the second session all the water that was available in the sky decided to fall and the session was quickly red flagged. We were able to redo the session after it cleared but I quickly found out that I had lost a bolt on the exhaust and it was dragging.
On the third and final session before the Superlap I decided to actually push the car a bit now as I hadn’t had any chance to actually test the limits of the car and get to know the track a bit better. But at the end of the main straight on my first full power pass the splitter simply couldn’t hold on :D. At around 230km/h it ripped through the bumper and hit the ground. Luckily it had only a few grazes and was able to secure it again to the bumper with an improved mounting strategy but this wasn’t to be enough.

During the superlap on the first lap it once again came loose and started chattering. So I had to take it very cautiously around the lap and then on the second lap my car decided to have a fuelling issue, and that was the end of the day. My pace during the day wasn’t too far off the pack but at not point during the weekend was I pushing the car (posted a similar time to last year); hopefully I can get these issues sorted and hit the track again to actually see the improvements over last year.

Overall I’m actually very pleased with the day because all the issues were fairly minor and can be worked upon and the engine really went without a hitch. An engine I built completely from the ground up actually went pretty well, so it has been a huge learning experience.

Twin external wastegate F20C. Look at the size of the turbo in comparison to the engine.

GD V2 – Part 23

May 18, 2016

It’s almost over, just a couple of things to finish up. Finally took the car out for a drive today after 6 months of working on it, and it was great to be back in this hard, uncomfortable and ridiculously loud car. The exhaust note has changed drastically from before; I’m not sure if it’s the cams or the tubular manifold or a bit of both but it’s high pitch and raspy, oh and so much louder. It’s almost embarrassingly loud when above 3000 rpm.

The splitter is on, but needs some additional mounting and refinement. I’ve already scraped it, and I haven’t got my scrape plates on it yet.

GD V2 – Part 18

April 23, 2016

A bit overdue due to lack of time and I’ll keep it brief. Suspension system went back in after I remade some new brake lines; was then able to put the engine and transmission back in and begin remounting everything.

Rolled it out for the first time in about 5 months! You can also see my ‘new’ old Lexus GS300 as the BMW (feeling sorry for itself in the back) broke. Will fix that once the Great Danton is finished.

Plumbed the new oil system in with the remote filter mount and hooked up the oil cooler. Will be running a oil temp sensor in the filter block.

Looking so much better now!

GD V2 – Part 13

March 12, 2016

A few important parts have arrived which means I could continue with the rebuild. I cleaned up the crank and replaced the chain sprocket with a new one. There was quite a bit of wear on the old one as can be seem in the photo; the tooth thickness is noticeably smaller than on the new one.

I then reassembled the crank into the block with new ACL Race main bearings and Lucas Oil Assembly Lube, and then torqued everything up.

I’m still waiting for the oversized pistons to arrive so I decided to carry on with what I could.

New chain, tensioner and guide were installed and set, then replaced the cover with the oil pump with a new crank seal. I checked and cleaned the oil pump and it was in great condition so didn’t change anything there.

I decided to install the water pump as well just so I could see the new light weight Aluminium pulleys.

GD V2 – Part 10

February 9, 2016

The engine components are now at the specialist to get reworked and they are already making progress. Chain cover cleaned and they are now working on the block. The cylinders are going to be over bored after they were found to be just outside the tolerance for roundness, while the wear was within limit. So they are being bored to 86.5mm and I will run oversize pistons.

After the head was inspected they were able to tell why one cylinder was down on compression; apparently one of the valve seals was worn and leaking, so after they clean the head they will sort the valve seals out too, as I’ve given them all the valvetrain.

As soon as I find time to measure the crank I will finally be order all the internal components and begin the rebuild process.

In the meantime additional progress was made on preparing the engine bay for some repair work. Front braking system and shocks are out and I’ve cleaned up the removed EVAP system piping. Its now all been shortened and loops around at the firewall.