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Malcolm's Race Car Build


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1430 replies to this topic

#121 Ollie_247

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Posted 28 May 2010 - 11:21 AM

he got the only 9j's in bronze :lol:

I still haven't decide on what colour im going to have one mine yet.

Malcolm you have my number and Nick's call any time you want.

:thumb-up:
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For 6UL wheels and Federal Tyres,

Mk2.5 Track and fast road car. Fully working weapon.

#122 Joe The Fish

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Posted 28 May 2010 - 12:25 PM

Epic thread and truely inspiring.. sure i'm not the only one wondering how many of your ideas I can steal!
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#123 Malcolm

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Posted 14 June 2010 - 09:35 AM

A brief update - progress has been happening although not very fast!

I have been prepping the car for paint, not a favourite pasttime for me but I had a stroke of luck! At a boys curry night recently I was talking to Hugo who is the Comp Sec to the CSCC and he gave me a contact for someone within CSCC ie a fellow racer who did good work at fair prices for doing a race car paint job. Music to my ears. All I had to do was get the car ready and to Nottingham! So that is what has happened.

I did some trial fit of body panels to see how things were going to line up. Nothing tricky thank goodness. The bumper mounting will be a bit creative I suspect but a lot lighter than the standard mounts.

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In this picture you can see a yellow door lying on the floor. That is my final choice of colour!

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I have stiffened up the boot and bonnet by riveting some ali U section to the undersides. I managed to lose a combined weight of 5.5 kgs from the bonnet and boot but only had to add back 0.5 kg of this U section to get it stiff enough for race purposes. A fair trade in my eyes. I have cut holes in the panels to give me "handles" to lift them off as with bonnet pins and no hinges you need something.

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I have also carried out a trial fit of the fuel filler cap. This wasn't as easy as it was supposed to be as there was some distortion in the rear wing panel here from when kids had been jumping on the car prior to my ownership! But it is recoverable. With the design of the new fuel tank progressing in my head, I will be able to have a shorter fuel filler pipe run from filler cap to tank than if I had left the system set up on the passenger side of the car. A small weight saving perhaps?

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I have put the OEM runnes back onto my race seat which raises it a little bit but still leaves my eyes level with the bonnet! I don't think I have shown a picture of the seat by itself so here is one for you.

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A disappointment in that having re read the MSA Blue Book I now see that the two towing eyes I have bought through MX5Nutz are not MSA compliant. The requirement is that the holes be a minimum of 60mm diameter and these are too small. Annoying. I will actually make something up now that will have a hole size of 80mm as in mainland Europe that is the requirement by some FIA confederations. Most likely now going to go for strap towing eyes. So the two towing eyes in this picture are for sale at what I paid form them ie £34 delivered. One set only, roll up, roll up!

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So right now my car is up in the Nottingham area to be painted. The timescale target is to be finished by the end of the month, so this final picture is the pile of parts and panels left with Stuart to be painted. It is nice to be having the car painted by a fellow racer as he appreciates how heavy paint can be and also knows what is important, and what is not important, in doing the paint job so keeping costs down to a bare minimum. The actual colour is Mazda Sunburst Yellow paint code HZ.

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Next time we all see the car it should be a very bright yellow! Fabulous! The delays to the engine delivery have been resolved with the exhaust showing up so that will be with me soon. All starting to come together quite nicely now. Shame I need to keep the house DIY on the go but hey ho that is how it goes!
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#124 Malcolm

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Posted 14 June 2010 - 10:51 AM

Towing eyes provisionally sold! Oh the power of the internet!
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#125 Steve-A

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Posted 14 June 2010 - 11:04 AM

Looking good :)

Not sure I'd wanna spend too much time in that seat though, looks like there's not much padding:P

Should look great in yellow.
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#126 Malcolm

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Posted 14 June 2010 - 11:27 AM

Seat has zero padding but is very comfortable as is. Everyone who has sat in the seat also says it is comfortable. :thumb-up:
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#127 Skuzzle

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Posted 14 June 2010 - 11:30 AM

Towing eyes provisionally sold! Oh the power of the internet!


Thankyou sir :)

This project is looking awesome too... but i cant help but get lumpy over the gt40
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#128 Steve-A

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Posted 14 June 2010 - 11:50 AM

Seat has zero padding but is very comfortable as is. Everyone who has sat in the seat also says it is comfortable. :thumb-up:


Ah cool :)


If its comfortable enough then it looks like an awesome seat! seriously light and supportive.
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#129 steve b

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Posted 14 June 2010 - 08:41 PM

All looking great, it will look like a brand new car (something mine won't)!

I fitted my V8 Roadsters front subframe today, I really think it'd be a worthy addition to your race car. Access to the engine is massively improved and a good weight saving as well as more rigid.

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#130 Malcolm

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Posted 15 June 2010 - 08:29 AM

That sub frame looks great, would love to have one on my car. Did you weigh it prior to fitting? My sub frame, as a bare item, weighs 14.35 kgs. It would be interesting to see the difference. I think they claim it to be 10 lbs lighter which is approx 4.5 kgs.
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#131 teamthink

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Posted 17 June 2010 - 07:35 AM

That sub frame looks great, would love to have one on my car. Did you weigh it prior to fitting? My sub frame, as a bare item, weighs 14.35 kgs. It would be interesting to see the difference. I think they claim it to be 10 lbs lighter which is approx 4.5 kgs.



Hi Malcolm, I've been meaning to phone you to tell you about a body shop in fleet, bit late now though - Doh! Let me know when you need the plumbing doing and i can feel a trip over to camberley coming on.
It actually looks a similar colour to my racer which i think i have worked out is Kia Safety Yellow, which is kind of strange seeing as evryone appears to hit me!
Matt
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#132 Ollie_247

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Posted 17 June 2010 - 09:43 AM

its moving on alot then Malcolm well done :worship:
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For 6UL wheels and Federal Tyres,

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#133 Malcolm

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Posted 17 June 2010 - 10:39 AM

Hi Matt, you missed a good curry evening the other day, maybe next time! I know of a paint shop on Ancells farm in Fleet where the guys running it did Britcar in a Honda? Last I saw them they had the Beechdean Aston N24 in for a respray. Nice car that, quite fancy one but unlikely to happen for the obvious reason. Did think of getting them to quote but didn't get round to it. If yellow is a magnet colour, maybe I can get them to quote on the next respray!!!!!!! Will be needing your services again for sure, so always welcome to come by. We had Hugo from CSCC in the car recently and he is 6 ft 4 or 5 inches tall. Plenty of headroom left so maybe you will fit under the roof too. Drop the floor it makes a lot of space!

With my car away at present it was time to tidy and reorganise the garage a bit so that on the cars return I can jump back onto it and make pernament progress. Up until now, everything put on the car has always had to be removed again. I look forward to the time when I can bolt something on and leave it on the car! So having cleared 4 years worth of Motorsport mags from the work bench, yesterday I began the depower of my steering rack. Actually a very simple job especially if you follow the instructions on the FM website. My rack is a later one than shown in their pictures but the principle is the same and so job now done. I am being held up on reassembly by needing to order in some new lock washers where the track rod ball joints join the rack and also after a tip from Jon, I am getting the valve joint in the pinion shaft welded up. Another very simple job and one I didn't know of as a tuning tweak prior to Jon mentioning it, so thanks to Jon for the steer (excuse the pun!). But as my welding is crap and this is a safety critical weld, I wll be getting it done professionally. I will put up the pictures when the job is completed.

I have also piled up all the bits that require painting before they are fitted onto the car such as the sub frames, pedal box, steering column and ARB mounts etc so that they will be ready to go when the car is back home. I like using the Hammerite Smooth spray paint from a tin for those kind of spray jobs. One tip I use is if you leave the rattle can standing in hot water for five minutes prior to using it, it really gives a much better bond and paint finish than if you just spray it on cold. Fortunately I can cope with rattle can painting so have ordered up 10 cans of satin black from Smith and Allen ( http://www.smithandallan.com/ ) who gave a very good price delivered, about 25% less than all my local shops.

One job that needs doing soon is the conversion of the gearbox from OEM 5 speed to the Quaife close ratio gear set. Does anyone have a link or other info for a gearbox rebuild? A how to step by step guide (for OEM boxes as I doubt one exists for Qauife parts) would be good.
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#134 Nico

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Posted 17 June 2010 - 10:46 AM

Great build. Really enjoy reading your thread.

Why not using a OEM 6 speed box for close ratios ?
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#135 Malcolm

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Posted 17 June 2010 - 11:30 AM

Hi Nico

Because the gear ratios are all wrong for racing. I am intending on using the 4.3 final drive ratio and with my RPM red line, I would only get 35 ish mph in 1st with a 6 sp box but with the Quaife I get over 50mph yet still keeping the top speed down at a useable realistic speed for the UK circuits I expect to run on. The start of a race is critical and I don't want to spend the first half of a race recovering the places I lost on the start from having to change gear at just the wrong moment! FM have a gear ratio calculator web page which helps you decide what the different gearbox ratios give you and is a very useful tool. The link is

http://www.flyinmiat...ech/gearing.php

Of course I had Quaife put together a 3rd close ratio gear set that isn't on this FM page that gives me what I think are even better ratios..... :whistle:
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#136 Schism

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Posted 17 June 2010 - 12:10 PM

Nice yellow door :rolleyes:

Fantastic thread matey.

Very very impressed with what can be done.

I miss my little yellow car so cant wait to see yours :)
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#137 Nico

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Posted 17 June 2010 - 12:13 PM

Of course I had Quaife put together a 3rd close ratio gear set that isn't on this FM page that gives me what I think are even better ratios..... :whistle:

:lol:

Thanks for the explanation and the link. It makes sense now. What you want is a long 1st, a "not too far" 2nd and very close 3rd, 4th and 5th.
4th, 5th and 6th of the 6 speed box are not too far off 3rd, 4th, 5th of the Quaife 5 speed, but then 1st gear becomes useless.
I have a 4.625 diff in my car and still wanted shorter gearing, so I bought a 6 speed box to go with it (not fitted yet). But I am doing only trackdays so I never thought about the standing start problem :thumb-up:
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#138 indykid

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Posted 17 June 2010 - 12:54 PM

what's the 4.6 diff out of nico? that's........low!

nice to see it coming together malcolm. there's someone on locostbuilders (clairetoo iirc) making tubular subframes for the v6 engine but i assume it's only the engine mounts that differ.

the price should certainly circumvent the branding and it's uk so no import tax.
tom
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#139 fenix

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Posted 17 June 2010 - 01:03 PM

Hi Malcolm

Following your build closely and a few things you're doing have run parellel to my ideas although your weightloss is slightly more extreme than mine (what weight are you hoping for by the way?). IE Handholds for pinned bonnet and boot and using tow strap rather than metal tow eye (was inspired by the ginetta race cars at a BTCC event).

Are you planning on putting anything around the hand holes in bonnet and boot to stop sliced fingers?

I was also looking at using bare shell race seats so glad to hear that they can actually be comfortable. :D
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#140 Malcolm

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Posted 17 June 2010 - 06:45 PM

what's the 4.6 diff out of nico? that's........low!

nice to see it coming together malcolm. there's someone on locostbuilders (clairetoo iirc) making tubular subframes for the v6 engine but i assume it's only the engine mounts that differ.

the price should certainly circumvent the branding and it's uk so no import tax.
tom



Hi Tom

Interesting to hear there might be a UK tubular sub frame. Any chance you have a link to look at?
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