BMW 120d Race Car
Discussion
I been lurking on this part of the forum for some time and I think it is time to contribute. As a hobby, I help run 3 touring cars in the UAE Touring Car Championship (one of our cars finished 2nd in class last season). In addition to the competing in the championship, 3 Dubai based racers got together and bought a BMW 120d off Rick Kelly (ex BTCC driver) to compete in the 2010 Britcar 24hr race. After a few minor issues (always going to happen in endurance racing isn’t it) we finished 34th overall, for which the team was really happy.
Fast forward to January 2011 and the team enters the Dubai 24hr race. After some appalling team driving by a class rival (who then got disqualified for their actions), we finished second in class.
Having firmly got the bug for endurance racing the team started to discuss where to race next. Creventic’s (who organise the Hungry 12hr and Dubai 24hr) have taken over the running of the Barcelona 24hr race. After reviewing the entry fee and tyre deal, a decision was made to enter the event. So Barcelona here we come.
Prior to the BritCar race, various modifications were made to the car to improve its endurance capability (as compared to short touring car races) through the fitment of a race spec limited slip differential (Quaife LSD), bigger AP Racing brake discs and calipers. In order to fit the bigger brake system, 18” OZ wheels were required to be fitted. All of these items where sourced through Dubai based Motor Sport Wheels (MSW) run by local driving ace Jon Simmonds. A dry brake refueling system had to be fitted.
Following the completion of the Dubai 24hr race, the team entered the last 2 national touring car race days to help one of the new drivers gain enough signatories for his international license. Gareth finished the three race with one 3rd and two 2nd place finishes in class. OK so there weren’t many other cars out in class, but you have go to be in it to win it.
As we hadn’t played around with the suspension we have had the car out on a number of track days to test set-up changes. All was going well until a track day in April when the turbo cried enough blew (ok so it had done 135,000 miles including two 24hr races!) So with that it was decide to fit the spare engine and turbo and to strip the original engine to look for signs of damage.
As part of the preparation for the Barcelona event, the team held its 1st formal race meeting to discuss logistics, staffing, equipment & spares and formulated a jobs list and most importantly dates by when each activity had to be completed by. Divide and conquer is definitely the order of the day.
As the team had a couple of months to work on the car, it was decided to try and lose weight through removing all unnecessary bracket, supports and swapping the doors and bonnet for fiberglass items (these saved 90kg alone). Currently we down to 1100kg semi wet (all fluids but no fuel), the minimum weight limit is 1050kg. We are going to struggle to take much more weight out of the car though. The team are investigating potential aerodynamic ideas as it could do with looking a bit more like a race car rather than a shopping car.
So here ends the 1st report of the teams preparation, and we will conclude with a few pictures of the car.
Fast forward to January 2011 and the team enters the Dubai 24hr race. After some appalling team driving by a class rival (who then got disqualified for their actions), we finished second in class.
Having firmly got the bug for endurance racing the team started to discuss where to race next. Creventic’s (who organise the Hungry 12hr and Dubai 24hr) have taken over the running of the Barcelona 24hr race. After reviewing the entry fee and tyre deal, a decision was made to enter the event. So Barcelona here we come.
Prior to the BritCar race, various modifications were made to the car to improve its endurance capability (as compared to short touring car races) through the fitment of a race spec limited slip differential (Quaife LSD), bigger AP Racing brake discs and calipers. In order to fit the bigger brake system, 18” OZ wheels were required to be fitted. All of these items where sourced through Dubai based Motor Sport Wheels (MSW) run by local driving ace Jon Simmonds. A dry brake refueling system had to be fitted.
Following the completion of the Dubai 24hr race, the team entered the last 2 national touring car race days to help one of the new drivers gain enough signatories for his international license. Gareth finished the three race with one 3rd and two 2nd place finishes in class. OK so there weren’t many other cars out in class, but you have go to be in it to win it.
As we hadn’t played around with the suspension we have had the car out on a number of track days to test set-up changes. All was going well until a track day in April when the turbo cried enough blew (ok so it had done 135,000 miles including two 24hr races!) So with that it was decide to fit the spare engine and turbo and to strip the original engine to look for signs of damage.
As part of the preparation for the Barcelona event, the team held its 1st formal race meeting to discuss logistics, staffing, equipment & spares and formulated a jobs list and most importantly dates by when each activity had to be completed by. Divide and conquer is definitely the order of the day.
As the team had a couple of months to work on the car, it was decided to try and lose weight through removing all unnecessary bracket, supports and swapping the doors and bonnet for fiberglass items (these saved 90kg alone). Currently we down to 1100kg semi wet (all fluids but no fuel), the minimum weight limit is 1050kg. We are going to struggle to take much more weight out of the car though. The team are investigating potential aerodynamic ideas as it could do with looking a bit more like a race car rather than a shopping car.
So here ends the 1st report of the teams preparation, and we will conclude with a few pictures of the car.
Before the turbo died, it was putting out 174 bhp and 400 Nm of torque (or at least those are the figures I think).
All we have done since is remove the airbox lid and put nacca style opening on the bonnet to feed more to air filter. The injectors are currently being cleaned as there operating at 10% below the specified pressure.
After that we plan to fit a BMW 330 intercooler, maybe remove the diesel filter and then put it on the dyno.
Noise wise, 84 dba so we call it the whispering assasin.
All we have done since is remove the airbox lid and put nacca style opening on the bonnet to feed more to air filter. The injectors are currently being cleaned as there operating at 10% below the specified pressure.
After that we plan to fit a BMW 330 intercooler, maybe remove the diesel filter and then put it on the dyno.
Noise wise, 84 dba so we call it the whispering assasin.
Edited by IanUAE on Friday 27th May 14:10
) but that is awesome! 
Surely it's everyone's dream to own a 'proper' race car!Since the first report on the car we took it out for a blast on a track day as we had fitted the spare engine and a bigger turbo. We had a bit fun “racing” with a Pinto powered Mark II Escort for about 10 laps until the Escort blew its manifold off the head. However as we were swapping drivers we noticed a pool of fluid building up under the car. It turned out that a seal or an o-ring on the return fuel feed had sprung a leak. It was quickly agreed to put the car back on the trailer rather than risk causing more damage. Well this is why you test the car before a race right!
As we were taking hoses off the car to find the location of the leak, we decided that it would be a good idea to send the injectors off for a sonic clean and full refurbishment as we didn’t know when or if the injectors were last cleaned.
The slim plan diet continued on the car, instead of milk shakes we use a disc cutter (more effective to!). The pile of brackets, supports and general unnecessary pieces is building up, so much so we are down about 1,070kg (only 20kg over the minimum weight). Removing the newly fitted air jacks would save some weight but then our pit-stops would be slower. We are happy to trade a spot of weight for the advantages the air jacks will bring. Fitting a polycarbonate screen would probably save some weight to, but again this has to be tempered with trying not to scratch the screen (racing screen film is not available in Dubai). We might try clear car film anyway.
To say the car is quiet is an understatement (84dba at 1,500 rpm, 1/3rd of the rev range) so we thought we needed a bit more noise from the exhaust. Now I haven’t seen the exhaust myself but I am lead to believe that the car now has a full racing side swept exhaust and is now a bit louder.
After we got the injectors back, fixing the fuel leak and fitting the new exhaust, it was time for the car to visit a dyno for a tune. With a big thanks to Morat at NFS Dubai the car now sports 407 Nm and 178bhp at the wheels.
It just so happened that a track day was being run last Friday so the team were eager (easy tigers) to “test” the car. One of the drivers has Clio 182 Cup Car (factory sequential gearbox, throttle bodies), lets just say the BMW is at least 3-4 seconds a lap quicker. Now we are talking.
The next stage is to try and loose a bit more weight as the drivers are not exactly the slimmest or smallest in the world. Getting down to 1,050kg will help when we are running in race spec. A larger intercooler may help release a few more ponies and fitting a splitter and a rear diffuser (we have a mould for a Seat SuperCopra in the garage) is still be discussed. By the time we finish with the car it might actually look like a race car.
Picture of the exhaust set-up is on its way to me, so I will post it up when I get it.
As we were taking hoses off the car to find the location of the leak, we decided that it would be a good idea to send the injectors off for a sonic clean and full refurbishment as we didn’t know when or if the injectors were last cleaned.
The slim plan diet continued on the car, instead of milk shakes we use a disc cutter (more effective to!). The pile of brackets, supports and general unnecessary pieces is building up, so much so we are down about 1,070kg (only 20kg over the minimum weight). Removing the newly fitted air jacks would save some weight but then our pit-stops would be slower. We are happy to trade a spot of weight for the advantages the air jacks will bring. Fitting a polycarbonate screen would probably save some weight to, but again this has to be tempered with trying not to scratch the screen (racing screen film is not available in Dubai). We might try clear car film anyway.
To say the car is quiet is an understatement (84dba at 1,500 rpm, 1/3rd of the rev range) so we thought we needed a bit more noise from the exhaust. Now I haven’t seen the exhaust myself but I am lead to believe that the car now has a full racing side swept exhaust and is now a bit louder.
After we got the injectors back, fixing the fuel leak and fitting the new exhaust, it was time for the car to visit a dyno for a tune. With a big thanks to Morat at NFS Dubai the car now sports 407 Nm and 178bhp at the wheels.
It just so happened that a track day was being run last Friday so the team were eager (easy tigers) to “test” the car. One of the drivers has Clio 182 Cup Car (factory sequential gearbox, throttle bodies), lets just say the BMW is at least 3-4 seconds a lap quicker. Now we are talking.
The next stage is to try and loose a bit more weight as the drivers are not exactly the slimmest or smallest in the world. Getting down to 1,050kg will help when we are running in race spec. A larger intercooler may help release a few more ponies and fitting a splitter and a rear diffuser (we have a mould for a Seat SuperCopra in the garage) is still be discussed. By the time we finish with the car it might actually look like a race car.
Picture of the exhaust set-up is on its way to me, so I will post it up when I get it.
Good to see!! I'll cross post this onto www.babybmw.net for them to enjoy too 
ETA: http://www.babybmw.net/viewtopic.php?f=11&t=26...
ETA: http://www.babybmw.net/viewtopic.php?f=11&t=26...
Edited by Ranger 6 on Tuesday 7th June 16:51
Exhaust, looks more we have just removed the back box and re-directed the new outlet to the side:
The engine bay:
And a virtual Brucey Bonus if you can name all the cars in this picture:
I have a couple of more pictures but the internet speed in the office is little above snail pace at the moment.....
The engine bay:
And a virtual Brucey Bonus if you can name all the cars in this picture:
I have a couple of more pictures but the internet speed in the office is little above snail pace at the moment.....
IanUAE said:
Exhaust, looks more we have just removed the back box and re-directed the new outlet to the side:
The engine bay:
And a virtual Brucey Bonus if you can name all the cars in this picture:
I have a couple of more pictures but the internet speed in the office is little above snail pace at the moment.....
2 honda civicsThe engine bay:
And a virtual Brucey Bonus if you can name all the cars in this picture:
I have a couple of more pictures but the internet speed in the office is little above snail pace at the moment.....
Land rover (defender?)
Nissan skyline R32
Mitsubishi 3000GT
BMW 3 series E36
Caterham (or similiar)
the one right in the corner next to the caterham has me stumped though....
Awesome thread by the way!! I'll be keeping an eye on this one....
ETA also a clio and an integra. Missed those, doh!!
XJ84 said:
2 honda civics
Land rover (defender?)
Nissan skyline R32
Mitsubishi 3000GT
BMW 3 series E36
Caterham (or similiar)
the one right in the corner next to the caterham has me stumped though....
Awesome thread by the way!! I'll be keeping an eye on this one....
ETA also a clio and an integra. Missed those, doh!!
Is that an Exige?Land rover (defender?)
Nissan skyline R32
Mitsubishi 3000GT
BMW 3 series E36
Caterham (or similiar)
the one right in the corner next to the caterham has me stumped though....
Awesome thread by the way!! I'll be keeping an eye on this one....
ETA also a clio and an integra. Missed those, doh!!
rallyeS2 said:
XJ84 said:
2 honda civics
Land rover (defender?)
Nissan skyline R32
Mitsubishi 3000GT
BMW 3 series E36
Caterham (or similiar)
the one right in the corner next to the caterham has me stumped though....
Awesome thread by the way!! I'll be keeping an eye on this one....
ETA also a clio and an integra. Missed those, doh!!
Is that an Exige?Land rover (defender?)
Nissan skyline R32
Mitsubishi 3000GT
BMW 3 series E36
Caterham (or similiar)
the one right in the corner next to the caterham has me stumped though....
Awesome thread by the way!! I'll be keeping an eye on this one....
ETA also a clio and an integra. Missed those, doh!!
the 3 series is an e46 though!
S3_Graham said:
exige is a good call,
the 3 series is an e46 though!
The left is a clio cup racer.. and its a m3 e46, and looks like and mark 1 exige in the corner.the 3 series is an e46 though!
So
Clio cup racer
e46 m3 and 120d
Some cut down defender
a teg
Honda Civic
mark I exige???
Lotus 7 or a Caterham
3000GT
skyline r32
Edited by joe_90 on Tuesday 14th June 18:21
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