The 2.0 Caged Lunar Grey Mk1 Clio Track/Hillclimb Project

[Zmaster2k]

Hi all! new here! (it appears i put my project in the "french bred" section completly missing readers cars.

Heres My Project so far!

Its a Mk1 Clio 16v With a lightly fettled 2.0 F7RA700 Williams engine producing circa 180bhp dependant on dyno...







Here is a brief spec of the car as it stands now.
Hybrid Spec

Engine
F7R 700 2.0-litre 16-valve
Kent RN2002 260 cams
Timed in By the ClioLord
Mapped by Voodoo Tuning
Omex 600 V0.70D
Piper Vernier pulleys
Mocal 13 row Oil Cooler
Mocal Thermostatic sandwich plate
K-Tec Racing Low Temperature Thermostat
K-Tec Racing Low Temperature Fan Switch
Custom Oil lines from a tractor
Full set of Orange Samco Hoses
Samco Vacuum Hosing in Orange
Re wrapped loom in “orange/peach”
Scuttle Group A Induction with Carbon intake
Williams Manifold
Mongoose Exhaust
Straight-through de-cat
Braided fuel lines
Group A 4th gearbox/subframe mount
F0xy 5th Subframe Mount
Rotated Standard new Dogbone mount
Highly Polished “Rocker” cover
Highly Polished Inlet Manifold
Highly Polished Fuel Rail
Highly polished Lifting eye
Powder coated Top Mount in Antique Silver
Powder coated Cam cover in Antique Silver
Powder coated Vacuum Lines in Antique Silver
Powder coated Slam Panel in Antique Silver
Powder coated Battery Tray in Antique Silver
Powder coated Gear box mount and strap in Antique Silver
Powder coated Alternator brackets in Antique Silver

Transmission
Jc5 014 rebuilt williams gearbox
Saches Clutch
New Genuine Renault Clutch cable
K-Tec Racing Short Shifter
Bolt In Diff Conversion

Brakes
Wilwood Dynalite 120-6805 calipers
Poly E brake pads
Custom Designed, Alloy Brackets
S/S braided Hoses (2″ longer then std) x2 with the correct fittings
High tensile bolts
259mm Red Dot grooved discs

Suspension
brand New Williams Shocks
Unknown springs -55mm
Rear Torsion bar adjusted 2 clicks and Bias valve adjusted
Williams wide-track conversion
Powerflex Poly Bushes all round
Manual Steering
Custom Cages international 8 point cage

Wheels & Tyres
Williams Speedline 7×15-inch wheels (road)
Painted 727 red
195/50/15 Yokohama Parada Spec 2

Body
Renault D60 Lunar Grey
Fibreglass Bonnet
Smoothed Bonnet
Locking Aero catches
Smoothed tailgate
Fog lights removed
Colour-coded and smoothed bump-strips
Rear bumper Nana’d

Interior
Stripped entirely
Race Technology Dash 2 Digidash

Performance
181.1bhp @ 6600rpm @ fly

Performance (before 2.0 f7r fitment)
117.6bhp @ 6800rpm @ fly

Full blog of the build is here http://www.mattscar.co.uk/ (yeh i know but its only cost me a tenner and i can upload the updates direct from the phone!)

Where im now struggling is with the interior, the custom cages cage means the stock dash no longer fits

I already have a electronic race technology dash2 for instrumentation but would really like a dash can anybody suggest sombody that makes fiberglass or carbon dashboards?

Today we fitted my lasercut sunroof blank!

Big thanks to Steve and Ryan @ http://www.pmapowdercoating.co.uk/ they previously used my car as a dummy for shot blasting.. all the engine bay has been done by those lads! Great turn around.

Fitted my black which steve powdercoated for me and powdercoated some sealed rivits for me but unfortunatly i had 2 missing... gutted its always the way isnt it!

Also set about fitting my seats aswell! Another job by PMA was to adapt my seat runners to fit the Phase1 adaptor plates another job they have aced! Thanks Lads!











So fitted passenger seat today



And set about marking up a newer mk2 Clio dash to try make that fit







Hopefully the vents will pop back in after but I may just fibreglass the lot lol

So got busy with grinder!We have a dash! Well a dash top! Out a Mk2 Ph2 But that’s all I need lol! Took a bit too much out but meh I’ll get another and use this as a template!













Got to keep heater vents too! A bonus! Will pipe them up to a lightweight T7 design heater.



Whoop quite happy dossnt look like it needs much more work to fit right!

[quote=Zmaster2k]So started the day early trial fitting new centre panel.
Fits OK needs more adjustment before I remake it out of fiberglass.





Even though the dash isn’t fitted yet the dash fit is solid with new panel in!

Then we set about fitting rear aerocatches to the bonnet a job I’ve put off for ages…so towed the car to father in laws for electrics Lil
Fitted catches only to find that it then sat waaaaay too high on the car.
So we had to fabricate and rivit on some basic “L” brackets in order for the pins to sit a lot lower as the thread pitch stops below the top of the wing



This solved the problem! Yay! Also has made it a lot stronger!











Then set about mounting the new washer bottle in the cabin.



Yes that’s right, finally I’ve removed the distrubutor cap and ht-leads.

The Omex can take care of this for me so now I need a newer “wasted spark” coil pack. The RS Clio uses one but requires Ht-leads to each spark plug. After some reading up found out the f7r in the megane uses a wasted spark setup. However unlike the RS Clio its coil pack sits directly on top of the cam cover and connects direct to the spark plugs. Meaning no ht-leads to worry about. This does however mean I must run the megane cam cover…this in my opinion looks better so wassn’t bothered.

Found both parts for sale on club within the hour…£65 later they were on their way.



New cam cover



Wasted spark coil pack.

So got busy with my spanners once again.



Removed the cam cover and old 1910 (year it was introduced to a production car by Cadilac) ignition system & cam cover.





Modified the coil pack with some old panel fasteners….



Found some washers in black the right size….



Old Setup



New setup!



Centre console Mould making and prototype

So basically I wassnt happy with not having a center panel in the car. So mocked up some ply panels to fit in its place. (this made the dash SOLID)



From this I turned it into a model to make a mould from



Covered this item in release wax and liquid wax…a release agent.

Then covered in gel coat.



This was left to harden over night
Then covered in resin and talc filler and then fiberglass matting



Left to harden overnight then another layer of the same



Then left to harden overnight again 3 layers later its about this thick.



Then “simply” pop the mould off the model…



Screwdriver and hammer required! Leaves you with this.



Run it through the band saw and trim off the rough edges….leaving excess… And then sand with 320grit and 400grit



Then add back plate and add a few layers of wax and liwuid wax (i did 4 but the more the bettrr) layer of gel coat and leave to go tacky… The layer in some material

Happened to have some carbon laying about… not enough but will do on the prototype



Layered it in as I’ve never used it in mould making… So had enough for first layer… Then used low weight fiberglass as replacement (use this normally)



I’ve done 3 layers of fiberglass on top…

Left for a day between layers.

Then simply demould….again…screwdriver required…more wax next time

Removed back plate
And trimmed fiberglass overlap with very sharp chisel



Then popped out of mould



You can see the carbon weave. But I’ve been inconsistent with my gel coat so I have some milkyness… and a few air bubbles...Will be more vigilant with mk2…



But fairly chuffed if this was flocked or painted you would never know.



an All carbon Mk2 coming soon!....

So had a few mins so thought it was a good idea to combine all my interior bits together for trial fitment.

Pics




Then thought I’d see what they were like in the car.

Passenger side



First gear selected in next set of photos for clearance checking... didnt want to be shifting into 3rd to find my hand hit the panel! (and i forgot to finish my other centre panel which is smoothed over...)




Check out the mirror finish of that panel! lol


Got the Race-Technology Dash2 fitted to the car to see if my modified panel fitted and didnt foul



Overall shot



V chuffed fits as it should and I now feel like I have a more complete interior! Yay!

Just got to make an all carbon mk2 now!

Waved goodbye to the stock inlet and plenum… the polished days are over!

Time for some performance









Looks so empty and bare! Individual throttle bodies will soon cure that! Yay

[Zmaster2k]

So today we hired a trailer and made the 320mile trip to Beaniesport.



Looking mean



Loaded and strapped down!



On route…….

Then 3 hours later….

Boom we arrive at Beaniesport greeted by moo and beanie.

These guys are going to be building me a beautiful looking and functioning bare bones loom.

Im very excited. Lol



Two track monster’s together



I really like it with out the plate lol







Pimping Beaniesport





Yes yes one in paint….one in primer lol

Primer one is clearly better lol

A huge sigh of relief when beanie said the fitment of his bonnet was as much of a bd to fit as mine was.

However

Where mine is hoping to achieve aroind 190bhp….Beaniesport’s is a crazy 220bhp.
As a passenger in.this car in tje the past when it made 170bhp it was very very fast indeed. … fibreglass doors, boot and carbon fibre roof and bonnet.

Means she weighs 760kgs….with 220bhp….. yes….thats 290bhp Per tonne! Crazy crazy power to weight.

It now has forged internals and a gripper diff….wow this thing go’s round corners like a fat man mopping up thw last of bacon juice from a bacon butty with his bread! VERY QUICK.

Ive given moo creative control. So lo should look pretty sweet lol

[150bhp]

Love it, some quality workmanship.

[AMH82]

Wow!! Amazing project, some really nice work (and £££'s) going into it!!

Loving the lunar grey as well. Would love to see/hear a vidof this once running.

[Ordinary_Chap]

Fantastic project!

All thats missing is some in-car footage

[anonymous-user]

There's plenty more power in the F7r's, but you have to get creative with the valve size and port profiles! The port design in particular is nowhere near as good (for flow) as the equivalent Peugeot engine (XU10J4RS) Unfortunately then the small bore / long stroke architecture becomes limiting at high rpm.

Looks like a fun car though, and should go well as it's fairly light ;-)

[Zmaster2k]

Thanks all,

Im going to be interested to see what a stock f7r makes with bodies and cams.

anything over 185 i'll be happy with, should see 160lbs of torque. which should be a giggle.

[AGK]

Love the colour.

[anonymous-user]

On a std exhaust system, i reckon you'll see a genuine 175bhp with cams/ITB's. My car runs an F7r, it's a little bit heavier than yours (960kg) but has a few more ponies to push it along ;-)

[Alx323]

I miss my Clio!! Had sooo many plans This looks amazing OP, and very very quick too

[Lee540]

Great project!!

but..

Zmaster2k said:

So today we hired a trailer and made the 320mile trip to Beaniesport.

Then 3 hours later….

Boom we arrive at Beaniesport greeted by moo and beanie.

Thats going some! Pulling a trailer..

[zedx19]

Awesome project, have a soft spot for Clio's, owned 2 myself and many of my friends had a few special Clios. One had a mk1 Clio 16v with a VAG 1.8T lump, which was nippy. Another had a Yellow Clio fully stripped with racing fuel tank, running around 180bhp, which he sold for a white Clio on throttle bodies. Great cars!

[Zmaster2k]

lol yeh it was a 320mile round trip lol
zedx19
The cars you mention, the yellow one with the Racing fuel tank, it known as the "Nana" for obvious reasons.
it has exactly the same engine spec as mine... rumors were it was 200bhp.... personally think thats severe bks lol.....i've seen similar spec engines make 200bhp WITH bodies. Think 185 is the absolute top for standard inlet manifold.

The Vag powered 1.8t, was built by Flan, then sold on two a few other owners. The shell degraded and has now been transplanted into another. Now running 280bhp and 280lbs ft...its very very quick indeed. One of the most powerful mk1's in the country...

that is, until flan built another with a williams shell and an AGU egnine and IHI turbo... made 305bhp.

The colour is deffo a love it or hate it affair, obviously i love it.


Max, what car your running, more ponies you say, your either high comp forged or boosted. OR BOOSTED AND FORGED :S

[anonymous-user]

Zmaster2k said:

Max, what car your running, more ponies you say, your either high comp forged or boosted. OR BOOSTED AND FORGED :S

My F7r is in a Seat Ibiza (long story) and currently knocking out just over 480kW @ 8200rpm. It is indeed boosted..... ;-)

[Zmaster2k]

lol Max i know your car!

very impressive indeed!... think your a bit mad! Ha ha!

I can't wait to get her running again, its been too long.

Then i can concentrate on forging a spare bottom end ;-)

[zedx19]

Zmaster2k said:

lol yeh it was a 320mile round trip lol
zedx19
The cars you mention, the yellow one with the Racing fuel tank, it known as the "Nana" for obvious reasons.
it has exactly the same engine spec as mine... rumors were it was 200bhp.... personally think thats severe bks lol.....i've seen similar spec engines make 200bhp WITH bodies. Think 185 is the absolute top for standard inlet manifold.

The Vag powered 1.8t, was built by Flan, then sold on two a few other owners. The shell degraded and has now been transplanted into another. Now running 280bhp and 280lbs ft...its very very quick indeed. One of the most powerful mk1's in the country...

that is, until flan built another with a williams shell and an AGU egnine and IHI turbo... made 305bhp.

The colour is deffo a love it or hate it affair, obviously i love it.


Max, what car your running, more ponies you say, your either high comp forged or boosted. OR BOOSTED AND FORGED :S

Aye, I knew the VAG powered mk1 when Flan had it, we drove a few hours in it from a pub to some birthday party on a farm lol surprising thing was, it was so docile when pottering around, then seriously quick when you needed it to be, even put the power down well without too much drama.

Is the Nana still alive then?

[andy_ran]

Hey Matt.

Car is looking awesome. When do I get to see her again

[Beedub]

utterly awesome!!

[Type 20]

There is a couple of usernames i have seen before.

Matt car looks smart as ever.

Andy, hey up bud.

Ed (kad 16v)

[Zmaster2k]

The nana is as far as im aware...still alive.
However its most recent owner bought it as a bare rolling shell...and its being rebuilt slowly. But im sure it will live on

Really looking forward to seeing mine running ning again...