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
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.
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.....
From left to right:
Clio 182 Cup Car
E46 M3 race car
SWB Defender (modified for desert use)
DC2 race car
Civic EP3
Dodge Viper race car (not exige)
Cateram
GT3000
Skyline (~600bhp)
In the workshop the owner is building a Mark 2 Escort race car (2L Duratec, sequential quife gearbox and AP brakes).
The garage has another "shed" that has 2 desert rally Nissan Patrols and a FJ Cruiser Baja spec desert rally car plus a load of Land Rovers.
Clio 182 Cup Car
E46 M3 race car
SWB Defender (modified for desert use)
DC2 race car
Civic EP3
Dodge Viper race car (not exige)
Cateram
GT3000
Skyline (~600bhp)
In the workshop the owner is building a Mark 2 Escort race car (2L Duratec, sequential quife gearbox and AP brakes).
The garage has another "shed" that has 2 desert rally Nissan Patrols and a FJ Cruiser Baja spec desert rally car plus a load of Land Rovers.
Small update time. The was booked for a rolling session on Saturday. The 1st thing the engine tuner did was increase the fueling by 20% (shows how the air / fuel ratio was wrong on the other map!). This increased the power big time between 4-5,000 rpm. For some strange reason during the run the steering lock activated and locked the ECU.
The was then trailered off to the local indy BMW garage for a ecu flash. So now we have to find out why the steering lock activated.
The engine tuner recons he can give us 190 bhp and +400 nm safely (car weighs 1050kg) so it should pull like a train. all being well the car will be out on a track day next Saturday and if all goes well we will commence:
1) Get the gearbox rebuilt
2) Strip and rebuild each corner
3) Borescope and service the engine
4) Fit larger intercooler
5) Sort out all gauges and lighting
6) Flat bottom the floor
The Barcelona 24hr event might be on the horizon.....
The was then trailered off to the local indy BMW garage for a ecu flash. So now we have to find out why the steering lock activated.
The engine tuner recons he can give us 190 bhp and +400 nm safely (car weighs 1050kg) so it should pull like a train. all being well the car will be out on a track day next Saturday and if all goes well we will commence:
1) Get the gearbox rebuilt
2) Strip and rebuild each corner
3) Borescope and service the engine
4) Fit larger intercooler
5) Sort out all gauges and lighting
6) Flat bottom the floor
The Barcelona 24hr event might be on the horizon.....
The team (well Shirt & RaBailey) have been really busy working on the car, to date they have:
Lights are out
Propshaft and diff removed
Gearbox off
Driveshaft out
Updated plans include:
Replacing all torx head bolts
Motorsport rad and intercooler
New bushes for rear suspension
Reoute all rear break lines inside car
Flat floor
I might actually be spending the week at home in Dubai next week (1st time for 10 weeks!!) so I might pop round and do a bit of light spannering.
Lights are out
Propshaft and diff removed
Gearbox off
Driveshaft out
Updated plans include:
Replacing all torx head bolts
Motorsport rad and intercooler
New bushes for rear suspension
Reoute all rear break lines inside car
Flat floor
I might actually be spending the week at home in Dubai next week (1st time for 10 weeks!!) so I might pop round and do a bit of light spannering.
Latest update from the team:
Steering column removed and components required for the power steering cooler identified
Replaced the worn suspension bolts in rear suspension
Started detailed inspection of wiring loom
Identify wiring requirement for de-mister fans
Identify new wiring requirement for lights and HIDS
Measure up for new motorsport spec radiator
Make buck and molds for bonnet NACA duct and instrument cluster
Make new bonnet NACA duct in carbon fibre (190g and you can stand on it!)
Pics to follow when I can download the images I have been sent by the team.
Steering column removed and components required for the power steering cooler identified
Replaced the worn suspension bolts in rear suspension
Started detailed inspection of wiring loom
Identify wiring requirement for de-mister fans
Identify new wiring requirement for lights and HIDS
Measure up for new motorsport spec radiator
Make buck and molds for bonnet NACA duct and instrument cluster
Make new bonnet NACA duct in carbon fibre (190g and you can stand on it!)
Pics to follow when I can download the images I have been sent by the team.
The support team for Barcelona 24hr is being put together. One of the team members who helped out at the BritCar 24hr has agreed to help us out again. The fact that he has just completed his degree in MotorSport Engineering (he graduated with a 1st!) means that he will be a valuable asset to the team and maybe he knows more than us in some areas....
Today we fitted the gearbox and then promptly removed as the selector fork hadn't been fitted and is belieived to be at the garage who serviced the box. Still good practice...... We will try again tomorrow night.
The drive shafts where re-installed only to find out that one of the bolts holding a toe link on has the wrong thread.
The 4 dials and head lights where connected up and work.
The drive shafts where re-installed only to find out that one of the bolts holding a toe link on has the wrong thread.
The 4 dials and head lights where connected up and work.
Look what rolled out of the garage last Thursday morning:
All being well the car will on the ship to Holland for last few bits of work before the Barcelona 24hr race in September this week.
Futher details can be found on: http://svdp-racing.co.uk/wp/
All being well the car will on the ship to Holland for last few bits of work before the Barcelona 24hr race in September this week.
Futher details can be found on: http://svdp-racing.co.uk/wp/
and the latest saga is that the boat the car was booked on has now entered dry dock for repairs. We are now booked an a boat leaving on the 15th. The ironic thing is the rabailey could end up inspecting the ship!!!
I tell you, you couldn't make the stuff up we have / are going through.
I tell you, you couldn't make the stuff up we have / are going through.
Our associateed Dutch Engineering company took the car car out for a quick blat up and down the road outside their workshop. On Sunday the car is being treated to a track day. Barcelona here we come.
http://www.youtube.com/watch?v=UUlwdc-i7Dg
http://www.youtube.com/watch?v=UUlwdc-i7Dg
Today was a great day for the team as the car was treated to atrack day at Assen. This test enabled the team to do a full system check, dial the suspension in and give Wubbe time in a right hand drive car. The word on the grape vine is that Wubbe was lapping only 2 seconds a lap slower than a BMW Cup Car.
Wubbe drove the car hard for 1 continuous hour towards the end of the session and the car ran perfectly. Happy days.
The team arrive in Barcelona this Wednesday to set-up the garage, start the paperwork etc ready for the track action starting on Friday.
Wubbe drove the car hard for 1 continuous hour towards the end of the session and the car ran perfectly. Happy days.
The team arrive in Barcelona this Wednesday to set-up the garage, start the paperwork etc ready for the track action starting on Friday.
One of the main items we need to sort out is a bigger fuel tank as the fuel cell we fitted was on 50L capacity when we were told it was a 65L capacity tank!. Thus we cannot run for 2 hours (which is the maximum a driver can drive in 1 go).
We have the Abu Dhabi motorshow in December so we might try and get the car displayed on a potential sponsor stand.
Further details can of course be found on the teams website svdp-racing.co.uk
We have the Abu Dhabi motorshow in December so we might try and get the car displayed on a potential sponsor stand.
Further details can of course be found on the teams website svdp-racing.co.uk
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