My Corsa Project - Track and fun

[DAL33S]

Been doing a few more bits over the weekend

Carried on this the dash, heres whats left on inside



Trial fitting with shift lights/warning lights




Got my bracket back from powder coating



Started to rebuild and cut light panel to allow room for coolant hose



Also shortened by vac hose for master cylinder



On the rebuild



Got my intercooler pipes "bead rolled"




All on and mock fitting Tial BOF




Then got these made, rose jointed lower arms and track control arms (note the TCA are placed the wrong way around here)



Lower arm



All fitted, I have kept from spacer plates as it gives me clearance from intercooler piping. Lower ball joint spaces don't fit but this isn't an issue as the lower arms clear with F28 fitted due to different pick up points. The chassis was drilled for 1/2" bolts for lower arm which was fun with engine in. In the end I removed the engine mount and lifted either side to make sure the chassis was drill straight! Over all very happy with the kit and quality of welds!



Fitted post radiator coolant temp sensor



Fitted air temp sensor in the oil cooler housing



Getting there slowely



Coil fitted with leads



All for now

[Greg_D]

you're getting there - keep on trucking...

[DAL33S]

Greg_D said:

you're getting there - keep on trucking...

Cheers...

Little update nothing great....

Got some new shorter lower arm to ball joint bolts as I had spacers before



Had alittle play with adjustment of caster....




Wheel and wing placed on



Then got my new Big block hub flanges (Not conversion hubs) and knuckles back...



Knuckles with part grinded off for clearance for Alcon brakes



These will be powder coated now

Then I carried on with Dash mock...

Feel Wet lay carbon 1mm thick (Not crapped "carbon wrap")



Cut out to go into housing



Cut out for dash



Front face on with the motec shift lights/warning lights at top can only just see

[joehirth]

Really like the carbon surround. I think too many people go OTT with carbon. What you've done it nice. Can't wait to see it in action.

Also have you, or are you, doing anything with the noise of the car - for track?

[DAL33S]

joehirth said:

Really like the carbon surround. I think too many people go OTT with carbon. What you've done it nice. Can't wait to see it in action.

Also have you, or are you, doing anything with the noise of the car - for track?

I agree, I think it adds a nice touch not overly interested in carbon TBH

Nope, it was 92db last time I checked on KKK16...... So hopefully won't be any louder as the external wastegate pipe is piped into the exhaust

[DAL33S]

Got a few more bits done...

First off modified the rocker cover to take -8 for the catch tank and the small breather will be blocked




Then on to my lockable aero catches what a pain in the ass to do....







Getting there slowely



Mike popped round to make the oil cooler lines too Top job thankyou...





Picking up the intercooler pipes from welding Monday and Steve @ GWR Motorsport is coming around Wednesday to measure the loom up

[DAL33S]

Been getting on with few more bits

Got parts back from welding

Pre cooler intake temp sensor boss and DV take off



Shortened Brackets on baileys coolant tank




Also got small breather blocked on rocker and -8 fitting welded on for catch tank



Checking fitment



Getting there



Made new adapter for EGT boss as I wasn't happy with first one....



Steve made new earth for the alternator



Mounted the Map sensor up out of the way



Mounted ignition amplifier, ground paint underneath and used heat sink bonding paste to create good connection.



Mounted boost controller solenoid valve



Mounted Batter + joining post

[DAL33S]

Little update and its get expensive

Motec GPS for dash



Motec M400 ecu with many options ticked



Motec "high" spec shift light model



Motec communication adapter and lead



Motec CDL3 Dash



EGT Adapter and loom



Wiring loom for the car, includes wiring for external fuel pump, connector ready for a 3rd fuel pump(won't be used yet) and connector ready for rear wheel speed sensors for Traction control (use as a reference point.)



Battery + and Battery -



Engine earth and alternator earth



Fitted battery + and - and plumbed in



All hidden and where it comes out



Fitted EGT sensor and loom



Fitted fuel pump wiring loom



New vaccum take off from TB, which was the old air temp sensor



Found some bungs that are used on BMW's to block the unused vacuum take offs



Thats all for now, the engine loom is currently being made

[Greg_D]

you're not joking with the expensive bit!!!

[mwstewart]

Great work as always

[DAL33S]

Greg_D said:

you're not joking with the expensive bit!!!

Not at all.....

mwstewart said:

Great work as always

Cheers

On to making the engine loom After measuring the loom up Steve came up with this..



Then started...



And you end up with this at present 95% done....





The "main man"



Then it was time to test the M400 and CDL3, setup on the bench...





Plan is to get him up and running over the jubilee bank holiday weekend as he is booked for mot Wednesday.

I thought I would clean a spare rocker cover out and have it sprayed as mine always had a chip in it..

With breather plate removed



Plate refitted



SBD breather mod swapped over from last one



Had it painted in white with breather to sump done black (all cleaning was done after spraying ensuring all the crap was removed...



-8 tank of for catch tank



Last few bits turned up from Roose motorsport, vacuum hose with internal diameter of 6mm (external waste gate, DV) 4mm internal diameter vacuum hose, 13mm internal diameter hose for "Mod" to the inlet as seen in previous posts!



Busy weekend ahead as all my powdercoating is now done, picking that all up tomorrow

[DAL33S]

Been working flat out recently probably doesn't look alot but its so close now

Picked my last parts up from powdercoating. Shafts with some new CV's. Built them up and fitted and fitted my new knuckles with VW/Audi wheel bearings (No pictures, shocking I know)



Steve finished off the dashboard loom



Made nylon spaces for the dash to be mounted



Added felt tape to the inside of the carbon not to vibrate



Fitted to see how it looks with trim surround



Plugged to and powered up to test, Screen needs to be setup to display all features still



Then got onto fitted the engine loom, mounted the fan fuses and relays out the way



A few snaps, we tried to hide as much as possible within reason!






Baffled catch tank with -8 fittings




Mounted



How the line will go, need to order 90 swept for the catch tank



How I left it, ready to turn over tomorrow to get oil around and do setup for starting....

[DAL33S]

Been mental couple of days.... I rebuilt the front end, wings and bumper. My current bumper I ruined cutting to far but i fitted to get me for mot tomorrow.

Made a temp catch tank put wire wool in there to help



Time for some gearbox oil would been easier to do this before oil cooler was fitted but oh well



Tool for the job




Fitted gps wiring for dash, gps was hiden under boot carpet



Tapped into dimmer switch for dash to dim with interior illumination



Steve came over we sorting timing etc, cranked with plugs out to check good oil pressure with fuel disconnected. Then primed the fuel system to check for leaks, all was good! This was also done with feed disconnected at rail to check lines were clear! There was also lots more calibration but I will be here forever writing about it....

Before start up safety first...



little shot of the laptop checking the whats been logged after the car had been run for a bit, it took a long time tinkering etc...



Another shot of dash with car running



then once everything was double checked it was off for quick lap round the block just checking it was safe to drive to mot station tomorrow, few tweaks here and there and now he is ready for tomorrow...



Still along way off but its a positive step....

[ALfooy]

Absolutely fantastic dude. Two years ago I would have flamed this but really warmed to vauxhalls and opels over the last couple of years. Stunning.

[DAL33S]

ALfooy said:

Absolutely fantastic dude. Two years ago I would have flamed this but really warmed to vauxhalls and opels over the last couple of years. Stunning.

Thankyou very much Glad you have seen the "light" I do like Vauxhalls having 3 myself

[ALfooy]

Lol, i do think they have a reputation they don't deserve tbh, i mean, they have made some bad stuff and some of the cars i've seen have been badly modified, but then look at some Fords, VWs, just as bad really. You should be proud of what you've done with a humble Corsa

[DAL33S]

More work on him once again....

First off, out the garage for for some fresh air



Then MOT time....



After that tracking was done to get me to PVS, will have proper setup/corner weight once he is back!

Then I headed back to steve's unit, we checked the base map at various RPM/Manifold pressure on several roads, once steve was happy we put 4k rpm limit and 6psi boost limit as above to get me to pvs and owen developments for mapping

Once this was done, back onto finishing the dash

How it looked in it current state..



Next was to fit the shift light module, spacers were made to mount it



Drilled the dash for "display controls" - "green" goes through menus, "red" accepts warnings and communication port for dash!



Drilled the dash for "ecu controls" - communication port, Traction control rate switch, Traction control on/off switch, High and low boost settings



Rebuilt dash with shift lights and leds for indicator left/right, ign light, handbrake light, rear fog light and main beam.



Parts turned up to fit my catch tank




Fitted some heat matting under the bonnet as the manifold gets nice and warm



Now after ruining my other bumper it was time to cut the new one, function over form now with cooling..... the end result might not be to everyones taste....



Also done the ducting to the oil cooler note the wonky screws oh well....



Finally a little video of shift lights and dash...

"Monty" Corsa turbo Base map Dash test.MOV - YouTube

[T.K]

Awesome. Some lovely parts and workmanship.

If I may be so bold, new bumper may have been a step in the wrong direction? I would do it as per the old one, but paint the intercooler and pipework matt black. :-)

[Greg_D]

I've got to agree with the previous poster, that bumper is a bit much IMO, I know you want to drop the odd hint as to the power within, but it comes across a bit mcdonalds car park to my eyes. Matt black and a bit of mesh would be much more subtle.

[RB Will]

Where is the numberplate going now?