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Been a member for a few months but thought I would post something about my Astra rallycar.
Originally built in 2001 for Kev Brown for the "Team Diseworth" rally team which ran 3 very similar Astras in the Midlands rally events from 2001 - 2006.
Then went on some travels around the country before ending up in Dorset. It was built with a 1300cc 8v engine but this gave up the ghost so was replaced with a 1400 16v engine in 2006.
In May 2009 it popped up on Ebay so after some negotiations with the seller as to spec, condition etc I bought it and trailered it back to the Midlands.
Spec when bought:
Astra 1.6L shell, non sunroof. 6 point bolt in cage. Seam Welded and skidded in several places. Been used as a forest car so quite a few scrapes, dents and knocks but still pretty straight. Fibreglass bonnet and boot, perspex windows and doors lightened etc.
1400 16v engine with twin 40s, MBE ECU, twin fuel pumps. F13 box, paddle clutch and std diff.
Bilstein inserts in modified front casings, rear bilsteins with gravel springs all round.
Astra 8v front brakes, Astra GTE rear beam and disk/drum brakes
Extinguishers, cut off, bucket seats and harnesses and various other safety kit fitted as expected in an MSA logbooked rallycar.
Getting it ready for its first event
Due to holidays and other time committed, we only had a week to sort the car prior to the Dukeries rally - its first event with me. Luckily a good friend already rallies a Mk2 successfully so he has a mountain of bits and knowledge to help me get it right. The car was duly shipped over to him for the work to begin.
The car basically needed some love and attention. It had a few (non structural) holes in the floorpan from forest rallying and needed a few upgrades. First we fitted some Bilstein coilovers for the front, studded the hubs, and as I already had an F13 with a s/c Hockley gearset in we fitted that. The engine was serviced and the carbs were balanced by hand although we knew they werent anywhere near right and the ECU wasnt mapped correctly. Also needed to remount the sumpguard and change the sump as it had been bashed about a fair bit!
Brakes were changed to 16v on the front, new disks fitted all round and 1144 Mintex pads for the front. Suspension topmounts are a "rare" Gp N item apparantly - heavy duty rubber ones rather than eccentric topmounts so we dint need to change those, even though we did buy ones to change!
Basically a week of afternoons and evenings on the car and it was ready for MOT (3pm Friday), then taxed on the way back to the trailer and straight to scrutineering for the Dukeries rally at 4.30pm Friday.
The Dukeries Rally 2009
After passing scrutineering, we started the event very cautiously. The car was very down on power - I reckon maybe 60bhp at the wheels, std diff, first time in the Forest for 6 years and first time driving a rallycar for 5 years. After a few moments through the morning stages (4 in total) we got into a safe rhythm and progressively quicker. At service we just checked the car and tightened a rear wheel bearing - nothing else needed - and back out for the afternoon and some good times for the spec of car. Unfortunately picked up a timing penalty but didnt matter as the goal was to finish the event, enjoy myself and make sure the car was OK.
Whats next?
So we knew the car was down on power but didnt realise quite how much until the rally itself. So have stripped the engine down post-event and we reckon its just a fuelling / ignition setup issue. Head is off and will be worked on a little to help it breath as well as being skimmed and the valves will be 3 angled too while its off. Bottom end will get some ARP bolts for safety so I can happily rev it to 7500 without worries and new rings etc. The carbs are being rebuilt and will be rejetted and the MBE set up properly - on the road initially then onto a rolling road for final setup. Reckon 100bhp at the wheels is easily possible which will be fine.
Removing the rear Bilsteins and comparing side by side, we can see that one of them is shot - doing little damping compared to the other. Guess thats why the back end was wandering all over the shop! New ones to be ordered.
I already have a 90% ZF diff to fit but the current front hubs are small shaft hubs so we didnt have time to do the mods as the ZF diff has big side gears. Have ordered some big shaft drive flanges and will swap the diff and drive flanges with Mk3 Astra shafts (slightly longer I believe) to stop any CV joint issues.
However that then means we need power steering as my arms arent like Popeye. So plan is to fit a GTE Power Steering rack with a 106/Saxo electric pump.
Also going to fit some Mintex F4R (like 1166s / 1177s) pads for the front and set the car up for braking and get her tracked / camber adjusted too as the next event will be tarmac.
Plan is to get the above done, do a tarmac event in her in Sept / Oct then back into Forest spec for the Premier Rally in November. Assuming she makes it through those safely then shes then having a complete strip down bodywork wise, a GTE makeover and a new paint job ready for the 2010 season.
Id be interested to buy a GTE front end, bumpers, wings, lights and bottom arms etc if anyone has any.
Will update as I get jobs done.
Paul..
Originally built in 2001 for Kev Brown for the "Team Diseworth" rally team which ran 3 very similar Astras in the Midlands rally events from 2001 - 2006.
Then went on some travels around the country before ending up in Dorset. It was built with a 1300cc 8v engine but this gave up the ghost so was replaced with a 1400 16v engine in 2006.
In May 2009 it popped up on Ebay so after some negotiations with the seller as to spec, condition etc I bought it and trailered it back to the Midlands.
Spec when bought:
Astra 1.6L shell, non sunroof. 6 point bolt in cage. Seam Welded and skidded in several places. Been used as a forest car so quite a few scrapes, dents and knocks but still pretty straight. Fibreglass bonnet and boot, perspex windows and doors lightened etc.
1400 16v engine with twin 40s, MBE ECU, twin fuel pumps. F13 box, paddle clutch and std diff.
Bilstein inserts in modified front casings, rear bilsteins with gravel springs all round.
Astra 8v front brakes, Astra GTE rear beam and disk/drum brakes
Extinguishers, cut off, bucket seats and harnesses and various other safety kit fitted as expected in an MSA logbooked rallycar.
Getting it ready for its first event
Due to holidays and other time committed, we only had a week to sort the car prior to the Dukeries rally - its first event with me. Luckily a good friend already rallies a Mk2 successfully so he has a mountain of bits and knowledge to help me get it right. The car was duly shipped over to him for the work to begin.
The car basically needed some love and attention. It had a few (non structural) holes in the floorpan from forest rallying and needed a few upgrades. First we fitted some Bilstein coilovers for the front, studded the hubs, and as I already had an F13 with a s/c Hockley gearset in we fitted that. The engine was serviced and the carbs were balanced by hand although we knew they werent anywhere near right and the ECU wasnt mapped correctly. Also needed to remount the sumpguard and change the sump as it had been bashed about a fair bit!
Brakes were changed to 16v on the front, new disks fitted all round and 1144 Mintex pads for the front. Suspension topmounts are a "rare" Gp N item apparantly - heavy duty rubber ones rather than eccentric topmounts so we dint need to change those, even though we did buy ones to change!
Basically a week of afternoons and evenings on the car and it was ready for MOT (3pm Friday), then taxed on the way back to the trailer and straight to scrutineering for the Dukeries rally at 4.30pm Friday.
The Dukeries Rally 2009
After passing scrutineering, we started the event very cautiously. The car was very down on power - I reckon maybe 60bhp at the wheels, std diff, first time in the Forest for 6 years and first time driving a rallycar for 5 years. After a few moments through the morning stages (4 in total) we got into a safe rhythm and progressively quicker. At service we just checked the car and tightened a rear wheel bearing - nothing else needed - and back out for the afternoon and some good times for the spec of car. Unfortunately picked up a timing penalty but didnt matter as the goal was to finish the event, enjoy myself and make sure the car was OK.
Whats next?
So we knew the car was down on power but didnt realise quite how much until the rally itself. So have stripped the engine down post-event and we reckon its just a fuelling / ignition setup issue. Head is off and will be worked on a little to help it breath as well as being skimmed and the valves will be 3 angled too while its off. Bottom end will get some ARP bolts for safety so I can happily rev it to 7500 without worries and new rings etc. The carbs are being rebuilt and will be rejetted and the MBE set up properly - on the road initially then onto a rolling road for final setup. Reckon 100bhp at the wheels is easily possible which will be fine.
Removing the rear Bilsteins and comparing side by side, we can see that one of them is shot - doing little damping compared to the other. Guess thats why the back end was wandering all over the shop! New ones to be ordered.
I already have a 90% ZF diff to fit but the current front hubs are small shaft hubs so we didnt have time to do the mods as the ZF diff has big side gears. Have ordered some big shaft drive flanges and will swap the diff and drive flanges with Mk3 Astra shafts (slightly longer I believe) to stop any CV joint issues.
However that then means we need power steering as my arms arent like Popeye. So plan is to fit a GTE Power Steering rack with a 106/Saxo electric pump.
Also going to fit some Mintex F4R (like 1166s / 1177s) pads for the front and set the car up for braking and get her tracked / camber adjusted too as the next event will be tarmac.
Plan is to get the above done, do a tarmac event in her in Sept / Oct then back into Forest spec for the Premier Rally in November. Assuming she makes it through those safely then shes then having a complete strip down bodywork wise, a GTE makeover and a new paint job ready for the 2010 season.
Id be interested to buy a GTE front end, bumpers, wings, lights and bottom arms etc if anyone has any.
Will update as I get jobs done.
Paul..
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