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Discussion Starter · #102 ·
Got the battery wiring done today.....

Terminals crimped....




Routed from battery to kill switch....


FIA kill switch and resistor in....




Also have a through panel connector where the cable runs through the bulk head but my cone cutter wasnt quite big enough....



Also put in the through panel connectors for the brake lines....




Just few little jobs to tidy up and be ready for some track action again.
 

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Discussion Starter · #105 ·
Ok for some reason forgot to update thread, mapping didn't go well the power and torque just keep dropping off so was obvious something was wrong. We did what we could in the time we had with the tools we had but to no luck. The mappers thought there to be a problem with either the cams being incorrect or the timing being out. So anyway after a week depression at the reasons i was close to getting rid of the car and being done with it but after a break away i looked into the problem. First rechecked compressions all reading ok @ 1-200psi 2-200psi 3-210psi 4-220psi. checked ecu setting, fuel pressure, throttle bodies etc etc everything was fine so onto cam timings. I didnt do this myself when built engine as i didnt have the correct tools/gauges etc to set up the verniers so i had a well known person (who im not going to name) do the job for me. After a few days waiting for the digital dial gauge etc to turn i could get on with making the brackets etc to get the job done. Using the "lift at DTC" method i carried out the job, below are the results and the settings....

Cam settings first....

Piper's setting Intake cam - 2.24mm DVA Powers setting for exhaust cam - 2.79mm
Piper's setting exhaust cam - 1.98mm DVA Powers setting for exhaust cam -2.41mm

And here are my findings....

Intake cam....



Exhaust cam....



So as you can see the exhaust is way out, im happy i had found the most likely course of the fault but not happy about being £200 down for the cost of 1 hours rolling road and mappers time.

Got it all reset now and run it up, the engine note is completely different now and it revs up a lot faster so be back to the rollers asap....

 

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Jeeeeez, what a ball ache, annoying when you pay for a job to be done and it isn't ! At least you found it ! So whens the first track day ? :)
 

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Discussion Starter · #108 · (Edited)
Sorry not posted in while guys lost my account since security update etc so will get you updated as a lot as happened :brekkie:

Finally going to get the race seat in while waiting for mapping, got the factory mount out today....



Got the head lights sorted today, they were in such poor condition were almost completely yellow, since I wasn't planning on using it on road again I painted the lights black but after a rethink I would quite like to attend a few shows next year so thought I would try clean them up. First of used thinners' to remove paint, then a 800-1200 wet flat, cut back with mid then fine compound and a polish all done using the mop. While there I also opened them and painted the black plastic to match wheels etc....





Finally got the out and the FIA floor bars welded in and the race seat fitted, only had a steady run out as the map needs redoing but about 4500rpm cars feels pretty quick indeed and the intake noise is amazing. Unfortunately had no idea on speed as no longer have a speedo since ABS has gone but the revs where going up quick....





Few more bits done, cleaned up and painted bars and weld's and got harness in....







All approved till 2020

Quick update, everything apart from getting the door strips painted is done and she's booked in at Emerald start of September for mapping. I will have 3 maps done being road, race and sprint so hopefully can get back on a trackday by mid September. Since ive got to drive it upto emerald and I've finally got the ZS wheels finished I'm putting them on the ZR as they have new tyres and if all goes well on mapping side I will probably use it for the month.....



Ok guys we are all mapped up and ready for track again. Thank God everyone went great at Emerald and I had a really enjoyable day there all tho wasn't nice driving there on the base map car drove horrible on road and was stuck in traffic on black cat roundabout at the A1 at 7am couldn't believe it. Anyway drive home was great and all smiles so was all worth the money, travel and early start. Came away with 2 maps which are switched in the car....

1. Track map- 7500rpm, full throttle gear change, over run enrichment etc 181bhp

2. Road map- toned down power, 7000rpm, over run fueling and flat shift off

So not quite at my 190bhp in my head figure yet but the person doing the mapping thinks with the Janspeed manifold and de-cat and timing set to 120-100thou on the cams should be about there but for now I'm happy and can honestly say the car feels very quick and I've had some fast cars in my Time. Anyway here's a video on the dyno and will get some "on the road videos done tomoz...


VIDEO CLIPS BELOW


http://m.youtube.com/watch?v=ggxZIEC0Mdw

http://m.youtube.com/watch?v=Y_MmCu5EiBI

Well few weeks in guys using the ZR and pleased to report still no problems to speck of so hopefully its all come good in the end. I also finally manged to get the bump strips painted glad to say the top coat was a great match and the new stickers also came out top.....



Well unfortunately my months insurance is almost at an end on the ZR but I'm pleased to say it has missed a beat, leaked anything and has been a real good laugh. Got a trackday booked on 5th November with 4 good friends (3x MX5's and a MR2) so cant wait for that hopefully weather will hold out so can use the slicks. Thought as was nice after work took the country road long way home....









Got a load of spares at weekend, local breakers had a MK2 1.4+ in so got a deal for £100 i had from 9a.m to 12 p.m to take what i could before it became a bean can....




 

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Discussion Starter · #109 ·
Went for a change on the sump baffle changed over to the viton flap version on the right....


 

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Discussion Starter · #110 ·
Well only few days left till trackday and everything turning into made rush again, got sump off at weekend to fit the baffle only to find my sump was different to the normal k series so been on a mad hunt to find another sump.....



As you can see mine had another bit of cast on the right hand side but anyway that done now and thought i would try some Millers NT oil see what all the fuzz is about hopefully with give me another full HP....



Also noticed i had a split c.v boot so be a cold one after work tomoz night getting that sorted.
 

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Discussion Starter · #111 ·
Ok guys quick update on trackday. Started off Friday night carrying out emergency repair and replacing a split c.v boot at 8pm....

Followed by a quick wash.....


And all was ready for a early start this morning with the boys (4x MX5's and a MK3 MR2).....

We managed to get a garage which was a bit of luck because morning was damp with a little shower so was on the road tyres till lunch. Thankfully by 1pm the sun was out so the slicks went on....


I'm glad to report the car was amazing, no problems to report, engine didn't mis a beat all day and pulled like a champ and only was passed by a 2014 M3, a new Focus RS and a 2015 GT3 RS and a set of piper cams wont do much against those. Had a really good day so looks like it all paid off in the end I had to be kicked out at end of day was only car left....

Was also another MG there which was nice a MK1 ZS180 not sure if anyone knows him was a older guy was good behind wheel tho but was glad the ZR with the work was faster on the straights....


Any way thats all for now got everything on video so will hopefully get those edited tomoz as takes hours and hours on my laptop.
Videos here at last....

http://www.youtube.com/watch?v=Jkd3ZiuIMKI&t=303s

http://www.youtube.com/watch?v=fhTSGzvFYec&t=106s

http://www.youtube.com/watch?v=Z-gfWAxYywk&t=124s

http://www.youtube.com/watch?v=5dlffGTVG9s
 

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Discussion Starter · #113 ·
Janspeed manifold and de-cat came today. Hopefully will get it test fitted at weekend and if the fitment is ok will get it heat wrapped. Must say tho the quality seemed a lot better on the Piper and Elise parts manifold, welds aren't that great and thought the pipes would be bigger than they are but see want happens when back on rollers at Emerald.



Finally got the Janspeed on, not rapped it yet just wanted to check fitted which is mm perfect all tho the lambda probe is completely in a different place. Luckily since I done my own loom had enough wire to reroute it. Doesn't seem much louder with the decat thankfully and car definitely feels quicker in mid-range. Just need to increase cam timing on Verviers and get back to emerald for map tweak....





Finally got my B&G adjustable top mounts today just need to make my mind up on the coilovers now and get them ordered. Been looking into KW Clubsports but not sure if there going to be a over kill both in terms of price and spec....



Few from a very dirty and slippery morning session at Snetterton 300 yesterday.....








Had another go in the 208GTI i done my ARDs test in loved it so much might have to get one to replace the ZR....


 
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