Team Highlights - 2001: Four podium positions, Summit Motors Award of Excellence.      2002 - Two podium positions.    2003 - Two podium positions.   2005-Oulton Park - Most Improved Driver   hello@dr-motorsport.co.uk

                              

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Recent happenings...

30/6 - Gallery updated

30/6 - About Us/Car updated

29/6 - News updated

 

 

June 27/28th 2009 - Lydden Hill Report

A successful but hot event!  With a newly prepared car we were aiming for a couple of fun but uneventful races to test settings and shake the car down.

Scruitineering was passed with the only sticking point being the tow points on the car protruding too far from the body work.  We were allowed to race on the condition they were replaced with the new strap type tow points.

Qualifying started with Dominic slowly building up speed as we have no experience of the tyre grip levels on the Toyo R888's.  This proved to be a sensible option as another car fell off the track on the second lap.  Dominic managed a time of 56.345 which was good enough for 8th in class and 23rd on the grid.

Race 1 was busy with a full grid and a lot of jostling for position on the first lap with several faster cars making their way from the back of the grid to their usual position.  This helped Dominic make several overtakes stick during an enjoyable battle with the Beetles. Improved confidence in the handling of the car helped to achieve a final position of 4th in class.

Race 2 was generally quieter and Dominic was able to concentrate on delivering some consistent lap times.  However the tyres struggled to perform on the hottest day of the year so far and so lap times were around 8 tenths down on the previous day.  However we achieved a respectable 4th in class again and the car performed brilliantly.

Detailed results here.

 

June 12th 2009 - Race entry confirmed + Tyres

We are now confirmed for the Lydden Hill round (entry list here).  Our tyres have also arrived after we chose to run on the Toyo Proxes R888 medium compound, which are road legal (just) but are the stickier MSA List 1B rubber.

 

June 6th 2009 - Brakes upgraded

We've now fitted the new EBC USR disks and Ferrodo Racing DS2500 pads to reduce fade and give a sharper bite on braking.

 

June 5th 2009 - Race entered

We've applied to enter the Lydden Hill round of the BARC Tin Tops as the car is now virtually ready to race.

 

June 4th 2009 - Interior finished!

A coat of paint has been applied to the floor to tidy things up, the door bars replaced and cage padded for the driver.  The rear door cards have been modified to fit around the cage.  The extinguisher is now mounted and plumbed in.

 

May 27th 2009 - Roll cage niggles

Having seen some other Fiesta's with the same OMP cage we've noticed a flaw in the kit we received and now installed.  Essentially the 'bolt in' feature of the foot mountings are upside down with the nut that the foot of the cage is bolted to being welded to the top of the reinforcement plate rather than underneath which other folk have received.

Now that doubt's of the mounting's safety have arisen with an impact possibly breaking the nut's weld and the cage foot then being free to deform into the car which is bad.

We've decided to enhance the safety margin by bolting completely through the car floor with higher tension bolts and with a sandwich of cage foot/welded nut/reinforcement plate/car floorpan/big washers.  Hopefully the scruitineers will approve!

 

May 24th 2009 - Mallory Park round

The results for this round can be found here, and yes we're still not on them :(

 

May 13th 2009 - Timing transponder fitted

The transponder which is required for accurate lap times and results has now been fitted under the battery tray so that it can have a clear signal to the track.  It has been wired up to the now spare emissions cable for a switched 12v and also earthed to the chassis.

 

May 9th/10th 2009 - Brands Hatch round

The results can be found here.  Unfortunately we could not attend as the car is still not quite ready and due to other commitments the Mallory Park round will also be missed.

 

April 18th 2009 - Rollcage fitted, MOT passed

Welding has been completed on the cage - just some painting to do now.  Also the car is road legal again with a fresh MOT.

 

April 13th 2009 - Castle Combe round

Due to lack of prepared car we've missed the second event.  Results here.  However the car is now booked in for the roll cage welding work and MOT retest, and the electric cut off switch is in progress.

 

April 5th 2009 - Fitted Seat & Harness

After finishing preparing the rollcage doorbars to ensure no clashes with the seat and door trim the seat was finally fitted and harness fitted and adjusted.  One harness mounting point will need to be welded onto the floorpan as the original seat incorporated the 3rd attachment point for the seatbelt.  As we're using a 4 point harness the 2 points to the rear of the seat can use the seatbelt points built into the car and the right hand lap point can also use the built in point, but a harness mounting plate needs to be used for the central point.  This needs to be welded in properly, but is just screwed in position for the moment until all the welding can be done together.

 

April 4th 2009 - Fitted Subframe

The subframe has arrived but is designed for a mk4 Fiesta floorpan which in 1 corner requires a spacer which we've had to get from a breakers yard.  Also as the subframe is for OMP seats and the seat is a Sparco there needed to be some modification of the subframe for the seat mounts to line up properly.

 

March 31th 2009 - Ordered seat subframe

Previously with the XR2's we've welded some box section in to act as a seat mount, but the floorpan of the Mk5 is a bit more complex and so a dedicated OMP subframe which will bolt to the floor and make things easier will be fitted.

 

March 29th 2009 - Prepared rollcage

The cage was starting to rust already, so have given it a quick coat of hammerite to tidy it up a bit.  Unfortunately the front legs of the cage fit very closely to the A pillar of the Fiesta which means some modification to the dashboard is required.  This was compounded by the metal beam and support mounts that run through the dash being in exactly the wrong place, and so after taking the dash in and out several times we've now chopped off about 3 inches from both ends of the dash.

The paint has now been ground away from the reinforcement plate positions to allow for welding and the door bars cut to length with the mounting positions marked on the cage legs which will need the fresh paint removed for welding up.

 

March 28th 2009 - Bought Wheels

Found some Zetec S wheels on eBay, 2 of which have decent tyres on.  We will now keep a set of wets/road tyres, and probably use Toyo R888 tyres for racing which although road legal would by lousy in the rain and wear out much too quickly.

 

March 15th 2009 - BARC Tin Tops race @ Brands Hatch

Due to lack of prepared car we've missed the first race.  Judging by the results though, we should be competitive in class as our old XR2 did sub 60 second laps which a fair few cars seemed to be slower.

 

March 14th 2009 - Failed MOT!

With February being a bit cold and snowy we've not had a lot of chance to do much prep work other than a little weight stripping.  As we're still needing the car to be road tested it is also necessary to get it's second MOT with us - which it failed on a bent alloy wheel.

Since it passed last year at the same garage with the same wheel and has not been crashed or kerbed at all since (in fact the car's only done 3000 miles in the last year) it shows how random MOT testers can be.

Unfortunately we've now got to blow some more budget on a Zetec S wheel which only seem to be for sale as a set.

On the bright side, the same garage does a lot of motorsport work and are willing to weld in the mounting plates for the rollcage for us.

 

February 5th 2009 - Seat and Harness bits arrive

We had good deal from Demon Tweeks with the Sparco Evo seat with mounts and a Sparco Clubman 4 point harness.  With the Euro exchange rate going the wrong way things are getting expensive for all these motorsport bits that need to come from Italy.  Fortunately there's little more bits that need to be bought.

 

February 4th 2009 - Rollcage finally arrives

Two months later after much chasing up with suppliers my cage arrive from Italy after needing to be built to order.  OK there was a Christmas in the middle but 2 months to weld some tubes together is unimpressive - and to annoy us further one of the backstays was bent in transit.  We've managed to bend it back to the right position as we're running out of time.

www.ten-tenths.com

www.thegrid.co.uk

 

Project: Fiesta Zetec S

 

Source suitable car

A 2001 Fiesta Zetec S was acquired from a local salvage dealer via eBay for the reasonable sum of £1200.  It has the stronger series 2 Zetec SE engine with only 60k miles, no sunroof, no air con and is in excellent condition except for the crash damage!

We shall keep the car standard for the time being which should allow us to race it in Class E of the Ford Saloons hopefully.

 

Fix Faults

The crash damage needed to be sorted out first.  Although the engine runs, there is no coolant in the system due to the bent radiator and as there is no history with the car there are some question marks.

  • Removed the broken bumper, grille and lights. 
  • Pulled out the top of the front panel and bottom radiator support to allow removal of fan and radiator.  Fortunately there does not seen to be any damage to the engine from the crash impact.
  • Removed the crossmember from the backing plate after drilling out all the spot welds. 
  • Tried pulling the chassis leg and backing plate back into shape but no joy.
  • Ordered new lights and fan.
  • Ordered new grille, bumper and radiator.
  • Removed damaged air box.
  • Changed oil and spark plugs - much easier to do with no bumper and radiator in place!
  • Bought slightly used K&N induction kit via eBay.
  • Fitted radiator and filled with coolant - engine now operational.
  • Hired trailer and took car to a bodyshop on Canvey to have the metal work properly straightened and painted.  New bonnet ordered to be fitted at the same time.
  • Ordered Gearknob.
  • Ordered steering wheel and boss kit.
  • Car now back at base and looking good!
  • Fitted assorted bits.
  • Now concentrating on getting the car road legal so am worrying about the airbag light on the dashboard - will it pass an MOT like this?
  • MOT inspector likes the car and it passed first time with only a slight tweek to the headlight beam.
  • Taxed and insured - now can test properly!

Test

All appears well except for a slow puncture in the front nearside tyre.  The car is fun to drive and engine is perfect.  Have now put about 2000 miles on the car.

The airbag light is still annoying.  Have tried removing SRS fuses and attempting to remove the bulb - but it's an LED.  May have to try the Homer Simpson technique of using some tape over it.

We may have joy by finding the SRS control unit which lives somewhere behind the dash but is nowhere where the manual says it is - will have to wait until the dash comes out during preparation then.

Also annoying is that all 4 wheels have completely different tyres on them - makes for interesting handling!

We will be keeping the car on the road while we are race preparing it as it's useful as a runabout.

 

Prepare

We are now planning the preparation and what toys to buy for the job.

Will need:

  • FRP Rear handling kit.  Done.
  • Coilover suspension units with suitable springs. Done.
  • Engine bay tidy up. Done.
  • Strip and reduce weight. Done.
  • Roll Cage. Done.
  • Seat. Done.
  • Harness. Done.
  • Fire Extinguisher.  Done.
  • Electric cut off switch.  Done.
  • Timing transponder.  Done.
  • Proper tyres. Done.
  • Race brake pads and disks. Done.

FRP Rear handling kit:

Although easy to fit in theory, it required using various combinations of sockets and extensions to remove the 4 bolts from the hub as 2 of the bolts were partially obscured by the damper which also made removing the ABS sensor a pain.  Once the drum was removed it was also necessary to drill out the 2 rivets holding the hub backplate onto the rear beam.  Now came the tricky part of threading through the new longer bolts through the beam, spacer, backplate and drum while keeping everything lined up.

Once fitted though there was a noticeable reduction in understeer and a more solid feel to the rear.

 

Coilover suspension units with suitable springs:

Have now ordered Gaz Coilover kit with 8" 300lb springs at the front and 9" 400lb springs for the rear.  Unfortunately they will take about 4 weeks to arrive as they are custom built to order.

Suspension now arrived - far quicker than expected!  Now need a whole weekend to fit, adjust and test.

After a full weekend the units have now been fitted starting with the easier rear end. The old units were removed with just 2 nuts holding each one on.  The top rubber donut was removed to be reused with the new units with the aid of spring compressors.  The ride height was set at 16cm and after some testing the dampers set at 10 out of the 24point bump/rebound settings.

The fronts were somewhat more difficult with the mounting point for the antiroll bar and brake pipe to contend with - however some serious bashing was required to knock the old damper out of the hub.  The ride height was set at the lowest possible which results in 12cm of road clearance.  Dampers were set at 10 as per the rears.

Strip & reduce weight:

Stripping out is the easiest but most time consuming job to do properly.  So far we have removed:

  • 14kg rear seats
  • 34kg front seats
  • 6kg stuck on sound deadening
  • 2kg sound & airbag/pretensioner wiring
  • 1kg nuts & bolts
  • 10kg heater & engine bay trim
  • 13kg carpeting & underlay
  • 1.5kg headlining
  • 19kg seatbelts & trim bits
  • 4kg surplus suspension parts
  • 2kg dashboard
  • 3kg rear wiper and motor
  • 16.5kg spare wheel & jack

       Total so far: 126kg!

Engine bay tidy up:

The removal of the heater unit has left the heater control valve and the coolant hoses floating around the back of the engine bay looking rather messy and needs to be replaced which will also save a little bit of weight.

Also the 'evaporative emissions system' has been removed.  This is a system to recycle petrol fumes from the tank into the engine inlet via a carbon canister and hoses and valves.  All this does is weigh, impacts on engine performance, and is unnecessary baggage on the race track - so must go!  Fortunately it's quite a simple unbolt and unplug job at both ends of the car but did upset the ECU which lit up the Check Engine light.  A reset of the ECU seems to have cured the light in the end.

Preparation for rollcage and seat:

The cage was starting to rust already, so have given it a quick coat of hammerite to tidy it up a bit.  Unfortunately the front legs of the cage fit very closely to the A pillar of the Fiesta which means some modification to the dashboard is required.  This was compounded by the metal beam and support mounts that run through the dash being in exactly the wrong place, and so after taking the dash in and out several times we've now chopped off about 3 inches from both ends of the dash.  The support bar also has been chopped but the dash is still supported in the middle and in 3 locations under the windscreen.

The paint has now been ground away from the reinforcement plate positions to allow for welding and the door bars cut to length with the mounting positions marked on the cage legs which will need the fresh paint removed for welding up.  It looks likely that the door cards will not need modifying to allow for the door bars as we've positioned the bars to run in front of the recess in the door card above the door handle.

 

Having seen some other Fiesta's with the same OMP cage we've noticed a flaw in the kit we received and now installed.  Essentially the 'bolt in' feature of the foot mountings are upside down with the nut that the foot of the cage is bolted to being welded to the top of the reinforcement plate rather than underneath which other folk have received.

Now that doubt's of the mounting's safety have arisen with an impact possibly breaking the nut's weld and the cage foot then being free to deform into the car which is bad.

We've decided to enhance the safety margin by bolting completely through the car floor with higher tension bolts and with a sandwich of cage foot/welded nut/reinforcement plate/car floorpan/big washers.  Hopefully the scruitineers will approve!

 

Develop

Things to do...

  • Replace tow points with strap version
  • Remove side strips
  • Move video camera mount
  • Remove engine bay sound deadening
  • Remove heat shield from exhaust
  • Source & install exhaust
  • Source & install LSD

 

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