cj1 Posted July 9, 2016 Author Report Share Posted July 9, 2016 2 minutes ago, mattarosa said: Cut that dash out, scrap the clocks, use a tablet instead, replace the glass it plastic. What with an obd reader/app? The dash has so much cut away it weighs hardly anything! plastic Windows good idea can cut the doors away as well then! Quote Link to comment Share on other sites More sharing options...
mattarosa Posted July 9, 2016 Report Share Posted July 9, 2016 yeah a cheap obd reader, the clocks are stand alone so, and just use the tablet/phone as an electronic dash Quote Link to comment Share on other sites More sharing options...
cj1 Posted July 10, 2016 Author Report Share Posted July 10, 2016 Quote Link to comment Share on other sites More sharing options...
mattarosa Posted July 10, 2016 Report Share Posted July 10, 2016 Yay wiring Quote Link to comment Share on other sites More sharing options...
WRC Posted July 11, 2016 Report Share Posted July 11, 2016 wow..mine has 979kg.. Quote Link to comment Share on other sites More sharing options...
cj1 Posted July 11, 2016 Author Report Share Posted July 11, 2016 11 hours ago, mattarosa said: Yay wiring Yay indeed! Only 23 we're now unsure of what they did, tracing back from the ECU connectors! Will get there :-) 2 hours ago, WRC said: wow..mine has 979kg.. That seems awfully heavy.... Isn't it around that in standard form? Quote Link to comment Share on other sites More sharing options...
WRC Posted July 11, 2016 Report Share Posted July 11, 2016 nope, standard si around 1050kg. i have the 40kg rollbar.. weighted will all liquids and 2 seats. keep in mind, that i have the 1.6 engine which is heavier than 1.0. anyway, the minimum accepted in our class is 900kg...and a lupo CUP has 905.kg Quote Link to comment Share on other sites More sharing options...
cj1 Posted July 11, 2016 Author Report Share Posted July 11, 2016 (edited) 7 minutes ago, WRC said: nope, standard si around 1050kg. i have the 40kg rollbar.. weighted will all liquids and 2 seats. keep in mind, that i have the 1.6 engine which is heavier than 1.0. anyway, the minimum accepted in our class is 900kg...and a lupo CUP has 905.kg Ah okay, that's not too bad then. Is the 900kg what it has to be at the end of a race? IE with fuel etc & driver, or just the car? Do you still have the heaters in etc? Edited July 11, 2016 by cj1 Quote Link to comment Share on other sites More sharing options...
WRC Posted July 11, 2016 Report Share Posted July 11, 2016 heaters yes, ventilation yes, but no AC compressor and radiator and belt. 900kg before the race. i posted in my topic also i managed to pick 3rd place this weekend. Quote Link to comment Share on other sites More sharing options...
cj1 Posted July 18, 2016 Author Report Share Posted July 18, 2016 Long weekend! Engine was ready to go in, we did a test fit and the bracket we'd made to hold the crank sensor was catching on the o/s chassis rail. Out we take the engine, and out of curiosity turned our attention to the 1.0 engine that has a crank sensor hidden behind the flywheel. Turned out that the wheel on that engine and the oil seal housing was a perfect fit on the AFH, so we put it on and got the engine in. Couldn't get it to line up properly with the gear selector bar at the back. What we hadn't done was swap the mounts on the chassis for the 1)v sport ones, when compared these move the engine forward around 30mm. Swapped over and engine fitted fine. Later that night we realised that the crank sensor was a Hall effect, which is no good for the DTA S40, only the S60 and above can handle that, which is a significant amount more to buy. Sunday we swivelled the engine round on a jack and created a new bracket to house the crank sensor using original trigger wheel on the aux belt pulley idea. Last night we set up the ECU, tested the new wiring loom that Martin had made all sensors etc... Had it cranking on the starter motor with the ignition switch, but I didn't go for oil yesterday as it wasn't expected it would be ready to start! Tonight should be the night pics not in any particular order : 2 Quote Link to comment Share on other sites More sharing options...
cj1 Posted July 18, 2016 Author Report Share Posted July 18, 2016 The ECU I'm using has an app that can be used for the dashboard display (minus fuel level) , so ordered a tablet for that today. First step, modified a USB hub to wire directly into car. Quote Link to comment Share on other sites More sharing options...
cj1 Posted July 22, 2016 Author Report Share Posted July 22, 2016 (edited) Updates in order: Connected driveshafts (including stub axle on drivers side) Filled gearbox with oil Came back next day to weld manifold to main exhaust, oil leaking out of drivers side driveshaft - odd we thought - couldn't weld exhaust as oil was leaking right where the joint would be Checked against another and there's a kind of spring cap, and a thrust ring that should go on the little stub axle which was also broken (On all three of the gearboxes I have!) Tapped end of driveshaft with screwdriver and put a hole in it. Drained gearbox Ordered new thrust ring Removed driveshaft and stub axle part Fitted new Polo stub axle (At the time we thought the bearing should have been in two pieces) Driveshaft outer end nut wouldn't go on - although it is the same thread Discovered the bearing was actually broken Removed driveshaft Welding original driveshaft hole to stop grease escaping and refitting that All in all a frustrating week with only time at night to do things. By now the exhaust should have been joined up and had the car testing. Things to do: Fit polo 6N cable pedal box Refit seat and move backwards Machine spacer for steering wheel to allow horn button to fit in the centre Tidy up wiring and remove unnecessary bits (Mainly there) Fit throttle cable Fit drives side thrust bearing and a few other bits! .. Around 40 days to next rally though.. Not worrying yet! Edited July 22, 2016 by cj1 1 Quote Link to comment Share on other sites More sharing options...
cj1 Posted July 22, 2016 Author Report Share Posted July 22, 2016 Tonight fixed the thread on the polo driveshaft, ran M20 x 1.5 die nut up and down it for a while and the nut now fits on perfectly, now to do the same for the other 3 I have! Removed pedal box , wish I'd have known this earlier but the only difference is the accelerator cable, anyway swapped it all over to the 6N pedal box, going to weld that up and modify it the same as the Lupo one to make it a by stronger and hopefully less prone to breaking. Tomorrow will be welding exhaust up, fitting new brass bearing in driveshaft stub axle and then getting on with bits! Hopefully be able to run the car for a bit as well. Quote Link to comment Share on other sites More sharing options...
cj1 Posted July 23, 2016 Author Report Share Posted July 23, 2016 6N / Lupo hybrid pedal box modified and fitted today, more wiring tidied up, driveshafts all connected properly now. Had car running for quite a while, all seeming ok , been changing some settings in the ECU. Ignition switch/key barrel/ steering lock removed also. More to do tomorrow!!! Quote Link to comment Share on other sites More sharing options...
cj1 Posted July 25, 2016 Author Report Share Posted July 25, 2016 Bonnet is back on, wiring strip down pretty much finished, re-assembling things now! 1 Quote Link to comment Share on other sites More sharing options...
cj1 Posted July 31, 2016 Author Report Share Posted July 31, 2016 Car all back together. Took it for a small drive yesterday, so much better! Love it. Needs mapping now , due to be done on the 15th August! Got a tablet with an app for the DTA ECU, so will be using that for the dashboard display. Quote Link to comment Share on other sites More sharing options...
cj1 Posted July 31, 2016 Author Report Share Posted July 31, 2016 1 Quote Link to comment Share on other sites More sharing options...
mattarosa Posted July 31, 2016 Report Share Posted July 31, 2016 Very nice, rest of the dash going? Quote Link to comment Share on other sites More sharing options...
WRC Posted August 1, 2016 Report Share Posted August 1, 2016 so you put an Android (?) tablet with ECU logging..and what app? very nice.. Quote Link to comment Share on other sites More sharing options...
cj1 Posted August 1, 2016 Author Report Share Posted August 1, 2016 18 hours ago, mattarosa said: Very nice, rest of the dash going? Not for now.... The original speedo does work, and so does the fuel gauge. The App relies on GPS for the speed, which whilst it's likely to be more accurate, it's also a bit delayed. The main thing for now really is the fuel gauge though. Maybe one day it will go, but certainly for now it's staying. 9 hours ago, WRC said: so you put an Android (?) tablet with ECU logging..and what app? very nice.. The app is called DTADroid, it's been developed specifically to work with a DTA ECU. Works quite well and the interface can be customized with loads of different bits of information. 1 Quote Link to comment Share on other sites More sharing options...
cj1 Posted August 13, 2016 Author Report Share Posted August 13, 2016 1 Quote Link to comment Share on other sites More sharing options...
666DUB Posted August 14, 2016 Report Share Posted August 14, 2016 Phew !!! mind boggling ( to me anyway ) what you've done to your car , looks great. Look forward to next update. Quote Link to comment Share on other sites More sharing options...
mattarosa Posted August 14, 2016 Report Share Posted August 14, 2016 Oooh the dohc 16v, leaving it n/a or? Quote Link to comment Share on other sites More sharing options...
cj1 Posted August 14, 2016 Author Report Share Posted August 14, 2016 2 minutes ago, mattarosa said: Oooh the dohc 16v, leaving it n/a or? Yeah it's the AFH from a 6N polo. Yes going to leave n/a, if I were to use forced induction then it would put me into a higher class where it wouldn't really be that competitive... Going to the rolling road for mapping tomorrow, excited to see what power it's producing! 1 Quote Link to comment Share on other sites More sharing options...
mattarosa Posted August 14, 2016 Report Share Posted August 14, 2016 It's a great little engine. And it's quite nice to look at too IMO Quote Link to comment Share on other sites More sharing options...
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