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Old 26-12-2010, 07:41 PM   #1
Steven Gault
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New Rally car build- Saxo S1600

Hi. My name is Steven Gault and I run a successful competition engine business and rolling road dyno here in NI.

I have competed in a 106 cup car since 2007 and have won 6 championships in it since then.

Having run several customer S1600 cars , I knew what i needed to do to further my own performance.

So having sold my previous 106:



I have now started on the build of a Saxo S1600.

I'll show you the build over next few months and hopefully you'll find it interesting.

I do however have a genuine works Citroen sport car to reference.. heres a pic or 2 of it..





all thoughts and comments welcome

Last edited by jameshilton; 09-01-2011 at 06:48 PM.
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Old 26-12-2010, 08:01 PM   #2
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Not enough of these about

Is it going to be all Citroen Sport parts or will it deviate at all?


One suggestion regarding the pictures, slightly smaller ones than 3027x2304 are preferred for quicker forum browsing
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Old 26-12-2010, 08:15 PM   #3
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Steven, cant wait to see some more pics of your saxo, ill stick those ones i took when i came over of the red one up when i get a minute!
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Old 26-12-2010, 08:18 PM   #4
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yea.. realised that about the pics.. sorry.

Citroen sport parts- no- I run a C2S1600 here for a customer and Citroen only really want you in it or a new DS3, they are not interested in older saxo so parts are discontinued. I managed to buy the last works shell and a few parts but im on my own with the others and will have to refer to the other works one here in order to make a few.. but engine wise.. no prob.

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Old 26-12-2010, 09:04 PM   #5
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looks VERY nice.. if you get chance i`d love to see some pics of how they revised the right hand engine mount.. i`ve seen pics of the bosses that go in the chassis rail on a 106maxi but have never seen the mount they use and the bracket that bolts to the block...

cheers
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Old 26-12-2010, 09:52 PM   #6
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so essentially a S1600 Kitcar
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Old 27-12-2010, 09:55 AM   #7
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good look to you pal, love the look of your old 106. what was the spec of the old one?
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Old 27-12-2010, 12:43 PM   #8
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nice to see another tuner on the forum
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Old 27-12-2010, 04:38 PM   #9
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hi, you will see the engine mounting very soon as im currently doing a drawing!!

welshpug- its not a Saxo Kit car.. having worked at several there are a surprising amount of differences between the kit car and the s1600...not just a different set of induction. eg top mounts, gearbox, shafts, Front hubs, rear roll bar, rear arms. I'll go thru the differences as i build it up.

My old 106- It went thru several specs as I developed the engine. I did a lot of work on cam profiles and the 2 head specs we used spent a massive amount of time going between our flowbench and dyno to arrive at a spec that now outperforms the last works engine we had here from Oreca.
it was originally a cup car and I ran it as such for one year, the final spec car had a Saxo Kit car 6 speed SMAN dog box, and our top spec 1600 engine. I set 5 hillclimb records with it in that spec and regulary ran it in the top 10 beating the 400bhp subaru boys etc.

Heres a link- im the last car thru in this section

heres the 2007 spec engine in my partners car (which is now for sale).




the shell: The shell is a geunine Citroen Sport number 554 (of 557) Saxo S1600. Its similar to a KC shell except for front suspension top mounting and gearbox tunnel (KC didnt have a sequential box).

Above is a pic of the bare shell being mocked up with my seating position. I have a steeringcolumn fitted and a pedal box mocked up to get my place in the car right. Anyone who knows me will testament to how ocd i am about my seating position.. thats why this took a whole week to get right.

The seat mount rails are already in the shell but i couldnt get the seat low enough yet far enough forward (im a short guy- 5foot6), so we had to modify the Sparco seat rails slightly. I suppose i could have changed the seat but Ive had it in my previous 2 cars and it just feels like home..

The bumpers were dummy fitted to fabricate the brackets, same with gearbox mounting and gearlinkage bracket which still isnt right and numerous fixings for looms, ecu, master switch and fire ext etc. A bracket was welded to the rear cage stay for the Dry-break fuel couplings for the tank, Then it was all taken apart and preped for paint.


Last edited by Steven Gault; 27-12-2010 at 04:38 PM. Reason: Automerged Doublepost
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Old 27-12-2010, 05:10 PM   #10
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I like your 1st vid clip, your 1k + rpm higher than any other car there.

Was that car built as a rally car rather then a speed event car?
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Old 27-12-2010, 07:01 PM   #11
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Hi Steven,looks like you are going to be busy and I'm looking forward to following this.
Do you do any work on the black Saxo kit car for David Lenard in Sligo?

PS. I'm the guy that called you a few weeks back about the cup car AP's
but you had them just sold.
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Old 27-12-2010, 07:37 PM   #12
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Quote:
Originally Posted by Steven Gault View Post
hi, you will see the engine mounting very soon as im currently doing a drawing
that`d be very kind... i`ve seen some that that they sell @ TRi motorsport but they look different to whats fitted to the maxi`s and the little bit i can see in that engine bay pic you posted...

i`m guessin its changed on these cars due to the tub`d front archs??
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Old 28-12-2010, 08:37 AM   #13
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heres the 2007 spec engine in my partners car (which is now for sale).

whats the spec and is it advertised somewhere?
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Old 28-12-2010, 10:32 AM   #14
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i can send you some pics if you want-. send me an email

190bhp/ sadev ST75 seq box, stack dash etc built from a new shell. A multi championship winner in its own right.

dieseldave- never worked on Davids car- although he did enquire about an engine recently. His car is a S1600 but has been changed a lot from the homologated car. eg its now RHD for example and has a upright pedal box in it. It is for sale at minute i think

here is what we have started with. direct from the Citroen Sport Evo 2 book.



and here is the top engine mount from the book.



which is no longer available, so im just about to make one...

Steven

Last edited by Steven Gault; 28-12-2010 at 10:32 AM. Reason: Automerged Doublepost
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Old 28-12-2010, 12:02 PM   #15
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ahhhh looks similar to what TRi sell...





look forward to seeing your version...
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Old 29-12-2010, 09:10 AM   #16
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Here is the completed part. Bottom of bracket is all machined away for lightness, its not a solid part.



Steven
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Old 29-12-2010, 09:27 AM   #17
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Very nice !
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Old 29-12-2010, 07:24 PM   #18
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Yes, I like that. I had two track cars that broke the bolt in the mount.

On my rally car I drilled and tapped out to M10 and fitted a 12.9 bolt
but that is a much better way to do it.
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Old 29-12-2010, 11:04 PM   #19
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Looks interesting, I'll be keeping an eye on this one
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Old 29-12-2010, 11:08 PM   #20
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Good luck with teh build.
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Old 29-12-2010, 11:27 PM   #21
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In the engine pic of the Citroen works car, is it single TB or on ITBs? The plenum looks interesting.
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Old 30-12-2010, 07:50 PM   #22
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Pete- I spy a single TB in the top left hand corner of the pic..

Steven- that engine mount looks lovely, top stuff

Steven, where did you source your saxo kit car front arches?

Are they the kevlar items? Does anyone produce a Fibre glass cheap alternative?

Last edited by Saxosteve; 30-12-2010 at 07:50 PM. Reason: Automerged Doublepost
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Old 30-12-2010, 09:07 PM   #23
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Aleksandr- plenum is single throttle , Gen Citroen Sport package and is for sale at the minute along with the Magnetti Marelli MF4 ECU and works tarmac map that matches it. .. You dont want to know how much these parts are from Citroen..

SaxoSteve- the S1600 or kit car arches are genuine Alloy ones from Citroen Sport, I got them with the shell. Over 600 each new and are no longer available. The can be got in fibreglass from like of PamSport and BPS Rallye in France. I have moulds of them and other parts - brake ducts/ front bumper, floor tray as we run several for customers and are the first bits damaged

Steven
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Old 31-12-2010, 10:09 AM   #24
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Very interesting build, love the workmanship of the engine mount :y:
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Old 31-12-2010, 04:32 PM   #25
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The shell is away for paint.
I know my limitations and paintwork is definitely outside them. A friend in the trade will be doing it between jobs. He will paint underside/ arches and inside to a final finish but leave outside just painted, so that i can build it all up and not worry too much about minor scratches as its very difficult to fit up a rally car and not mark the paint. Then it'll go back for final finish to outside.

So while its away Ive been doing those jobs that you keep putting off-

Here is the Ecu bracket fitted to the rear of the navigators foot tray.



and the view thats seen.



The pedal box:

Its a genuine Citroen Sport one but a friend gave it to me for free as he had cut it up and used bits from it when converting his car to RHD. It was a mess. I had to fabricate new pedal pivot posts, new pivots, bushes for them, master cylinder mounts and the gearbox mount to master cylinder stady bracket. I used some typical Mk2 escort type balance bar and bias adjuster to complete the unit.

Here it is


Last edited by Steven Gault; 31-12-2010 at 04:32 PM. Reason: Automerged Doublepost
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Old 31-12-2010, 07:40 PM   #26
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Aleksandr- plenum is single throttle , Gen Citroen Sport package and is for sale at the minute along with the Magnetti Marelli MF4 ECU and works tarmac map that matches it. .. You dont want to know how much these parts are from Citroen..

SaxoSteve- the S1600 or kit car arches are genuine Alloy ones from Citroen Sport, I got them with the shell. Over 600 each new and are no longer available. The can be got in fibreglass from like of PamSport and BPS Rallye in France. I have moulds of them and other parts - brake ducts/ front bumper, floor tray as we run several for customers and are the first bits damaged

Steven
Some more detailed pictures of it would be great if it's not too much hassle. I doubt I could afford it but I'm interested to see how it all fits together.
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Old 05-01-2011, 12:23 PM   #27
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Looking good Steven. Have a look at my thread as it may be of some interest to you also. I had a look at your website there and noticed you had some snaps of Bic's old car (or version on there) whcih grabbed my attention. Can you source kit car exhaust systems at all, as that's the last part I need to get my Rallye finialised for set up. I have a KRS manifold already, just need the rest of the system. Cheers,

Lewis
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Old 06-01-2011, 03:18 PM   #28
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we use the group 4 escort ex and then modify it to suit as the proper one is a fortune and is really nothing special. Our dyno results would back this up too. our noise regs stipulate 108db, the works system is on the limits... ours is normally around 100-105 depending on which monkey measured it and at which event.
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Old 07-01-2011, 09:26 AM   #29
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looking foward to seeing this as i have just got a saxo kit car with s1600 up grades on it and it just about finished.
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Old 07-01-2011, 10:02 AM   #30
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looking foward to seeing this as i have just got a saxo kit car with s1600 up grades on it and it just about finished.
Don't just talk about it then, get some photo's up man!


Steven: Problem being is I need a 2.5'' system to mate the KRS manifold that I have. As per this pic:

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Old 07-01-2011, 10:47 AM   #31
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Don't just talk about it then, get some photo's up man!


Steven: Problem being is I need a 2.5'' system to mate the KRS manifold that I have. As per this pic:

Is your car on the road yet lewis or are you still talking bout it? ;p
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Old 07-01-2011, 11:33 AM   #32
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Don't just talk about it then, get some photo's up man!


Steven: Problem being is I need a 2.5'' system to mate the KRS manifold that I have. As per this pic:

New to forum how do you upload photos?

[img]100_2428[/img]

Last edited by kitcar; 07-01-2011 at 11:33 AM. Reason: Automerged Doublepost
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Old 07-01-2011, 12:17 PM   #33
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You'll need to use an image hosting service like http://tinypic.com/
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Old 07-01-2011, 12:20 PM   #34
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Is your car on the road yet lewis or are you still talking bout it? ;p
I am still talking about it!

No I do have it in my mind to finish it this year mate, just expensive, and no longer have the same disposable income hence the delay...
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Old 08-01-2011, 11:01 AM   #35
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Looking good Steven. Have a look at my thread as it may be of some interest to you also. I had a look at your website there and noticed you had some snaps of Bic's old car (or version on there) whcih grabbed my attention. Can you source kit car exhaust systems at all, as that's the last part I need to get my Rallye finialised for set up. I have a KRS manifold already, just need the rest of the system. Cheers,

Lewis
http://www.britishrally.co.uk/classi...ew.php?id=4276 this may be of some interest to you lewis!
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Old 08-01-2011, 11:40 AM   #36
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http://www.britishrally.co.uk/classi...ew.php?id=4276 this may be of some interest to you lewis!
Cheers dude, but I think Colin off Saxp has already bought it. He's building a tarmac rally Saxo, not sure what his engine spec will be but pretty good from what i've seen of his parts list!
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Old 08-01-2011, 08:13 PM   #37
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Yeah I got that LOL.

My cars ready to rock, new engine will be 190bhp I hope!

Steven, Im completely mad on Saxo kitcars and s1600s, will keep my eye on this!
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Old 08-01-2011, 11:34 PM   #38
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Get some pics up Kitcar and Colin, the more knowledge and spec'd up motors are very welcome!
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Old 09-01-2011, 02:42 PM   #39
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Hi Kitcar.. what s1600 upgrades did you put on kitcar?


Steven
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Old 09-01-2011, 05:06 PM   #40
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Steven, is Andrew Bushes car ex Max Mckillen / Niall McShea and used to run a H pattern box? Famous car in my eyes!
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Old 09-01-2011, 08:58 PM   #41
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Andrew had indeed the ex Mcshea car. He bought it damaged , it was repaired and he ran it with H pattern Sman box.

He kept breaking the box, so it was replaced with a Sadev St75. I bought the Sman box and rebuilt it and used it in My 106 for 2 years.. Never had a single problem with it.

The saxo is in Spain now

He then had a Ex French tarmac s1600 saxo. It was a fabulous car. It is still being run by ourselves.

Andrew has been running a C2R2 S1600 for last couple of years.
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Old 10-01-2011, 11:33 AM   #42
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Hi Kitcar.. what s1600 upgrades did you put on kitcar?


Steven
Stevan, sent some pics of kit car to your email, having problems putting them on here.

Chris


Last edited by kitcar; 10-01-2011 at 11:33 AM. Reason: Automerged Doublepost
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Old 10-01-2011, 01:56 PM   #43
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Andrew had indeed the ex Mcshea car. He bought it damaged , it was repaired and he ran it with H pattern Sman box.

He kept breaking the box, so it was replaced with a Sadev St75. I bought the Sman box and rebuilt it and used it in My 106 for 2 years.. Never had a single problem with it.

The saxo is in Spain now

He then had a Ex French tarmac s1600 saxo. It was a fabulous car. It is still being run by ourselves.

Andrew has been running a C2R2 S1600 for last couple of years.
So the "ATC" reg'd car is not the "TIL" reg'd car? Yeah noticed Andrew swapped to a C2, hes very quick! Thanks for the info Steven
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Old 13-01-2011, 09:35 PM   #44
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Old 13-01-2011, 09:49 PM   #45
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those arches are awesome!
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Old 15-01-2011, 04:37 PM   #46
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Ah! I recognize that car still on iTBs too
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Old 15-01-2011, 04:41 PM   #47
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Interesting pedal box, any more information on it?
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Old 15-01-2011, 05:40 PM   #48
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heres first bit of paint on mine.. starting to look like it should..



and underneath



Steven
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Old 15-01-2011, 11:35 PM   #49
scottmmw
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looking well, make sure to keep us updated
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Old 16-01-2011, 05:53 PM   #50
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Looks very nice mate. Who's doing the engine and what power you expecting?
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