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Old 21-02-2011, 10:36 PM   #1
dunc
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Dunc Conway - S1 competition car build

The last few years I've not had much motivation for my car, even though I enjoy driving trackdays etc a hell of a lot, I just found new hobbies, friends etc so was enjoying other things can you say. I gradually did bits to it, new engine bought off Sandy, brakes, brake lines, suspension etc but I never had the umph to 'finish' it per se, and after having so many problems with bits it gets to you! Last few months have been feeling quite refreshed about it so I stripped it down to a shell to start again, sounds a bit silly as it was built up and just needed a few things doing to it, but I just hadn't put enough heart into it and know I can do a better job again if I go over it again, with a few more mods added in there too.

It was always a road/track car, however I am now building it with the intention of some form of tarmac rallying, so the shell will be seam welded, some strengtheners added in, and built according to the regs. I already have various bits and bobs for it, and luckily have the facilities to keep it in the state it is in. Here's a few pics.


JP4 with about 4k miles on it, had flywheel and clutch issues so had to come out anyway. Need a new flywheel and clutch combo now, already have a Helix paddle plate. GTi cams, springs and followers installed and running on DTA management.


The shell as it sits at the moment, on 2 trolleys All suspension and tank is removed, Cleaned all the tank gubbins up, ready for refitting. Will be installing new fuel lines too.



Bay getting prepped for seam welding.






Once its all welded the bottom will be treated and waxoiled etc, not done it before so need advice on what needs doing etc. The bay and interior will just be sprayed by myself, I don't have the funds to get it done proffessionally so will do the best job I can.


Interior loom has been stripped of everything not necessary, added in another fusebox for guages and some more ancillaries I will need. Cut off wiring to go in too, front of the dash is in my lounge.




Old seat rails cut out, new ones to go in. Shell getting prepped for seam welding too. Cage is in temporarily for when the seat rails get welded in to make sure they dont foul.




Steering rack stripped and cleaned, waiting for the Quaiffe quick rack now.




Suspension bits, rear beam is in pieces, need some new bearings and will put that back together.








Had a short gearstick that fits the quickshift made up before the Satchshifts came out




Am currently getting all the measurements done for the new seat rails, will be getting welded in soon, then everything can come out and seam welding can be done. Got my hands on a spit for that luckily, some rust to chop out too from a jacking point.

Theres lots more stuff for it but no more pics!

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Old 21-02-2011, 10:49 PM   #2
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Looking good Dunc, nice sized workshop for it too!
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Old 22-02-2011, 04:55 PM   #3
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Cheers Phil, yea its so handy having decent space to work in.
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Old 22-02-2011, 06:15 PM   #4
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Glad to see it's still on the go.
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Old 22-02-2011, 09:43 PM   #5
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Whoop whoop!
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Old 22-02-2011, 10:09 PM   #6
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Nice to see it getting some love again Dunc
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Old 23-02-2011, 06:28 AM   #7
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Have to admit i was always fond of this car, just had something different about it that caught my eye!!

Like the plans Dunc, keep up the good work mate.
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Old 23-02-2011, 10:44 AM   #8
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Progress eh? :O
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Old 24-02-2011, 05:04 PM   #9
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So, brakes. What a ball ache!

I bought some Wilwood 4 pots, which turned out once fitted that the bleed nipples were leaking, and are in dire need of a refurb. Pity I left it so long before trying them, as i paid over the odds and were told they were in good working order, lesson learnt!

So I got my hands on some 266mm 206 brakes. Turns out the dust seals were all ripped, althought they were sold as in good working order too So I stripped em completely, cleaned em up and fitted new seals.



Painted them up, went to fit them and the disc was rubbing on the outside of the carrier... How the hell someone has fitted them and then used the car as well just baffles me.



Turns out the disc was wrong, even though the right part number was on it. Faulty batch, I dont know? So at least I can use the calipers, and steelies will fit over them



Onto the rears, I bought some new refurbed calipers from BigRed, can't fault there service, very quick and in great working order.




Onto another problem I was having.

My clutch was dragging when engaging gears, after looking at countless 106's I noticed my clutch arm was sitting at a different angle to all the others, which led me to believe there was a flywheel issue. The flywheel I did have was a 1.3 one machined to fit a 1.6 size clutch. I think the combination of the machinist possibly machining too much off the face, and what I was told was a std 1.6 cover (running a Helix paddle plate), meant the release bearing was sat a lot further down the input shaft, and not getting enough travel to release the clutch fully when pressed.

How it was...


How it should be, borrowed a standard GTi flywheel and clutch off Mike, thanks


So I need a new flywheel and clutch!


And now something I've been doing this week, stripped the rear beam down to check my pins. They are OK, so cleaned up the moutning points, removed the bushes and have started spraying it.








dunc.
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Old 25-02-2011, 12:27 PM   #10
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Great stuff, you're really getting this going now!
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Old 10-03-2011, 09:25 PM   #11
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Mostly been working on Mikes S2 to get it ready for the season so not too much progress here.



Put an XSi strut on the NS and an old rear beam (Cheers Mike) on the back so I can attach it to a spit and turn it on its side and get the seam welding and rust treating done.

Made a mistake when ordering the site mounts, they cause the drivers seat to sit a bit off centre as they angle out and push the seat away from the exhaust tunnel. Bearings and bushes for the rear beam will be ordered at payday, so then that can go back together.

Cleaned up the fuel tank and breather system, just need to super glue the breather back together (doh!) so that is ready to go back on too.
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Old 11-03-2011, 09:13 AM   #12
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Keep up the good work, il be keeping an eye on your thread!
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Old 11-03-2011, 09:17 AM   #13
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What are you going to do about the seat mounts?
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Old 12-03-2011, 09:25 AM   #14
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What about this? (from Nickheads thread)

From this:


To this:
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Old 12-03-2011, 11:38 AM   #15
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This has shocked me

Great work Dunc nice to see its being looked after still and not rotting away. I look forward to seeing it in action - Eventually

Hopefully we will see regular progress updates
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Old 12-03-2011, 01:42 PM   #16
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Good spot Mike, only thing I can see as an issue is I have a plate welded above the handbrake so will have a look tonight.
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Old 12-03-2011, 10:20 PM   #17
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Tonight I have mostly been.... drilling spot welds. Just gotta cut the plate welded around the handbrake mount out and then can remove the skin.

Beam got degreased and painted up too.

Looking into the benefits of the diesel rad setup now..
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Old 13-03-2011, 11:58 AM   #18
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Have a look for the 306 version of that rad my man, it's got the thicker core but also has the built in header tank. I would have used it initially but the tank fowls the charger. If I remember it's only on the older 306 diesels, the newer ones have the bigger rad like the Gti-6.

I'm going to keep an eye on your seat mount progress, the door bars on my SD cage make seat fitment a problem. Would be good to get the seats lower and away from the bars.
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Old 13-03-2011, 12:46 PM   #19
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Cheers for the info.

These are the seat rails I have...



Got em from... http://www.motorsport-tools.com/inde...ucts_id=246157

Will be welding them in this coming week so will be sure to get pics. What seat mounts are you using now? I do like my seats low so the bars will be run along the floor and stitched along the bottom in a few places too as well as at the ends.
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Old 13-03-2011, 02:13 PM   #20
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Nice! They look lovely jubbly.

The guys that did my cage welded in bars for me at the same time. The door bars are pushed right up against the seats though, so much so that I have to pull the door bar in with a ratchet strap to get the sleeve back on. Not sure if it's just the shape of the seats or what but its not ideal!
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Old 16-03-2011, 10:06 PM   #21
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So I removed the middle double skin, leaving some more space, and less weight. Started to neaten up around a plate already welded over the handbrake mount as that had started cracking. Plan on a hydraulic handbrake so need to get some measurements of one to plan how its all going to fit in!


As I'm mounting the bars as low as possible, I chopped the lip off the bottom of the brackets so they don't foul the floor. Spent a while after planning where the bars are going to go across etc.


Pic of my beam
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Old 29-03-2011, 09:09 PM   #22
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Slow progress, but its progress. Got round to sorting some new side mounts, thanks to YB Racing. My welder friend has been quite busy so getting him round to working on mine has had to wait! Got all my measurements done for my seat rails and started tacking them in place to check everything, lowered the floor near the sill for the rear rail as I like the seats low so wanted them as low as poss.










Unfortunately, a mistake when measuring meant I chopped one of the rails too short so need to source another Once the passenger side mounts are in place I will continue to finish off the spreader plates at the end of the rails etc and mount the tabs for the sidemounts.
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Old 29-03-2011, 09:12 PM   #23
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Nice one Duncan-onio
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Old 29-03-2011, 09:17 PM   #24
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A few other bits have also been painted/bought...





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Old 29-03-2011, 09:19 PM   #25
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Was that delivered to your work? Or were you going to fit it into an R8???
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Old 29-03-2011, 11:01 PM   #26
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Did you cut the seat rails far too short? Have you factored in some 5mm mounting plates at either end?
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Old 30-03-2011, 09:30 AM   #27
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you have the same seat rails as me Nice work dude
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Old 30-03-2011, 11:40 AM   #28
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They're the seat rails I'm after. Don't seem too bad for the money! some sets are well expensive.

What make is your roll cage? I have the same one fitted in mine, I'm pretty sure its an OMP cage but not 100% sure.
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Old 30-03-2011, 11:51 AM   #29
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Yep its an OMP, I have the part number at home if you want for your records.
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Old 30-03-2011, 11:56 AM   #30
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Thought it was. If it's not too much trouble then that would be great.

Have you got the seat rails finished yet? Be good to see the job done as I'm planning on doing the same thing. Mine are currently bolted straight through the floor.
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Old 28-04-2011, 09:53 PM   #31
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Had a busy few weeks and finally got hold of the mechanism to put the car on its side and started cleaning up the underneath. Chopped out some rust under the drivers footwell, more needs to be chopped in the arch. Day off tomorow for the royal wedding so will be continuing.




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Old 20-05-2011, 11:08 PM   #32
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Been making progress with getting rid of the rust! The NSR jacking point was bad, on the brink of snapping it was that thin so all thats sorted, put in a new jacking point. Plated up a few others bits and bobs, removed the OSF chassis gusset thing as that was starting to go, also some running along the footwell seam which has been removed.






Hopefully get some more done tomorow once we have put Mike's head back on his S2
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Old 02-06-2011, 08:02 AM   #33
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Good work Dunc - some serious stuff going into this by the looks of it!
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Old 21-06-2011, 10:11 PM   #34
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Cheers Lewis.

Welding has been slow as welder has been hassling, cracking on with it now though. Seam welding is half done, most of the rust sorted, just got what seams the norm on s1's left to do now, the drivers footwell gusset thingy to weld in.



Rear beam is all built up with new bearings too.



Polybushes not arrived yet
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Old 06-07-2011, 08:03 PM   #35
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Picked up a tank guard last week, gonna modify it to fit a bit better whilst the car is on its side. Need a sump guard and fitting kit now!

Quick trial fit of the guard, needs bending straight and a few tweaks.


Polybushes arrived


Got my quickrack and correct pinion on the weekend so put that back together tonight
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Old 06-07-2011, 08:11 PM   #36
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Project really looks like it's coming on mate!
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Old 12-07-2011, 07:10 PM   #37
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Thanks bud, how's yours coming along?

Front antiroll bar options. 18mm and 22mm. Looking for a 20mm to complete the set!
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Old 12-07-2011, 07:31 PM   #38
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whats that little extra bit thats on the rallye one?
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Old 12-07-2011, 08:12 PM   #39
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you don't want the 20mm one ,,,bushes are really stupid prices - 50 iirc !
If you really want one then I could maybe be talked into selling one ;-)
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Old 12-07-2011, 08:32 PM   #40
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Its to hold the roll bar in position Craig.

I did have what I assumed was a 20mm one, came off an xsi, but turns out its 22mm so getting rid of that as I don't need 2! Didn't realise the bushes were so expensive, how odd.
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Old 12-07-2011, 08:34 PM   #41
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the 1.6 xsi came with a 22mm ft arb
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Old 12-07-2011, 08:42 PM   #42
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It was a 1400 :S

It's alright, il put the bushes on Mike's bill
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Old 12-07-2011, 08:53 PM   #43
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lmfao !!
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Old 13-07-2011, 12:21 PM   #44
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Just had a look and the powerflex ones are about 20quid? Or are you not a fan of them?

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Originally Posted by Garry.M View Post
you don't want the 20mm one ,,,bushes are really stupid prices - 50 iirc !
If you really want one then I could maybe be talked into selling one ;-)
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Old 13-07-2011, 01:18 PM   #45
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Which bushes are you after as I've got some PolyRace ones.
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Old 13-07-2011, 04:40 PM   #46
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do they list ones to suit the 20mm Xsi bar ? ,,,I've seen 19mm ones listed but thats for the poverty spec arb which are totally different
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Old 13-07-2011, 04:46 PM   #47
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http://106parts.com/s2/page1.php?are...=19&part=16282

Without seeing a pic its hard to tell, wonder if Mark has some in stock, could get a pic...
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Old 13-07-2011, 05:18 PM   #48
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Tin top racer? (title change) - you racing with Mike?
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Old 13-07-2011, 06:15 PM   #49
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Old 13-07-2011, 06:49 PM   #50
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Truce?
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