Kit Car Magazine October 2013 Preview

BOOST IS BETTER

Also inside

300bhp Road Runner SR2 Turbo

October 2013 / £4.50 / www.kit-cars.com

SUPERCHARGED COBRAAK Sportscars 580bhp Cobra Replica

TR1ke Build Continues ◆ IVA Advice ◆ Your Q&As ◆ Tech Tips ◆ New Products ◆ And more

Plus...Club News ◆ Show Diary ◆ Viper & Aeon Builds ◆ And much, much more

kitcar magazine / O

ctober 2013 / “Your essential monthly resource to build, restore and buy”

Tech

TURBO REBUILD

Plus...TURBO REBUILD

Learn to rebuild your turbo

Find us: Kit Car MagazineTweet us @welovekitcars

+

Your essential monthly resource to build, restore and buy

“Established for 34 years and still going strong”

Z-Cars Monte Carlo TurboDriving a wild 340bhp Hayabusa Turbo Mini

FRS Motorsport FRS3Bonkers front wheel drive tandem two-seater tested

10

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CONTENTS / OCTOBER 2013

20 TURBO’D ROADRUNNER

Testing the SR2 at Blyton

30 SUPERCHARGED AK

Can Rob Hawkins handle 580bhp?

36 CLASSIC GENTRY

The RMB Gentry is almost 40 years old

42 HAYABUSA TURBO MINI

Keith Wood test drives at Snetterton

49 DONINGTON SHOW REPORT

All the latest from CKC’s August show

86 FRS3 ROAD TEST

FWD Suzuki Bandit action, on the road

FEATURES

REGULARS9 NEWS

Dutton on TV and a new Caterham

12 FRESH AYRE

Turbo or supercharger? Iain decides

13 COMPETITIONS

Win a Dremel and tickets to the NEC Classic

16 CALENDAR

Forthcoming trackdays, races and shows

18 COMPLAINTS AND COMPLIMENTS

What do you really think of Kit Car magazine?

26 CLUB NEWS

Iain Ayre’s roundup of the club scene

Tech+56 TECHNICAL PRODUCTS

Find out what Forge can create

58 TECH QUESTIONS

Pinto engine trouble resolved

61 IVA EXPERT

Nigel Dean covers more updates

64 TURBO REBUILD

How to strip and rebuild a turbo

70 MEV TR1KE PART THREE

DIY quick rack conversion

76 READERS’ BUILDS

Aeon and Cobretti Viper builds

30

36

42

86

64

7049

4 Kit-Cars.com / October 2013

ISSUE 450 / OCTOBER 2013

PublishingKit Car Magazine is produced by

Silverback Publishing Ltd14 Victoria Road, Sutton, Surrey, SM1 4RT.

Telephone: 020 8395 2653

Publisher: Tom Saunders

Tel: 020 8395 2653Mobile: 07841 412199

email: [email protected]

Editor:Rob Hawkins

Tel: 07932 190756email: [email protected]

Advertising:Tom Saunders

Tel: 020 8395 2653Mobile: 07841 412199

email [email protected]

Classifieds ads:Tel: 0208 395 2653

email: [email protected]

Designed by: Keith Wood @ Hype Creative

Get in touch! We want to hear about your exploits in the garage,

the tears, the dramas and of course the joys of building and owning a kit/specialist sports car. Send

us your news, builds or club info to: [email protected] or

14 Victoria Road, Sutton, Surrey, SM1 4RT.

Copyright Silverback Publishing Ltd 2013.No part of this publication may be used or

reproduced without the written permission of the publisher. All the content in this magazine is for information only and as far as we are aware is correct at the time of going to print. Silverback Publishing Ltd cannot accept any responsibility

for errors or inaccuracies in such information. All readers are asked to check prices and services with the advertisers in this magazine as they are subject to change. Although great care is taken Silverback Publishing Ltd can not be held responsible for this publications contents, nor that of its freelance and

contributed material.

HELLO / WELCOME

My first taste of forced induction was over twenty years ago when I read Pat Ganahl’s book, Street Supercharging, which was largely aimed at the American custom car scene. As time progressed, it wasn’t long before turbos and superchargers were

finding their way into the kit car market thanks to production cars such as the MR2 and the growing popularity of forced induction amongst mass produced cars, making them the ideal donor components.

My memories of test driving forced induction kit cars start with a PRB Clubman in Australia that was armed with a turbocharged Toyota 4AGE engine. Even with a windscreen fitted, the air stung my nostrils on full boost. Over the years, I’ve driven everything from a supercharged J2 Midget to the 580bhp AK 427 on page 30. I will never forget the time Duncan Cowper set off in his Hayabusa turbo powered Dax Rush with me strapped in the passenger seat.

There’s no denying the exhilarating performance offered by forced induction, but there are other issues to consider, so this month we’ve covered the stripdown and rebuild of a turbo and tried to highlight some of the difficulties associated with supercharging and turbocharging, especially when it comes to test driving.

20

Nigel Dean / Technical EditorFirst kit car: RW Karma built at the age of 17

Other kits cars owned/built: Westfield SEiWide, Westfield Seight, Ultima GTR, Dax Tojeiro Cobra 427 replica, Dax Rush

Iain Ayre / Overseas CorrespondentFirst kit car: The first ever six-cylinder JC Midge

Other kit cars owned/built: Falcon Caribbean, Ayrspeed Swallow, Cobretti Viper, 2CV Manx, Ayrspeed Six & Eco-Ace

Tom Saunders / PublisherTom has been involved in the motoring industry for over 16 years, working on CCC before moving to Kit Car in ‘01. He’s

also worked on Performance French Cars, TRC & PPC Mags

Keith Wood / DesignerOver 12 years in the magazine industry and an impressive

22 years of motor racing experience. Keith found developing race cars as his most rewarding role.

OUR TEAM

Rob Hawkins / Editor

5

BOOST IS BETTER300bhp Road Runner SR2 Turbo

October 2013 / Kit-Cars.com

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Spal High Perf Fans£73.68from

Stack ST8100 Display£957.60from

Switches£3.01from

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Polybush Sets£26.99from

ITG Filters£15.00from

Racetech Single Seater£27.54each

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Aerocatch Bonnet Pins£45.10from

Rubber Bonnet Hooks£5.41from

Samco Hoses£9.02from

DCOE Carbs£345.60from each

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STACK ST8100 dash display systems from £957.60SPA DESIGN Dash £918.00RACE TECHNOLOGY dash 2 display £600.00ETB DD2 - lite dash display £418.80SPA Design Digital Speedometer £195.07Bright 6 Warning light module from £45.42

80MM SPEEDO AND TACHO’S STACK ST200 stepper motor tacho's £238.80STACK ST400 action replay recording tacho's £378.00STACK professional programmable speedometerfrom £186.00STACK ST700 tacho with intergrated dash displayfrom £450.00SPA DESIGN professional speedometer £286.02SPA DESIGN Combined tacho's from £264.61SMITHS speedo's and tacho's from £125.64

VDO speedo's amd tacho's from £106.34REVOTEC speedo's and tacho's from £132.92RACETECH speedo's and tacho's from £126.24

52MM ANCILLARY GAUGES SPA DESIGN digital dual display from £160.91SPA DESIGN stepper motor analogue from £112.61STACK pro control stepper motor analoguefrom £159.60STACK electrical/mechanical from £38.40VDO Vision range from £37.26SMITHS Classic range from £40.96SMITHS International range from £33.19SMITHS Telemetrix range from £34.50RACETECH gauge range from £40.84RACETECH gauge range from £41.26TIM gauge range from £12.80

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REVOTEC complete cooling kit inc radiator £238.80REVOTEC tailor made cooling kits available for mostclassic vehicle applications from £161.94KENLOWE high performance fan kits from £154.32Lightweight Heater £105.00Micro Heater £77.50DAVIES CRAIG electric water pumps from £155.99REVOTEC Electronic fan controllers from £65.04Aluminium hose inserts and joiners from £6.74REDLINE Water wetter £13.20REVOTEC Fan installation kit £17.94REVOTEC Fan pull through tie kit £7.14

Made in the UK, high quality, blue and classic matt blackin stock in popular sizes. Other colours to order. We have

Samco silicone hoses in stock for immediate despatch.

Straight 1m lengths from £18.4045 degree elbows from £10.4860 degree elbows from £10.4890 degree elbows from £9.73120 degree elbows from £12.44135 degree elbows from £12.44180 degree elbows from £14.40Straight reducers from £9.02

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AIR FILTERSITG Filters from £15.00K&N Bolt on filters single carb £31.93K&N Universal air box from £108.42K&N 57i induction kits from £31.85PIPERCROSS Ram pipe single socks pair £26.39PIPERCROSS Single carb filters inc base plate from £53.98PIPERCROSS Twin carb/throttle body inc base platefrom £104.38PIPERCROSS Air box kit cold air feed £221.99

STEERING WHEELSMOMO Model 26 non drilled suede260mm, 280mm or 290mm

£156.59SPARCO Model 300 drilled suede300mm inc horn push £169.99OMP Racing GP drilled Polyurethane330mm inc horn push £74.27MOTO-LITA Classic wood rim wheelsfrom £155.40Boss kits to suit most productionvehicle steering columns from £36.76

Quick release boss's from £96.00Steering wheel spacers from £58.99

WHY NOT VISIT OUR MASSIVE SUPERSTORE AND HIGH TECH 8 RAMP FITTING CENTRE MONDAY - SATURDAY 8.30am - 5.30pm

SPA DESIGN formula race from each £30.92RACETECH F1 from each £27.54RACETECH single seater each £27.54Kit car centre £33.54Universal short stem race (pair) £35.40Lightweight each £26.20Vitaloni Californian each £33.29Wide angle 14" or 17" cage mountedeach from £24.38

Huge rangeof fastenersand latchesavailable.

Aerocatch bonnet pins from £45.10Quick release s/steel bonnet pins from £8.63Terry/boot springs s/steel or black from £10.68Leather bonnet/boot straps £8.89Large or small rubber bonnet hooks from £5.41Dzus fasteners from each £3.62

AVO (each) Spax (each) CATERHAM Front Rear Front Rear7 de dion axle loop/loop fitting £96.00 £96.00 £99.99 £99.997 de dion axle stem/loop fitting £96.00 £96.00 £79.99 £79.997 Live axle £96.00 £96.00 £79.99 £79.997 K series £96.00 £96.00 £99.99 £114.99FORDCortina Mk3, Mk4, Mk5 £78.00 £72.00 £79.99 £79.99Sierra 2wd £120.00 £78.00 £119.99 £79.99WESTFIELDStd Body (English diff) £96.00 £96.00 £89.99 £89.99Wide Body Std track (Sierra diff) £96.00 £96.00 £89.99 £89.99

UNIVERSAL SHOCK ABSORBERSAVO single adj from each £72.00AVO double adj from each £132.00SPAX KSX single adj from each £64.72SPAX CSX double adj from each £113.18Springs 1.875", 2.25" or 2.5" from £20.90

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COOLING

SWITCHESCarbon ignition switch panels inc switchesfrom £45.00Alloy switch panels inc switches from £17.33Plastic toggle switches from £3.47Metal toggle switches from £3.01Push button momentary switches from £3.10Push/pull switches from £2.46Engraved aluminium push button switchesfrom £23.99Sealed push button switches from £11.14Illuminated rocker switches from £11.52

WARNING LIGHTS17mm screw fitting Black rim £2.96Polished ally rim £6.12LED indicator lights £5.99Warning LED labelled and waterproof £9.10Set of 3 (amber, red and green) 5.99Engraved aluminium warning lights £20.39

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KCAR SP 07-08-13_KCAR SP 08/08/2013 08:25 Page 1

BULLETIN

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Above: Floating fun in the shape of Dutton Surf. Below: Filming for the Gadget Man series on Channel 4

News, upcoming events, opinions and the latest gossip from the world of Kit Cars and the industry

9

Dutton GetS on GADGet MAn

Photographed here is the Dutton Surf being filmed for Channel 4’s Gadget Man series at Frant Lake in Tunbridge Wells. The Surf is an amphibious kit car based on

the Suzuki Jimny’s mechanical components, including its 1.3-litre petrol or 1.5-litre diesel engine, 4WD gearbox with transfer box, front and rear axles, dashboard, seats, wheels and tyres.

Whilst the Dutton Surf uses the Jimny’s powerplant to drive on land, when in the water, it uses a mechanical take off from the back of the transfer box to drive an eight inch diameter cast impellor made from marine grade LM6

Rory McGrath drove the car in 2010 as part of their programme, Three Men Go to Ireland.

Anyone wanting to see the Dutton Surf in action on Gadget Man can watch the entire episode that was screened on the 2nd September by visiting channel4.com and clicking on 4oD. More recently on the 2nd October on the National Geographic channel, Tim Dutton was featured on the programme Stripper – Cars for Cash, buying a Suzuki engine for a Surf.

For further information on the Dutton Surf, call Tim Dutton Amphibious Cars on 01903 713313 or visit:

www.timdutton.com

aluminium (direction control is via a stainless steel rudder). The drive is engaged and disengaged via a dog clutch lever between the front seats.

The Surf’s bodyshell is made from GRP with marine grade stainless steel spreader plates imbedded into the laminate for load bearing areas including the engine, gearbox, transfer box, steering, front and rear axles and dampers.

This isn’t the first time that the Dutton Surf has been featured on television. Comedienne Jo Brand drove the car for her Big Splash series covering weird things with a water theme. Griff Rhys Jones, Dara O’Briain and

october 2013 / Kit-Cars.com

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Forced PerFormance at Blyton

Roadrunner Racing have turbocharged their Mazda MX-5 engine SR2. Rob Hawkins meets up with them at Blyton to witness the results.

20

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Kit-Cars.com / october 2013

21

s

“I usually get up to 104mph on the straight,” comments Rachael Longstaff as we roll into the paddock and I realise my weight knocked

a whole 10mph off this top speed. Despite me being a handicap, Rachael still manages to impressively hurtle around the twisty circuit at Blyton with bags of confidence. Once the tyres had warmed up, she almost treated the long sweeping left hander of Lancaster as a straight section, accelerating hard in third before changing up to fourth and pressing hard on the throttle to get the best possible reading on the Stack dashboard. The only obstacle on this back straight is the infamous Wiggler – a

purpose made chicane consisting of a left, right, left with rumble strips. As we approach it, the dashboard’s speed reading is still in the Nineties, but an aggressive stab on the middle pedal sees the four pot Hi-Spec callipers with alloy bell mounted discs efficiently scrubbing off enough speed to be able to negotiate the twisty corners. Knocking down to third gear, Rachael negotiates the Wiggler with ease, manoeuvring the front wheels via a modified Mazda MX-5 steering column, connected to a custom quick steering rack with 2.4 turns from lock to lock.

As we head down the remaining back straight to the sharp left of Bishops, Rachael is back on the throttle for as much time as she

can before braking hard and turning in. This is a fairly uncomplicated corner, but then we’re soon onto the Bunga Bunga, which on the circuit map looks like it should be treated as two corners. Rachael manages to line up the SR2 and work her way through it competently, picking her lines and sticking to them each time.

The weather is warm and there’s masses of hot engine air blowing into my passenger footwell, so I’m becoming comfortably cooked from all angles. Fortunately, the tyres are still sticking to the tarmac and there appears to be no limit to the amount of abuse Rachael can give this car, especially when cornering. This becomes even more apparent as we head


What is turbOcharging?

In brief, turbocharging involves pushing air into the engine, instead of simply relying on it being sucked into the engine when the pistons move down. This is accomplished by the turbo, which is a sort of fan. It’s driven by the exhaust gases as they leave the engine, allowing fresh air to be sucked in and diverted into the engine. The results are simply greater performance because the air is pressurised, so it contains a greater quantity of oxygen, which is the key ingredients for combustion.

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FJ13004 Kit Car AWK A4 Bleed.indd 1 01/08/2013 16:27

Blown AwAyAK’s latest demonstrator is equipped with a 580bhp supercharged V8 engine and

six speed gearbox. Rob Hawkins eagerly steps into the driver’s seat.

30

AK427 CoBRA

EssentialsContact:

AK Sports Cars 01733 267633

[email protected] www.aksportscars.co.uk

W hen you’re faced with test driving a kit car that produces a ridiculous amount of brake horsepower, there’s little

chance you are going to find the limit of its handling and performance. Instead, you have to simply look forward to flooring the throttle in a straight line on an empty, dry road and seeing what comes next.

The first time I drove one of AK’s Cobras was back in 2003 when the manufacturer had a normally aspirated Edelbrock carb-fed Chevy V8 powered demonstrator (see the September 2003 issue for a full report). With around 300bhp at the flywheel, the performance was astonishingly good, but what was particularly important was the fact that the chassis and suspension could handle that amount of power. When the opportunity arose and I could accelerate hard, there were no vibrations

through the chassis or battles with the steering to keep the car continuing in a straight line.

Armed with fond memories of a refined ride quality, I have to admit I was a little apprehensive when AK told me they had supercharged their latest demonstrator and now had 580bhp at the flywheel. The power doesn’t scare me, but a car that cannot handle such power does.

The only way to discover whether my admiration of the AK would be wrecked or not, was to drive the demonstrator. First, AK’s Jon Freeman and I set out to take some photographs at one of Peterborough’s most well-known roundabouts, especially where motorbikers are concerned. Known for its frequent use by Motor Cycle News (MCN), Jon steadily drove around the large roundabout, allowing me to take a handful of action shots. Once we had finished, it was time to head onto the A-roads and dual carriageways around

Peterborough to see how the demonstrator performs.

Heading down a slip road to join a dual carriageway, I was eager to accelerate up to the national speed limit, but equally aware this AK could probably propel itself along at almost double this figure without a moment’s hesitation. It could be all too easy to approach the dual carriageway too fast and have to slow down instead of speed-up.

The familiar refinement in ride quality was still apparent as I worked my way steadily through the gears. The trouble with such a car that offers masses of performance is that you have to watch the speedo. Don’t trust your sense of speed because in most cases, you will be travelling a lot faster than you think.

After a few minutes spent travelling along the dual carriageway surrounded by several other cars, the opportunity arose to get ahead. With Jon sitting in the passenger seat, he


31October 2013 / Kit-Cars.com

What is sUPERchaRging?

Supercharghing is the oldest form of forced induction and dates back to 1860 when Francis and Philander Roots patented a blower for pumping large volumes of air into a furnace. However, it wasn’t until 1901 that the first supercharger was fitted to a combustion engine.

In brief, the principal of supercharging is to compress air and force it into the engine. A pump is used to draw and compress the air, then feed it into the engine. This pump is usually belt driven by the engine in the

same manner as a water pump, alternator or power steering pump.One of the problems of forcing air into the engine is that it can reduce the lifespan of the motor unless precautions are

taken. Ideally, the compression ratio of the engine should be low (below 10:1) and components including the pistons and conrods need to be uprated.

The benefits of supercharging are of course masses of extra performance, plus that performance is always available, unlike turbocharging where in most cases it’s only available once the turbo has started to spin.

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Option 1. After an initial outlay of £595 + VAT, for the Avon chassis, you can then start toadd the remaining components at a pace to suit either your spare time or your budget. Youcan either source components yourself from a ‘donor’ vehicle, and recondition them priorto fitting, or purchase components new from Tiger as, and when you need them. Eitherway, you dictate the build time scale.

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BUILD YOUR OWN KIT CAR:Layout 1 19/1/13 15:06 Page 1

Feb 2013 Pagination 2.indd 1 24/01/2013 12:32:38

Monte Carlo or BustZ Cars has created a monster of all Monte Carlos, featuring a Hayabusa turbo engine with 340bhp.

Keith Wood hangs on for dear life.

42

ZCars MInI

essentialsContact:

Z CarsTel: 01964 527725

Email: [email protected] Website: www.Z Cars.org.uk


Photography: Andrew Brown

43

I’m not the biggest fan of the Mini. Well, in the respect that I’m not a fan of any one car in particular - I enjoy driving and the thrill of driving. I couldn’t care less what the car underneath me actually

is so long as it’s making my arms work, my behind twitch and my mouth smile from ear-to-ear - the fun I crave behind the wheel could be in a Citroen Saxo or a Porsche GT3, if it’s good fun then I’d happily continue to play until I’m told to stop. For me the Mini, in its classic format, for a number of reasons doesn’t quite float my boat. Yes it has a character, yes it’s a wonderful chassis and yes it has the kind of loyal following that requires its own niche title magazines and multitude of specialists. But there’s only so much the chassis can take.

It’s a fact and for years the home grown revolution has created some wonderfully inspiring variations of the original Mini concept. I’m sure if you’re a Mini nut you don’t need me racking through the list of the landmark cars like the Vauxhall red top twin-cam conversions, the long nose Honda V-Tec kits and, more recently, a whole host of rear-engine models from Z Cars. However these road based converted models have lead onto establishing some of the most frightening space frame racing cars ever seen on our race tracks. These legends of the circuits (and hill climbs) were more silhouettes rather than Mini, a ‘step-back-and-squint’ resemblance of what was once the regular shape we’ve become accustomed to yet with a chassis developed for one purpose - going much, much quicker. Although the likes of KAD and UltraMini are still around today, the space frame market - for those of us outside the compact Mini circle - seems to be dominated by the charismatic Chris Allanson and his East Yorkshire based company, Z Cars.

His daft creations from steel shell Minis to his own space frame design came about after the ex-bobby spent his years pounding around Autograss events, knocking together his own racers kitted out with bike power. During the early years as a driver he didn’t do too badly either, winning himself the National Championship trophy in 1993 and gaining a wealth of car setup knowledge in the process. It was the placement of bike engines in cars that helped propel Allanson’s Z Cars to new heights, crafting road and race builds for customers. Of the 700 plus units produced it’s fair to say a large proportion were Mini shaped and easily the car we all associate with Z Cars.

Things were kicked off with Z Cars relatively simply, comprising a rear subframe with suspension, bike power and chain driven driveshafts. This kit revolutionised the way bike engines were fitted into the back of cars and (although Z Cars has created front bike engine conversions) does away with the rear bulkhead and the rear seat squab completely,


literally dropping onto the new subframe and bolting into place. With the A-Series ditched, the old engine compartment became the home for the fuel tank and the radiator. Before long a rear subframe kit turned into an optional full cage kit and the old engine bay was home to a Z Cars subframe with bespoke upper and lower wishbones and, much like the rear, again housed the pushrod suspension.

As you can tell, there was a pattern emerging - more and more of the original Mini was slowly being replaced by more track specific equipment or bespoke Z Cars designed elements. In fact, so much so that before long Chris and the team had created a complete space frame chassis with a moulded Mini style shell developed from fibreglass. I was the first to test the Z Cars space frame mule way back in 2005 and again with Honda K20a VTEC power a year later, and after both of these opportunities I stumbled away from the experience overwhelmed by the shear pace of the aptly named Monte Carlo. Z Cars had built a barnstormer of a car, one with outrageous acceleration combined with the type of grip reserved for aerodynamically efficient Sports Prototypes.

Without the aid of the original Mini shell it promoted Z Cars into a fully-fledged independent manufacturer, a landmark in the company’s history. Two years down the road from our initial first drives, the Monte Carlo has now grown up significantly. It has a drastically more user friendly body shell (the rear end removes completely to allow easy access to the engine) and for one man in Romania, even more power. Whether it was fitted with a K20a Type-R engine or the screaming 1.3-litre Hayabusa engine, the Monte attacked the circuit with as much velocity as the bravado of the pilot could handle, so the thought of even more power is unimaginable, but for the rally and hill climb competitor, Victor Baldescu, it was crucial.

Although a man with clearly no perception when it comes to sticker design or placement (check the graphics yourself if you need any proof), Victor certainly knows the basics when it comes to attacking a hill climb. So much so he employed the services of Z Cars to create one of the wildest Monte Carlo’s to date. But this wasn’t where his background and love for motor sport stems from. Back in his native home of Romania, Baldescu is a bit of legend in motor sport circles - a domestic rally champion aboard a Focus WRC and very popular with the spectators, too - although he is distinctly hell bent on winning inside anything with four wheels, whether that’s along a stage or up a hill.

The fact that winning comes as second nature to the team at Z Cars meant there weren’t going to be any problems in accommodating the Romanian’s needs. After all, they’ve built hundreds of special one-offs for s

Comprehensive Monte Carlo kit: £19,499+VAT (£23,398.80)Kit contents: Space frame chassis, GRP bodywork, aluminium panelling, glass and Perspex windows including heated windscreen, all suspension and brake components, hubs and uprights, driveshafts and drive chain with sprockets and LSD, engine/gearbox mounts, reverse kit, exhaust system, seats, fuel and brake lines, coolant pipes, cables, 13in wheels, Wilwood pedal box, steering rack and column, dry cell battery.

2 CPR Magazine

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SHOW REPORT

▲

SHOW REPORT: DONINGTON 2013

49

Iain Ayre spent the August bank holiday weekend at CKC magazine’s kit car show at Donington.


Complete Kit Car’s Donington show was remarkably well attended, given that the only news on the radio, television and newspapers during the preceding week

alternated between a girl who got run over by a taxi in New York, and continuous moaning that the weather for the coming bank holiday weekend was going to be crap.

Support from the kit car manufacturers was rather sparse, which was disappointing, given the huge effort the organisers put into the show. However, there was a pretty decent attendance from the public despite the weather warnings, and assuming that bad luck with

weather and media “news” doesn’t recur in 2014 as well, next year’s crowds will be much bigger as the show becomes established, and more manufacturers will show up.

Donington is a rather expensive venue for running a show because it has a racetrack, an excellent location and all sorts of other advantages that bring in lots of crowds. But of course kit car manufacturers during a depression are in a rock-and-a-hard-place position: they can’t afford to do the shows, but also can’t afford not to.

AK, Gardner Douglas, Hawk and Dax represented the Cobra theme, with Dax showing an interesting detachable Le Mans-

style hardtop of complex construction that looked both waterproof and cool, with the original bootlid retained, and nicely executed brightwork around the windows.

Healy Design showed a car inspired by the Austin Healey and based on the very useful Mazda MX-5 base. This uses BMW Mini headlights to update the 1950s Healey front end, and work has been done on disguising the Mazda door skins, so it doesn’t immediately scream MX-5 as most such body kits do.

MEV’s new Aston Martin DBR1 lookalike is interesting in the flesh, and is also Mazda based. Both of those kits should have been based on an updated British RWD twin-cam

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Tech+24 PAGES OF TECHNICAL INSIGHTS, GUIDES AND NEW PRODUCTS TESTED

56 TECHNICAL PRODUCTS

Find out what Forge can create

58 TECH QUESTIONS

Pinto engine trouble resolved

61 IVA EXPERT

Nigel Dean covers more updates

64 TURBO REBUILD

How to strip and rebuild a turbo

70 MEV TR1KE - PART THREE

DIY quick rack conversion

76 READERS’ BUILDS

Aeon and Cobretti Viper builds

61

6458

70

Turbo charging has gradually become one of the most popular engine modifications along with other forced induction methods such as supercharging. Most

modern diesel engined production cars are turbo charged and so too are the majority of high performance sports cars. Within the kit car market, many people are appreciating the huge power gains to be had from fitting a turbo.

Whether you are considering turbo charging, or already have a kit car equipped with a turbo charger, one aspect of this performance product that hasn’t been extensively reviewed is how to stripdown, inspect and rebuild a turbo. Few specialists are willing to give away their trade secrets, especially when it comes

to stripping and rebuilding, yet the parts and technology that go into most turbos isn’t particularly complicated.

The following pages provide step by step guides and information on how to inspect a second hand turbo (useful if you’re buying one at a show), strip one down, rebuild it and diagnose a number of turbo related problems. Rebuild kits are available for overhauling a turbo yourself, although as our rebuild steps show, it is essential to have a turbo balanced, which can be completed by a number of turbo specialists.

If you are stripping a turbo, you may find some parts are different to the ones shown in our photographs. However, the general construction of the turbo should be similar.

OVERHAULING A TURBO Rob Hawkins provides a comprehensive guide to inspecting, stripping and rebuilding a turbo.

EssentialsThanks to:

AET Engineering: www.aet-turbos.co.uk 01924 894171

Turbo Solutions: 01325 485800 www.turbocharger-solutions.co.uk – turbo

rebuilds from £160+VATTurbo rebuild kits:

(01253) 813396 [email protected] www.turborebuild.co.uk

TECH: TURBO REBUILD


PROBLEM: Engine stalls under acceleration SOLUTION: High boost pressure, which triggers the ignition cut off switch. Check the wastegate and actuator

PROBLEM: Engine lacks powerSOLUTION: Leaks, dirty air filter, worn engine, dirt on compressor wheel. Check air filter. Look and listen for leaks. Check pipework is secure and not blocked. Check condition of compressor wheel (remove with non-caustic cleaner).

PROBLEM: Black exhaust smoke SOLUTION: Leaks, dirty air filter, worn engine, dirt on compressor wheel, damaged turbo. Check air filter. Look and listen for leaks. Check pipework is secure and not blocked. Check condition of compressor wheel (remove with non-caustic cleaner).

PROBLEM: Blue exhaust smokeSOLUTION: Blocked induction system, internal engine or turbo wear. Obstructed oil drain line for turbo (renew).

PROBLEM: Engine uses oil SOLUTION: Blocked induction system or engine breathers. Obstructed oil drain line for turbo (renew). Turbo’s core sludged or coked up. Dirt on compressor wheel (remove with non-caustic cleaner). General engine problems (piston rings, valve guides). Check induction system. Strip turbo to check for internal wear.

PROBLEM: Whistling sound from turboSOLUTION: Blocked air intake duct to turbo’s compressor. Dirty or damaged compressor wheel – remove with non-caustic cleaner.

PROBLEM: Oil leak from turbine sealSOLUTION: Obstructed oil drain line for turbo (renew). Turbo’s core sludged or coked up. Blocked engine breathers. Worn turbo. Dirty compressor wheel – remove with non-caustic cleaner.

TROUBLE SHOOTER

Source: AET Engineering

PART ONE: Scrapyard InSpectIon

s

check there’s a nut on the end of the shaft at the compressor end of the turbo. this is usually a left hand thread, so if it’s missing, it hasn’t spun off. Someone has probably removed it or there’s a problem with the turbo.

check the blades on the wheels inside the compressor and exhaust turbine. If they are damaged, they must be changed, but this can signify internal wear of the bearings.

check inside the compressor inducer where the compressor wheel sits. Look for any burr marks caused by the rotation of the compressor wheel. If there are any marks, this indicates excessive wear in the bearings.

try to move the turbo’s shaft in and out to check for thrust play. there should be no more than 0.1mm of movement. Move the shaft up and down. there should be no more than 0.5mm of play.

rotate the shaft, making sure the blades rotate together on the exhaust turbine and compressor sides. If they do not, the shaft is broken and the turbo will need a complete stripdown and rebuild.

check inside the exhaust turbine around the blades for any burr marks (similar to step 3). Look for any cracks around the flap valve and ensure the flap valve is shut tight.

check the actuator body isn’t crushed or damaged and the arm is straight. attach an air line set to 2 bar of pressure to the actuator and make sure it operates the flap valve and doesn’t leak or stick.

Look for signs of sealant on the oil outlets and inlets. also, look for exhaust paste on the mating surfaces of the exhaust turbine. there should be no sealant or exhaust paste because it can cause internal damage.

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65october 2013 / Kit-Cars.com

20850

666666222626662626266626 SUPERSTORES NATIONWIDE666222626662626266626 SUPERSTORES SUPERSTORES NOWNOWNOWNOWNOWNOWSUPERSTORES NOWSUPERSTORES NOWSUPERSTORES NOWSUPERSTORES SUPERSTORES NOWSUPERSTORES NOWSUPERSTORES NOWSUPERSTORES

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GENERATORS Honda enginemodels available

FROM ONLY98EX.VAT

£79.98INC.VAT

£95 CHECK FRAME TYPE

WHEN ORDERING MODEL KVA HP EX VAT INC VATG720 0.7 - £79.98 £95.98G1200 1.1 - £159.98 £191.98FG2500 2.4 6.5 £189.98 £227.98FG3000 2.8 6.5 £219.98 £263.98FG3050 3 8 £359.00 £430.80FG4050ES 4.5 11 £459.00 £550.80FG5100ES 5.5 13 £539.00 £646.80

Ammeter Multi-position charge regulator Overload protection on charging cycle

BATTERY CHARGERS ENGINE STARTERS

MODEL MAX AMPS CHARGE/BOOST EX VAT INC VATBC100N 15/100 £47.99 £57.59BC130N 15/120 £59.98 £71.98BC190 38/180 £89.98 £107.98BC210N 25/200 £94.99 £113.99BC410E 35/400 £129.98 £155.98BC320E 35/310 £159.98 £191.98BC520N 50/510 £184.99 £221.99

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CPSB100

ANTI FATIGUE FOAM FLOORING

• 6 interlocking foam tiles protect fl ooring & provide comfort when standing or kneeling

Ideal for use in garages, workshops etc.• Each tile is 610x610mm & includes detachable, yellow borders

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£21FOR 6 TILES

MODEL START BOOST PEAK AMPS EX VAT INC VAT 900 400A 900A £49.98 £59.98 910 400A 900A £59.98 £71.98 4000 700A 1500A £109.98 £131.98 12/24 1000A@12v 2000A@12v £129.98 £155.98 500A@24v 1000A@24v

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Integral work light Extra long 1M leads 910 includes air compressor Long life battery

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IG2200

CAR RAMPS• Lift cars safely and quickly • Tough angled steel construction

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6 SPEED METAL LATHE

WITH 12 SPEEDMILL DRILL

- CL500M

SIZE (LxWxH) EX. VAT INC. VAT4.9 x 3.7 x 2.6M £299.00 £358.806.1 x 3.7 x 2.5M £349.00 £418.807.3 x 3.7 x 2.5M £399.00 £478.80

NEWRANGE

HEAVY DUTY INSTANT GARAGES/WORKSHOPS

• Ideal for both temporary and permanent use• Triple layered weatherproof, heavy duty fabric• Heavy duty powder coated tubing• Ratchet tight tensioning

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ZIP CLOSE DOOR

LENGTH UP TO 24'

PRESSURE WASHERS

KIT INCLUDES Compact Patio Cleaner,

Rotary BrushWORTH £67.97 INC.VAT

C120.6-6

120 bar, 1740psi 1400w heater 440ltr/hour water fl ow440ltr/hour water fl ow

KIT INCLUDES KIT INCLUDES KIT INCLUDES

440ltr/hour water fl owNEWNEW

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Compact Patio Cleaner, Compact Patio Cleaner,

PACKAGEDEAL

PRESSURE WASHER KIT

Compact Patio Cleaner,

V

BARNSLEY Pontefract Rd, Barnsley, S71 1EZ 01226 732297B’HAM GREAT BARR 4 Birmingham Rd. 0121 358 7977B’HAM HAY MILLS 1152 Coventry Rd, Hay Mills 0121 7713433BOLTON 1 Thynne St. BL3 6BD 01204 365799BRADFORD 105-107 Manningham Lane. BD1 3BN 01274 390962BRIGHTON 123 Lewes Rd, BN2 3QB 01273 915999BRISTOL 1-3 Church Rd, Lawrence Hill. BS5 9JJ 0117 935 1060BURTON UPON TRENT 12a Lichfi eld St. DE14 3QZ 01283 564 708CAMBRIDGE* 181-183 Histon Road, Cambridge. CB4 3HL 01223 322675CARDIFF 44-46 City Rd. CF24 3DN 029 2046 5424CARLISLE 85 London Rd. CA1 2LG 01228 591666CHESTER 43-45 St. James Street. CH1 3EY 01244 311258COLCHESTER 4 North Station Rd. CO1 1RE 01206 762831COVENTRY Bishop St. CV1 1HT 024 7622 4227CROYDON 423-427 Brighton Rd, Sth Croydon 020 8763 0640DARLINGTON 214 Northgate. DL1 1RB 01325 380 841DEAL (KENT) 182-186 High St. CT14 6BQ 01304 373 434DERBY Derwent St. DE1 2ED 01332 290 931DONCASTER Wheatley Hall Road 01302 245 999DUNDEE 24-26 Trades Lane. DD1 3ET 01382 225 140EDINBURGH 163-171 Piersfi eld Terrace 0131 659 5919

GATESHEAD 50 Lobley Hill Rd. NE8 4XA 0191 493 2520GLASGOW 280 Gt Western Rd. G4 9EJ 0141 332 9231GLOUCESTER 221A Barton St. GL1 4HY 01452 417 948GRIMSBY ELLIS WAY, DN32 9BD 01472 354435HULL 8-10 Holderness Rd. HU9 1EG 01482 223161ILFORD 746-748 Eastern Ave. IG2 7HU 0208 518 4286IPSWICH* Unit 1 Ipswich Trade Centre, Commercial Road 01473 221253LEEDS 227-229 Kirkstall Rd. LS4 2AS 0113 231 0400LEICESTER 69 Melton Rd. LE4 6PN 0116 261 0688LINCOLN Unit 5. The Pelham Centre. LN5 8HG 01522 543 036LIVERPOOL 80-88 London Rd. L3 5NF 0151 709 4484LONDON CATFORD* 289/291 Southend Lane SE6 3RS 0208 695 5684 LONDON 6 Kendal Parade, Edmonton N18 020 8803 0861LONDON 503-507 Lea Bridge Rd. Leyton, E10 020 8558 8284LONDON 100 The Highway, Docklands 020 7488 2129LUTON* Unit 1, 326 Dunstable Rd, Luton LU4 8JS 01582 728 063MAIDSTONE 57 Upper Stone St. ME15 6HE 01622 769 572 MANCHESTER ALTRINCHAM 71 Manchester Rd. Altrincham 0161 9412 666MANCHESTER OPENSHAW* Unit 5, Tower Mill, Ashton Old Rd 0161 223 8376 MANSFIELD 169 Chesterfi eld Rd. South 01623 622160MIDDLESBROUGH Mandale Triangle, Thornaby 01642 677881

NORWICH 282a Heigham St. NR2 4LZ 01603 766402NOTTINGHAM 211 Lower Parliament St. 0115 956 1811PETERBOROUGH 417 Lincoln Rd. Millfi eld 01733 311770PLYMOUTH 58-64 Embankment Rd. PL4 9HY 01752 254050POOLE 137-139 Bournemouth Rd. Parkstone 01202 717913PORTSMOUTH 277-283 Copnor Rd. Copnor 023 9265 4777PRESTON 53 Blackpool Rd. PR2 6BU 01772 703263SHEFFIELD 453 London Rd. Heeley. S2 4HJ 0114 258 0831SIDCUP 13 Blackfen Parade, Blackfen Rd 0208 3042069SOUTHAMPTON 516-518 Portswood Rd. 023 8055 7788SOUTHEND 1139-1141 London Rd. Leigh on Sea 01702 483 742STOKE-ON-TRENT 382-396 Waterloo Rd. Hanley 01782 287321SUNDERLAND 13-15 Ryhope Rd. Grangetown 0191 510 8773SWANSEA 7 Samlet Rd. Llansamlet. SA7 9AG 01792 792969SWINDON 21 Victoria Rd. SN1 3AW 01793 491717TWICKENHAM 83-85 Heath Rd.TW1 4AW 020 8892 9117WARRINGTON Unit 3, Hawley’s Trade Pk. 01925 630 937WIGAN 2 Harrison Street, WN5 9AU 01942 323 785 WOLVERHAMPTON Parkfi eld Rd. Bilston 01902 494186WORCESTER 48a Upper Tything. WR1 1JZ 01905 723451

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20850 CAR 3 RH.indd 1 14/06/2013 15:38

STEERING RACKRob Hawkins returns to MJ Motors to continue building his MEV tR1ke from Road Track Race. First he has to modify a Sierra steering rack.

Kit car building can often turn into an education, rather than a matter of bolting several parts to a chassis. When we delved into the contents of our kit from Road

Track Race and found a complete steering rack, but a spare pinion gear and rack, a quick phone call soon resolved our concerns. The steering rack is from a Ford Sierra and it can benefit from a quick rack conversion to reduce the number of turns from lock to lock. This entails

dismantling the steering rack and fitting the new parts supplied in the kit.

Some people may argue that Road Track Race should supply an already converted steering rack in their kit, but the labour involved in this has to be accounted for somewhere. Plus, there should surely be more to kit car building than bolting parts onto a chassis. Dismantling a steering rack for instance, allows you to see how it is constructed and understand what is involved in a quick rack

conversion.Our only dilemma when it came to the

steering rack was finding a suitable tool to undo a large plastic tension cap. We eventually made our own, using a half inch Whitworth nut welded onto a bolt. There is probably an official tool somewhere.

So with the steering rack converted and fitted to our tR1ke, we’ll be fitting the steering column next month and starting to assemble and fit the front suspension.

EssentialsUseful Contacts:

Road Track Race0115 978 0677

www.roadtrackrace.co.ukMJ Motors

01924 472404

TECH: TR1KE BUILD

TR1KE BUILD PART 3


Project CostsMEV tR1ke comprehensive kit £4800Bag of pop rivets £10Clarke pop rivet gun £35.98Yamaha R1 donor bike £1900Less sale of unwanted R1 parts -£450

Total Cost So Far…£6295.98

PART ONE: Sierra quick rack converSion

s

a standard Ford Sierra steering rack can be fitted to the tr1ke, but road Track race recommends uprating it with a quick rack conversion and can supply a new rack and pinion. The following steps show how we converted a standard Sierra steering rack.

First, we secure the standard steering rack in a vice and unscrew both steering ends using a large pair of water pump pliers. These steering ends attach to the track rod ends, which in turn attach to the steering arms.

using a blunt centre punch, we undo the aluminium cover shown here that secures the pinion gear. This is very difficult to undo and takes several minutes to unscrew the aluminium cover by tapping it round with the hammer and punch.

once the aluminium cover has been removed, the pinion gear can be extracted along with its centre bearing, which will need to be refitted onto the new pinion gear in step 10, so we place these parts aside and keep them clean.

There’s a plastic tension cap that needs to be undone to be able to extract the steering rack. We found a half inch Whitworth sized nut fits inside the cap, so welded it onto a bolt and used this homemade tool to undo the cap.

after undoing the plastic cap in the last step, we find there’s a spring and a plastic plunger/piston behind it. These need to be removed and stored aside before we can extract the main part that needs to be changed - the steering rack.

The standard steering rack can now be extracted. There’s nothing obstructing it, so Dan manages to pull it straight out and place it aside. it isn’t required for the tr1ke as a new one with a different set of teeth is supplied in the kit.

The bearing on the old pinion gear needs to be fitted onto the new pinion gear. First, we have to carefully extract a circlip from the pinion, which will need to be reused, so we make sure we don’t lose it.

1 2

4

6

87

5

3

71october 2013 / Kit-Cars.com

REVISIONS RETESTRob Hawkins returns to FRS Motorsport to reassess their tandem two seater, FWD bike engined kit car,

which has undergone several modifications, but is it noticeably better?

86

FRS3 TEST

EssentialsKit price:

£5,695Turnkey price from £15,750

Estimated build costs from £11,000Estimated build time: 4-6 weeks of spare time

Contact:

FRS MotorsportTel: 0113 2854 369

Wesbite: www.frsmotorsport.comEmail: [email protected]

“W hy do they have paddle shifts instead of a stick shift?” asks Jason

Reeve of FRS Motorsport with a cheeky look in his eye. I immediately have to think like Jason, who has spent most of his life racing a variety of motorbike derived machinery. “When you roll, a stick shift will break your legs!” he calmly answers.

Anyone reading this, who knows little about FRS Motorsport, may be gob smacked at such an attitude, but Jason is aware of the problems of racing, so he has safety at the top of the agenda. Spend some time with him and he will amusingly recall the triumphs and ‘offs’ he’s had over the years, which have allowed him to develop the FRS to the specification you see here.

I have returned to FRS Motorsport for two

reasons. Firstly, to test the latest changes to the demonstrator, which promise to make it easier to drive and more practical. Secondly, to prove to FRS Motorsport that I can drive their three-wheeler into their yard without stalling several times.

The FRS3 as it is now known, is an interesting slant on three-wheeler kit cars, which appears to work very well.

“You need to drive it like a front wheel drive car,” comments Jason. “If you push it hard around a corner and lift off the throttle, the back end will come round, just like a front wheel drive car.”

This may seem alarming, but the FWD ingredients of a three wheeler are arguably easier to drive than a RWD set up.

Under the GRP skin of the FRS3, which consists of 15 separate panels, there’s a multi-tubular spaceframe that’s constructed in house at FRS Motorsport, who are based near

Leeds in West Yorkshire. The suspension at the front consists of semi-elliptical double upper and lower wishbones connected between bespoke aluminium uprights and the chassis, with long connecting rods leading to a single coilover that features an adjustable pivot. By fitting different grades of polyurethane bush, the ride quality can be adjusted. A similar set up is used on hill climb cars, but with Belleville washers that look like a sprung washer, which cost around £12 each. Swapping bushes is a cheaper approach.

At the rear, the FRS3 has an in-house manufactured steel swing arm with a single coilover. FRS initially designed this to use the popular Golf style solid disc and single piston caliper with handbrake that’s used on many Seven types (available from the likes of Car Builder Solutions and Rally Design). However, they found the set up was heavy and the handbrake wasn’t as strong as they wanted

Kit-Cars.com / October 2013

▲


kitcar magazine / July 2013 / “Your essential m

onthly resource to build, restore and buy”

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2CV MehariFacelift your old 2CV for the

Facelift your old 2CV for the Summer & for under £5k

SDR V-StormSDR V-StormSDR V-S350bhp Subaru WRX

350bhp Subaru WRX engine three-seater

Your essential monthly resource to build, restore and buyTAKE A

LOOK INSIDE AT OUR FRESH NEW LOOK!NEW LOOK!NEW


RS200 TESTEDGet a donor car & build this kit for only £4k

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Plus...Club News ◆ Show Diary ◆ Crystal Palace Show

Show Diary Crystal Palace Show

Show Diary ◆ And much, much more

TechTechHEAD REPAIRHEAD REPAIRHEAD REPAIRHEAD REPAIRK-Series head gasket guide

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DASH 2 PRODISPLAY

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Plus...Club News ◆ Show Diary

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◆ And much, much more

TechTR1KE BUILDPlus...TR1KE BUILD

Our very own project beginsFind us: Kit Car Magazine


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Vintage Ribble PilotClassic Triumph Vitesse

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Kit Car Magazine October 2013 Preview