Ghall2004 "RoboCoop" 220 Coupe Turbo Spec/Progress

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ghall2004
Forum User
Posts: 69
Joined: Thu Jun 30, 2011 2:20 pm
Location: Edinburgh

Re: Ghall2004 "RoboCoop" 220 Coupe Turbo Spec/Progress

Post by ghall2004 »

Updates

Thanks to Ryan ( RY220) for the following work( please excuse the iphone 3gs tech images, Kelso is a small town who just recently got wap enabled mobile devices
:P :P )


front hubs supply
sand blast
replace front wheel bearings
primer
base colour coat
seal

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ghall2004
Forum User
Posts: 69
Joined: Thu Jun 30, 2011 2:20 pm
Location: Edinburgh

Re: Ghall2004 "RoboCoop" 220 Coupe Turbo Spec/Progress

Post by ghall2004 »

Quick update, full write up to come later once i have had the tracking/alignment done

Major front and rear end works
Gaz fitted
Top mounts fitted

Just getting the front and rear setup and all the niggling things sorted out. hoping to get TRE changed and a initial geometry reset/adjustment tomorrow

Car has been off road for a week and a half.

but its getting there, front is currently slight higher than rear, but this is where i left it for the night as car was feeling better at the front at this height. initial first drop after fitment i think it was too low and bottoming out :(

Recently re coated superleggera's and new parada spec 2's fitted

Camber was more aggressive but had to dial it out as it had thrown the already massively different TOE values, making the car un drivable. will get it setup again for around -1.5 to -2 once i have it drivable again and a baseline solid setup

need to fart about with some more things to get the best out of the front struts, then adjust bump/rebound as i go

iphone and scotch mist = rubbish images, and excuse the poor colour match on the flap

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ghall2004
Forum User
Posts: 69
Joined: Thu Jun 30, 2011 2:20 pm
Location: Edinburgh

Re: Ghall2004 "RoboCoop" 220 Coupe Turbo Spec/Progress

Post by ghall2004 »

Rear End make over

Objective here is simple. Replace and renew. Source parts as follows taken from the fallen hated N261FDH

All poly bush fitment where obvious
Rear trailing arm assembly
rear upper and lower lateral links
Skunk2 LCA
ARB D bushes and drop links
Upper shock shaft/top mount

Also to be installed
260mm zr/zs brake setup
overhaul calipers
Gaz rebuilt coilover package
Rear CABLEGUY lower brace
Upper rear brace
Stainless brake lines

things started slow, pissing down rain the whole weekend ( 17/5 + 18/5)

I feel most of the components on this car are original to an extent. Never have i encountered such rust/seized items

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Off to a good start, had to spend most of the first day cutting, and grinding the inner lca bolt to chassis on both sides of the car. All bushes and roll pins solid, perished.

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bolt seized in bushing/roll pin
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after years of pee ing about
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condition of the trailing arm bushes " leave it alone they say" what evs

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lca inner bush, well whats left of it
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Then this happened, just was too far gone the fitting, simply snapped when i attempted to free

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Other side started to be tackled
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Moving on....
Lower rear brace offered up for template/pilot holes
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Waxoly the arches

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Arb in mid installation
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The following day i was able to start to put the puzzle back together

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skunks offered up
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New lines made for both sides at the back
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Attention then turned to removing the top mounts from old struts
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new bushes
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Had to get the support of gaz, down to my rebuilt rear struts having this chammfered element to them as opposed to a traditional " step"
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this meant i had to get gaz to make up some tapered washers to allow me to successfully install the rear top mounts

Now these are rebuilt "gha" bodies but uprated internals *laymen terms summary of response from gaz to the gha vs gold saga

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Sneak of the goodies up front, just figuring out how to put it all together

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Back to the rear end folks

struts in place and getting more complete by the minute
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upper rear brace
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lower shot again
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Rear brakes and pretty much the rear end rear for a test run. ride height i played super safe with for initial road test
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Go genuine carbon effect oz center caps or go home. simple as that
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Front write up to follow
ghall2004
Forum User
Posts: 69
Joined: Thu Jun 30, 2011 2:20 pm
Location: Edinburgh

Re: Ghall2004 "RoboCoop" 220 Coupe Turbo Spec/Progress

Post by ghall2004 »

Front end works

Objective here

all suspension bushes
new low control arms
track rod ends
coil over installation
adjustable top mounts
refurbished hub assembly and new wheel bearings

Again bushes in the their biggest part already taken care of previously

No bolts snapping or delays, front end work was more pleasurable as i had been working on front end in recent weeks

sheer stopping power of 262mm
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awww nawwww, that bad already! this was just my attempt to help reduce flex on the union and hopefully not snap
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20 year old tre
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boom!
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no pictures sorry as it was over so quickly ( thats what she said)

Had a fair bit of swapping over and re in statement to do, so i got cracking

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abs brackets, aint coming off in one piece you just know it
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h&r and oe FTW
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the 262mm beauties again
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snap!
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recon untis thank to my good man Ryan paxton ( RY220)

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lines also from ryan
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abs sensor complete, again from ryan
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rebuilding
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preparation is key
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top mounts first install and initial fixing process

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new fixings where possible
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PLEASE NOTE AFTER A SLIGHT DISASTER THE STRUTS WERE ROTATED TO SOLVE THE ADJUSTER FOULING THE WHEEL/TYRE

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a lot of fine tuning needed for the ideal stance, and ride height, being a daily i need to negotiate speed bumps on route to work and also my driveway getting in and out

Off for geometry set up tomorrow and hopefully back on road for Monday.

initial camber was throwing the already mad toe off the chart and making car, combined with all other elements impossible to drive

so i brought this back a tad, and raised the front end as i need to tweak the front inset and top hat/washer combination,as i suspect aspects of work i had to do to get the shaft locked into the top mount bearing caused me to loose some tolerance on the shaft movement? hope that makes sense

adjusted bump/rebound on fronts and adjusted tyre pressures and its getting better.

this
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gave this

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but now is like this

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thanks for looking
ghall2004
Forum User
Posts: 69
Joined: Thu Jun 30, 2011 2:20 pm
Location: Edinburgh

Re: Ghall2004 "RoboCoop" 220 Coupe Turbo Spec/Progress

Post by ghall2004 »

Back on the road today.

Car is now drivable
Tracking ( toe and camber) were adjusted, print out to follow

not 100% happy, some values are suspect, and the place i have went to in the past after top service seemed to have changed hands
car is pulling to left and steering is off. and can just feel its not happy

I have some adjustments to the front struts over the weekend and will refine the height on all four corners. Track rod ends to be replaced next Thursday when, no only that car is drivable i can travel down to kelso to see Ry220 and his Hunter setup.

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Had a semi fire this morning, right rear caliper seems to be sticky! so was a bit puffy when i pulled up at lights lolz

Also my Roversport tomcat racer by Cableguy radiator arrived. this will go on next weekend along with new water pump and revised matrix to heater valve hose ( weeping at moment)

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And the best for last

h8 away fools *laughs*, say what you want. THIS FLOATS MY GOAT
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ghall2004
Forum User
Posts: 69
Joined: Thu Jun 30, 2011 2:20 pm
Location: Edinburgh

Re: Ghall2004 "RoboCoop" 220 Coupe Turbo Spec/Progress

Post by ghall2004 »

Been down to see me old muckka RY220 last night

Kindly replace the track rod ends, needed some amount of heat to make the locking nut workable!

Due to my failure as a human being i forgot some nuts that i need to make some modification to the strut setup ( wont bore with details)

Have some issues to resolve

Need a new fuel tank! ( replacement from previous car now has a massive dent in it after the jack slipped last week and went into it!) and now wont read any lower thant 1/4 tank!

Radiator, water pump and a matrix to heater valve hose to replace this weekend
Front Strut re configuration
Exhaust re align and install poly hangers and pull tight with hose clips ( exhaust is fouling lca )

Car is defiantly getting there in terms of grip and handling through the corners. Corner entry speed, poise and overall feel and feedback greatly improved and i was seeing an improvement in speeds i was able to carry through the drive home from kelso to Edinburgh

Ryan was able to get from tow pretty much bang on "dead ahead" as suggested by ttrw2

camber isnt too bad out, as close as i could get it tbh and castor is again fairly close. after all i am a rookie *laughs*

Getting read to get a initial reading
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Before just after track rod end change out
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And how things stand at the moment
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ghall2004
Forum User
Posts: 69
Joined: Thu Jun 30, 2011 2:20 pm
Location: Edinburgh

Re: Ghall2004 "RoboCoop" 220 Coupe Turbo Spec/Progress

Post by ghall2004 »

Latest round of works completed

Roversport by cableguy radiator installation
Water pump replacement
Matrix to heater valve hose swap out


Didnt get many images this time, as it slows your down and no one really cares *laughs*

T series, water pump and rad replacement, so most of us should know the steps needed to get to where the pictures start.

This needed to be a full front end strip down, in my experience this is in the long run easiest and the most effective way of changing the rad and pump, especially when you end up encountering issues.

Everybody will have their own process this is mine, coupled with the fact the RS spec rad is DOUBLE the thickness of the oe fitment

The chaos begins
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Rs Rad supported by "ram foam! :*laughs*: :*laughs*: Private joke peeps
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Fan frame, bolts snapping left right and center from this ! *laughs* jesus
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Existing rad frame to be reused/modded
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Old rad, which actually was in pretty good nick, and didnt leak, so hopefully move this on to keep another t series on the road
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And fast forward to now, where we start to see what will be needed to allow Rs rad to sit further forward, excuse the MS paint type skillz
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Water pump now nice and accessible
Every bolt nice and easy, back top, negative , snapped instantly
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Removed the cover to attempt to free the pump from the housing in the hope that there would be enough stud left to work with, just aswell i was changing this and my bodge days are over * ( claimed) check the nick of this bad boy!
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Which left a fair bit of studd/bolt to work with heat and plusgas
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Some time passed then boom! Great success
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Socket cap stainless FTW, pump replaced
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Then turned my attention to the RS radiator
The top brace that provides the secondary position for supporting the oe inter cooler and secures the rad into place needed to be modified slightly, i just rudely drilled a couple of holes, ghetto style yes, but worked fine, the same was needed on the lower fixing point of the rad frame too

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Now fits
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Rad then installed and time to check clearances and any other points that needed adjusting/trimming

Water pump to rad clearance, yes it is close but have verified against other RS installs, all A ok
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General shots
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fan Frame needed some attention, blue paint was an undercoat solution until i was able to get some better color match, see later images

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And now not fouling
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Thats better
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Fans back in place , Pas cooler also back in as is bonnet catch assembly
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Filled up with water for initial water test. all was ok, so proceeded to drain and filled with coolant.
Ran to temp and fans kicked in stage 1, heaters hot

Then just a case of re assemble
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Some shamless plugs
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Got some new RT stickers for the up coming summer event i have on the cards, thanks to Null_Byte for these as ever super fast dispatch
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Front drivers side is a tad low, and lower than pass side. so need some further fine tuning, please excuse the open window fail and lack of tyre dressing
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ghall2004
Forum User
Posts: 69
Joined: Thu Jun 30, 2011 2:20 pm
Location: Edinburgh

Re: Ghall2004 "RoboCoop" 220 Coupe Turbo Spec/Progress

Post by ghall2004 »

Engine bay day
Samco sport facebook page

Chuffed with that

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ghall2004
Forum User
Posts: 69
Joined: Thu Jun 30, 2011 2:20 pm
Location: Edinburgh

Re: Ghall2004 "RoboCoop" 220 Coupe Turbo Spec/Progress

Post by ghall2004 »

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ghall2004
Forum User
Posts: 69
Joined: Thu Jun 30, 2011 2:20 pm
Location: Edinburgh

Re: Ghall2004 "RoboCoop" 220 Coupe Turbo Spec/Progress

Post by ghall2004 »

Only decent thing about rain

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