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The buggy thread

what do you have an how are you doing it? Cars or trick bits, put your shots up here.

Postby Rippthrough » Fri Sep 14, 2007 8:44 pm

Just a basic rundown for now, I'll flesh out the background later but I'm a bit busy, tea-break at the minute [;)]

Anyway, the only photo's I have currently are from my rather poor phone camera, a situation I intend to remedy asap, as it's nearly the end of the farming season and work will begin in earnest again.

Here she is at the last event:

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Believe it or not but that's the sighting lap where you take it steady to learn the course....[:p]

<b>A little background, which I'll later flesh out so check back, I'll stick a new post in when I update it though:</b>

The buggy is owned by a close friend of mine, Ed, who also gets to drive as he conveniently managed to mount the bucket seat too close to the pedals for me to get in.....[;)]
I met him a few years back when he had built the initial frame of the buggy and done a few events to shake it down, a friend moved in to one of the barns they had sold off for housing conversion, and he showed us the buggy and gave us a spin.

The first thing I said to him that day, was he was going to have problems with the distributor setup on the VW engine the first time he used it in anger.

The partnership really started then next weekend, when I got a phonecall from my mate that had moved up there, saying his dizzy had fallen off in the event, at this point I fell off my chair laughing.

Since that he rung me up for suggestions and formed an instant friendship, so the last few years we've been working the buggy over between us with upgrades here there and everywhere, ready to enter it in the british championship rather than the few clubman events we've run in on shakedown tests.
Being a 2wd vehicle this is going to be a good challenge for us, instead of using the 4wd, which is a <i>little</i> more advanced, and a shedload more money, these are driven/designed/financed mainly by Ed's elder brother, but guess who gets to do the building work and tweaking?
[xx(]

4wd:
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Along the way the buggy has had 3 complete new rear ends, 4 suspension setups, a new front end, 4 different gearboxes/linkages/pedal setups, and 3 different braking systems, I'll go into detail on these at some point.
Now, that may sound excessive and a bit chop and change - but usually they've coincided with a change in the chassis (or an exploding gearbox...) in order to keep the entire chassis working perfectly.

<i>The first change came shortly after it's second event, in which there were a few problems, the first was the greenstuff rear pads, sponsors of the series so they had to be use, fell to pieces, and the backing plates then ground into the disc, welded themselves there and then ground away at the hub.
The result of which was some mintex 1144's painted green, the Hi-spec 4 pots fitted and some new laser cut discs.
The second was the gearbox exploding, this was the original box sourced with the engine so it was to be expected, another box was duly sought, and the engine and rear frame pulled out for fitment, the new box was a five speed version though, which gave us a little more pace as the VW tended to drop off cam, this was later resolved through some careful carb jetting and linkage tweaks, but the shorter gears were welcome at the time.
Of course, the problem with a five speed box is that it's slightly longer, which meant a simple gearbox change meant we had to rejig all the linkages, the cabling, and the entire back from and engine mounts needed moving an inch back.
This in itself mean the driveshafts had to be altered, and new panels formed up out of ally sheet.

So next time you are swearing during a gearbox swap, just remember, it could be worse....


The fun is in getting the engine on the box (yes, that is the right way around), which takes 4-5 goes to get the splines located right, which, when you are holding an engine made from sharp aircooling fins, gets you some funny looks from the missus when she sees 'scratch marks' in a pattern down your arm, whoops.
</i>

<b>The second box came around 2 events later on, after a final drive turned itself into smeared lump in objection to landing a 10ft drop off a small quarry under full power.
This time we sourced several boxes while we decided what to do with it, the engine was down on power and there was a brand new 3.2 Nissan V6 sat on a crate in the workshop, a porsche carrera 4wd box was duly acquired, along with a standard 2wd box.
It was decided to stay 2wd as they're more fun to drive, and it's more fun when you leave the 4wd boys, unfortunately the next events were fairly soon, and there was no way the 3.2 V6 was going to shoehorn in with the necessary plumbing without a complete new rear end and suspension setup, so in went a 5-speed Renault Master gearbox, complete with 9" differential, again, this meant new linkages and tweaks to the chassis, along with a spring change due to the different CoG, we finished at 4:30 the morning of the next event....

More later, going for a drink... </b>

<i>Now, the problem with concentrating mainly on sorting out the rear, is that, at 5:30am, the morning of the event, after a short nap, you really don't want a whining noise to appear on the shakedown drive before loading it up on the lorry.
You most definately don't want that sound to be whining front wheel bearing, and you definately don't want to be 2 miles from home when it starts getting worse.
Once a bearing goes on something like this, they don't last long at all under the stresses, unlike in a car where it'll whine for 2000 miles, you're lucky to get 2000 yards...
Unfortunately, the smallest of the workshops must be 2010 yards away, because the wheel fell off trundling around the last corner back to it.
In itself that's not a problem, the way the buggy is setup you can post a respectable time with just 3 wheels.........
What IS a problem, is that beautiful machined steel wheel, meeting a beautiful but rather softer alloy wilwood '5-star' hub.
After turning the 5-star hub into a 1-disc smear, it decided to take a chunk out of the from calipers just for kick before it did it's party trick of wandering off down the lane.
Shiiiittttt.

We've got plenty of spare bearings, but no spare hubs, so that's the end of that event already, what fun.

The next event was the final one we attended this year, a clubman-type event where you can just turn up and drive, all went well that morning, bar getting the lorry stuck in the staging area and having to tow it out with the car.
The engine was running a little rough, but then, it's been due some new piston rings for a while, but we couldn't see the point of spending money on the VW engine, it does the job but when it goes bang, well, there was that V6 waiting in the workshop....
This probably annoyed the poor overworked veedub, after being originally designed as a 1.6 with about 40 horsepower, for some greasemonkey to pull it apart, subject it to a bore out of existing holes, put in holes that shouldn't be there, push the output to 120bhp and then run it at 5000rpm, solid mounted to a buggy driven by a pair of nutters with suicidal tendancies, well, perhaps it had every right to to be a bit ****ed off and spit a shell that day....

The competition in the 2wd class wasn't all that impressive bar an RS200 look-a-like, and a similar machine to ours but with a long-travel double wishbone front end, 1.6 turbo engine with (supposedly) 240bhp.

We promptly ****ed of aforementioned turbo powered car by setting a time 12 seconds faster than him (7 mile stage), which got us the cold shoulder and some mutterings about his power steering failing and his engine overheating, all in the spirit of competition [;)]

What we didn't tell him was we'd had to stop for 30 seconds at the bottom of the hill as the carbs flooded the engine because of bouncing floats, and my pace notes listed adjustments that should pick up another 15 seconds...well, no point rubbing it in is there, that's what the next lap is for....
Especially when you'd lost time yourself as the VW had thrown a belt and you'd lost PAS and overheated the engine yourself.

After rigging a new belting system up and making a hasty set of float dampers out of a couple of o-rings, some tube and a pen (see, blue peter is useful!), we were ready to go out for the second stage, with the updated notes allowing Ed to pick up the pace on the corners and avoid the ripples on the exit to get the power down, we worked out at 43 seconds up two thirds of the around the course, on par with the fastest of the 4wd guys running there, but we were loosing power, the engine was starting to blow a little smoke, but we had to finish the stage to get nback to service area anyway, so full throttle it is.
Out of the marshland they called a corner (see vid.) the car simply would not slog it's way out of the mud, struggling to pull second gear where normally we would have been in the top of third, onto the next straight, top of 5th at 80-90mph over ripples - imagine speedbumps 2 feet apart at 90mph - and the engine spun the shell, the shock and friction as it attempted to weld to the crank stopped the engine and with a locked rear axle and the back end already snaking as it was putting the power down over the ripples, the car immediately spun several times, we ended up travelling backwards at around 60-70mph, downhill on wet grass toward a stone wall.

Now, we weren't too concerned about the buggy as we know how strong it is, but we knew for a fact that there were spectators behind the wall and the buggy would flatten it like a bowling ball hitting smarties tubes.
With Ed hard on the footbrake and attempting to bring the front end back around with the steering, I hung onto the left hand fiddle brake and between us we managed to slew the buggy around to a stop away from the wall.
Some good natured cursing ensued in the fight to restart the engine, which had luckily unwelded itself, and once it fired into a nice, uneven beat with lashings of rattles, we limped the remainder of the stage in first gear, and announced our retirement to the marshalls.

We posted an 8m40s stage time.
Faster than a third of the competitors, woo.

The diagnosis as terminal, we went home and hatched plans, coming to the conclusion that the 3.2V6 was just too big for the current chassis and we may as well start from scratch with it as we could use it as a stressed member for a double wishbone front and rear.
Given the buggy was meant to be a low-budget challenge, this was wiped off the list and an RX-8 renesis engine accidentally made it's way into the workshop. [:)]
230bhp as standard and with mild porting work and our own exhaust system, plus a haltech ECU, the estimated output is somewhere around 260bhp, with ****loads of torque from 3k-10k rpm.
You can pick it up with two people, it'll fit virtually anywhere, and the only problem is where the hell to mount a radiator without it getting plastered in mud...

Unfortunately it was harvest time by then, so work has stopped until next month, when the fun starts...
</i>



Anyhow, here's a rough current spec. sheet, as it stands this minute, as far as I can remember:

2.3L VW aircooled engine
- 4-1 manifold,
- PTFE gaskets,
- Dellorto 45's,
- performance inlet manifold,
- Engle 110 camshaft
- Needle roller rockers, high lift 1.4:1 ratio
- Currently on a Transporter gearbox, with custom bellhousing.
- Weber pumps
- Full flow casing with external oil coolers
- Modified cowling with electric fan assist.
- Counterbalanced steel crank.
- 3D ignition system (MegaJolt, built it for him after the dizzy problems), all mapping done by me:

Image

Chassis-

- Mixture of 2-3" T45 steel tubing, mandrel bent and TIG welded, weight is a touch over 600 kilos. You can quite happily lift the front with one person and walk around with the car.
- Rear setup are 4 gas pressure monotubes, 2 bilstein dampers, 2 fox adjustable coilovers, all remote res. nitrogen charged, giving around 16 inches of rear suspension travel, these act on a rear torsion bar setup with heavily braced arms, again, made from T45 tube, the bars are rising rate and there's a secondary assist bar which comes into play after 10" of travel.
- Front setup is now 2 Fox coilovers aiding a rising rate twin torsion bar front end adapted from the VW setup, approximately 12" of travel up front.
- Brakes are a mixture of small 4 pot wilwoods up front and beefy Hispec 4 pots on the back, linked with braided hoses to 2 AP master cylinders on a balance bar with a homemade pedal box, it also sports a hydraulic handbrake and a fiddle brake setup to brake individual wheels for Image turning the front end in quicker. Solid discs (less weight) all around matched with 1144 pads.
- Wheels are our own steels - 15x7J, weighing in at 5.8kilos, fitted with 215/75 bridgestones.

Our current problem is then engine did this:

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Which meant getting the engine crane out:

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And accidentally buying this:

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More later, out of time [:p]


Poor vid:
http://smg.photobucket.com/albums/v89/Rippthrough/?action=view¤t=Buggy01.flv

I'll get some proper video showing the true pace of the car soon, it's far faster than it looks there, ask Gez_Rallye on the gti6.com site, who now has a bad back...
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Postby Rippthrough » Sun Oct 28, 2007 2:08 am

Muhahaha!

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Postby StuBeeDoo » Sun Oct 28, 2007 8:27 am

<font color="blue">Amazing! [:D]</font id="blue">
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Postby Rippthrough » Sun Oct 28, 2007 12:46 pm

Thanks, we're expecting RS4 levels of acceleration. On mud. [:D]
Should be even faster on the gravel/tarmac bits though.


I think we negated the 'Practical' side of PPC slightly.
You can get 3 bags of shopping under the bonnet, does that count?
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Postby edthedrummer » Sun Oct 28, 2007 1:14 pm

<blockquote id="quote"><font size="1" face="Trebuchet, Arial,Verdana" id="quote">quote:<hr height="1" noshade id="quote"><i>Originally posted by Rippthrough</i>
<br />Thanks, we're expecting RS4 levels of acceleration. On mud. [:D]
Should be even faster on the gravel/tarmac bits though.


I think we negated the 'Practical' side of PPC slightly.
You can get 3 bags of shopping under the bonnet, does that count?


<hr height="1" noshade id="quote"></font id="quote"></blockquote id="quote">

RS4 levels of acceleration? on mud? ? ? do you have an endless supply of trousers and undercrackers? I think i'd need them.
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Postby Richard » Sun Oct 28, 2007 2:09 pm

You could fit perhaps 3 shopping bags full of trousers and undercrackers in it....
Awesome thread, look forward to hearing more. That machine looks frankly a bit terrifying but very cool.
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Postby Rippthrough » Sun Oct 28, 2007 6:20 pm

^2 bags of undercrackers and 1 bag of deep heat.
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Postby Rippthrough » Sun Oct 28, 2007 6:31 pm

Oh, and there's a centrifugal supercharger kit planned for easter next year, provided we can use some better tyres, if not there's no point though.
Last edited by Rippthrough on Fri Apr 30, 2010 1:01 pm, edited 1 time in total.
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Postby MFrV1 » Sun Oct 28, 2007 8:18 pm

3 bags of shopping sounds practical to me [:D]

On a more serious note: Damn, that sounds fast.
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Postby Richard » Sun Oct 28, 2007 8:54 pm

<blockquote id="quote"><font size="1" face="Trebuchet, Arial,Verdana" id="quote">quote:<hr height="1" noshade id="quote"><i>Originally posted by Rippthrough</i>
<br />^2 bags of undercrackers and 1 bag of deep heat.
<hr height="1" noshade id="quote"></font id="quote"></blockquote id="quote">

Sounds like a party to me...
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Postby Rippthrough » Sun Oct 28, 2007 11:22 pm

There should be a few with a bit of luck.
It's curry night on the friday before the competition events, if any more PPC'ers want to join us for a pint and a weekend of competition.
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Postby V8DNW » Tue Oct 30, 2007 2:15 pm

So what's the association to the GSR racer subtly lurking in the background?

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Postby Rippthrough » Tue Oct 30, 2007 2:17 pm

Aha, a fellow nutter!

That's Guy's car, Edd brother, he builds all the 206 GSR's, etc, you see about, as you already know!
Who was your money on for this weekend then?


That one's a Fouquet he bought to tide him over between cars, it's for sale if anyone wants it ;)
There may be a thread on his next car but that depends upon permission from Guy to cover it.
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Postby Rippthrough » Tue Oct 30, 2007 3:38 pm

Were you at Waterbeach earlier on this year V8DNW? Pretty sure I had a wander around your car?

That and you keep taking the piss out of bumpy's wee problem....

(see what I did there? [;)] )
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Postby V8DNW » Wed Oct 31, 2007 12:31 pm

Difficult to predict who would win this year's overall championship (Matador Tyres MSA British Off Road Championship - www.britishoffroadchampionship.co.uk or www.marches4x4.com) wasn't it? Seems to have been one of the most open for a while. My interest was more in the sub-4ltr class (the small engines...) as the Tomcat works car driven by John Cockburn (they look after my car for me) was up against Toby Jefferson in a "Peugeot 306" in a very tight battle. John tied things up at Round 4 after an unfortunate engineering incident left Toby and Julia stranded out on the course.

Team Tomcat in action at Bleddfa:

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I only did the BORC this year so was only at Baden Hall, Castle O'er, Bleddfa and Sweet Lamb. There's a few Bowlers like mine around but pretty sure that it's the only orange one in this country.

You expect to be up and running next year? Which championships?

I think rip through (see what <i>I</i> did there?) is what Bumpy's afraid of... Though it has stopped people going on so much about how he almost always manages to end up on his roof (pot/kettle moment...). He's actually racing my previous car and is a top bloke so hope he's fitting fit for next year.

Here's Bumpy Mike in action:

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This is the College car everybody:

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Is this the other vehicle referred to?

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Whilst we're at it, here's a Guy Smith Racing 206 (driven by 2007 Championship winner Richard Kershaw):

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And for even more pictures like these...

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...have a look at my flickr account:
http://flickr.com/photos/58203759@N00/sets/
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