The TR-42 under Brad's ownership.

[golftdibrad]

Let me start this by saying that cars like this are never ending projects. There will always be that 'one more thing' to do, fix, upgrade, etc. Its also worthy to note that different people will prioritize different things. I like to go fast around a turn, so that is more important to me than.... say a parking brake or a radio. I'm in no way being critical of the designer or builder of the prototype, I'm just making it my own. I hope that I can help make the future cars better as well.

That said, let get on with it!

When I picked up the car it had what I consider significant issues for a car I was planning on flogging the everliving crap out of. The three most serious were the push-pull type throttle cable without kickback accelerator pedal to match and it was too low/not sprung stiff enough. The engine was also pinging from bad/low octane fuel or incorrect timing.

I ordered a lokar throttle cable 10' long and fabbed up a little bracket. This was a simple enough job.
http://i510.photobucket.com/albums/s342/golftdibrad/TR-42/throttlecable.jpg

Pook had some springs he sent me (THANKS!). went from 225R 200F to 275R 225F. This has mostly addressed the ride height issue. While I was at it, I weighed the car. Half tank of gas, no windshield, no wing.

http://i510.photobucket.com/albums/s342/golftdibrad/TR-42/weight.jpg

And corner balanced it...
http://i510.photobucket.com/albums/s342/golftdibrad/TR-42/xweight.jpg

got that to work with three of the adjusters maxed out. So r1's are an option. I have way more stuff to do before I need those last 2% from the perfect shock, so these will do just fine for now.

While the lid was off i attempted to relocate the blinker to a more comfortable position.

http://i510.photobucket.com/albums/s342/golftdibrad/TR-42/stock.jpg
http://i510.photobucket.com/albums/s342/golftdibrad/TR-42/hellafrush.jpg

Better, but still in the way a little.


So....1500 lbs. Not bad, but its a bit porky for what it is IMHO. Fortunately, there is some very low hanging fruit.
1. Battery is a neverstart from walmart. Braille anyone?
2. Stereo. Cant hear it at anything other than idle with a helmet on anyway. This will also solve my problem of not having a glove box for license, registration, insurance, and wallet, keys etc.
3. Wheels and tires are 40lbs a piece. DOT-R's should be good for 5-10 lb per corner.

http://i510.photobucket.com/albums/s342/golftdibrad/TR-42/awheel2.jpg
http://i510.photobucket.com/albums/s342/golftdibrad/TR-42/awheel.jpg


Other stuff I need to do:
Had a brake light go out, must investigate.
Continue to tweak on motor/carbs
parking brake
MSD 6al ignition/revlimiter
fix cv joint grease leak
stiffer throttle pedal/throttle stop (i've bent the pedal twice)

now.... racing pron from me driving how it was intended (or not with all that facing the wrong direction business!)

Car is awesome, and as I refine the setup it will only get faster. Even with it being my first time out, setup being 'eye balled' in, and crap tires I was ~0.1 seconds off FTD. It was freaking AWESOME.

http://www.youtube.com/watch?v=poDi8NxMiww

-Brad

[pook]

Awesome vid! Hey is it the camera or are the front tires about a foot toed in?
PooK

[Karlo]

What kind of car had the FTD and how much horse power?

[badermatic]

Great video! Thanks also for documenting your tweaks. They may come in handy on our build (TR-82).

[Steve Jarvis]

Very good info and loved the video. Especially the 180 degree views.

It just shows the lengths you'll go to for a good video. :)

Later, Steve

[golftdibrad]

Thanks all

Awesome vid! Hey is it the camera or are the front tires about a foot toed in?
PooK

its the super wide angle of the camera, alos making it look as if it has ungodly amounts of anti-arkerman.

What kind of car had the FTD and how much horse power?

350z with bolt ons and way better tires.

[pook]

That looks sooo fun! I miss racing....
Great job for the near FTD!
Will you go with a wider tire and wheel and keep those for the street?
Also, and I know I seem to have a fixation with the camera, but what kind of mount is that? It seems to be mounted everywhere.
PooK

[golftdibrad]

That looks sooo fun! I miss racing....
Great job for the near FTD!
Will you go with a wider tire and wheel and keep those for the street?
Also, and I know I seem to have a fixation with the camera, but what kind of mount is that? It seems to be mounted everywhere.
PooK

http://photos.autoexpress.co.uk/images/front_picture_library_UK/dir_520/car_photo_260391_7.jpg

Its just a sticky pod for a gopro hero camera.

I need to look up the weights for the wheel and tire, but I plan on running dot-r's on the street. On such a light car it shouldn't be a big deal.

[Steve Jarvis]

I'm really suprised a street car took FTD. There must not have been a lot of spec racers out there.

I know the "R" coupound tires will easily give your the edge versus the 350Z, but the Hankook's are a pretty sticky street tire. Were you suprised your 1,500lb. car still wasn't faster relative to the 3,000+ lb. 350Z?

Later, Steve

[golftdibrad]

I'm really suprised a street car took FTD. There must not have been a lot of spec racers out there.

I know the "R" coupound tires will easily give your the edge versus the 350Z, but the Hankook's are a pretty sticky street tire. Were you suprised your 1,500lb. car still wasn't faster relative to the 3,000+ lb. 350Z?

Later, Steve

low turn out at this event. The hankooks are not rs3's, they are v12's or something. These cars a too light to use a tire like that, even UHP street tires struggle to make grip. For a pleasure car the MIGHT see 3000 miles a year, i can afford a set of takeoff DOT-R's every year.

Gotta remember too that it was my first time in the car, and there is lots of tweaking to do with the setup. Needs a proper alignment that is not eyeballed, shock settings, may need to tweak the spring rates, etc.

[Steve Jarvis]

The V12's are actually pretty good, slightly faster that the Michelin PS2. See the link below.

http://www.caranddriver.com/reviews/comparisons/09q2/tire_test_nine_affordable_summer_tires_take_on_the _michelin_ps2-comparison_tests

I would think "R" compound tires will be fine for an exocar as long as your'e not driving it in cold weather. Under 50 degrees and "R" compound tires are like driving on plastic. :) I used to drive to and from the roadcourse on "R" compound tires (approximately 115 miles each way) and wheel spin was the norm on my Supra. Much less grip than street tires in cold weather. The fun of spinning tires from a 60mph roll in third gear does wear off. :)

Later, Steve

[golftdibrad]

The V12's are actually pretty good, slightly faster that the Michelin PS2. See the link below.



I'm sure they are good street car DD tires, but they are crap for a 'toy' car. Also, it doesn't get that cold in Louisiana very often, and the last thing on my mind will be driving the open car with no heater for fun :D

[lo2erf]

Nice job on the improvements and first try at an AutoX in the new car! I think some super sticky tires will do great on that little car. It sounds really good in the video, thanks for sharing. The exhaust / engine sound great too!!! I would guess you can save about 25 pounds with a low weight battery and another 20-25 in removing the stereo (sell the stereo stuff to pay for the new battery?). Take the mufflers off to save another 20 pounds or so, and you will be sure to get the attention of everyone at the next event!

[golftdibrad]

Nice job on the improvements and first try at an AutoX in the new car! I think some super sticky tires will do great on that little car. It sounds really good in the video, thanks for sharing. The exhaust / engine sound great too!!! I would guess you can save about 25 pounds with a low weight battery and another 20-25 in removing the stereo (sell the stereo stuff to pay for the new battery?). Take the mufflers off to save another 20 pounds or so, and you will be sure to get the attention of everyone at the next event!

thanks, it does sound good, but its already WAY loud, lol.

[pook]

Hey Brad, Do or did you drive it to the autoX?
PooK

[golftdibrad]

Hey Brad, Do or did you drive it to the autoX?
PooK

absolutely. Froze my butt off on the way over in the morning :D

[ViperJustin]

Even if you wear pants in these cars, the air still goes right up your legs (unlike a motorcycle). But it's worth it! Nice video, too.

[Steve Jarvis]

You just need to have plexi-glass panels sealing the sides and top with a set up like this in the cockpit. :)

http://lucillehowe.com/USERIMAGES/Canoe.jpg

[Steve Jarvis]

I can't believe I didn't get at least one comment from my above post. :)

I was talking about the thing sealing her waist to the Kayak.

Later, Steve

[golftdibrad]

I dont want to seal it up all the way, thats kinda the point :D

[pook]

WITH reflectors...safety third! :thumb2:
http://www.amazon.com/M-Wave-Bicycle-Safety-Reflective-Pant/dp/B001NGD4BM
PooK

[golftdibrad]

I was thinking more like this
http://farm1.static.flickr.com/27/46021983_8da9490451.jpg (http://www.flickr.com/photos/saintmurse/46021983/)
Don't Tread on Me flag (http://www.flickr.com/photos/saintmurse/46021983/) by St. Murse (http://www.flickr.com/people/saintmurse/), on Flickr

[golftdibrad]

So I installed the MSD box tonight and set the timing, and HOLY SHIT. This thing will now blow your socks off. Its SO fast. Now that i can keep the go pedal buried till it hits the limiter, holy cow its so fast.

I'm just speachless really.

-Brad

[FIAROADSTER]

I can't believe someone would kayak the canals of Venice!! eck!

[pook]

So I installed the MSD box tonight and set the timing, and HOLY SHIT. This thing will now blow your socks off. Its SO fast. Now that i can keep the go pedal buried till it hits the limiter, holy cow its so fast.

I'm just speachless really.

-Brad
Awesome! Now throw some real tires on the thing and show em why you don't need 1000hp and a 12lb car to go fast around a track!!
PooK

[golftdibrad]

http://i510.photobucket.com/albums/s342/golftdibrad/TR-42/PhotoOct0250944PMHDR.jpg

Had an issue with it losing grease through the extra holes in the CV's. The RTV was starting to let some out and it was goining EVERWHERE, making car very dirty... So I JB welded some plates over the holes. I've put a couple of test drives on it and had it.....very fast.... and they are all still there and not leaking. So, problem solved for now!

Cant wait for Friday to be over to go drive some more :D

[pook]

I hated the cv boot kits when we got them! Why the back plate is drilled for 6 holes on a four bolt cv I'll never know!???
If it won't stop the oe kits don't have that.
PooK

[golftdibrad]

I hated the cv boot kits when we got them! Why the back plate is drilled for 6 holes on a four bolt cv I'll never know!???
If it won't stop the oe kits don't have that.
PooK

I thought the same thing. I'm pretty sure this will do the trick, I jb welded the right way. Cleaned, scuffed, and decreased both sides before applying.

[golftdibrad]

Here we can see the wild cheery picker in its natural environment preparing to pounce on its next victim. It's spotted mostly around cars that are low on power, have windows where they should not, or have been rendered immobile.

Oddly enough, it usually leaves then better off than when they were when initially spotted, right before it retreats back into storage.

[FIAROADSTER]

They seem to expand into a Praying Mantis position in my shop

[ViperJustin]

You got me!!! What's the plan??? "I've gots to know."

[golftdibrad]

You got me!!! What's the plan??? "I've gots to know."

pull engine, pull heads and etc., find problem, fix it, installation is the reverse of removal.

If it costs too much (like over 1k)..... might do a swap.

[golftdibrad]

Well, its apart....

http://i510.photobucket.com/albums/s342/golftdibrad/TR-42/pistons.jpg

Looks like way too much deck height. 2.0l crank and vw rods leaves the problem to pistons. supposed to be ~0.060 inches, more like 0.162 inches. :run:

http://i510.photobucket.com/albums/s342/golftdibrad/TR-42/deckhight.jpg


How it sits. Going to get on the horn tuesday to try and get some correct pistons on the way.

http://i510.photobucket.com/albums/s342/golftdibrad/TR-42/enginestand.jpg

[pook]

I still think its the case, or the jugs. The reason is the push rods also seemed short...ie the rocker angle was a bit much.
They can be machines down or spacered up because they don't use gaskets, you can achieve any comp ratio you want, and cheaper than new.
PooK

[golftdibrad]

I just talked to AA pistons, they only cast one piston for the 103's and its for a 71mm stroke. He said that they did make some with long liners, so mabye that is what is going on. When i get back I have to take some pics and measurements and get this figured out.

[pook]

I wonder what they made longer jugs for? Turbo charging!?
PooK

[golftdibrad]

So, update time. Turns out that the deck is supossed to be less than .060". Even with the large deck, static CR was 7.6:1. A good fellow over on shoptalkfourms measured is stock jugs, and what ya know, mine were 2.2mm longer. This also may have been throwing off something called valve geometry, and while I'm sure there is something to it its not where the power was, the power was missing from the big cam and high deck.

SO, the plan is to shave 0.105" off the bottom of the jugs, brinigng deck to about .055". Static cr of 9.8:1. dynamic will be 7.8:1. The stock 2.0l was 7.4:1. I will run premium fuel. If it becomes an issue, electronic timing. If it cooks, so be it. I'll either get new heads at that point (the likely failure point) or do a different engine.

So, while its all apart I've been doing some other work.
http://i510.photobucket.com/albums/s342/golftdibrad/TR-42/radio.jpg

30+ pounds of not useful things gone....

Now.... I need a 'glovebox'. I have the old DIN blank from my golf....so this car will always have a lil dub in it.
http://i510.photobucket.com/albums/s342/golftdibrad/TR-42/vwtray.jpg
trimmed up, not to seal those holes...

http://i510.photobucket.com/albums/s342/golftdibrad/TR-42/lightlocostfuny.jpg

used some 3m spray glue, and its laminated. Light and locost. Little message there too :D

http://i510.photobucket.com/albums/s342/golftdibrad/TR-42/glovebox.jpg

Big enough for a fish.

http://i510.photobucket.com/albums/s342/golftdibrad/TR-42/fuelline.jpg

With that amp out the way I can properly mount the MSD box.
[commercial voice]MSD stands for MULTIPLE SPARK DISCHARGE[\commercial voice]


http://i510.photobucket.com/albums/s342/golftdibrad/TR-42/msd.jpg


poking around the rear.... look what I find.


http://i510.photobucket.com/albums/s342/golftdibrad/TR-42/fuelline.jpg

would anyone care to venture what type of fluid that carries?


The parking brake has me stumped. Once its back on the road I'll figure something out.

With some luck, motor goes back together Saturday. Maybe in Sunday.

-Brad

[pook]

Ouch, that could have been bad!!! Did he rout it at the crank pulley? I also can't help on the e-brake either unless you have a pic of how he ran the cables?
As for the jugs THAT I did miss. (If that's the only set they sell wouldn't everyone that buys 103's have the same issues?)
PooK

[golftdibrad]

Ouch, that could have been bad!!! Did he rout it at the crank pulley? I also can't help on the e-brake either unless you have a pic of how he ran the cables?
As for the jugs THAT I did miss. (If that's the only set they sell wouldn't everyone that buys 103's have the same issues?)
PooK


1. Yes
2. Its not only running of the cables, the ends need to be captured somehow.
3. Yes. BUT.... i though about this because it drove me up a wall for about 2 weeks. If one had, say, a tired old 2.0l and decided it needed a rebuild... and why hes at it go to 103's. Reuse crank and rods. Well between the extra .4 liters and the fresh parts the end user would feel like he had a big upgrade, but the engine actually dropped a bit of compression and stayed safe...and picked up 15-20 hp over stock.

The heavy cam might actually hurt it without a higher static CR.

Its done as of today; the engine will be .21 inches less wide. Like all modifed motors that are tuned within an inch of their life.. there are three options
1. It will run like shit
2. It will be awesome for about 20 minutes and blow up OR
3. It will be awesome and not blow up.

[superq7]

So, which of the three options did it turn out to be? Have you orderd a wankle yet?

[golftdibrad]

Motor is back together and ready to be stabbed for over a week now, but I've been away fora a week. Should be a runner by next sunday at the latest. Or have blown up.

[superq7]

Any news?

[golftdibrad]

Runs, sounds mean. More detailed update in a few hours.

[golftdibrad]

Been away a lot for work, so progress has been sporadic. I got the juts cut at the base to bump the compression and reduce deck height. was aiming for 0.050" and 9.5:1, got about 0.038" and 10.2:1. Decision was made to roll with it.
The engine went together pretty smoothly, but at one point i forgot a piston circlip, whoops. I had to pull that jug to fix it, but the sealant was still tacky so I put some more and rolled out. The tins fit the more stock width engine way better, but I did have to trim one just a little.

http://i510.photobucket.com/albums/s342/golftdibrad/TR-42/engineready.jpg

Complete engine ready to be stabbed!

http://i510.photobucket.com/albums/s342/golftdibrad/TR-42/dontforget1.jpg

My god dont forget this!

So being a real smart guy, when pulling it the bolts for the mounts were a royal PITA to back up with a wrench, so I tack welded them in. The engine mount has to be clearanced to fit the now fixed in space bolts.

http://i510.photobucket.com/albums/s342/golftdibrad/TR-42/motormount.jpg

Nothing an cutoff wheel and a dremel cant do.

I got it all back together and started it. The power connections have always been crap, and it was having trouble spinning it over. Yesterday on the way home I also had an epiphany; i never kicked the clutch to center things up. So I loosened all the bolts, kicked the clutch and now it has plenty of ommph. At some point I stripped the hole in the block for the starter too so I had to back it up with a thin nut and through bolt.

Today I got it running better, starting by itself, and the timing set. The carbs need to be rebalanced and the idle tuned, but it runs, revs free, and sounds MEAN. No pinging yet either free revving it hard.

I was hoping to be driving today, but the axles are still giving me hell. the 100mm cv's I got are too thick for the 914 axle. They are EMPI high strength high flex units. (E98-5084-B) They are too thick to put the circlip on. So I need regular units if they are thinner, or maybe a different axle shaft? Suggestions welcome. Good news is the aero CV boots clears the shock even at full droop, something even the 914 setup did not do.

So, I'm very close. Just need to get the axle problem solved for good and I'll be driving again. I could put the old setup in, but seems kinda pointless to undo what I've done so far.

-Brad

[golftdibrad]

Axles found to correct the issue, ordered.

Soon...very soon.

[golftdibrad]

So I got my new axles.

http://i510.photobucket.com/albums/s342/golftdibrad/TR-42/newaxle.jpg

shinny. I went to put them together and the place sent me load washers for freaking 90mm cv's. In the pounding i messed up some hardware. and they didnt send me enough hardware. I am miffed. I used standard lock washers for now and thank god driving vw's for years yielded just enough bolts to make this happen. Even if they were the newer torque to yield kind.

http://i510.photobucket.com/albums/s342/golftdibrad/TR-42/almostdone.jpg

Took way too long and lots of cursing and hammering later but they are in. I should have run a tap through the holes first.

So.... first drive. Fired right up, shifter was aligned, time to do this. It still needs tuning/balancing but it is WAY stronger. Face melting stronger. After a few spins around the block I parked it to check for bolts/leaks/etc. And to set up the display to read the head temp sensor.

I then refired it and it started pinging on one cylinder REALLY bad, like i could not even touch the throttle.

Today i took it for a spin to see if it still did it, and it seems better, but still a light ping at high rpm. I'll back the timing off a bit. Its really quick now!

Went to the Ludachris concert last night, fo free. Worked hard and played hard.
http://i510.photobucket.com/albums/s342/golftdibrad/TR-42/luda.jpg

[superq7]

Do you haz fast?

[golftdibrad]

Do you haz fast?

it will melt your face. Come for a ride.

[golftdibrad]

http://www.youtube.com/watch?v=XPGSLbXREe0

ordering the jet kit and colder plugs tomorrow....

[badermatic]

Nice vid! Congrats!
No need for a windshield where you live??

[golftdibrad]

lol, that vid sucks! just a quicky.

We NEED a windshield, but......... :D

[golftdibrad]

Guys i need some help, I'm drawing a blank on how to make a throttle stop. I have significant manufacturing capability, and would like a no welding on frame solution. Any ideas would help.

Thanks,
-Brad

[pook]

Something simple like this?
PooK

[golftdibrad]

YES! I like. is that panel stiff enough to support it you think? I was concerned it'd be too flimsy. Unlike that big V-8, in need to get all I've got out this little four banger :D

[pook]

Should be and a doubling plate could be added if you think its needed.
PooK

[golftdibrad]

Cool, I'll get on it. Thanks.

[golftdibrad]

Got alot done today. First up, the koso temp sensor died from what i expect were out of its range. So i found another thermistor that had the same curve (i measured using the one I still had) that had a higher max temp. I took this guy (0.80 each at digikey, 6141019-nd) and stuck in in a drilled out Porsche head temp sensor and jb welded it in there. FYI, jb weld is a electrical insulator, and reasonably good thermal conductor.


Result is that this thing is near impossible to install. I managed by modding a 1/2 wrench.

Next was the throttle stop solution and new, hopefully stiffer, throttle pedal.

Also readjusted the action and stuff.

Put in my NGK's that are a few ranges colder than the ones that were in there.

Next I changed jets and air jets. went to 145 and 190 from 135 and 175.

Drove the car, still seems a little lean in the midrange, (lots of poping and what not off throttle, BUT less of it than before) but it seems WAY happier, and more power from the but dyno. Now its very cool out today (70) but no pinging, head temps were lower (never saw past 300) so these are all good things. I know that I'll have to stay on top of the tuning with this thing.

About ready to put the nose back on and declare it 'done'. For now at least.

-Brad

[superq7]

Have the parts come in yet?

[golftdibrad]

Yes, more jets. Its drivabe now. Had a huge valve cover gasket oil leak yesterday.

[superq7]

Oh the parts are on now? What's left to do?

[golftdibrad]

Still have to fiddle with jets and timing, proper alignment, tweak on the suspension, sticky tires, etc. But I'm declaring it 'done'. But a project like this is NEVER 100% done.

[superq7]

Will mean green be on the track Sunday?

[golftdibrad]

probably not. You know that is mothers day, right? I probably will be occupied :(