VTS Track Project -Updated Spec Page 6 | Caged | Buckets | Sachshift | LSD | Rebuilt JP4 | Ported + Cammed - PIC HEAVY

[Chris245]

Right then....

Over the past 3 years (since my last post), the car has gone from being my daily drive, to a shared (dedicated) track car with my dad and brother.

I'll go through all the bits I've done whilst running it, then get onto the most recent parts when it was taken off the road about 6 months ago.

So, the fibreglass bonnet was mocked up...



and painted...




I was having a few issues with my sunroof blank...







So I decided to do it right with a proper carbon blank...





Bonded it in using some black tiger seal.

Next was a small aesthetic change, Osram Diadem indicator bulbs to de-tango the front...









My J4 cam covers were leaking from the oil filler, so I fitted the JP4 covers off of a spare engine I had in the garage...







This is by far the best mod I've done, satchshift gear linkage...







Then another little trip to the Nurburgring...



Up at Adenau Forst with my mums GT86...



No lapping that year, was too wet and too risky.

That'll do for now, I'll post up some more in a bit.

[Chris245]

Right then, this is how it became a shared track car with my dad and brother...

I was still using the car everyday and getting a little bored of strapping myself into the buckets, not having a proper boot, not having a radio, the solid ride and the unbearable noise of the supersprint on the motorway.

I was thinking about selling the car and after a chat with my dad and brother, I decided to go in with them on the track car that they had, a 16v S1 Rallye...



It was basically the same spec as the saxo, but with HiSpec 4-pots, Quaife LSD and a Safety Devices cage.

The first trackday we booked together was Spa.

We got the car all prepped...






...and after about 8 laps...






My brother hit some coolant put down by a lambo race car at Blanchimont, put them into the wall at about 80. Luckily both of them were fine, the cage seemed to do its job as the car stopped crumpling where the cage started.

After many many many beers, we got the car home and got it stripped...





Off to the scrap yard with what we didnt want...



At first, the plan was to buy a cheap donor car, and put all the parts from the Rallye onto it. But after buying a 106 GTi that turned out to be full of rust, and me not having much luck selling the VTS, we decided to scrap the 106, and my dad and brother bought two thirds of the saxo off me.

So the Saxo went to its new home...



...and I picked up my new daily run about....

[P-I-Staker]

Gutted about the rallye, unlucky.

Where did you get the carbon sunroof blank?

[Chris245]

Originally Posted by P-I-Staker

Gutted about the rallye, unlucky.

Where did you get the carbon sunroof blank?

Cant remember the name of the company, pretty sure they went bust though.

[Chris245]

Now that the saxo was off the road and in the garage, we needed to get it stripped and decide what parts we were using (form the rallye or saxo) and sell the parts that weren't required.

As they were both of a similar spec, we were left with quite a lot of similar parts (seat, harnesses, suspension, etc).

So we got the saxo up on some axle stands....



...and got it stripped...









All the parts were inspected and we sellected the best from both cars, all the other stuff was sold.

We've also been collecting some new parts for the car over the past few months.

Compbrake bias valve...



Genuine OMP Corsica wheel...



Some heat protection...



Flocked the dash...



...and a used procomp intake which I don't have picture of.

[Chris245]

Right then, made loads of progress on the car over the past couple of months, I'll post up as much as possible over the next few days.

So after stripping all the suspension off the Saxo/Rallye, we picked the best set, loaded all the parts into the S2000, and I took it all to work for a refresh.

The plan was to strip, clean, inspect, paint and then rebuild the front struts with new wheel bearings and top mounts.

Started with the springs...







Spring top caps...







Damper retainers...





New seals...





Top mount caps..









Struts and hubs...











Damper tops repaired...







Removed the broken bolt from one of the caliper adaptor brackets...







New wheel bearings and bolts...





Wheel bearings pressed in...



Hubs pressed in...





Adaptor brackets fitted..



Dampers installed...





Caliper studs made up...



Fitted...



Finally, spring and top mount installed...



Thats it for now, I'll try and post some more pics up over the weekend.

[Chris245]

Next up was to rebuild and modify the Hi-Spec 4 pots.

The plan was to rebuild with new seals and machine the caliper to accomodate a k-nut/stud rather than the standard bolts that attached it to the strut.

This is how they looked when I started...





Stripped...



Machined...













New seals...





Assembled...



New pads...



Fitted...

[Chris245]

Right then,

Next up was to give the non PAS steering rack from the Rallye a quick rebuild.

This is how it started...







Stripped, cleaned and blasted ready for paint....



Ready to reassemble, all the internals were cleaned and inspected...



The finished product...







All new inner and outer track rods were fitted too.

[VTR_Craig]

Wow, you have been busy.

Awesome build so far, great attention to detail

[SimpleJoee]

Awesome work!

[Codey_H]

Chris245, what is the gear stick your using??

[Chris245]

Originally Posted by VTR_Craig

Wow, you have been busy.

Awesome build so far, great attention to detail

Originally Posted by SimpleJoee

Awesome work!

Cheers boys.

Originally Posted by Codey_H

Chris245, what is the gear stick your using??

We're using a Sachell Engineering Gearlever...

http://www.kamracing.co.uk/car-tunin...lever-kit.html

[Chris245]

Small update...

Got the wishbones painted and put some new ball joints in them.

Before...



Sandblasted + new ball joints ready for paint...



All done with all new high tensile bolts and k-nuts...





Next up will be the JP4 engine build progress.

[deano_123]

Sweet build, attention to detail is impressive

[saxokid100]

Very nice build..

[holdawayt]

Easily one of the best Saxos on the forum, definitely the best written progress thread.

Top work.

[Chris245]

Originally Posted by deano_123

Sweet build, attention to detail is impressive

Originally Posted by saxokid100

Very nice build..

Originally Posted by holdawayt

Easily one of the best Saxos on the forum, definitely the best written progress thread.

Top work.

Cheers boys.

Here are a few pics of the progress made the last time I worked on the car.

Here's how it started...



Flocked dash, non pas column, battery + cut-off + Anderson wiring, cage, plus a few other bits...









The rear end got some attention too.

My Dad wire-brushed all the loose paint and underseal off, then gave it a degrease...



Then undersealed it all...







I'll try and get some engine pics up later.

[Milney8989]

Very nice motor this. Doing a great job between you

Can't wait to see finished product

[Chris245]

Right then, the engine build....

So I bought a low mileage (less than 15k) JP4 a few years ago from a Xsara Picasso. It was just sat in the garage as a spare but the original saxo engine has now done 140k and was leaking a bit of oil.

I priced up the rebuild parts and we decided to give the JP4 a refresh and put it in the saxo.

I stripped all the xsara parts off that weren't needed, removed the head, and loaded it all into my car to take into work.

Heres what it looked like to start with...















The engine was then stripped and all the parts inspected and given an initial clean...

[Chris245]

I then ordered all of the parts...