Astra H VXR Sprint

Brake Servo Vacuum Hose

Jan 29th. 2015
By mapw

Time to change the original hard plastic brake serve vacuum hose for an aftermarket one, mainly due to the fact that the original hose does not sit quite as well as it could do with the aftermarket high flow inlet manifold fitted. The replacement part is made up using reinforced servo hose with OE fittings.

So here are the required parts. A length of servo hose, an OE one-way valve and and OE fittings:

Brake Servo Vacuum Hose and Fittings

The aftermarket servo hose is strong, reinforced and more flexible and as it is cut as needed is can be routed slightly differently compared to the original hose. Once measured and cut as required the OE one way valve and elbows are fitted. The finished hose can then be routed out of the way behind the inlet manifold and plenum and across the bulkhead to the brake servo.

Original Servo Hose – Top and Replacement Hose – Bottom

Original Hose (Top) Replacement Hose (Bottom)

And fitted:

Modified Brake Servo Hose Fitted (Servo End)

Modified Brake Servo Hose Fitted (Manifold End)

Time to fit the KW Clubsport kit

Jan 12th. 2015
By mapw

The KW Clubsport coilover kit was fitted on Friday. The build quality of the KW parts is excellent and fitment is very straightforward.

So a reminder of the kit:

KW Clubsport 2 Way Coilover Kit

Some fitted pictures of the rear set up:

Rear Helper Spring Upper Seats

The above upper support had to be opened out using a flap wheel attached to a drill from 46mm to about 53mm to allow it to fit over the OE bump stop. See below:

Rear Helper Spring Upper Seats fitted to OE Rear Bump Stops

Rear Upper Support

Rear Spring Adjuster

Rear Spring

Rear KW Clubsport Set Up

Front Set Up:

Front Strut

Solid Top Mount

Front Strut

Front Bump Adjust

Front Strut

After an initial road test to settle everything, the height was adjusted and then it will be chassis alignment time (again!) to recheck everything and just get it all back to the required settings prior to the next track day.

The first real test will be back at Snetterton at the end of February.

Engine Bed and Bush Replacement

Jan 12th. 2015
By mapw

In preparation for replacing the engine bed bushes and front anti roll bar bushes a second engine bed was sourced. I decided to prepare another engine bed with the uprated polyurethane bed bushes and then swap the beds over, rather than to fit the new bushes to the current subframe already fitted to the car. It also meant the replacement subframe could be painted first before being fitted to the car, as the subframes are subject to surface corrosion. Preparing a second subframe will make the whole process easier, rather than having to remove and then paint the current subframe fitted to the car.

The new subframe will be cleaned up, the areas of rust removed, treated with a rust neutraliser, primed with a zinc primer (given several coats) and finally painted with a rust-proof metal paint, again given several coats. Then the uprated subframe bushes can be fitted to the new subframe.

The existing subframe will then be removed from the car, the front anti roll bar (with new uprated anti roll bar bushes), uprated rear engine mount, wishbones and power steering rack will be transferred across to the new subframe which will be fitted onto the car. At the same time a PAS fluid change will be carried out.

So to begin, one engine bed after a quick clean up and degrease to get rid of the worst of the grime, and with the original subframe bushes and wishbones removed:

Engine Subframe

So the next stage was to strip it back and remove the main areas of surface rust, after which the subframe was treated with an anti-rust neutraliser to give a stable sound bonded surface, followed by zinc priming in preparation for the top coat.

Engine Bed (underside) prepped and being primed.

Engine Bed (top) primed.

Engine Bed (top) prepped and being primed.

Engine Bed (top) primed.

The final stage was to paint the subframe with a metal protection paint to give it an OE look.

Finished Subframe

During preparation, priming and painting particular attention was paid to the areas that are most susceptible to corrosion, mainly the areas where the subframe has been welded.

And with the uprated bushes fitted.

Astra Subframe with Uprated Polyurethane Bushes Fitted

Just the the swap over to do.

12/01/2015
The original subframe was removed from the car and the front wishbones, front anti roll bar and power steering rack were swapped over onto the new subframe with the uprated black series Powerflex bushes which was then refitted onto the car.

At the same time the factory anti roll bar bushes were replaced with Powerflex black series uprated anti roll bar bushes and the power steering fluid was replaced with new Pentosin CHF 202 fluid, as it had most likely been in use since day one.

The exposed captive nuts and subframe bolts were treated to some AL1100 anti-seize spray when refitted, as it is not uncommon for the bolts to seize in. This is especially common due to corrosion from winter salt, which fortunately the car does not get exposed to. Additionally the exposed areas of the chassis were treated with Waxoyl underseal.

Underside

Radiator Support Brackets

Jan 6th. 2015
By mapw

Ready to be fitted to the replacement subframe, another pair of radiator support brackets which have had a refresh in the same way the subframe has. Cleaned, zinc primed and finished in satin black metal paint.

Replacement Radiator Lower Support Brackets

Revolution Millennium Alloy Wheels

Dec 10th. 2014
By mapw

These are the wheels that came with the car. They have been given a good clean ready to sell.

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Bed Bushes Arrived Today

Dec 10th. 2014
By mapw

Uprated polyurethane engine bed bushes arrived today. So a big Thank you Powerflex for supplying these bushes.

Poly Engine Bed Bushes

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Build 2015
95 Shore . Bed Bush . Black Serie . Poly Bush

Uprated Engine Bed/Subframe Bushes

Nov 30th. 2014
By mapw

One area that is often neglected, along with front anti roll bar bushes, are the engine bed/subframe bushes, mainly because the bed needs to be dropped to replace them, so there is a reasonable amount of work involved. Additionally because the engine bed captive retaining nuts are floating (i.e. they can move once the subframe bolts are undone) there is a danger that once removed the engine bed could be refitted out of alignment unless the correct jig to re-align the subframe onto the car is used. Correct alignment of the subframe is essential because the wishbones are bolted to the subframe and if incorrectly aligned the chassis settings will be out, affecting the handling.

With the factory subframe mounts there is some compliance/flex in them as they are designed for road use and have a rubber core to help dampen out vibrations, however stiffer bed bushes reduce this compliance removing any flex in the bushes, ideal for improving the chassis and feel both on road and especially on track.

These front subframe mounts feature two polyurethane ‘top-hat’ style bushes that make for simple installation and durability. The bushes house a stainless steel sleeve and are supported by zinc coated steel washers at each end for increased support under load. The stainless steel sleeves should also help to prevent instqances where the bed bolts seize into the factory bushes over time.

These polyurethane uprated subframe mounts are manufactured from two material types; either 80 shore purple material or 95 shore black material. Purple is ideal for road use and black is best suited for track use.

I have chosen the black 95 shore bushes for the car due to its use on track. They are all but solid removing the flex in the bed bushes during hard use, so improving front end feel, especially during cornering and under high loads on track.

Whilst there are also some solid engine bed bushes on the market, manufactured from aluminium, they were unavailable at the time these upgrades were being carried out hence opting for these uprated 95 shore poly mounts.

All being well I will get the engine bed bushes fitted during December.

Uprated 95 Shore Black Polyurethane Engine Bed Bushes:

Black Polyurethane Engine Bed Bushes

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Build 2015
95 Shore . Black Series . Engine Bed Bush . Powerflex . Powerflex Black Series . Subframe Bush

KW Clubsport Coilovers Arrive…..

Nov 28th. 2014
By mapw

The KW Clubsport 2 Way Coilover Kit arrived today, a couple of weeks ahead of schedule. Cannot wait to get this fitted onto the car ready for 2015 track days. A huge thank you to Richard Good at KW Automotive for organising this.

KW Clubsport 2 Way Coilover Kit

KW Clubsport Coilover Kit

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Build 2015
2 Way . Clubsport . Coilovers . KW . KW Clubsport . KW Clubsport Astra H

Polyurethane Anti Roll Bar Bushes

Nov 26th. 2014
By mapw

The car is currently running the original factory anti roll bar bushes (which have now covered 88,000 miles) and these have never been changed so it is about time they were replaced. To replace them I have a pair of Powerflex Black Series track spec (95 Shore) anti roll bar bushes ready to fit.

This will be a job to do when the engine bed/subframe is dropped as I will be fitting a set of uprated engine bed bushes over the winter. Due to the location of the front anti roll bar on the engine subframe, replacing these bushes with the subframe on the car is all but impossible. With the subframe off it makes the job so much easier.

The aim is to get these fitted during December.

1 Piece Replacement Poly Bush (shown in road spec 80 shore purple material – left) and Original 2 Piece Rubber Bush (right):

Poly 1 Piece ARB Bush and Original 2 Piece ARB Bush

Front ARB Bushes in Black track spec 95 shore material:

Anti Roll Bar Bush – Black Material 95 Shore

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Build 2015
95 Shore . Anti Roll Bar Bush . Black Series . Poly Bushes . Powerflex . Powerflex Black Series

Trackday Snetterton 22 November 2014

Nov 23rd. 2014
By mapw

The MVS Trackdays (www.msvtrackdays.com) organised track day at Snetterton was a fantastic day. The weather varied between almost dry, drizzle and moderate rain throughout the day and track conditions varied from damp to wet, making driving conditions a little more challenging but still very enjoyable.

It also meant that the car wasn’t given quite such a hard time and it kept temperatures down. It was obviously harder to get heat into the tyres, meaning starting with higher pressures, but it also meant they were not subject to overheating. Speeds were slightly lower and reduced grip meant braking had to be smoother but progressive meaning that brake temperatures were lower and cornering speeds were also slower. Overall this also kept gearbox oil temperatures lower and the water temperature didn’t go above 90 on track due to everything being worked less and not put under as much stress.

The wet conditions meant that the usual ‘dry’ lines were abandoned in favour of ‘wet’ lines meaning searching for grip off the usual lines round the corners where more grip was available, keeping away from the apexes and braking slightly offline where more grip exists. Overall the Nankang NS-2R tyres performed faultlessly, gave excellent grip levels and offered a lot of confidence given the conditions and far outperformed their price point.

So the last track day of the year for me, now heading for the closed season giving some time for a few more improvements to be carried out. Counting down to the first planned track day of 2015 in February.

Image courtesy of Torque Photography: