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Badgerwagen - 2012 Race Season Castle Combe

Discussion in 'Badger5' started by ibizacupra, May 4, 2012.

  1. ibizacupra

    ibizacupra Jack-RIP my little Friend
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    2012... the year Badgerwagen comes out again to race in Castle Combe Saloon car C'ship.

    as usual.. given very little "me time" is possible with customer cars and business being the priority, its again last minute and not as planned. So much easier to have a plan in your head than to realise it :think: :shrug:

    mapping to do... its run in.. and geometry to reset..

    Its first Race for 2 years is Monday 7th May.. Live Race Meeting on Motors Tv.. 2 Races for us during the day.
    Quali is 10.10 for 15min
    Race 1: 13.55 for 15min
    Race 2: 16.40 for 15min

    Some pix of remedial work it needed.
    Belts had expired, Fire extinguisher had gone out of date, new race seat (I had it so might as well bolt it in), finally got a fuel gauge programmed into the lcd dash so I have a vague clue as to what fuel (weight) I am carrying.

    The Car
    [​IMG]
    The Engine
    [​IMG]

    The old-new seat
    [​IMG]
    [/img]
    changing harness's - out of date but used less than 20 times!
    [​IMG]

    teaching the dash its got fuel sender now.. reads in ltrs on other screen, not just mV
    [​IMG]
     
  2. Damoegan

    Damoegan Sir Bob,a geordy legend..

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    Good luck for the race, Bill :thumbup:
     
  3. traumapat

    traumapat Leon Cupra IHI

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    Excellent! I`ll look forward to your usual report. Good Luck :flag:
     
  4. m0rk

    m0rk sarcasm comes free
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    Looking good - looking forward to the video's again
     
  5. sambryant

    sambryant RoadRunner meep meep

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    yay exciting times bill and the very best of luck for monday :)
     
  6. 1.8t pop

    1.8t pop Guest

    going to be great to get back at it:D every one do a sun dance for monday please:dance:
     
  7. fourtwofive

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    sun dance! good luck bill have fun
     
  8. 4wdibiza

    4wdibiza 4wd all the way

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    When is big day mate
     
  9. chungster

    chungster SCN Veteran

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    What happened in the last 2 laps of Race 2 Bill? You were looking good for a top 6 finish but final standings put you down in 19th!!

    Was proper good race to watch tho, that Di Claudio's Pug 106 is damn fast!

    Saw you make a cracking start too going past a few cars on 1st lap. :)
     
  10. sambryant

    sambryant RoadRunner meep meep

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    gutted i couldnt make it :(
     
  11. wild willy

    wild willy Full Member

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    Well done Bill, must have been nice getting re aqainted with the beast. How did the car perform.
     
  12. 4wdibiza

    4wdibiza 4wd all the way

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    Yeah I also watched this just now on motors tv , fair play looked awesome on track, well done mate
     
  13. RobT

    RobT Full throttle trip

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    what ya doin with your old harness?
     
  14. ibizacupra

    ibizacupra Jack-RIP my little Friend
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    Hiya

    race 1 and quali were for me a disaster in terms of finding anything out about the car, beyond AD08's suk in the wet, and on actuator (12psi) pressure I had no traction as soon as boost climbed.. I was changing up at 4500rpm!!! doh!

    The car was untested, so a real learning experience of how it delivers its power and its new build spec.. all learnt in the wet and oiled track.. lol Awesome.. not.. :hide:

    I only had AD08 tyres to use, and some 4 year old AD07's which I took as spares in case of puncture.. Obviously hoping for a dry race re-debut, but the weather put pay to that pretty much.

    Survival was my objective after quali... and if I could improve pace during the 1st race (hoping for dry) then all good.. and it nearly happened.. Sat waiting for our race it was drying but a big downpour just before we went out put pay to that.. and a car dropping oil onto the wet track for 3 laps (you could see the 3 distinct oil trails on different lines in the wet track) made it somewhat slipper.. lol, like I needed that. Actuator pressure for me and changing up as soon as boost started to build was all I could do. Bringing it back in 1 piece was objective #1.

    We did have a good outing all said and done, enjoyed it whilst being frustrated at how little grip the AD08's had in the wet.. litterally cold to touch when I returned to the paddock after the 1st race... :doh:

    Race 2 was a couple of hours later, so I was hoping for a dry track for the last race.. Luckily, it came to be. Starting mid pack for race 2 after passing a few folks in race one, so was slightly "better" positioned, and with a dry track I would finally get to see how the car hooked up.

    Result was, quite well... I have a boost button on my steering wheel, which had been off all day, and was used to get me off the line and into the race whilst I "felt" how it was, braking,cornering,traction etc........ All felt really good from the get go, so I could push it more and explore what it was going to do.. It seemed to click into place really quickly, confidence built rapidly and enjoyed passing a few cars, now my traction issues had gone.

    After a few laps, I decided to test my boost button down the start straight to see what it felt like, expecting manic wheelspin, but what I got made me smile :D Elastic band acceleration kinda like fast and furious pushing a nos button on tv.. It just took off like a rocket... I was lovin that.. tractable power and acceleration . I was only using the boost on and off during the lap seeing where it would help, and how well it would carry speed on its actuator pressure vs the blast it down the straights bit.. This race meeting for me was its test day and the first and only time I had driven the car since last minute getting it together. Zero testing.. so all of this was well new to me. I only mapped it on saturday, and we all mucked in resetting geometry, ride heights, cambers etc sunday, and wired in the boost switch etc.

    Wiring the boost switch was key to knowing the weather forecast was 99% wet race day.. and I know the power wont ever be usable in the wet so off button was essential.. As it turned out, 12psi actuator was far too much for my AD08's to handle so.. not great, but that was tyres more than its 12psi power level.

    Back to race 2, and enjoying the additional power/acceleration the button gave me, I was using it at a couple of points on circuit, exiting old paddock, main straight and occasionally out of quarry to the esses.. Instant gap on anything following me at the press of a button..

    I had no idea what position I was up to but could see the mini of funnel, which was a good sign as he was close to the front guys.. Catching seemed pretty simple at the rate I was exploring the power button.. As with most things, something had to give... and the boost I was so enjoying earlier seemed to be getting slower to come in and less... and louder..

    Something pre turbine was occuring obviously in my mind.. turbo to mani was my thought... I felt a wave of heat come into the car like a hot air blower had fired up (i dont have a heater) which was a "hmmmm, thats not good" feeling.. Smelling burning things also not being a good sign either. :rolleyes: I was wondering how many laps were left, and whether it would last until the end.. I was dog slow now and being passed by guys I had romped by earlier. It could barely muster 0.5bar boost, eventually, and then as I passed the pits, the burning smell was alarming, and at the same time I thought, nah, stop pull off by some marshalls as I thought I must be on fire under the bonnet, the clutch pedal went to the floor and stuck there.. Bugger, my fears confirmed.. Stop Stop Stop...

    I pulled up just up avon rise into quarry next to a marshall post. and hopped out. The smell and smoke coming from the bonnet confirmed that was wise, but also needed some attention! After what felt like an age of faffing trying to get an extinguisher under the bonnet I pulled my own plumbed system to put out the flames which were creeping out by the bulkhead and master cylinder area. The clutch to the floor was the master cylinder having melted, and I sprayed brake fluid onto the uber hot turbo and downpipe = flames.

    Downside of having to set off my cars extinguisher is it all or nothing, so the drivers seat area also got foamed to death, before a marshal finally appeared with an extinguisher to gave it a quick "squirt". Better late than never I spose ( :no: ) Wet arse for me on tow back to pits.. ewwww.

    so.. that was the end of that.. Promising when it was hooking up.. and it felt awesome.

    What transpired was turbo bolts/studs had all back out of the manifold, so the exhaust gases were jetting into everything around.. now anyone who knows my work knows I heatshield stuff to death.. Despite this however, the 2 layers of heatshield between the turbo and clutch master cylinder had melted away.. yes melted.. as in not there any more. The heatwrapped rubber hose to the master cylinder had survived somehow, but the master cylinders end is well melty.. and what caused the small fire. some flames had tracked up the rubber hose to the resevoir and thats a little melted, and dripped down onto and into the heatshielded steering column boot, which is a little charred now. One of the silicon pipes to the tial was mullered to its component de-construction also.. lol.. Silicon can burn too. lol

    so.. I was actually very pleased with its dry performance, as it had tractable power even on its higher boost... loved it. :D

    12psi actuator 24-26psi on high booost being as far as I took it mapping wise.. More than enough power for fwd. comfortably #1 on the badger 5 top 10 dyno powers is what I will say.. :p
     
  15. ibizacupra

    ibizacupra Jack-RIP my little Friend
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    its for sale for anyone who wants it.
    Sabelt 3" 6 point with harness straps.. just not FIA approved for me any more :(
     
  16. sambryant

    sambryant RoadRunner meep meep

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    wow bill what an eventful day. still gutted i couldnt make it. let me know the next race and i will be there :)
    no real surprise traction in the wet was an issue but you need a quick car to win races. the power button (i love that, fast 6 :))
    seems like a awesome idea, sort of like when a f1 car goes round corners they dont use all cylinders, so yours its the turbo version :)
    sad to hear about the fire and things melting, i am aware of the quality of your work and i bet this surprised you.
    anyway onwards and upwards, look forward to the next race :)
    welldone badger 5 team
     
    #16 sambryant, May 8, 2012
    Last edited: May 8, 2012
  17. fourtwofive

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    Nice one shame about the weather! And few troubles
    I think you should put badger wagon on the top ten dyno :)
     
  18. ibizacupra

    ibizacupra Jack-RIP my little Friend
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    some pix

    the got showed some water and washed off the workshop dust which has been settling on it over these months whilst sat being ignored :(

    [​IMG]
    [​IMG]
    [​IMG]

    @ Castle Combe we had nice little signs made for us
    [​IMG]
    mind the flames indeed... lol... oh the irony.. (see the small text on the sign)

    In its little tent.. (read too small for an ibiza)
    [​IMG]

    and onto the post race 2 meltage... This is thru 2 layers of aluminium corrugated heatshield remember.
    [​IMG]
    [​IMG]

    [​IMG]

    brake resevior slightly melted from the brake fluid having squirted out of the clutch master cylinder when it finally melted
    [​IMG]

    Studs backed out of manifold causing the hot exhaust gas to blow onto the heatshielding
    [​IMG]
     
    #18 ibizacupra, May 9, 2012
    Last edited: May 9, 2012
  19. ibizacupra

    ibizacupra Jack-RIP my little Friend
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    After it returned back to the workshop it was quickly stripped back to see the extent of the damage in readyness for changing its spec to eliminate this from happening again.

    turbo off - was'nt hard lol, it was'nt exactly bolted on much any more..
    [​IMG]

    Clear view of the absence of heatshielding here
    [​IMG]

    The rubber feed hose to the clutch master cylinder lives under heatwrap, behind 2 layers of heatshield, and amazingly survived intact.. its only rubber too!
    [​IMG]

    main control pipe to tial wastegate bought the farm.. extreme melty.
    [​IMG]
    [​IMG]

    The wrapped lambda wiring survived, although its heatwrap did'nt enjoy the experience
    [​IMG]

    Clutch Master Cylinder is toast
    [​IMG]

    did'nt look like much, but a hot jet of exhaust gas blasting away > melting piont of aluminium clearly aint so good..
    [​IMG]
    Despite there being an overlap there.. it expired and just melted it away
    [​IMG]


    Poor clutch master cylinder... and brake pipes look a little singed below it also
    [​IMG]

    Steering rack boot copped it also, I think from dripping brake fluid on fire.. charred. this too lived behind fabric heatshield..
    [​IMG]
     
    #19 ibizacupra, May 9, 2012
    Last edited: May 9, 2012
  20. PhilW

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    Wow. Some serious melting going there Bill. Looked like you had plenty to start with.

    Whats the plan fabricated ceramic coated affair next?

    BTW, your section really could do with a sub section for all the stickies.
     
    #20 PhilW, May 9, 2012
    Last edited: May 9, 2012

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