Liam's Z4C race car project

After all the effort you have put into the build it's great to see you got rewarded with a brilliant result on your 1st outing. :thumbsup:

It's just a shame spectators still aren't allowed as I am missing going to race meets like yours. After all social distancing wouldn't be an issue at most circuits.
 
exdos said:
Excellent positioning behind that green Ginetta to line yourself up for an overtake. :thumbsup:
That's a Lotus Europa (Elise coupe with Vauxhall 2.0T engine) :D

Thanks for all the kind words. Next race is 22nd August at Silverstone (International circuit) once F1 have finished using it :wink:
 
This looks fantastic, are you going to be at Donnington any time soon?
 
Silverstone went well. This was the first real test for the car. A dry day, on a circuit I've won at before.

Qualifying was disappointing. Massive understeer everywhere - just couldn't get the car to turn-in like usual. Came in to reduce tyre pressures but ran out of laps to improve. Fortunately it was good enough for P3, half a second off class B pole - a BMW 130i with M135i engine and a 50bhp advantage!

I dropped the tyre pressures for the race, resisting the temptation (and others' advice) to add front camber. Put a couple of clicks on the rear dampers instead. That did the job, and the car was much better in the race. Although the early laps on a full tank of fuel was still a struggle.

Plenty of carnage in the race. 44 cars on the smaller International circuit is busy, but plenty of people throwing it off all on their own, including a Clio on its roof. Exploding tyre on a Lotus Exige brought out the safety car which lasted a good while, but allowed a cheap (mandatory) pit stop.

Net result was I took the class lead before the safety car and stretched it out to a 23s gap by the end. We're definitely down on power, but can brake later, and carry more corner speed than most. Off-season work will need to go into further lightening, and extracting whatever I can from the engine.

[youtube]_N8cME08EUg[/youtube]
https://youtu.be/_N8cME08EUg

I have also, finally, figured out how to fully disable DSC whilst retaining ABS. Disconnect the steering angle sensor! Works a treat, and although the trio of orange lights illuminate, Sport mode is still available if you want it.
 
I really mourn the absence of a proper dipstick!

The N52 oil level system on the dash isn't useful for track work, and at some point this year it stopped working altogether. It doesn't seem to matter under what conditions I push the button, the "checking..." indicator just goes across for about 5 minutes and then stops. It never shows a reading.

I then discovered that my OBD scan tool can show the oil level in mm. So I thought that would do - I can plug-in whenever I want to take a digital dipstick reading. But how many mm equates to full? And what's the range?

So I planned to calibrate the oil level sensor by doing an oil change and taking readings every 0.5l, all the way to the 6.5l capacity. Genius! 8)

But after approx 5 litres, the oil level reading stopped increasing. Bugger. Broken sensor... that'll explain why I can't get a reading from the dash any more. Or so I thought.

Oil level sensors aren't cheap, so I found the most recent part number and bought a used one off eBay and did another oil change. With the sump drained I removed the old sensor. Two out of the three studs sheared off with the slightest effort. Bugger. Thankfully one of the sheared studs left just enough to get a nut onto, but with only one revolution. So I added a little RTV sealant around the new sensor and attached a nut around the other sheared stud with 2-part epoxy. It's a bodge but if it leaks, it ought not to be catastrophic. A proper repair will require the sump to be removed (including front subframe/crossmember) and careful replacement of the studs.

20200906_144228.jpg

Attached the scanner and started refilling with oil. The sensor is working, but again, no readings above 5 litres. And then I realised: the sensor is not very tall and designed to measure the level with the engine running. So with the engine stopped, the sensor is fully submerged.

oil level sensor.png

Meticulously added 6.5 litres and then another 100ml so that I have an absolute max to aim for. Started the engine and watched the oil level while the water temp was at 30-40ºC. So now I have 65mm as my cold max level. I'll do a few more cold starts this week to see if it's consistent and reliable. The dash level check still isn't working. Perhaps because I can't actually drive it. Of course, the ironic thing is that the old sensor was working fine, and there was no reason to change it! But until I physically saw the sensor I did not realise that it is fully submerged with a stopped engine while filling.

I have my third race of the year this Saturday at Brands Hatch with MSV SuperCup. The car ought to be competitive in class A but I'll be a non-point-scoring invitation entry as I didn't want to splash out on a set of the control tyres just for a taster. Either way, it will give me a chance to take a hot oil level reading on the scanner.
 
enuff_zed said:
Would that have placed you higher overall?
Yeah. I was in 4th overall before that. I was so cross I did my fastest lap of the race right after the drive-through (on lap 39) :roll:
 
Liam22 said:
enuff_zed said:
Would that have placed you higher overall?
Yeah. I was in 4th overall before that. I was so cross I did my fastest lap of the race right after the drive-through (on lap 39) :roll:

That's a shame then. Must have been well clear in your Class then?
Will you be investing in the tyres and doing more?
And, following that line of thought, how would the control tyres have affected your performance do you think?
 
The entry was disappointingly small (19 cars). Tyres are Yokohama, at £1100/set. That's almost double what I'm paying for Nangkang AR-1s. They are apparently closer to a slick in terms of performance. So I'd have qualified better but still been disadvantaged on power-to-weight.

It's annoying. The car is very good, but doesn't fit well into any of the PTW class structures.

I did get weighed in parc fermé after the race. 1305kg with 1/3 tank of fuel and me inside. I reckon that's about 1230kg without driver and close to empty. Extreme dieting required over the winter! (the car, not me)
 
Hydro_Z4 said:
Just wondering if you've made any upgrades to the cooling system?
None. I'm still using the original rad. The aircon heat exchanger sits in front of the rad so once removed the original rad is in very good condition (no bent fins, etc). Water temp is very stable at 100ºC even after 45 minutes of racing. I don't check the oil temp regularly, but never seen it over about 120ºC.
 
Liam22 said:
Hydro_Z4 said:
Just wondering if you've made any upgrades to the cooling system?
None. I'm still using the original rad. The aircon heat exchanger sits in front of the rad so once removed the original rad is in very good condition (no bent fins, etc).

And for those of us who still have AC, the condenser is smashed to f*ck. Pretty sure mine is the source of slow leak.

Love these vids - quite hard to capture what feels like to drive around Brands though, I bet.
 
Had a more difficult race last weekend. Back in Roadsports at Snetterton. Wasn't expecting much overall - thought I would be fighting for a podium, having fluked a win last time. Track was damp/greasy at the start of qualifying but seemed to dry up quickly and I put in a couple of decent laps just before a red flag cut the session short. I must have got up to speed quickly as I was 3 seconds quicker than the next class B car.

Expected to be quickly caught in the race, and that is exactly what happened. Had a good battle with the M3-powered E36 Compact, and also 2.4l Honda Civic. Both much quicker in a straight line but the Coupe was quicker through the fast corners. I got the lead back for a while and then the Civic got back in front and started to pull away. His fastest lap was 0.8s quicker.

And then I made a schoolboy error in the pit stops and applied the MSV SuperCup format (pit in to pit out) instead of measuring stationary time. The result was a short stop and I got hit with a 54s penalty! Then I got a further 5s penalty for track limits. Messy. Very messy.

Got bumped back to 3rd in class. But any time you come home with a trophy is a good day. I will not repeat those mistakes.

In fact, the biggest problem was the brakes. The pedal went to the floor unless I furiously pumped it up with my left foot before every braking zone. I didn't have any big moments, but it was a constant worry, and somewhat dangerous. With the engine off I can hold the pedal firm but with the engine running it will sink to the floor, and without pumping just go straight down with no pressure. I suspected a vacuum leak, servo problem, or master cylinder. No big deal... but only one problem - I'm back out racing this Saturday - so just a week to get it sorted.
 
Bought a decent looking servo and master cylinder as a single unit from eBay. Then started worrying about being able to bleed the system through the ABS unit. Tried and failed to get INPA up and running on an old laptop but could not get it to recognise the DSC/ABS unit.

Bled the system again, just in case I had some air in there. No dice. So I took the plunge this evening to replace the servo+master cylinder. All fairly straightforward except. The trickiest part is attaching the actuator rod to the brake pedal. Took about an hour to replace the hardware and then another hour to bleed it through. But I have a normal feeling pedal again so looks like my hunch was right. Chances are it will need bleeding again after the first track session.

So just about ready for the Birkett 6h relay at Silverstone GP on Saturday. In a team with 3 other Z4s (E85s from the ZCars series). Should be fun!
 
Glad you got the brake sorted, i ran one track session like that last year, not a good thing, and shows in confidence and times, not to mention that if it really isnt there when you need it, then thats a whole other kettle of fish...

Glad you still came home with a trophy. good job man.

Cant wait to hear how you go with brakes sorted. :thumbsup:
 
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