Ford Capri Mk3 Track/Race Car Project

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Simon
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Re: Ford Capri Mk3 Track/Race Car Project

Post by Simon » Thu Jan 28, 2016 6:46 pm

Great to see you have kept the momentum up on this project Will!
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Will01
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Re: Ford Capri Mk3 Track/Race Car Project

Post by Will01 » Mon Feb 15, 2016 1:20 pm

Ok so i have done a few little more bits and pieces.
Something which is obvious is i need to package parts i have painted a little better. Plus it would also help greatly if i can do a little more to the car after paint or primer as i keep finding areas i have to redo as i am leaving the car for long periods without doing anything and primer cannot keep the moisture out indefinitely.
Lots of practise at least!

So i have had the front strut caliper bolts machined out by a local engineer shop as drilling these by hand was not happening since they are drop forged and you cannot drill out this size of hole with electric drill since you cannot get the pressure and low cutting speed.
Trial fitting of calipers has went well, but i will need to re-paint a few areas since alot of paint has been chipped whilst stored in workshop! Doh!

Also i had ordered some parts from GAZ and the rear coilover 1.9" items have arrived.
Still loads more parts required but they are slowly making there way to my front door. W
Whilst the weather is awllful i am spending the time doing little things and buying lots so the parts are there from when the weather has improved.

I should add that this front brake and suspensino setup will be tied up with 300-450lb front springs. I will also be using GAZ adjustable inserts.
This will buy me some time, but for race use it is not extreme enough. The inserts are fastroad/track items. Because of the small reservoirs they will not live upto racing with out performance drop off.
Therefore i will eventually upgrade to GAZ Mono setup with external reservoirs, at the same time these will be tied in with my Brembo 4 pot Alfa brake setup using 305mm discs. At the moment funds do not allow so these will have to wait.
Attachments
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Adjustable dampers
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100lb helper springs
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Spring seat spanners to help with pre-tensioning of spring
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Nice pair GAZ rear coilvoers to compliment single leaf setup
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Pair front setup
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Caliper setup with adaptor brackets
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Caliper and disc fitted 285mm
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Strut ready for parts, 7/16unf mounting threads were machined out to 12mm. This is because new bolts thread into adaptor bracket
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20160212_173117.jpg
Adjustable dampers
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20160212_173110.jpg
100lb helper springs
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20160212_173102.jpg
Spring seat spanners to help with pre-tensioning of spring
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Nice pair GAZ rear coilvoers to compliment single leaf setup
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20160130_110011.jpg
Pair front setup
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20160130_105115.jpg
Caliper setup with adaptor brackets
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20160130_105218.jpg
Strut ready for parts, 7/16unf mounting threads were machined out to 12mm. This is because new bolts thread into adaptor bracket
20160130_105218.jpg (152.11 KiB) Viewed 1710 times
Last edited by Will01 on Wed Apr 27, 2016 12:50 pm, edited 1 time in total.
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Will01
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Re: Ford Capri Mk3 Track/Race Car Project

Post by Will01 » Tue Mar 29, 2016 12:27 pm

Been working hard on the Capri again. Spent alot of time rebuilding my MIG welder to try and improve how it welds as it was very tempramental and hit or miss if i could make it work!
Anyway after a bit of fettling and reinforcing the rollers and repalcing the inner core with a steel liner, new wire etc, the MIG is great once again.
Soo good in fact i have welded in the cage spreader plates myself as i was getting a good clean(ish) weld. Not bad for a hobby mig.

I will post more pictures once the cage is in and everything is cleaned up and painted. But the cage is now in the car.
Just awaiting a good time to try out some bucket seats so i can get them in the car and start mocking up position for seat rails. Then i can paint her :)

I have also bought another car so have 6 currently! Therefore the spendature has been very low, so many parts were put on hold.
Maybe i will start another build thread for Alfa 156 Sportwagon 2.4JTD. My wife is very happy with it, but it does need a little work to make it great once again. Bargain car due to mileage but perfect for our needs.
Not had the best of luck as the Mini has generated many issues recently, so it is coming off the road. Unfortunately the other Alfa(GTA) has developed a large fault after a new timing belt tensioner bearings have failed!. Therefore things maybe slow for a while on the Capri front.

One big not of change however is i have sold my Jaguar XJ8 4.0 V8. I was going to use its engine in the Capri, but common sense has prevailed and now i will be fitting a Ford Cobra 5.0 V8 out of a Mustang! Although i may settle for a S/C 4.6 32V V8.
Capri's need a V in the front, its about noise aswell obviously.
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Spider 1969
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Re: Ford Capri Mk3 Track/Race Car Project

Post by Spider 1969 » Tue Mar 29, 2016 8:17 pm

Hi Will,

Good to see things are progressing. I have been missing your (bi) weekly updates!
Alfa 156 SW is an enjoyable car. My wife had one for 6 years and many many km's. Front suspension can be a bit of a headache to identify causes of rattling.
Sorry to hear about the GTA since you have been putting a lot of effort in it.

thank you,

Charles
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Will01
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Re: Ford Capri Mk3 Track/Race Car Project

Post by Will01 » Thu Mar 31, 2016 12:05 pm

Thanks Charles
Yes the GTA is a major pain, after investing time and money into it, for a brand new part to fail on such a critical area.
I will be chasing it with the manufacturer at somepoint, luckily the area i work in means i am in the right place to diagnose exactly what has gone wrong.
However it is going away either this weekend or next to be repaired as we need two cars, so i look forward to getting it back working again. I miss the GTA greatly.

The 156 SW is fantastic, i have been using it alot since we bought it and almost clocked up 1000miles. It has run really well. Just have an annoying slow puncture that will be sorted next week hopefully after i get new wheels back from having some work and tyres fitted. As said i will post a new thread for him(Alfie is the name my wife has given the SW! haha)

The SW and GTA are very similar, but i agree they can be a pain with front suspension and like to eat parts regularly.
Because we intend towing alot with this car i am replacing all the shockers and springs with a kit from AP which comes recommended as a budget upgrade setup. When i do this i will be repalcing the lower arms with OE as a matter of course and i will PU bush the upper wishbones with the parts i have left over from PU bushing the GTA.
We are also going to fit the thicker Standard ARB's off the GTA front and rear which will make a good upgrade for the Standard non V6 setup on the SW. This is one of the reasons why I wanted another 156 because i know the cars quite well now and i can use some parts as hand me down parts. I have my eye on a new Alfa Guilia SW when it finally gets released in the UK, so the SW has to give us good service until then.

Back to the Capri.. Since we are refurbing the wheels on the Alfa SW we are also going to tie in this session with applying the same silver to the Capri wheels which are currently sitting in Primer.
This will also mean i can then start looking at assembling these wheels and sealing them up ready for tyres to be fitted. Then i can start checking real world about clearance issues in the arches with new suspension etc. This is very important as the wheels are considerably larger and the suspension setup has changed somewhat from factory. It must be clear and have space for tyre deflection under full bump/rebound and lock otherwise more fettling will be required. Tyres touching anything is a no go for me, been there done that and had the tyre damage to prove it!
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Will01
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Re: Ford Capri Mk3 Track/Race Car Project

Post by Will01 » Wed Apr 27, 2016 12:40 pm

So update is we have made alot of progress recently which is nice to see.

The Inner & outer rims have been primed and painted, just got the centres to finish. these have been rubbed down, but need more primer.

Other jobs included coating all the parts i had lying in etch with high build primer and some of these parts also got their final colour aswell.

We have finally fully finished welding in all the roll cage spreader plates and i have also started adding extra structural reinforcement panels to where i expect to fit extra strengthening braces.
Using 3mm plate i made up some clamps for the rear strut towers and i have also welded in spreader plates at the back of the car which go across the rear section sof the chassis legs. The brace i am making up will go across the rear struts and then down into the rear of the chassis to stiffen that up and prevent flexing in the rear chassis area.

We also completely rubbed back the interior of the car and where required stripped back to bare metal. The whole interior was primed with etch and then high build. Then finally sprayed satin black. This should help keep the glare to a minimum and also looks pretty cool.

We also rubbed down the engine bay and have started painting that Signal Yellow to see how it will look. It is some colour but i love it.
Pinto rocker cover was painted same colour, but i am sure it will not be used for long.
Attachments
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Engine Bay YELLOW!
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Inner wing reinforcement
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Inner wing stiffners from v6 model
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Before inner wing stiffners fitted
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Lots of parts black
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More parts
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High build primer
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Axles in etch
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Another axle
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Interior satin black
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Satin black
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Cage fitted and bolted down
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Catherine showing off the door bar
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Rocker cover for Pinto in yellow
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Door bar
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Will01
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Re: Ford Capri Mk3 Track/Race Car Project

Post by Will01 » Wed Apr 27, 2016 12:47 pm

Few more pics

Apologies for poor order of pictures, but my camera has died and i had to use another phone camera to get pictures and i haven't uploaded in a while. It also appears i loaded photos in wrong order anyway starting with newest and getting older!!

It gives you an idea on the progress we have made however
Attachments
IMAG0803.jpg
Front floor cage feet spreader plates
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IMAG0806.jpg
Inner sill front cage floor spreader plates
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IMAG0805.jpg
Holes to pass tube through floor and then cut back an weld into floor
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Welding in floor plate
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Fully welded and boxed in floor plate
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IMAG1037.jpg
Inner and outer rims getting primer and paint
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IMAG1047.jpg
First part of rear strut brace getting mounting tabs welded into strut towers
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IMAG1112.jpg
Rear chassis leg strut brace mounting points welded in across the rear chassis leg
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IMAG1049.jpg
Hydraulic handbrake tab welded on for attaching to master cylinder
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Will01
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Re: Ford Capri Mk3 Track/Race Car Project

Post by Will01 » Mon May 02, 2016 11:47 am

A few more pictures. The cage is now fully fitted. THe only thing i want to do now is to thread lock all the bolts, i know they have nylock but just to be sure as i never want to hear anything coming loose.
I also thought i would get a good action shot of the driving position! haha. I haven't seen a picture with a smile on my face for a little while, this car is turning back into a kid again.

On the subject of door bars, this is not quite as easy as the roll cage instruction make out. They say place where required, in that meaning (i think)that they can be placed at any angle and any height!
On this subject i referred to the MSA Blue Book, but even in here it is not 100% clear. Therefore on this subject i contacted a good friend and took his advice. Thanks to Kip a good friend for helping me out. You really want to have the door bar at a good height to prevent a side impact impeding on the driver or passenger. Therefore using a good rule of at least a 1/3 to 50% up the height of the door. All in all i have measure the door bar height at 1 foot from the floor which is almost inline(bit lower) than the door locking hinge for the door. Because they are bolt in bars if i need to go higher at a later date this is still possible and all i would have to do is to shorten the door bar. I may upgrade to a full cross door bar later on, but for now the single bars are good.
Attachments
IMAG1186.jpg
Passenger footwell area with door bar
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Driver side footwell with door bar
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IMAG1191.jpg
Getting the driving position right! :)
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Will01
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Re: Ford Capri Mk3 Track/Race Car Project

Post by Will01 » Tue May 31, 2016 11:58 am

So we have made a little more progress. Now the weather is good and the evenings are getting lighter i am now spending some time after work and making sure i get home in time for bathing the kids.

The seats arrived. Cobra Monaco Pro, with steel sidemounts.
This meant i could now start measuring and mocking up a good seating position for my wife & I.
In a race car, this is extremely important, so we did take our time her. In fact a whole day!! Everyone i want to be able to drive it at least in terms of different size people could all get comfy. Last night i fixed that position finally by welding in the weld in seat rails.
These are 25mm CDS tube with mounting brackets welded to them. I have mounted them as low as i can possible mount them. Plus you still need to be able to weld around them.
The passenger seat will be set a little further back to allow a better view out the side for the driver. I will start that tonight.
Then once the seats are in, i need to move on to mounting brakets for harnesses. These will be 6 point 3inch harnesses. Unfortunately becasue of the cage, it is not possible to fit the original Inertia reel seat belts. This may cause some issues at time of MOT, but i cannot get around that. I would never use inertia belts with a fixed bucket anyway!

Anyway i have added a few shots of my wife & I trying the position out. Plus my son trying out the comfy seat.

Once the seats and harnesses are sorted i need to mock positions for driver controls and switch boxes so i can reach when strapped in.
I also need to get on with rear cage reinforcement as i intend to use it to mount tank and other parts to.
We are making progress, still a long way to go
Attachments
IMAG1284.jpg
Cobra Monaco Pro, steel seat
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Oscar trying out the seat for comfort. It is comfy by looks of things :)
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Catherine trying out a nice comfy position
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Not my best look!
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Weld in rail, after welding on mounting brackets
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IMAG1309.jpg
Floor before weld in cross rails
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IMAG1318.jpg
Reinforcement brackets welded into inner sill, excuse the poor looking welds. They were tidied up after
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IMAG1317.jpg
Reinforcement for rails in transmission tunnel. I decided to drill through the shell to pass the tube through. Underneath the tubes will be cut back and then have a plate welded over them to stop crud geeting through seat rail and into the sills
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IMAG1325.jpg
Seat rails welded in
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IMAG1320.jpg
Front rail was nothced to fit around crossmember. This was then welded into crossmember aswell.
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Seat rail view
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IMAG1319.jpg
Another view for placement. For reference i am 5ft 10. THis works well for my wife who is a bit shorter aswell.
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Seat bolted into rails, enough space between door bar and seat bolsters
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IMAG1315.jpg
Seat position before welded in
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Will01
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Re: Ford Capri Mk3 Track/Race Car Project

Post by Will01 » Wed Jun 01, 2016 11:47 am

Spent last night fitting up the passenger seat rails aswell. Not quite finsihed, but i am sure that will be finished off this weekend. Hard work fitting in time, but somehow i managed to fit in Work, Dinner,Garage,Bath the kids,Garage and shower and bed last few nights. Properly wron out now! Tonight i am having a rest.

Pictures to follow.

I suppose i really should try to get the wings and doors sorted for fitting. I also have some spare doors in a mess which i want to cut up and get as much weight out of them as possible. Prefer to keep steel where i can. Easier to repair than Fibreglass (for me at least!)
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Will01
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Re: Ford Capri Mk3 Track/Race Car Project

Post by Will01 » Sat Jun 04, 2016 9:49 pm

Ok so both seat rails are fully welded in. I also spent time cleaning them up and then they have been primed up nicely ready for paint.

I also got the rear strengthening brace mocked up and welded up. The rear chassis rail mounts were also made up and then welded into the strengthening brace i welded in across the chassis rails. The tube which connects to the rear turrets is drilled and bolted. I just need to drill the rear chassis mounts and then the rear brace is fully fitted. I may still weld in another cross brace for this. But for now i am happy with it.

I have now started fitting in the 6 point harness for the driver side. First off i need to get a good position and make sure for the for and aft extreme seat bolted position the harness mounting points comply with MSA regs. After all i am trying to make sure the car is suitable to be driven by more than just me if required.
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Will01
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Re: Ford Capri Mk3 Track/Race Car Project

Post by Will01 » Mon Jun 06, 2016 11:41 am

Pictures as promised

Just measuring up, drilling and welding in 6 point harness eyelet mounts.
Can see the harnesses are mocked up already. Shoulder harnesses will need mounting adaption, but i am pretty sure this can be done, without damaging the belt.

Also got cracking with rear brace. I may still add another cross brace across the rear mounts, but for now i am happy with it. It is pretty substantial and i am sure it will help reduce a little twisitng from the rear of the shell. As said, it is not completely finished, but i can't finalise anything else with it, until i have the other parts to mount in the boot area and see what space i have available.

I am starting to get a really happy feeling as i can see i am only a few weeks away from being able to drop the grinder and just start bolting things on.
Attachments
IMAG1327.jpg
Both rails
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IMAG1343.jpg
Cleaned up and primed ready for paint
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IMAG1344.jpg
Cleaned up and primed ready for paint
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IMAG1361.jpg
Seat position mocked up with 6 point harnesses. Just measuring out mounting points for all extremes of seating position by using MSA/FIA regs, also working off Schroth online installation manual
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IMAG1353.jpg
Chassis rail mounting point for rear brace
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IMAG1354.jpg
Chassis rail mounting point for rear brace
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IMAG1364.jpg
Rear brace bolted into rear turrets using same bolt type as roll cage 8.8 Grade
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IMAG1363.jpg
Rear brace in position bolt at the front turrets. Still to drill out rear chasis mounting points
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Will01
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Re: Ford Capri Mk3 Track/Race Car Project

Post by Will01 » Sat Jun 18, 2016 11:26 am

Plan is to get harness mounts sorted in the next week and then i can move forward with more fun things :)
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Guy Croft
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Re: Ford Capri Mk3 Track/Race Car Project

Post by Guy Croft » Sat Jun 18, 2016 7:15 pm

Hi Will et famille!

What a super post full of interest, machine and human!

Cannot believe how Oskar has grown, life is passing me in the blink of an eye, I swear time is accelerating, seems only last week you married Catherine....

Love the manic shot in the driver's seat minus steering wheel...!

As I told you so long ago, don't race this car. Please, don't. It will far too valuable.

I send my greetings,

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Will01
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Re: Ford Capri Mk3 Track/Race Car Project

Post by Will01 » Tue Oct 11, 2016 7:20 pm

Thanks Guy, don't worry it is not going to be raced. I can't afford it for one and the second, it is not going to be competitve enough. If i go racing it will be in a more modern vehicle. Maybe an Alfa 156 as i know my way round those pretty well.

Yes the manic picture is a little worrying haha, but i like to think of myself as a little mad! :)

The family sure are growing up fast. TIme just flies.
We will be down again to say hi, Abigail also wants to get a hug with you. Take care Guy.



So a small update, harness mounts welded in and everything is linished back and primed. Just need to get the harness to harness bar adaptors so the harnesses are fully secure in the car.
Just need to clean inside of car and spray primed areas with satin black.

Also finished securing rear strut brace mounts into rear turrets and the rear sections of the floor above the chassis rails.

Also finished cleaning up and priming the rear strut brace i have made. It now bolts in and out, which is nice and convenient and will also help me be able to use the car in different competitions. (Non-race, just looking at sprints, hillclimbs and speed trials e.g. time attack). Some regs don't allow chassis strengthening behind rear turrets, but it depends on the regs.

I have also been busy converting the front struts to coilovers. I purchased a threaded sleeve and Grp4 strut stiffening set. Also got 2.25" 8 inch 400 or 450lbs front springs. Just need to purchase adjustable inserts now.
I have tack welded the sleeve in place set 25mm from top of strut, but i can't fully fix this until i have down some measurements with the inserts.
I just need to make sure i can get the car low enough for competition needs, but still have a bit of adjustability either way.

Next jobs still need to sort out front radiator and mounts, then design some diverters to make sure air is forced through rad properly.
Still need some diff covers as all the ones i have have been to shot blasters and all are perforated with many holes. I i will be replacing with an alloy tickford style atlas diff cover. This will also help increase oil capacity in diff housing and has cooling fins to aid cooling of the diff. If that doesn't work it will also be easy to adapt the cover to fit an diff cooling system!

Going to have to take another break from the Capri again as i now have to fit a bathroom!
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