Sirion AWD conversion/ autocross build




The usually excellent work we see from you Mick. Well done.

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Yesterday was the last race of the season. I met up with two fellow club members, Jorgen with his VW Sirocco, and Kai with his Opel Astra, both very nice cars.

We set off on the two and a half hour drive to Melle, but not on the Autobahn, no, we decided to take the Landstraße, the back roads. As we headed south the landscape began to change, no longer the boring flatness of the northwest but rather winding roads through hills surrounded by colourful autumn trees. It was a fantastic drive. I tried my best to keep up with them, but with the car full of tyres and tools, along with the extra passenger, I found myself left behind more than once.

Over the last few weeks I have been messing around with the car, I made a new flange for the headers so the exhaust is tip top and widened the car 50mm front and rear. Some test drives confirmed everything was in order, only it wasn’t. During the drive yesterday the engine light came on again, again the o2 sensor was causing a fault… I erase the code and press on. The rest of the drive was problem free, then we arrived at the airstrip in Melle.

The final round for the NWD Cup, Niedersachsen Cup and Weser EMS Cup, also near the border with Nordrhein Westphalen where the season has already ended, we were greeted by over a hundred competitors from all over Germany. We arrived at lunch time, the youngsters had finished and the group 2a was in action. We signed up and went through scrutineering, watched some racing then came group 3, so I was up.

With so many competitors the racing continued through the lunch break and we didn’t get a chance to walk the tracks. At this event we had 2 tracks, you drive the first track then line up for the second directly aftwards, so warm up, warm up, first run, first run, second run, second run. I thought it was a fantastic system.

The warmup round on the first track went well, some pylons were hit but otherwise smooth and fast. The second track warmup was a catastrophe, I entered the hairpin from the wrong side, completely missed a door and came in way to hot for the last 90° turn and ended up on the grass. No problem, just the warmup run. The following runs were all very clean and fast, except for one in which 3 pylons were hit at the exit when I came in a little bit sideways :sweat_smile: The wider wheelbase helped the car alot, the rear axle seemed to handle better and oversteer was less extreme and more predictable. A fantastic day.

In my group there were 13 competitors, I finished 10th (could have been 5th if not for the 3 pylons) and 8th. The fiat retired after the first warmup run due to technical problems. The first 4 places were occupied by two teams, both very professional.

After calculating the points it looks like the championship will end with the 2 Polo drivers in 1st and Second, followed by myself in 3rd. Very happy to have come this far in my first year, driving in the highest class!



3rd overall fantastic. Well done.

I managed fourth outright at my last event in the old wagon. One test was complex and I had taken my hardtail race MTB. I rode the course as fast as I could on the bicycle easily twenty times. Nearly everyone joked with me about how embarrassing it would be if I got a wrong direction. Anyway all the top guys stuffed up which drastically elevated my position. Last khanacross for me is in two weeks, new AR1 Nangkangs. We are not getting fields of a hundred, more like 40-60.

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The results are up. I misunderstood the scoring system, I was under the impression the best 70% of the races was added to the final score. But it looks like only the best 70% of the races are used for the final score. I think my German has some room for improvement :sweat_smile: 5th in class, still not too bad!
NWD-Cup 2018.pdf3a (1).pdf (35.4 KB)



Hi guys, its been a while but things are starting to kick off again, getting ready for the new season.
After the last race the car was parked up and I spent some time working on my suspension tuning app .
I just started getting back into it, currently working on adapting some adjustable coilovers to the front, a copen gearbox was bought for the ridiculously short final drive, and im working on widening the body 50mm. Here are a couple of photos to start off the year :slightly_smiling_face:



Here are the finished coilovers, custom strut tops and lower mounts :slight_smile:

And here is the strut brace, the original braces are being “boxed in” to strengthen them and the middle bar will have some extra pieces welded in



Amazing work Mick!

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Strut brace is coming along nicely :slight_smile:



oh really nice work Mick I have those bits (plates from the gtvi I wrecked) and wanted to make something similar.

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well done mick that looks really good

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Looks stock. I mean that as a compliment. Well done.

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Very nice work on the Coilover mounts and the top strut bar.
Did the coil over struts work better than the Bilsteins?
Where did you get the Coil over struts from?

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The coilovers are one of the cheaper brands on the market, to save myself the embarrassment I shall not name them, but they were designed for a Subaru GC and were chosen because the lower mounts were steel, meaning I could easily modify them. They were bought second hand ridiculously cheap and were still practically brand new, even if they dont work I still have a pair of pillow ball top mounts for a reasonable price. Unfortunately I did not try the bilsteins as price was a factor, and also the available sizes made things tricky. These have very heavy compression, and adjustable rebound, the last step will be swapping the springs out from 10kg to 5kg with the aim of having the vehicle sprung at close to 2.5Hz (if my maths is correct that means 5kg front and 4kg rear)



I love the top mounts, where would one find a bearing like that?



Made up some proper mounts for the air filter today

@DaleJeffree the bearings you can buy from any bearing store, they are called spherical plain bearings. You would just need to turn a flange on a lathe to be able to bolt it to the camber plate. Lucky everything was there on my coilovers, I just had to make the camber plates

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For spherical bearing tops I use Minebea ABT12T®. A bit of a std. @DaleJeffree



Another small part finished



The latest project