Stage Car Project

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Gaverick

New member
Joined
Aug 12, 2010
Messages
60
Hi everyone,

I recently joined the forum as me and a friend have purchased a 1999 Melina Blue 1.7 Puma, with the intention of turning it in to a dedicated track weapon. We bought the car from a friend with 70k miles on it with 6 months MOT and 4 months tax for £350.

It is generally in good nick, the only issue when we bought it was a broken starter motor, so we fixed that and it was running nice.

I should mention we have no formal training in mechanics, just learning as we go along and also seem to be accumulating new tools at an alarming rate!

The first job was to strip it out, we went to the extremes on this, removing everything that isn't needed. This included removing the heater matrix, blower motor, carpets and soundproofing, spare wheel, rear wiper motor, airbag, etc. There really isn't a lot left in there now and the suspension has raised about 10cm haha.

We then removed the old seats and put some buckets seats in, they weigh around 8kg each which is a hell of a lot lighter than the standard seats which seems to weigh a tonne.

We have also fitted an induction kit and are going to install a heatshield around it to keep intake temps low, I work at an insulation company making heatshields for cars and planes so have access to high quality insulation. We decided on the induction kit over a FRP airbox as we knew once we got it insulated properly it would perform just as well as, if not better than a FRP airbox.

The engine bay received a tidy up and the cam cover was painted green, we also changed the oil, oil filter, spark plugs and fuel filter.

The next big purchase was a full Milltek 4-2-1 system from Tyeboi off of here. We spent all of yesterday fitting it in the pouring rain, but now it is on and sounds awesome, should free up some more power too as the standard manifold and cat looks like a pretty rubbish design to me.

We have had the car for about 3 months now and are just buying parts as funds allow.

Future plans include:

Harnesses
Roll Cage
Coilovers
Re-profiled cams
Bonnet Pins
Mondeo Throttle Body
Fiesta ST front and rear disc brakes
Cambelt needs changing
Momo wheel
Trackday tyres + lightweight alloys
Possibly remove the ABS.
Replace window glass with polycarbonate if we can find a good deal

After the engine mods are done we plan on getting it mapped to run on 98 RON and to take advantage of the new cams we will be putting in.

It's a long term project and we are in no rush, just taking our time to do things properly. Initial targets are to run somewhere around 150bhp and see if we can get the weight to around 850kg. It should be ready for a track day in a few months.

Long term plans include LSD and throttle bodies, but thats a long way off.

I will get some pics up when I'm next working on the car, oh yer, the colour scheme is fluorescent green and Melina blue :lol:
 
Gaverick said:
I will get some pics up when I'm next working on the car, oh yer, the colour scheme is fluorescent green and Melina blue :lol:

I was with you all the way.

Until then.

Welcome :)
 
XIIVVX said:
Gaverick said:
I will get some pics up when I'm next working on the car, oh yer, the colour scheme is fluorescent green and Melina blue :lol:

I was with you all the way.

Until then.

Welcome :)

Haha we aren't taking ourselves too seriously on the cosmetic side of things, just making it look a bit mad and quirky so it stands out on track. It's the mechanics side of things that we are being serious about.
 
I will take the blame for the blue and flouro green :lol:

As above its more just to make it stand out a bit, the real work will come over the next few months.
 
sounds like a good little project you got yourself there mate! look forward to the progress and the pics :eek:k:
 
Given that it is a track car, you should certainly consider a FRP gearbox (not that I am biased...), the shorter final drive would help to keep the car in it's sweet spot. If you want one, let me know.
 
Some photos I took this evening, sorry about the quality I only had my blackberry.

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Just love the dashboard finish....did you do yourself ? If so, could you explain ?

Very well interior stripped ! I just had a lesson watching your photos....
 
We bought a DIY flocking kit off the internet, think it cost around £10. Just apply the glue to the dash and spray the fibres over the top. You can achieve a good finish with it, probably not as good as getting it flocked professionally but it does the job and looks good enough.
 
philalix said:
Just love the dashboard finish....did you do yourself ? If so, could you explain ?

Very well interior stripped ! I just had a lesson watching your photos....

Here is the kit we got, the price seems to have gone up a bit as i paid about £15 inc postage.

http://www.frost.co.uk/item_Detail.asp?productID=9441&frostProductName=Flock%20Kit%20Black&catID=21&frostCat=Interior%20Trim&frostSubCat=&subCatID=" onclick="window.open(this.href);return false;

Its quite easy to do but you need to be patient to get a really good uniform finish and you will need to take the dash out unless you want your car full of fibre. I rushed it so its a bit patchy although there is plenty left to go over it so i will be doing that at some point.

Im starting to think that there is only us building it who like the green/blue theme :lol:
 
A few pics with the harnesses in now, might have a quick vid later if I can work out how to get in on here.
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sweet

when you get the mondeo throttle body send it my way with a few choccy bars and il flow it for you
 
We bought some Mondeo 300mm callipers on Friday. The callipers have now been ground, spaced and tested fitted under the 15" props, it's very tight under there but they do fit. This won't be a permanent solution though, we will be getting some wheels which give more clearance. Here is a pic of the callipers painted up ready for fitting tomorrow, they cleaned up very well and are unrecognisable from the lumps of rust we bought on Friday. The brake system is now dry and won't be refilled until the rear disc conversion is complete, just need to get hold of the parts needed first.

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