Archive for the ‘ Courtenay Sport ’ Category

Astra H VXR Stage 4 K06 Coversion

Another fabulous conversion on an Astra H VXR.

This car first came to us for mapping to Stage 3 (hardware requirements are a full 3″ exhaust system and uprated intercooler). The car was fitted with a Forge lower front mount intercooler, but on the exhaust side only had a pre-cat removal pipe, and a Piper 3″ cat back exhaust system and was still running the factory main cat section. Obviously with this restriction in place it would be down on expected power, and upon checking on the rolling road this was found to be the case, but still making a respectable 283bhp.

Remedial action was simple; fit a 3″ front pipe and sports cat section. Once the mapping was finalised the results were a very good 299.99bhp and 332 lb ft torque on a cold January day.

In the hunt for more power, the car returned to us recently for a full K06 and inlet manifold upgrade.

ZRP steel rods and uprated ARP rod bolts were fitted, stem seals and retainers were done at the same time, and then when being put back together the K06 turbocharger, Courtenay Turbosmart uprated actuator, Courtenay Klasen high flow inlert manifold,thermal inlet gasket and high flow 340 fuel pump were all fitted. This was also the ideal opportunity to replace the cambelt and water pump and fit a lightweight allow bottom pulley.

Z20LEH engine being fitted with steel rods

Z20LEH engine being fitted with steel rods

An uprated CSRacing clutch kit and lightweight billet steel flywheel were also fitted, as a safeguard against the increase in power and torque, and to top it off a huge K Sport 8 Pot 356mm brake kit was also fitted, to bring everything safely to a halt. The car already had a Wavetrac LSD in the gearbox.

Rolling Road Mapping

Rolling Road Mapping

The end results after mapping 333bhp and 350 lb ft torque.

Astra J VXR Stage 2

Astra J VXR’s are becoming more and more popular for tuning now and here is another example. White seems to be a popular choice on this model.

This car was brought to us for a Stage 2 Tuning package which consists of a replacement 76mm downpipe to remove the restrictive pre-cat, a revised silicone inlet hose with a free flowing replacement air flow meter housing and large AEM DryFlow air filter assembly followed by custom ecu remapping, datalogging and full rolling road set up.

This car acheived 334bhp and 385 lb ft torque.

Astra J VXR Day

Returning after the Christmas and New Year break to work on more Astra J VXRs.

Mapping on a Cold Day – K06 at 349bhp

This Astra H VXR has been with us before for mapping and has a K06 turbo, full 3″ exhaust, Courtenay Klasen inlet manifold, CSRacing intercooler, steel rods (plus all the other required components) and achieved a very respectable 329bhp and 350 lb ft torque when last seen in the July heat this year.

Astra H VXR K06 Conversion

Astra H VXR K06 Conversion

Previously running a standard actuator, the car came back to us for checking and additional mapping after a Courtenay Turbosmart uprated actuator and recirculation valve had been fitted. We were able to have some further changes made to the boost, fuelling and ignition timing after the replacement actuator had been fitted, but the biggest change was the colder November temperature, meaning the dyno cell was lovely and chilled.

Final mapping saw a recorded power figure of 349bhp and 370 lb ft torque with more boost through the mid range helped by the stronger actuator. It goes without saying that the car was running Shell V Power 99RON fuel.

K06 Graph

K06 Graph

We still quote expected gains for this conversion at 330-335bhp, becuase we see and map more cars during the hotter months, but it only goes to prove how much turbocharged cars love cold dense air!

Astra J VXR Development

This summer has seen a substantial increase in tuning demand for the A20NFT engine. This combined with the ECU’s use in the new Corsa E VXR has seen us spending many hours on the dyno looking at data with Stephan getting his teeth firmly into the intricacies, oddities, protocol and hidden depths of the Delco ECU required for example in bigger airflow and turbo applications.

With Stephan visiting us this week we took the opportunity carry out some further testing work on our own  Astra J VXR, already fitted with our Courtenay Sport Racing intercooler and full turbo back 3″ (76mm) twin silenced exhaust system. A lot of time was spent with the car on the rolling road and further updates were made to the software. One of the objectives this week was to further test and calibrate our soon to be released induction kit in order to to fully understand where the best gains are made. To do this a number of filter and air mass housing combinations were tested before finally settling on our preferred design for the A20NFT engine.

Enlarged Silicone inlet Hose for Astra J VXR

Enlarged Silicone Inlet Hose for Astra J GTC VXR.

A direct replacement for the factory inlet hose, this silicone hose has been enlarged throughout its length for improved air flow, tapering only at the end to fit onto the turbo. This hose is smoothed out removing all the steps and convolutes found in the factory hose. It also features a moulded spigot for the breather pipe.

£119.95 Available in Blue, Red or Black or Yellow, Green, Purple or Orange to Special Order.

Astra J Inlet Hose

Astra J Inlet Hose

Courtenay Trio Excells at Thunder Road

For the third year in a row Courtenay Sport powered cars have come away victorious from Thunder Road, which this year was held on Saturday 8th August at the former RAF Woodbridge airbase.

The Thunder Road event is aimed at Performance VAUXHALL road going cars including all VXR models and is only open to road legal, taxed, tested and insured road vehicles. The competition comprises of 5 x 1 Mile Speed runs along the the 2 mile runway with the highest Terminal Speed at the 1 mile mark to count.

Congratulations to Andy Carr and Ben Gibson, who took first and second place in Class B for cars between 1601-2000cc and Tim Crane who won Class B for cars up to 1600cc. All three cars have been mapped by Courtenay Sport.

Andy driving his Courtenay Sport mapped Garrett equipped (GTx3076R) Astra G GSi 2.0 Turbo achieved a top speed of 173.86mph to win the class, beating the 2014 winning time for Class B.

Ben’s Courtenay Sport mapped Zafira B VXR with Garrett GT2871HTA turbo took second place at an extremely respectable top speed of 160.26mph; not bad for a 7 seat bus!

2015 was the third year that a Courtenay Sport car has won Class B. 2014 saw Rob Dennis run his Courtenay Sport mapped Garrett Turbo quipped Astra G across the line at 171.59mph, and 2013 the outright Class B winner was Wayne Townsend’s Courtenay Sport Astra H VXR.

Tim Crane was the winner of Class A, for vehicles up to 1600cc. His Stage 4 Corsa D VXR Sprint crossed the timing line at 138.73mph.

To show what an achievement Andy’s ‘almost’ 174mph top speed actually was, he would have also won Class C (2001-2800cc) and Class D (2801cc and above). It would have also placed the Astra in 4th place in Class E (for cars above 2800cc Turbo or Supercharged).

Overall 173.86mph placed Andy 4th overall (only loosing out to a couple of Monaros and a VXR8!), and Ben’s 160.26mph saw him 12th overall.

Thunder Road 2015

Thunder Road 2015 Andy Carr’s Astra GSi

Thunder Road 2015

Thunder Road 2015 Class B Winner

Thunder Road 2015

Thunder Road 2015 Class B Winner

Thunder Road 2015

Thunder Road 2015 Ben Gibson’s Zafira VXR

Thunder Road 2015

Thunder Road 2015 Tim Crane’s Corsa VXR

Thunder Road 2015

Thunder Road 2015 Ben’s Trophy and Engine

Something Different

Something a little different……

Brought to us for an independent examination and mechanical inspection. The subject of an insurance claim (from a well known ‘local’ insurer) the car had suffered lower front end damage to the water radiator and dry sump set up. We were asked to carry out an inspection and to check that the engine was not seized.

Ferrari 575M

Ferrari 575M

New Advert June 2015

Our Latest Advert revealed in Evo and Performance Vauxhall magazines.

Courtenay Sport Advert

Courtenay Sport Advert

Vauxhall Drivers’ Club Rolling Road Day

Saturday 16th May.

We had a varied selection of cars turn out for the VxDC Rolling Road day on Saturday 16th May, 2.0 16v Turbo Z20LEx engines being the most popular offering due to the wide range of tuning options available for this popular engine.

We were fortunate to have good weather, with sunshine for the most part of the day and a very good turnout of cars and people.

Thank you to everyone who attended the day and made it an enjoyable one.

Look out for the feature in a forthcoming edition of Performance Vauxhall magazine.

Classic 911 in for MOT

There is just something about the lines of a classic 911…. we had this immaculte car in recently for headlight bean alignment and MOT.

Porsche 911 Targa

Porsche 911 Targa

Turbosmart Recirculation Valves Now Available

Turbosmart Recirculation Valve

Turbosmart Recirculation Valve

Turbosmart Kompact Shortie Series Recirculation Valves have been specifically designed to suit BorgWarner EFR and KKK turbos.

Unlike the standard, plastic valves that use un-reinforced rubber diaphragms and are known to crack or split under increased boost, the new BW/KKK Kompact valves uses an O-Ring sealed piston which, coupled with their billet aluminium construction give them over 30PSI of boost handling capability.

Designed as a bolt-on direct replacement replacement for the factory valve on all BorgWarner EFR, KKK turbos, the Kompact Shortie Plumb Back provides better boost response and greater boost handling capability.

Included with each Kompact Shortie kit is:

  • 1 x Model Specific Valve
  • 1 x Straight Nipple
  • 1 x Banjo Nipple
  • 3 x Mounting screws

Finished in Black as shown. This recirculation valve is a really nicely machined and finished item, with a quality look and feel about it.

Features and Benefits:

  • Machined from Billet Alluminium.
  • Lightweight, brass/aluminium, two-piece piston.
  • More Reliable than the factory valve.
  • Substancial Construction.
  • Improved Boost Responsive.
  • Single Spring – No Requirement to Change when Tuning.
  • Finish: Anodised Black as shown.

Suitable for ALL BW EFR KKK (K04/K06) Z20LEx and A20NFT Turbo units:
Astra G SRi/GSi 2.0 Turbo
Astra H SRi 2.0 Turbo including VXR
Astra J GTC VXR 2.0 Turbo
Zafira A GSi 2.0 Turbo
Zafria B SRi 2.0 Turbo including VXR
VX220/VXR220 2.0 Turbo

£120.00 inc VAT

Coming soon for Z16LEx 1.6 Turbo Vauxhall Engines.

Turbosmart Recirculation Valve

Turbosmart Recirculation Valve

Astra H VXR – Uprated Clutch and Lightweight Flywheel

This Astra H VXR Nürburgring came to us for an uprated CSRacing clutch and lightweight billet steel flywheel, due to the fact the factory clutch had started to slip occasionlly.

The car had covered a shade over 91,000 miles and was originally modified to Stage 3 in 2008 at around 3,500 miles, virtually from new. So for nearly 7 years the car has been running at between 290-305bhp having had further changes made in later years, and the factory clutch and dual mass flywheel have given an exceptional service life considering the huge increase in power and torque to the car.

Replacing the original dual mass flywheel for a solid (single mass) lightweight billet steel one reduces the flywheel weight giving better acceleration due to the engine’s willingness to rev more freely as it is not having to rotate such a heavy mass. The CSRacing uprated clutch is a stronger unit, with an uprated cover with much more clamping pressure and an uprated sprung organic clutch disc to work with the single mass flywheel. The sprung disc is essential to fit if the dual mass flywheel is removed and replaced with a single mass item.

Also fitted at the same time was an uprated polyurethane gearbox mount insert as the original factory mount was starting to show signs of age related fatigue.

Astra H VXR Nürburgring Clutch and Flywheel Replacement

Astra H VXR Nürburgring Clutch and Flywheel Replacement

Don’t forget we can also fit standard original equipment (OE) replacement parts as well as uprated parts!

VX220 Tuning

Recently in for some fairly extensive modifications were this brace of VX220s.

The 2.2 underwent a Stage 1 supercharger conversion, an uprated fuel pump with 48L alloy fuel tank and rolling road set up.

The turbo model had a chargecooler system fitted, along with uprated fuel pump and uprated clutch, 80mm air flow meter and 495cc injectors, followed by a full rolling road mapping session, to complement the already fitted VXR turbo and full exhaust system.

VX220s undergoing modification work

VX220s undergoing modification work

Engine Bed/Subframe Bushes – Astra G/H and Zafira A/B

We prepared a second subframe and fitted the uprated bushes to it prior to fitting it to one of our track day cars.

Astra H Subframe with uprated purple road spec polyurethane subframe bushes fitted.

Astra Subframe with Poly Bushes Fitted

Astra Subframe with Poly Bushes Fitted

Astra H Subframe with uprated black track spec polyurethane subframe bushes fitted. This is due to be fitted to our track car. The front anti roll bar and power steering rack will be swapped over onto it.

Astra Subframe with Uprated Black Poly Bushes Fitted

Astra Subframe with Uprated Black Poly Bushes Fitted

And some close up shots:

Purple Spec: £22 each Black Spec: £24 each

6 complete bushes required per subframe. Kit includes 12 ‘top hat’ type bushes, 6 stainless steel sleeves/inserts, 12 zinc coated upper and lower washers and a grease sachet.

Brake and Chassis Upgrades – Astra H 1.9 CDTi

Enhancements being carried out to the brakes and suspension on an Astra H 1.9CDTi (150 PS) 3 door sport hatch.

Astra H 1.9 CDTi (150PS)

Astra H 1.9 CDTi (150PS)

To improve the chassis our Courtenay Sport Clubman Plus fast road suspension upgrade was fitted, which is a full kit that includes original equipment (OE) genuine Astra VXR dampers and a set of DAP Road springs, which not only improves road holding but also lowers the car by around 25-30mm.

The front and rear brakes were upgraded with EBC Turbo Grooved front and rear discs with EBC Red Ceramic (fast road) pads all round, and the system was bled with DOT 5.1 fluid.

Front EBC TGD Discs and CSR Suspension

Front EBC TGD Discs and CSR Suspension

Rear EBC TGD Discs and CSR Suspension

Rear EBC TGD Discs and CSR Suspension

Speedline Turini Alloy Wheels

Type 2120 – Turini. 8″x18″, 65.1mm, 5x110PCD ET38mm (possibly ET35mm) for Astra H VXR fitment.

Speedline Turini in Silver

Speedline Turini in Silver

Speedline Turini in Anthracite

Speedline Turini in Anthracite

Speedline Turini in Gold

Speedline Turini in Gold

We would like to have these Speedline Turini flow-formed 18″ wheels manufactured for Vauxhall/Opel fitment. If there is enough interest we will get a small batch of wheels made in 3 colours: Silver, Anthracite and Gold. The flowforming process makes these wheels extremely strong and light. They are fully heat treated up to motorsport specification and ideal for trackday use.

This would be a limited production run of wheels, meaning we do not need huge numbers of people to get this moving for delivery early 2015, and limited numbers would mean a certain level of exclusivity.

Target Price £936.00 per set of 4, depending upon the level of interest. (List Price £1008 inc VAT)

Please contact us as soon as possible to confirm interest giving your preferred colour. There is a contact form at the end of this post. If we achieve the desired numbers an order will be placed with Speedline upon receipt of payments from all participants.

Specification: 8″x18, 65.1mm, 5x110PCD ET38mm (possibly ET35mm) for Astra H VXR/OPC fitment. Will clear big brake kits such as AP 4 Pot and K Sport 8 Pot/D2 6 Pot.
These will not require a ‘fitting kit’ (spigot rings) or wobbly wheel bolts.

Colour Suggestions:
Gold suits White and Arden Blue cars.
Anthracite suits Silver, Red and White.
Silver suits most colours.

An iconic Speedline design, the Turini wheel is known for it’s classic good looks, durability and light weight.

The wheel comes with the ‘seal of approval’ from some of the worlds most important car manufacturers, as an original equipment option or line fitment. The 18″ version employ the world renowned Speedline patented Flowforming production technology, ensuring the ultimate marriage of low weight with high strength.

NOTE: These wheels are listed as available online on other suppliers’ websites, however having spoken directly to Speedline they have confirmed there is no stock of these wheels in a correct Vauxhall fitment, except by placing a minimum quantity special order.

FLOWFORMING – What is it and how does it differ?:

Speedline’s flowforming process is a unique solution to a common problem – how to make a wheel both light and strong.

Speedline’s flowforming method is unique within the wheel production industry, and patented.

This means that only Speedline can provide this precise technology.

The casting used to produce the wheel is much narrower than usual, but with the same amount of alloy that would be present in a conventional casting.

The casting is then placed in a specially designed machine within an additional mould. The hot casting is then spun at high rpm within the mould, and formed into the shape of the final wheel.

The resulting grain structure within the alloy of the wheel is linear, flowing in a single direction (see image below).

Cast versus Flow Forming

Cast versus Flow Forming

This grain structure pattern (shown above), combined with the exceptional quality of casting required for the process, gives the rim area of the wheel huge mechanical strength, and elongation. As a result of these mechanical characteristics, Speedline are able to reduce the thickness of the rim area resulting in reduced weight, without compromising strength and resistance to impact (see images below).

Pressure Cast Rim Profile

Pressure Cast Rim Profile

Flowformed Rim Profile

Flowformed Rim Profile

As can be seen from these images above, the flowformed wheel rim profile is much thinner that the usual cast wheel, resulting in lower weight and reduced inertia, making the wheel respond faster to acceleration and braking forces.

Note: Library Images

Speedline Turini in Silver

Speedline Turini in Silver

Speedline Turini in Anthracite

Speedline Turini in Anthracite

Speedline Turini in Gold

Speedline Turini in Gold

Astravan 1.9 CDTi Stage 3+ Tuning Package

We had this Astravan 1.9CDTi here recently for a few days undergoing some fairly extensive upgrades to cover the engine, brakes  and chassis.

Performance:
A Stage 3+ conversion. The van was fitted with our hybrid turbo charger, full 2.5″ stainless steel exhaust system (turbo back), full height CSRacing Intercooler and 80mm Air Flow Meter with revised inlet air path. At the same time an oil and filter change was also carried out.

After the hardware had been fitted, it was round onto the rolling road for ecu remapping and a full set up, which achieved 223bhp and 377 lb ft torque.

Astravan 1.9CDTi 150

Astravan 1.9CDTi 150

Braking:
At the same time a K Sport big brake kit was fitted, under the 17″ wheels, to greatly improve the stopping ability over the original factory 308mm brake set up. Red 8 Pot calipers, 330mm x 32mm 8 grooved and ventilated front discs with EBC Yellow Ceramic Pads. The brake system was bled through with DOT 5.1 brake fluid.

K Sport 8 Pot 330mm Brake Kit

K Sport 8 Pot 330mm Brake Kit

To ensure adequate clearance between the wheel spokes and the calipers a TÜV approved 3mm spacer has been fitted with longer 28mm black wheel bolts.

Handling:
The van has also had our Courtenay Sport Clubman Plus fast road suspension upgrade which is a full kit that includes original equipment (OE) genuine Astra VXR dampers and a set of DAP Road springs, which drops the chassis significantly, as can be seen on the before and after pictures below. Ideal for fast road and light track day use.

Before:

Astravan 1.9CDTi Standard Suspension

Astravan 1.9CDTi Standard Suspension

After:

Astravan 1.9CDTi Clubman Plus Suspension

Astravan 1.9CDTi Clubman Plus Suspension

Gold Plug Magnetic Sump Plugs

Gold Plug Magnetic Sump Plug

Gold Plug Magnetic Sump Plug


Gold Plug manufactures Magnetic Sump Drain Plugs of the highest quality. Constructed from a 303 Stainless Steel body that houses the strongest, highest temperature, N45SH Neodymium magnet available.

The magnet is secured in place with a proprietary 2 step process and will never come out. Advancements in technology and materials means Gold Plug is continually evolving and at the forefront of technology.

The strong Neodymium magnet collects any swarf or wear particles missed by the oil filter. These particles are abrasive and potentially damaging to the engine. The magnet will hold any collected metal firmly, unaffected by temperature variation until the oil is changed.

Magnetic sump plugs are a proven product and even used by some manufacturers as standard, examples are available on the market today however few match the quality of Gold Plug and those that do are very expensive.

  • M14 x 1.5 for most Vauxhal Sumps.
  • High Quality Stainless Steel.
  • High Temperature Neodymium Magnet.
  • Collects particles which are not filtered out by the oil filter.
  • Simple to Fit.
  • Made in the USA.
  • Includes Sump Plug Washer

Some Vauxhall/Opel engines using M14x1.5 Sump Plugs:
X18XE X20XEV X25XE X30XE (FWD)
Y26SE
Z10XE Z12XE Z12XEP Z14XE Z18XE Z18XER Z32SE
1.6 Turbo: Z16LEL Z16LER Z16LET
2.0 Turbo: Z20LEL Z20LER Z20LET Z20LEH
1.6 Turbo: A16LER A16LET A16LES
A16XER

If you are unsure on your particular fitment please check with us.

Price: £15.55

Insignia VXR Remap

We had this 2009 Insignia VXR with us recently for ecu remapping and full set up. It had covered about 55,000 miles and had already had the second cat removed by the owner, with the pre cat still in place.

Mapping and set up resulted in 348 bhp and 396 lb/ft torque, up on a car with a remap and standard exhaust with both cats still fitted, with gains of almost 100bhp and 100 lb/ft torque throught the mid range.

Insignia VXR

Insignia VXR

The Courtenay Sport Blog

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