Archive for the ‘ Courtenay Sport ’ Category

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

Please use this contact form to ONLY contact us regarding the purchase of Speedline Turini Alloy Wheels.

Thank You

* indicates required field

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

Stage 3 Corsa VXR

We had a lovely 40 something thousand mile Corsa VXR in with us recently which had been fitted with a full 3″ exhaust system, twin silencers and pre cat removed and also our high flow CSRacing full height intercooler.

Compressions were checked all found to be good, then the ecu was remapped and the car underwent a full rolling road set up with full ecu datalogging and the software was optimised to suit the fitted components resulting in 240bhp and 249 lb ft torque and running on 99 octane fuel.

As we are sure you all know what a Corsa VXR looks like by now, we will show you the power and torque graphs instead:

Corsa VXR Stage 3 Power and Torque Graph

Corsa VXR Stage 3 Power and Torque Graph

Corsa D VXR Engine Mounts

Due for imminent release, expected within the next 3 weeks, uprated engine mounts for Corsa D VXR models.

Corsa VXR Engine Mount Group

Corsa VXR Engine Mount Group

Pricing from £93.60 – £138.00 Further details to follow. Contact us now to pre-order yours.
Read more

Corsa VXR Nürburgring Stage 2 Upgrade – Take 2

It has been a busy week for us for Corsa VXR tuning.

This Glacier White car is our second Corsa VXR Nürburgring Stage 2 Upgrade in a week. We fitted our full 3″ turbo back exhaust first:

Corsa VXR Nürburgring Exhaust Fitting

Corsa VXR Nürburgring Exhaust Fitting

Followed by custom mapping, datalogging (including ignition timing, knock retard, injectors, boost pressure, fuelling), map optimisation to suit the new exhaust and full rolling road set up:

Corsa VXR Nürburgring on the Rolling Road

Corsa VXR Nürburgring on the Rolling Road

Corsa VXR Mapping

A busy week for remapping Corsa VXRs on our rolling road with this A16 engined Corsa VXR in for mapping, injectors and set up earlier in the week, reaching a respectable 217bhp for a car with a 70mm cat back exhaust.

Corsa VXR on the Rolling Road

Corsa VXR on the Rolling Road

Garrett Built Astra G GSi Turbo 503bhp

Garrett Build Astra G GSi Turbo 503bhp

Garrett Build Astra G GSi Turbo 503bhp

Another Garrett build, with Garrett GT30 Turbo, V Band Manifold, Courtenay Klasen Cams and Inlet Manifold, Engine rebuild, 90mm AFM, injectors, 3″ exhaust; all the usual requirements for a Garrett conversion, previously mapped by us and making a respectable 490bhp; brought in for checking now its a little cooler. Up 13bhp to 503bhp due to the lower temperatures.

Another Garrett Build Astra H for Mapping

Astra H Van with Z20LEH VXR Engine

Astra H Van with Z20LEH VXR Engine

This Astravan with Z20LEH engine, steel rods and GTX2867 garrett build was brought in for mapping and full rolling road set up.

The map it was brought to us with (which was not our software) was checked first and shown to be running 320bhp, with some fuelling and ignition timing issues.

We switched to a 3 bar map sensor (from a standard 2.5 bar one) and recalibrated the map so the ecu could correctly read boost pressure as the 2.5bar map sensor will go out of range on capable of reading up to 22psi of boost, hence the change to a 3 bar sensor. Correctly recalibrated the ecu can then read up to 29.4psi boost presure.

Also changed were the 875cc injectors to a much more suitable 630cc injector for the required power, again with suitable ecu recalibration. 875cc injectors for the required power prove way too big, and cannot be controlled accurately enough for part throttle fuelling (essential on a fast road car) due to the spray pattern plus fuel consumption will be higher, again another consideration for a car with road manners. When checked and datalogged first this car was running at 0.88 lambda on cruise, so clearly the map needed some work at this point. This is too rich and can cause bore wash and potentially internal engine damage. Big injectors are fine for stand alone management and for race cars which do not run at part throttle or cruise, but were just incorrectly specced for this particular applcation.

With a couple of bits still to do and after mapping and set up the result for now is 390bhp and much better, more controlled fuelling at part throttle and cruise. Fuel consumption will improve as well as 630cc injectors control part throttle fuelling more accurately.

Why the change of injectors? For better road manners; in simple turns the bigger injector (875cc) does not atomise the fuel as efficiently at slow duty cycle/engine speeds. So a 630cc injector can provide more than enough fuel for the power but still return better fuel economy due to its ability to better atomise the fuel.

DAP Springs Astra J VXR

DAP Springs Astra J VXR

DAP Springs Astra J VXR

  • Manufacturered Exclusively for Courtenay Sport.
  • Probably the ultimate fast road springs for this chassis.
  • Lowers the VXR chassis by about 20-25mm.
  • For excellent road holding whilst maintaining good ride quality.

Priced at £183.95 per set.

Following our very successful and much acclaimed DAP R Astra H VXR spring kit we now have our DAP R Astra J VXR spring kit available.

Vauxhall set the bench mark very high with the original Astra J set up which didn’t make our job very easy however after an extensive period of development we have achieved what we feel is the ultimate fast road set up.

Visually the car now sits typically between 20-25mm lower. The straight line ride quality is slightly firmer but not at the detriment of ride quality and certainly does not feel crashy, however press hard into the corners and the suspension tightens, firming up giving more control through mind corner bumps and undulations whilst communicating with plenty of driver feel and feedback.

DAP Rs are wound from high tensile chrome silicone steel and are manufactured in a cold winding process for maximum durability in all weather conditions. They are powdered coated Diamond Black to give a very OE look and feel and have the DAP signature discreetly placed on them.

Corsa VXR Nürburgring Stage 2 Upgrade

This lovely 2012 Corsa Nürburgring in Lime Green Pearlescent was brought to us for a Stage 2 upgrade, so initially into the workshop and up in the air so the original exhaust could be removed to be replaced with the full 76mm (3″) turbo back stainless steel exhaust system:

Exhaust Fitting - Corsa Nürburgring

Exhaust Fitting – Corsa Nürburgring

and then onto the rolling road for custom mapping, datalogging (including ignition timing, knock retard, injectors, boost pressure, fuelling), map optimisation to suit the new exhaust and full rolling road set up:

Mapping on the Rolling Road - Corsa Nürburgring

Mapping on the Rolling Road – Corsa Nürburgring

Courtenay Sport at Trax 2014

A few pictures of our display at Trax 2014, Silverstone Circuit Sunday 7th September.
Thank you to everyone who came along on the day and for some fantatsic cars as part of the display.

Trax 2014 Video by Nankang Tyre UK

A short video from Trax 2014, by Nankang Tyre UK. Watch closely and you’ll spot Courtenay Sport in a couple of places.

Astra G GSi Turbo Z20LEH

We recently had this Astra G GSi Turbo in for a rolling road session. This car had previously had a Z20LEH Astra H VXR engine fitted (replacing the original Z20LET unit), running VXR turbo, injectors and 80mm Air Flow Meter. Additional upgrades now include steel rods for strength, high flow inlet manifold and 76mm full exhaust (upgraded from a 63.5mm exhaust system).

Astra G GSi with Z20LEH engine

Astra G GSi with Z20LEH engine

Mapping Session Astra H VXR

Rolling Road mapping session to optimise software settings on this Astra H VXR, which has had some hardware alterations since it was first mapped. Before and after mapping saw gains of between 12-34bhp and 5-20 lb ft torque.

Astra H VXR on the Rolling Road

Astra H VXR on the Rolling Road

Astra H VXR – PowerCool 180 Conversion

We had this very well speced Astra H VXR in with us recently for a full enhanced service, changing all the filters, fitting uprated NGK spark plugs, brake fluid change to DOT 5.1 and adding our high quality fully synthetic Valvoline SynPower 5w-40 oil. Already fitted with Team Dynamics Pro Race 1.2 Alloy Wheels, VXRacing AP 4 Pot 343mm Front Brakes, 285bhp upgrade with full 76mm exhaust system it is a great road car and can sometimes be seen making the odd appearance out on track from time to time.

In addition to the enhanced service, we also carried out a conversion from the traditional water based antifreeze to Evans Waterless PowerCool 180 Coolant with all the associated benefits that the waterless coolant brings.

Astra H VXR - Enhanced Service and PowerCool 180 Conversion

Astra H VXR – Enhanced Service and PowerCool 180 Conversion

Astravan Z20LEH 2.0 Turbo Conversion

A 294bhp Z20LEH engined Astravan in for a service, MOT and some additional TLC. This van has a huge spec including Quaife LSD, Astra H VXR brake set up (front and rear) with uprated discs, CSR Intercooler, 76mm Full exhaust system, 80mm AFM and VXR injectors, uprated clutch and flywheel, a B8 damper and Eibach spring kit, rear ARB and Revolution Millennium Alloy Wheels. We carried out the coversion on thsi van several years ago now and it is still kept in immaculate condition.

Z20LEH Astra Van

Z20LEH Astra Van

Astra H VXR – from Standard to Stage 3

Another one of our more recent jobs was to give this Astra H VXR Racing a much welcomed performance increase.

Booked in for a full Stage 3 conversion, the vehicle came to us as a standard spec car. We fitted our full 76mm (3″) turbo back exhaust system, our full height CSR front mounted intercooler, an uprated actuator with new bracket and finally a set of cooler running iridium spark plugs and a CS high flow foam panel filter were added. Mapping and set up saw a very respectable 289.5bhp and 336 lb ft torque, considering the heat at this time of year doing its best to reduce power.

For further details on the conversion, pricing and additional tuning information please visit our webpage on Astra H VXR Tuning >>>> HERE <<<<

Astra H VXR Stage 3

Astra H VXR Stage 3

The Courtenay Sport Blog

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