- Apr 17th. 2015
- By CourtenaySport
This Vectra B is now sporting a KW V2 Coilover kit as its latest addition and is sitting pretty.
This Vectra B is now sporting a KW V2 Coilover kit as its latest addition and is sitting pretty.
We had a couple of cars in recently for D2 big front brake upgrades, both receiving D2 6 Pot kits with 330mm alloy belled discs to fit under 17″ Alloy Wheels:
Also available with 356mm discs to fit under 18″ Alloy Wheels.
Kit prices start at £1022.00 including DOT5.1 braked fluid, discs, bells, calipers, brackets, bolts, shims and braided front brake hoses.
Some people are under the impression that we only modify and tune Vauxhalls, but we do also carry out regular maintenance, servicing and repairs.
This modified Astra H VXR was brought to us for a full enhanced service which includes a thorough inspection, an oil and filter change, replacement of the air and pollen filters (or cleaning and re-oiling a high flow panel filter), replacement of the spark plugs with NGK iridiums and a brake fluid change to DOT 5.1 brake fluid. We use OE/OEM filters and high quality Valvoline 5w-40 fully synthetic engine oil.
Additionally at the customer’s request, the rocker cover gasket was replaced as it was leaking. We also replaced the oil filler cap seal which was also leaking and allowing oil to escape, which was picked up during inspection.
During the inspection it was also noted that the factory hydraulic gearbox mount had failed, which is not uncommom, splitting and leaking all its oil and causing the engine/gearbox to move excessively. The mount was replaced and additionally strengthened with a polyurethane insert to help reduce engine/gearbox movement and reduce the likelihood of the mount failing in the future.
This very clean low mileage VX220 2.2 came to us for some pre trackday checks and upgrades prior to its owner getting involved in doing some UK track days.
Apart from the obvious fluid changes; oil (5w-40 Fully Synthetic) and filter, brake fluid and gearbox oil (75w-90 Fully Synthetic), the spark plugs were also replaced with NGK platinum plugs. A thorough inspection identified a few other areas that required some work. The rear spring seats/damper collars were corroding quite badly, which is not unusual over time and so were replaced, both side engine mounts had separated and were replaced and an uprated polyurethane insert was fitted to the front engine mount to help reduce engine movement. The header tank had started to crack and degrade, again another quite common issue, so to prevent premature failure on track a new one was fitted.
The brakes pads were getting low and so M1155 brakes pads were fitted front and rear as a starting point. Further attention will be paid to the brakes and suspension as the driver finds his ‘track legs’, so to speak.
To improve performance the ecu was remapped and a K&N Induction kit fitted. One a rolling road set up was carried out we saw results of 156bhp and 163 lb ft torque.
Finally front a rear towing eyes were fitted (essential for trackday use) and a set of Team Dynamics pro Race 1.2 alloy wheels with some trackday tyres finished off the package.
This should prove to be a very good and enjoyable track day car.
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:
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:
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
Coming soon for Z16LEx 1.6 Turbo Vauxhall Engines.
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.
Don’t forget we can also fit standard original equipment (OE) replacement parts as well as uprated parts!
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.
We have recently fitted a KW Clubsport Coilover kit to our Astra H VXR track car, which was running a Bilstein B8 set up with Courtenay DAP Race Spec springs.
The Clubsport kit is the prefered choice for a track biased suspension for a car that is used predominantly on track (more than it is on the road) and is the next step up from the excellent KW V3 coilover kit, which is an ideal fast road kit also suitable for light light trackday use.
Full stainless steel dampers, height adjustable springs with helper springs, solid top mounts on the front struts and 2 way damper adjustment on both the front and the rear dampers for compression and rebound adjustment to fine tune the set up.
A reminder, this is the kit as supplied:
KW Clubsport coilovers were developed for customers who demand a better handling car when participating in track day events, but also require a setup that is still acceptable for road use such as to and from trackdays. The Clubsport kit was specifically designed for the Nordschleife using track day tires. The independently adjustable rebound and compression damping technology allow the suspension setup according to the vehicle load, tire characteristics and different track conditions. KW Clubsport meets every demand regarding a coilover for on road use but more importantly track use.
Here are some pictures of the fitted kit:
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 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.
And some close up shots:
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.
Over the next few months EBC GD Sport Discs will change from gold to black. The current gold coating is being phased out and will be replaced by a Black GEOMET coating, which is a new long lasting corrosion resistant finish.
This means that over the next few months the traditional gold finished EBC discs will be replaced with black coated discs. They will still be manufactured to the same high standards.
Front End Improvement for Astra G/H and Zafira A/B.
Poweflex have engineered a solution to replace the factory engine bed/subframe bushes in Astra G/H and Zafria A/B which can be prone to failure and contribute to vague handling. These stiffer engine bed bushes help improve the front end feel of the car especially during turn-in and cornering. By removing the flex in the subframe bushes the handling is improved giving a more positive feel to the front end.
These Front Subframe Bushes feature two polyurethane top-hat style bushes that makes for simple installation and durability. The bushes house a stainless steel sleeve and are supported by zinc coated steel washers at each end for increased support under load.
Poly bushes will be resistant to corrosion and the addition of a stainless steel sleeve should help prevent the bed bolts from seizing into the bushes, which can happen with the factory bushes.
Suitable for Astra G, Astra H, Zafira A and Zafira B All Models.
These new bushes replace OE part numbers 90498689, 9223022, 9223023 and 13107328 used across the model ranges.
The application of corrosion resistant materials, robust design and the Powerflex Lifetime Warranty ensures the subframe need not be removed again once fitted, unless removal is required for other service work to be carried out.
These bushes are available in Purple Series 80 Shore Road Spec material for vehicles that are mainly used on the road and also Black Series 95 Shore Track Spec material that suits vehicles being used in Motorsport or predominantly on the track.
6 bushes required per subframe.
Professional installation is recommended. The ideal time is when the subframe is removed to allow access to the gearbox or clutch.
One of our recent jobs was this Astra H VXR, brought in to have a K06 turbocharger fitted (complete with an uprated recirculation valve), along with our CSRacing Full Height Front Mounted Intercooler. Whilst in our workshop it was also converted to Evans Power Cool 180 Waterless Coolant.
Already fitted with a 70mm exhaust system it was onto the rolling road for mapping and full set up. During mapping the mid range and top end boost was reduced slightly due to the 70mm exhaust system giving more back pressure than a 76mm system and also because the engine did not have steel rods or uprated valve springs. Once the ignition timing and fuel were optimised we saw results of 304 point something bhp (so nearly 305bhp!) and 341 lb ft torque. With a 76mm system estimated gains are 305-310bhp so this particular car is making good power on a 70mm system.
There is still some in reserve to come for this car once it has a 76mm exhaust system to help with back pressure reduction as 310bhp+ is more than possible, with potentially even more should an inlet manifold, steel rods and uprated valve springs/shims be fitted.
We have just taken delivery of a KW Clubsport 2 Way Coilover suspension kit for our Astra H Sprint track car, which will be fitted over the coming weeks and set up prior to its first outing in 2015.
Here’s a preview:
What makes KW so good? Apart from their build quality, assembly process, attention to detail and technical support?
Their durability and resistance to rust, meaning KW coilovers continue to work, unlike cheaper competitors where spring perches corrode onto the struts making adjustment impossible.
All KW coilovers are made using high quality and perfectly matching components and materials. So both their renowned racing applications for international motorsports benefit, but also your KW coilovers for the road.
All KW coilovers, Variant 1, Variant 2, Variant 3, Street Comfort and the adaptive KW DDC coilovers from the KW iSuspension range are made from stainless steel. Whether the strut or the trapezoid thread or the vehicle-specific connections – KW only use stainless steel. KW stainless steel “inox-line” coilovers in conjunction with corrosion-resistant springs and elastomers stand for a long-term driving pleasure.
How resistant to rust are the KW coilovers “inox line”?
KW wanted to know precisely and therefore worked together with the Fachhochschule (University of Applied Sciences) Esslingen. The chemists and engineers of the FH tested the KW coilover struts made of stainless steel. So in total nine coilover struts from six different manufacturers went through a quality check.
The image shows the results which speak for themselves:
30th Anniversary Advert:
30th Anniversary Picture Montage:
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.
Some Vauxhall/Opel engines using M14x1.5 Sump Plugs:
X18XE X20XEV X25XE X30XE (FWD)
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
If you are unsure on your particular fitment please check with us.
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.
We were asked recently to carry out rework to a pair (obviously) of 3.2 V6 cylinder heads; porting, polishing and gas flowing to improve the efficiency of the heads to maximise potential gains.
They were sent to us by the customer after they had been removed from the engine:
And after cleaning, rework and a reface to the heads:
This low mileage Corsa VXR was booked in with us recently for an engine rebuild. It was a very late car with a B16LER engine.
The whole process starts with removing the engine and gearbox from the car, separating the gearbox from the engine and then stripping the engine down to a bare block and head. The block is then rebored and honed to suit an oversize 79.5mm forged piston and to achieve the correct piston to bore clearance. Once it is fully cleaned the block is then rebuilt with new forged pistons and rings, steel rods, uprated ARP rod bolts, new big end bearings, new gaskets and head bolts. On such a low mileage engine (4k) the main bearings, timing belt, tensioner, pulleys, oil pump and water pump were all as new and could be refitted. On higher mileage engines we recommend that these are replaced as necessary. As necessary the valve stem seals are replaced and the valves reseated. If either of the block or head faces need refacing this is carried out at ther same time as is additional balancing work if required.
Once the engine is built back up with its ancillaries and timed up, it is refitted to the gearbox and then fitted back into the engine bay. Engine oil, suitable for running in and coolant are added and the engine is then run up and road tested. We recommend the addition of Evans PowerCool 180 Waterless Coolant as part of an engine rebuild.
It takes approximately a week for this type of work to be completed.
Here are some pictures of the process:
since we have found some of these on a car, but occasionally it still happens.
They are the transport blocks which are fitted in between the front spring coils each side, especially on lowered cars, which prevent the springs from compressing keeping the chassis height higher allowing for lowered cars to be moved onto and off transporters more easily and to help the front valances clear better preventing damage. Thay are however meant to be removed by the dealerhsip when the car undergoes its PDI (Pre-Delivery Inspection) for obvious reasons……..
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