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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

New Astra for the Racetrack

Rüsselsheim…. Opel is expanding its activities in customer touring car racing. Based on the new Astra, which will celebrate its world premiere at the Frankfurt Motor Show (IAA) this September (2015), the motorsports division of the Rüsselsheim-based carmaker is developing a touring car in accordance with the current regulations of the TCR series for national and international customer racing.

The TCR series, inaugurated in 2015, is based on a three-pillar concept that includes national and continental championships along with the global TCR International Series – all of which have exactly the same technical regulations. Therefore, a TCR vehicle can be used worldwide without undergoing any technical modifications. The two-liter turbo-charged engines have an output of 330 hp and maximum torque of 410 Nm.

“Touring car racing has always been an important part of Opel. The philosophy of the new TCR series corresponds to our idea of customer racing. We want to give ambitious privately owned teams a platform for exciting sport at reasonable costs,” said Opel Group CMO Tina Müller.

The Opel Astra TCR is currently under development and the technical specifications will be announced at a later date. Testing of the new customer sports touring car is set to start in October.

Opel Motorsport Astra K

Opel Motorsport Astra K

Opel Motorsport Astra K

Opel Motorsport Astra K

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

EBC GD Sport Discs

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.

GD Discs - Gold and New Black Finish

GD Discs – Gold and New Black Finish

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

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.

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

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.

Engine Bed Bushes - Purple Series

Engine Bed Bushes – Purple Series

Engine Bed Bushes - Black Series

Engine Bed Bushes – Black Series

Corsa 1.6 Turbo VXR Aluminium Water Radiator

Due to increasing demand  we have once again joined forces with market leader’s Pro Alloy to fabricate an uprated aluminium water radiator for the VXR and 1.6 turbo engined Corsa D.

The new radiator had to be an all alloy construction featuring welded end tanks; this eliminates the common issue on Corsa D water radiators where they leak from the plastic end tanks.

Additionally the core depth has been increase from 26mm to 40mm, whilst the surface area has been increased by 7.7%. Furthermore by reconfiguring the tube layout and foil pitching we have increased the flow area by 67% making the radiator much more efficient in cooling and ambient airflow through the core.

Finally the bottom lower water connection on the right hand end tank has been make one piece, getting rid of the factory eclip/circlip configuration that also has been known to separate at high pressure.

It is available to order and can be finished raw in Natural Aluminium or powder coated in Stealth Black finish (at additional cost).

Ideal for direct replacement on any fast road or trackday car.

Price £558.00 including VAT.

It is also worthwhile considering an upgrade to Power Cool 180 Waterless Coolant at the same time. No Water, No Corrosion, No Pressure (less likelihood of leaks, less strain on hoses and other components) More BHP, No Hot Spots, No Overheating…….

Corsa D 1.6T Water Radiator Front

Corsa D 1.6T Water Radiator Front

Corsa D 1.6T Water Radiator Rear

Corsa D 1.6T Water Radiator Rear

How Waterless Coolant Works.

Water is an excellent fluid for cooling whilst in a liquid state, but when water turns to steam it has virtually no capacity for heat transfer. Evans is a superior fluid for transferring heat in engines because it remains in a liquid state until above 180°C. This article details the benefits of a significantly higher boiling point.

Within an engine cooling system the hottest surfaces are those adjacent to the combustion chamber, specifically the cylinder liners and cylinder head. In these hot spots water is likely to vaporise preventing efficient cooling and causing loss of performance and unnecessary engine damage. When the coolant fails in this way the engine becomes even hotter causing more hot spots and more steam.

Evans waterless coolants will not boil around these engine hotspots maintaining efficient cooling performance even when the engine is put under extreme conditions. When water turns to steam it pressurises the cooling system putting strain on hoses and other components. The significantly higher boiling point of Evans coolants means 75% less pressure than water resulting in a less stressed cooling system.

Water contains oxygen which causes corrosion and also allows electrolytic activity which further damages engine metals (chemical limitations of water). Evans waterless coolants eliminate corrosion and electrolytic activity significantly increasing the life of the engine.

Nucleate Boiling

Nucleate Boiling

Traditional water based coolants regularly cross the thermal boundary that separates efficient Nucleate Boiling (A) from inefficient Critical Heat Flux (CHF). CHF is synonymous with the condition ‘Departure from Nucleate Boiling’ (DNB). When DNB occurs, a layer of steam bubbles form adjacent to the engine hot spots (B).

Steam dissipates less than 1/30th of the heat that water does, rapidly over-heating local metal, causing premature detonation. The high boiling point of Evans Waterless Coolants, such as Power Cool 180, prevents DNB providing more efficient cooling in engine hot spots.

Convert your car to Waterless Engine Coolant:

Astra J VXR Remapping

We had another Astra J VXR in for mapping this week and it is good news that we are now seeing more and more of them. ECU remapping alone makes such a big improvement.

Otherwise a standard car, the ecu was treated to some enhancement offering much more mid range power and torque with good top end gains too, and the software was optimised, whilst the ecu was datalogged on the rolling road and a full set up carried out, checking AFR, boost pressure, inlet air temperatures, ignition time etc. A massive improvement all round, with mid range gains of between 10-40+bhp and torque with overall peak power at a shade over 300bhp.

Astra J VXR

Astra J VXR

Astra J VXR

Astra J VXR

Astra J VXR

Astra J VXR

Turbosmart Recirculation Valve

We have been sent this lovely looking Turbosmart recirculation valve to try for the KKK K04/K06 turbocharger, which we rather like the look of. Once we’ve had a chance to evaluate it fully we’ll report back. In the meantime please enjoy this stylish piece of automotive add-on

Turbosmart Recirculation Valve

Turbosmart Recirculation Valve

Turbosmart Recirculation Valve

Turbosmart Recirculation Valve

Turbosmart Recirculation Valve

Turbosmart Recirculation Valve

Turbosmart Recirculation Valve

Turbosmart Recirculation Valve

Uprated Exhaust Mounts

We have noticed that the universal exhaust rubber/mount used on many many popular Vauxhall/Opel applications including Astra H VXR, is not very strong and over time has a tendency to perish, stretch and split, consequently requiring replacement. Often failure can occur quite quickly, especially on a modified car.

Added to this on performance models and modified vehicles with larger diameter exhaust systems, any exhaust movement in the rubber exhaust mounts can lead to knocking from time to time, especially when the mounts start to fail.

Have you ever noticed the occasional knock on start up, or from time to time when driving? This could be an indication of the first signs of weakening rubber exhaust mounts. So worth giving them a checkover at the first signs of a problem.

So we approached our friends at Powerflex to look at a solution for us. Because none of their universal exhaust mounts were close enough in size to the Vauxhall/Opel rubber mount, they set about making a polyurethane exhaust mount as a replacement.

Powerflex Exhaust Mount

Powerflex Exhaust Mount

They have looked at the OE item and manufactured a replacement, which is slightly larger overall but retaining the factory dimensions internally, in their high temperature polyurethane material with a Shore A hardness of 67, compared to the original rubber mounts which measured 55 Shore A.

The result is a much stronger, more durable mount with much less flex, offering far greater resistance to tearing and rot. Ideal for any standard or modified fast road vehicle; these exhaust mounts are equally at home on the track too.

An inexpensive and worthwhile upgrade. The number required per car will vary but this mount will suit Astra G, Astra H, Vectra B, Vectra C, Meriva A, Meriva B, Signum, Omega, Corsa C, Tigra B, Zafira A and Zafira B where 90466688 is specified.

Note: This mount cross references to OE Part Number 90466688

Do you have a Hotmail, MSN or Live email account??

If you have any of the following types of email accounts from the likes of Hotmail, MSN, Live, Gmail, Googlemail, Yahoo then please please please check your spam folder for emails if you have been in contact with us.

It has become apparent over the last few months that Microsoft web-based email accounts especially, but also certain others, are placing any email correspondence from us into the spam folder.

If you have contacted us by email, or ordered something online and have not received a reply or an order confirmation from us please check your spam folder, and make sure our email addresses are added to your safe senders’ list.

Time Attack Set Up Check

We recently had the Courtenay Sport backked DCE Motorsport run Time Attack Astra VXR back for set-up check, after a spot of bad luck at the previous round at Donington Park. Some gravel ingress into the cambelt area caused severe damage to the engine, resulting in a last minute engine swap for the car, to ensure it was up and running for the final round at Brands Hatch on Sunday 29th September.

So with a borrowed ‘spare’ engine, Will and his pit crew worked tirelessly over the weekend and once the engine swap had been completed and all the ancillaries, turbo, manifolds and such like had been refitted the car came to us for a mapping session just to check and alter the parameters, due to the fact this engine was running slightly different compression than previously.

After a few hours set up, all is now well again and we’re looking forward to Brands Hatch. Good Luck to Will and the whole team.

Pagid RS29 Pads Available

Pagid RS29 Pad
Pagid RS29 Pad

For the serious fast road and track day enthusiasts who appreciate an excellent brake pad, we now have in stock Pagid RS29 pads for the following calipers:

AP (VXR) 6 Pot (used in 362mm Vectra VXR kit)
Alcon 4498 4 Pot Monoblock calipers (used in the Alcon Xtreme Brake Kits)
K Sport 8 Pot (356mm and 330mm kits)
D2 6 Pot (356mm and 330mm kits)

These Pagid pads are also available from us for the AP 4 Pot 6600 caliper, and also the AP 4 Pot VXRacing 6600 caliper (343mm discs) which uses a slightly slimmer D50 pad.

From our own testing and from customer feedback, these Pagid pads are an excellent trackday brake pad and extremely well suit to that environment, that also works well for fast road use, benefiting from good feel even from lower temperatures.

Pad Spec.
Friction Level:
Cold 0.40
At 100o C – 0.43
At 300o C – 0.47
Max At 550o C – 0.49

Constant Working Temperature: 400-700o C
Maximum Temperature: 750o C (Short Period Only)

Pads range from £240.00 – £290.00

RS29 is a direct development of RS19, with a very similar friction coefficient to RS19, improvements in initial bite offering quicker response and slightly more temperature stable at the upper levels of the temperature range. Developments in raw material selection and compounding have resulted in improvements also in pedal feel and feedback, helping with modulation particularly on lighter applications.
Read more

Time Attack Results Round One Cadwell Park Club Class

Time Attack 2013 Astra H VXR - Picture: © Rich Sams
Time Attack 2013 Astra H VXR – Picture: © Rich Sams
We are pleased to report a very successful opening round at Cadwell Park for the Courtenay Sport Racing backed DCE Motorsport entry in the 2013 Time Attack series, driven by Will Watson.

In somewhat ‘chilly’ but dry conditions, (the word Baltic was heard mentioned on more than one occasion) Will improved his times throughout the day, bettering them on every single occasion out on track.

In the end after posting the fastest time in the practice session at 1:47.733, Will bettered this time in the qualifying session with a time of 1.47.116 putting him second in the class and earning 40 championship points. In the Final Will went faster again posting a 1.45.357 to finish second in the Club Class adding a further 90 points to his total.

All in all the mechanics were untroubled during the day with little more to do than than routine checks to tyre pressures and brakes. The car, and driver both performed faultlessly. A massive congratulations to everyone concerned for a fantastic opener.

The Club Class Results can be seen below (Click to Enlarge):


Further Details can be found on the: DCE Motorsport’s Website.

Pictures: Time Attack Image Gallery

Full Class Results: Time Attack Website

E&OE. Results and points subject to confirmation.

Time Attack 2013 – Courtenay Sport Racing Astra VXR – The Season Begins

Monday April 1st sees the start of the 2013 Time Attack Championship at Cadwell Park in Lincolnshire.

For 2013 Courtenay Sport Racing are backing and sponsoring the DCE Motorsport entry into the Time Attack Series. The car is an Astra H VXR which is driven by existing customer and owner Will Watson and has been entered into the Club Challenge Class FWD. The car features a number of our components, including our high flow inlet manifold and full exhaust system and the engine ecu has been bespoke remapped and a full set up carried out on our rolling road.

The great thing with this car is that the parts fitted and used on it are available for your everyday road and trackday car.

Time Attack 2013 Astra H VXR

Time Attack 2013 Astra H VXR

For those unfamiliar with this series Time Attack events take place across one day. Competitors drive hard against the clock to set the quickest lap time around each circuit. After the formalities of scrutineering and drivers’ briefings have taken place, the on-track element of  a Time Attack event consists of four sessions:

Warm Up – 15 minutes
Practice – 20 minutes
Qualifying – 20 minutes
Final – 15 minutes.

If you would like to keep updated with our progress and the series you can get all the latest news and find information from a number of sources online:

Our Dedicated Time Attack Webpage The Courtenay Sport Blog The DCE Motorsport Website

Via Facebook and Twitter:

Courtenay Sport on Facebook DCE Motorsport on Facebook Time Attack Website
Courtenay Sport on Twitter DCE Motorsport on Twitter Time Attack on Twitter

We wish Will and the whole team the best of luck for the opening round on Monday.

Astra VXR GTx3076R Development…… 559bhp & Video

Further Development of this car has seen us change the turbo to a Garret GTx3076R along with a custom made 100mm diameter inlet pipe.

Target BHP was something on the right side of 500 BHP. With 99 octane UK pump fuel we saw 525 BHP but this was on the limit of our UK fuel quality; Stephan in Germany had seen well over 550 BHP with this turbo on 102 ocatane pump fuel available to them.

At this point we thought it might be fun to add some methanol to bring the octane value up; a stainless tank was fabricated and installed with an Aquamist pump in the spare wheel well, to sit alongside the already installed swirl pot and Pierburg pump.  The spare wheel well has had a number of vents installed and a laser cut acrylic panel made and installed to protect the contents and seal the wheel well off from the car’s interior. With further mapping mostly based around a much more efficient timing curve we saw the power rise to a peak of 568 BHP and finally settled with a comfortable figure of 559 BHP.

Final testing on the road proved very interesting and memorable for Mark R when he found some additional work was needed to stop the meth from puddling in the inlet manifold, which occurred on part throttle when the throttle was being feathered due to wheel spin! Fortunately the functionality and adjustability of the Aquamist ECU made this quite straight forward to achieve.

Engine Spec features numerous Courtenay core products as follows:

Ported Cylinder head
Forged Pistons
Steel Rods
Klasen Cams
Klasen Inlet Manifold
V Band Cast Manifold
Tial External Wastegate
Custom 3” front pipe mated to a Piper 3” exhaust System
GTx3076R Turbo with Tial Exhaust Housing & 100mm inlet
Courtenay Intercooler
Courtenay Water Radiator
Lightened Flywheel
Paddle Clutch plate
Reworked Sach’s Uprated Clutch Cover

To name but a few items…

Hopefully this should keep the ever power hungry Wayne T content for a while. 🙂 A thoroughly enjoyable conversion to do cheers Wayne…

Spare Wheel Well with Swirl Pot, Pierburg Pump and Aquamist Pump and Methanol Tank.

Spare Wheel Well with Swirl Pot, Pierburg High Pressure Pump, Aquamist Pump and Methanol Tank

Laser Cut Acrylic Spare Wheel Well Cover

Laser Cut Acrylic Spare Wheel Well Cover

Poly Gearbox/Side Mount – Astra H/Zafira 2.0T, VXR and CDTi

We identified a weakness in the gearbox mount (left had side mount) on Astra H VXR and CDTi models, whereby these are prone to failure caused by splitting. Additionally for fast road and trackday use the ability to strengthen this factory mount will reduce its movement.

With Powerflex we have now produced an insert which compliments other uprated engine mounts and polyurethane inserts.

Inserts are an effective way of reducing engine movement, aiding power delivery and reducing damage to exhaust downpipes and other hoses and improving handling with less engine movement to unsettle a car during braking and cornering.

The gearbox insert fits Astra H 2.0 petrol turbo engines (Z20LEL, Z20LER), Astra H VXR (Z20LEH), Astra H 1.9 CDTi Models (Z19DTx) and Zafira B 2.0 Petrol Turbo (Z20LER), VXR (Z20LEH) and 1.9 CDTi (Z19DTx).

This mount is available in Yellow Material with a shore hardness of 70 for fast road use and light track use and in the new Black Material with a shore hardness of 95 (recommended only for race and dedicated trackday use)

Priced at £27.54 £24.00 (Yellow – Shown Below)
and £30.30 £27.00 (Black Series)

Poly Gearbox/Side Engine Mount Insert

Poly Gearbox/Side Engine Mount Insert

Astra H VXR Carbon Fibre Parts

A new range of Carbon Fibre components are soon to be available from Courtenay Sport. We have recently carried out trial fitting and evaluation and will will release the items very soon.

We will have available for Astra VXR the ‘V’ for the front grille, the Front Lower Splitter, the Rear Diffuser and covers for the inserts on the OE rear bumper.

All these parts are made in Real Carbon Fibre, they are not carbon wrapped/covered parts or backed with fibreglass. They are all very high quality items, with an excellent fit and lacquer finished.

Other parts will be following very soon, including the Rear Tailgate Strip for Astra VXR.

Astra VXR Carbon Fibre Front Splitter and V Grille

Astra VXR Carbon Fibre Front Splitter and V Grille

Astra VXR Carbon Fibre Rear Diffuser

Astra VXR Carbon Fibre Rear Diffuser

Astra VXR Front Splitter

Astra VXR Front Splitter

Courtenay Sport Key Rings

Courtenay Sport Key Ring.

A black simulated leather key ring with metal surround and a high quality Dome Resin Courtenay Sport Logo in Silver on a black background, giving a 3D look.

Measures approximately 84mm x 28mm (excludes ring) Overall Length approximately 106mm

£5.50 Now Available from our Online Web Shop. Buy Now Click Here!
This link will take you away from our blog and directly to our Web Shop.

Courtenay Sport Key Rings

Courtenay Sport Key Rings

The Courtenay Sport Blog

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