Roxanne - budget milano/75 track car

[Mezevenf]

Quote:

Originally Posted by AR4me Bernard, I suppose you just used 3 clutch discs per side, correct? Any ill effects (mechanically)? Jes

[AR4me]

So, I have started taking the doors apart. I hope to fire up the angle grinder today to cut out excess metal. My plan is to leave the rear windows permanently closed (with stock glass - no points to spare in D). The fronts will have stock glass either completely closed or out - out during events, closed for commuting to track. That is 1 point, which is exactly what I have to spare. I'm considering to use a set of GTV6 wheels (very light - stock size) instead of the TD Pro Race 1 (17x7) since it will save me 4 points. The GTV6 wheels would have R-compound tires (similarly to the 17). I will then use the 4 points to tweak the suspension in order to reduce roll and understeer. Regarding the transmission and LSD, I'm contemplating putting in a good Platinum box I have, but other options are in the air too. Everything will fit in D
Jes

[AR4me]

So, a day with the angle grinder... All 4 doors are completely gutted. Didn't get time to chip out the sound insulation on the skin. I weighed all the stuff I took off and cut out of one of the front doors: 26 lbs. This does not include the door panel trim piece which was already off. All in all I probably got 80-90 lbs off the car. Perhaps another 4-5 lbs in sound insulation material still to be chipped out.

Some pics:
1. All motors, regulators, etc. out of the front door.
2. The inner sheet metal cut out of the front door - look at that heavy door beam
3. All gone
4. All the stuff out of the right front door - 26 lbs
5. The rear door gutted.

Jes

[AR4me]

A few more pics:

1. Left side - gutted doors.
2. Right side - gutted doors.
3. All the stuff removed from the car today - guesstimate: 80-90 lbs.
4. Roxanne.

All 4 doors had the heavy duty door beam, both front and rear doors.

For track activity the front side windows will remain out, while the rear side windows will remain in (as I only have 1 point to spare). I will chip out the sound insulation in the doors and then prime them.

Jes

[Former 75 Owner]

AR4ME..... Mate i have Just Spent the last few days going through all 15 pages.
Thank you very much for taking the time to post in Detail, all of the pics and explations of what you have been doing,it all has been very informative.

What would you say has been total cost so far for this car.

[AR4me]

Quote:

What would you say has been total cost so far for this car.

[Fortis 621]

Quote:

4. All the stuff out of the right front door - 26 lbs Jes

[Grant]

The doors really don't feel that heavy compared to more modern cars or even mercedes 190e of the same time period. The mercedes feels much more solid and even has a 6 cylinder powerplant yet weighs about the same as a Verde if my spec sheet is correct. What gives??

[AR4me]

I spent some time today pulling newly obsolete (due to the door gutting) wiring - quite a bit I pulled it to the main connectors at left and right side, respectively, up under the dash. I also spent time chipping out the sound insulation on the doors. The total for all 4 doors: 4 lbs - worth the pain (2-3 hours)? After chipping it out I cleaned the remaining black stuff with mineral spirits - see pics.

Of weight saving I got hood, trunk lid, and rear bumper left to do, the former being the most important to address (to some weight off the front).

Jes

[Philip Hehir]

Hi jes..

What is holding the glass up? Have you put some bolts in somewhere to keep the glass from sliding down?

Also what are you going to put back onto the doora? Will you cover with sheet alloy or did you have something else in mind?

Regards
Phil.

[AR4me]

I will be mounting some little straps that will hold the window. For events I will pull the front side windows entirely to save the weight up front a spent my last 1 point in the budget for group D.

I plan to leave the doors like that. The Milano door handle is pretty convenient for this as you can push the "opposite" side from the inside and open the door (you can see it in the two pics above - to the right of the back side of the door handle) - no need to mount a strap/device for opening the door. If you cover it with a CF sheet you need to mount a strap or similar to pop the door.

Jes

[AR4me]

So, small progress today - gutted the hood without going extreme. The insulation was already long gone which left excess metal to be cut. I basically cut out the cross bracing and trimmed back the metal towards the windshield. No dramatic weight saving: 5.5 lbs Could probably been more aggressive...
Jes

[AR4me]

Did a few minor things on the car today. Not much progress as I have been too busy with work

Anyway, I got around to mounting the quick release window straps. All 4 side windows come in and out in 1-2 minutes. They are either completely closed or completely open (for the front that would be completely out). However, straps of any length can be mounted in minutes. The idea is that commuting to the track will take place with all side windows closed, and the front side windows are taken out for track activity. The rear side windows remain in at all times.

I also got an affordable momo steering wheel off ebay. I have been looking for either a Momo or Sparco smallish (~ 350 mm) suede wheel with ergonomic grip at 3 and 9 o'clock. I got a new Momo mod. 78 and have ordered a quick release similar to Colin's. Though, I will mount the quick release on Ron's (RS Racing) alu steering wheel extender and omit the typical aftermarket hub to fit an aftermarket wheel.

Pic:
1. Rear side window quick release straps.
2. Mounting holes for front side window quick release.
3. Front side window with straps
4. Momo steering wheel.

I'm hoping to gut the trunk lid tomorrow and get started on other little things.

Jes

[AR4me]

Spent quite a bit of time on the car today. Initially, I gutted the trunk lid - not really a whole lot of weight - I didn't go overly aggressive with the angle grinder. I didn't even bother to weigh the removed bracing. Probably 3 lbs or so.

See pics.

Jes

[AR4me]

I spent most of the day gutting the rear bumper. Another myth put to rest. The rear bumper on a US Milano weighs 40.5 lbs Being able to shed about 20 lbs would meet my expectations. Given my experience gutting the front bumper it took much less time as I could anticipate the structure underneath the skin. I used the angle grinder almost exclusively - only final clean up was with a wire brush.

Pics:
1. Bumper off.
2. Side view.
3. Has that same composite backing plate as the front bumprt.
4. Drill out the 3 rivets and it can be pryed off.
5. Vrmm, vrmm... cutting away...

Jes