Hayman Motorsport

Delta Tarmac Assault Car Almost Finished

2012-01-16T01:04:00.000-08:00

So i got to spend a little more time on the Delta over Xmas, and its just about ready for track time. The interior is basically done apart from a few things, and the engine is running nicely. I am now back onto the 128 engine trying to get that rebuilt (just awaiting some piston rings). I don't really have time to do a full update here, but pics speak louder than words right ?

Captain Slack.

2011-10-24T16:29:00.000-07:00

I am so incredibly slack at updating this blog, its no wonder anyone ever reads the damn thing. I must apologise profusely for this. Well - i managed to tuck myself away into the garage for part of the weekend to carry out a few more upgrades to the Lancia. Believe it or not, its starting to look like a race car. I can't even remember what the last thing that i posted about was so heres a quick rundown of recent additions: -
1/ Full FIA spec rollcage thanks to Lynchbuilt Engineering (http://www.lynchbuilt.co.nz/)
2/ Custom race springs made by Chamberlains Springs in Christchurch NZ (350lb front 400lb rear)
3/ Custom built shocks to suit the springs (Boge shocks shortened to suit the springs and dyno'ed to correct rates).
4/ Momo Start 2007 bucket seats, on custom fabricated rails (see pics below).
Also the battery now resides behind the passenger seat.
Heres some brief pics ..

Milo Gone .. Lancia on the go ... Yellow 128 going.

2010-04-02T19:14:00.000-07:00

Well ... i've been pretty busy once again with the cars ... Milo (the black 128) has since been sold, and i now see it driving all over the shore frequently. Dads 128 (the yellow one) is all up and running again .. reset the timing, and hes had it out for a practice day at pukekohe. It turns out that the engine in that is a real snarler. It seems to have plenty of go, and sounds fantastic. I need to make some adjustments to the front suspension, but that car really seems to go well.

I've now made some progress with the Lancia also .. found a guy who lives close by called Tom who has an immaculate Mk II delta HF turbo, and even more nuts about it than myself. I went for a ride in it .. really sweet little machine. He's sold me a few bits and pieces for mine. So to add to the upgrade list, the Lancia now has an Autosport drivers race seat, a Momo steering wheel, a custom cold air box, a manual boost controller, and a few other bits and pieces. I have purchased a set of white Advanti Racing Hart CP035 15X6.5" racing wheels for it which look amazing, i just have to get some race rubber and redrill them to suit before they will be put on the car. Also, a mark II front bumper which is alot more like the Integrale bumper. This didn't fit straight away, so i have cut and added an alloy plate into it, resprayed it, and cut the notches etc to fit it to the car. I think it looks fantastic - and gives me room for the larger intercooler i have to mount in front. Heres some pics of the bits and pieces anyhow ..

Its all about to change ..

2009-12-29T04:39:00.000-08:00

Hey guys how are you all ? ..

Things are ever changing in the development of our 128 race cars .. so much that we have decided to move on. Ever evolving rules and regulations in the race class we run in has changed where we now run in the class - and in the spirit of a "classic car" decided that the car is really as modified as we want it to be. The reality is, if i want to make the car any faster, its going to need some very serious cutting and modifying of original components - things like glass windscreen will have to come out, and lexan fitted - fibreglass panels or carbon fibre - wings, etc etc etc. Its all getting a little bit outside what the car was really intended for .. so we have decided to run the car a few more times, then it will be up for grabs for some lucky new owner !

At the same time, this means that not only the Blue/White race car will be up for sale, the yellow/black car will also be for sale. Its almost complete, and will definitely be finished over the next few weeks.

ALSO to top that off .. i have been working furiously on the black car (originally brown, nicknamed Milo) to get that one finished too .. it was too good to use as a donor car for the race car, so turned it into a hot little road car :). Please contact me if your interested in buying it ...

Its about 95% ready to sell .. just awaiting the freshly rebuilt carb to come back for it.

The black car is an NZ new, genuine 3 owner 1979 Fiat 128 Sedan. When i bought it this time last year, it had a 1300 in it, with very low oil pressure, and suspected run bearings.

The motor was lifted out, and an early Fiat X19 1500 plonked in the hole. Its got a 128SL inlet manifold (opened up to suit the 34DATR carb that will be shortly put on), 128SL headers, and a larger freeflow exhaust. Its also got a freshly rebuild radiator, new battery, lowered suspension, Fiat X19 wheels with good tyres, and pioneer CD player. The paint is a subaru black with heavy

red pearl (it looks almost burgundy/purple in the sunlight). Its the most rust free 128 we have ever stumbled across. Its also got a pair of really nice RS legacy bucket seats fitted, and will be sold with a brand new WOF & Rego. - $3500 O.N.O

Heres some pics of "Milo" as it sits now after alot of man hours of work :)

I think you'll be surprised at how good it looks (and drives). I've also got a new project to share with you .. Its almost a Fiat .. some would think, possibly even cooler.

Engine Rebuild Underway

2009-09-19T02:22:00.000-07:00

Hey guys .. ive been taking a long time to get my A into G on the race car once again, but slowly & surely its starting to come together. Ive now completed the cylinder head, its all back together, with new stainless valves, and everything is once again spotlessly clean.

Today we dummy assembled the engine - two pistons in the centre bores, valve clearances set, and a new Felpro head gasket. we strapped it all together, timed the engine up with plastigauge on the pistons to make sure we had adequate valve to piston clearance. The result ... not so much. Any amount on the Inlets, (0.080" +) but only 0.004" on the exhausts - needing somewhere between 0.056" and 0.076" more clearance (we are going to go with the latter of the two as this engine is going to be the "safe" option.

With any luck the exhaust valves in the pistons should be pocketed within the next few weeks - so not long now until the engine build is well underway. Will keep you posted !

Take care all.

Progress once more ..

2009-06-20T23:35:00.000-07:00

Hey guys how are you all ? its been a long time since i last updated the blog. Theres been a bit happening in that time .. ive been on contract for a new company, and got relocated to wellington for almost 3 months.

Now that im back, ive been working on the cars and trying to get things happening. My cylinder head for the race car has been welded, and the port/chamber reshaped, and new seat put into it, now awaiting me to lap in the new stainless valves, and reassemble with new valve springs, and take some clearances.

Ive been working on Milo (the brown road car) which is starting to come along nicely ..

It is now sitting on king springs in the front, lowering blocks in the rear, the 1500 a new battery, and autosport bucket seat, and is almost ready for paint.

I have chosen a Fiat metallic red to be two tone with a subaru black, which has an amazing red pearl in it. It looks red in the sunlight, black in the shade. Once i get it sprayed up ill take some pictures !

Anyway, i went and saw a friend Scott McIntosh's 128 today, its the straightest 128 ive ever seen without exception. It has an Uno 1300 in it at the mo, but shortly to recieve an Uno Turbo engine.

Check it out for yourself ..

Team 128

2009-02-23T12:54:00.001-08:00

I put together a summary of our cars for your reference

Bumblebee Buzz's Once More

2009-02-22T14:39:00.000-08:00

Thursday night (19th of Feb) we got dads car ready for the dyno run in .. just to bed the rings in, and make sure theres no leaks etc etc.

We did roughly 40km on the dyno, and pulled it off quite happy that everything is run in and seated. Engine seems to pull nicely, and has a smooth delivery of power.

The engine is identical to mine, except that it has a touch less compression, and cast pistons instead of forged (they are 87.5mm rather than 88mm).

A gently run through the range saw 97 front wheel hp, without running it to redline, and without having checked timing etc. The engine was running 10.0 Air/Fuel which is quite rich under load, and we didnt have a timing light or any jets available to us, as the exercise was only to run the engine in.

Heres some pics of the car with new wheels, all ready to run.

Engine rebuilding ..

2009-02-12T18:07:00.000-08:00

Well .. I'm almost getting sick of the sight of the inside of Fiat SOHC engines .. but alas, here i am putting my race car engine back together.

Block is now dummied up with the two centre pistons in, a new Felpro head gasket which has been re-fire ringed for the 88mm bore, head welded ready for reshaping, and all new valves.

Hopefully i should be ready to assemble the head early next week, and then check piston to valve clearance, and then start the re-assembly proccess.

We will get there soon !

On the flipside, the new brown car (1979 NZ New) nicknamed Milo is now finished .. with an early X19 1500cc standard engine, 128SL intake manifold, 34DMTR carb, and 128SL headers and a 2" free flow exhaust. It goes nicely for a daily driver.

Slow Progress

2009-01-27T11:40:00.000-08:00

Im way too slow at updating this damn thing, sorry about that.

Last meeting out was a disaster .. i had previously split a hose, overheated my nice new engine, and blown a head gasket, so being a largely over-bored engine, i have to get head gaskets made.
I only run around 0.036" piston to head clearance on a 0.060" crushed head gasket.

I sent the head gasket out to my gasket maker, and he unfortunately destroyed it in the proccess of enlarging the fire rings, so he used his own material and made me a new gasket.
I measured the gasket, sure enough it was the same uncrushed thickness, but this came back to bite me.

I ran the car for 3 laps out at pukekohe, and as i came past the start/finish line i heard the engine pitch change and quickly killed it .. however, it was too late. I pulled number 4 sparkplug, and the damage was already obvious ..

We pulled the head off once i got home, and sure enough, all the exhaust valves had touched the pistons, the pistons had touched the head, and it had smashed an exhaust valve off and punched it right through the top of a piston.

It turns out that the new head gasket had crushed 0.020" MORE than the gasket i had supplied.
Absolutely gutting !!

I have since pulled the engine out and stripped it .. its hammered the big ends a little because of the pistons touching the head. I should get away with a light hone on number 4, a new piston, checking the conrod for straight, a light crank polish, welding the cylinder head and reshaping, and a new set of valves once again.

Its all a bit disheartening, but i guess thats motorsport. I guess the moral of the story is, if there is something you aren't going to do yourself, check it, double check it, triple check it, then STILL don't trust that the person has done there bit correctly.

Hopefully ill have the old girl running for the end of Feb.

New Project

2008-12-14T13:01:00.000-08:00

Well .. exciting things happening with team "Engine Parts 128".

We have purchased a mint NZ new 1979 Fiat 128 Sedan which is almost completely rust free, and very straight.

Over the next year or so we are intending to have it acid dipped to be seem welded, and lightened, with thoughts of lexan windows, flared guards, a front spoiler, and a few extra additions.

I will keep you up to date with this as things happen, but keep an eye out for the white/blue car at the track as i will be still racing it competitively over the next year.

Brake enhancements.

2008-10-19T12:50:00.000-07:00

Another big weekend on the car up at Lynchbuilt Performance - involved two early mornings, some cutting, welding, and more of the good stuff.

We started out by grinding the paint off the front panel, and welding a couple of tags on in crucial spots. Then, while tony heated it with a gas torch, i leaned on it with a bar and chain, and we pulled most of the front of the car back into place. With a few test fits of the radiator and bonnet, the front is pretty close to original.

We then cut away all the support for the new bonnet, making it approx half its original weight.

Who needs rigidity in a race car ? its only a cover to stop animals and small children from falling in right ?

After the front was about 90% finished (in need of some finishing bog) we started on brakes ..

fitting in a fully reco'd stainless sleeved Vauxhall Firenza master cylinder, brand new bundy tube, and a wilwood bias valve instead of the factory fiat item.

I also threw the old radiator cooling fan in the bin, and fitted an aftermarket one which is about half the depth to get more space in the engine bay to fit my new electric waterpump.

Theres still a bit more to do to finish it off - will post more pics when its done.

Engine runs !

2008-09-08T18:28:00.000-07:00

A busy weekend last weekend was very eventful.

Over the last week i have acheived the following:

1) done a final assemble on the engine

2) degree'd the cam in

3) put the engine and gearbox in the car

4) fired the new engine up for the first time

5) been to the dyno and run it in under loading

6) done several power runs and changed timing and jetting

7) changed the master cylinder

8) done all preliminary checks ready for racing.

The car pulled 160bhp at the flywheel, and 155Nm of torque from 3500RPM through to redline on an absolutely flat torque curve.

We are now ready to run the new engine at the track and see how she goes. With a touch more compression, and the same spec carb's / cam / pistons / stroke etc etc it should all be very similar. I am really looking forward to driving it.

Heres a few new pics !

Oh and in the video - yes thats RUST coming out of the exhaust.

It had been sitting for 4 months after only ever being run on Avgas.

Getting Closer

2008-08-20T14:58:00.000-07:00

Hey everyone,

Knuckled down and got most of the block assembled for my 128, then popped one piston into number 1 cylinder to get ready for a valve to piston / piston to head clearance check, and found that number 1 conrod has quite a big twist in it.

I've now got another steel conrod away being shot peened after i had it balanced.

All valves are now swirl polished, the sump has been cold tanked and completely cleaned, and i now have a piston back in number one cylinder to do the crucial checks before assembly.

Will keep you posted.

New Motor Almost Done

2008-08-12T18:23:00.000-07:00

Hey guys, sorry about the late update on the car .. i've managed to get a nasty round of Sinusitis and been pretty slack.

However, i have been busy preparing my new block for next season (which is only a month away, so i better haul ass).

The new block is decked, honed, bored, final cleaned, and ready for assembly.

The cylinder head has been welded, skidded, had new seats put in, had a full new set of valves sized, and is ready for the valve heights to be set.

Ill keep you posted as it all goes together, but heres a few photos of the new engine being prepared.

Success at last !! (then failure - oops)

2008-04-02T13:51:00.001-07:00

Well .. two meetings have passed, on the 15th/16th of March, then the 30th of March. It appears as though we may have solved the tripode/gearbox issue by drilling a couple of holes and milling a few slots in the gearbox case to get oil around the LSD diff to the other side.

The Car ran perfectly on the 15th/16th, competing in 3 races, the first being a scratch race, starting 9th on the grid, finishing 5th, then in the handicap races, starting 9th in both, and finishing 2nd, then 3rd respectively.

I also set a new personal best lap time in that car of 1.17 around pukekohe - which we haven't gotten managed to get to for about 4 years.

On the 30th, we got to the track after a bit of a nightmare - on the 29th she blew a head gasket between numbers 1 and 2 cylinders at 5pm in the afternoon, and after sourcing a head gasket, and getting it sorted, strapped it back together to fire it into life at 12.30am.

The car ran like a charm - lapping pukekohe in 1.16's ! it felt fantastic, driving it alot harder than previously. Finally i put in a new personal best of 1.16.49 - of which i could see another half a second that i could be faster.

Unfortunately in the 2nd race, i gave the car an over-rev when i missed 3rd gear, which didnt seem to do any harm, but was later revealed that all the exhaust valves had touched the pistons.

The car went on to finish that race in good time (3rd in the first scratch race, and 5th in that handicap race) - then on the next race out, was climbing through the pack, only to have the head of an exhaust valve drop off at 8200RPM in top gear at 210KPH.

Needless to say, that was the end of my race day, and am now trying to source a set of stainless valves, a new piston, and need to do a bit of repair work on the cylinder head.

Well on the way though ! The car is now running in the top 3 cars in AES/Tradezone, with hopes of maybe a few first placings next season.

Break it and improve it ..

2008-01-29T11:01:00.000-08:00

Its been a while since i last posted, so time to update this thing.

The stackup between the X19 5 speed gearbox and the 4 speed 128 box is somewhat different - when you bolt the casings together, the gears jam up and dont move. I have since found out that i need a Fiat Ritmo 5 speed gearbox to make the conversion work.

SO as a result, i ran through my 4 speed gearbox parts, of which the input and cluster shafts were in good condition, and so were all the gears and synchros, so i bolted that back into the 4 speed casing, with my new LSD, and all new bearings.

Last meeting out i discovered another breakage - which i believe has been contributing to my unbearable high speed vibration at race pace.

I dropped off the inner CV Boot and had a look to the inside of the diff, and discovered that my tripode joints were now sqaures.

The Tripode's had given us issues in the past with needle rollers not being able to hack the pace, and either tearing out of the bearing caps, or crushing, and turning to smush inside the gearbox, so we had rebushed the tripode's with aluminium bronze bushes.

The problem we have discovered is that by pressing the bushes into the caps, and making them too large, the cap cannot move about 4 - 5mm in and out on the pin of the tripode, it is stationary, which means when the driveshaft moves on an angle under cornering, its dragging the cap instead of allowing it to turn.

Tony from Lynchbuilt Performance Products (http://www.lynchbuilt.co.nz/) has since rebushed them for me with bushes that press onto the caps and allow the caps to walk sideways as well as turn freely.
Im out at the track this weekend after yet another gearbox rebuild to see if the new style tripode's do the business.

Fingers crossed ..

Also, my friend Chris took a quick video in-car as we did a few brief laps at pukekohe while testing out the new diff - this can be seen here http://www.youtube.com/watch?v=lJ8BxEJSPmo Its just a few laps at low speed, just starting to get some pace on in about the last 15 seconds of video.

Waiting Waiting Waiting

2007-10-24T12:38:00.000-07:00

Not alot has really happened in the last few weeks - my Fiat 128 4 Speed diff has been sent to Phil Buggee in Australia to be turned into a clutch type LSD, and should be ready by the end of the week. I have been down the line and met up with a guy called Darren who is restoring a Fiat X19, and done a bit of a parts swap, him ending up with a 1300cc long motor (ported head, hot cam etc), and us ending up with a couple of spare 1500's, a spare 4 speed, and a 5 speed gearbox.

The 5 speed has been stripped - and is in decidedly average condition inside, but nothing a bead blaster shouldnt tidy up. I also have my 4 speed stripped from the incident at pukekohe where it had a bit of a "moment" - but the internals all look good.

Im going to start building the 5 speed as soon as i see my diff back in the country. Will keep everyone posted.

Front Suspension Dramas

2007-09-23T11:25:00.000-07:00

Hey guys - ive had gearbox issues with my car for quite some time, and we finally nailed down the cause.

The Front springs in my car are far too soft - (approx 180lb we think). This allows passenger side driveshaft to be able to move upwards far enough to touch the housing on the outer edge of the gearbox - causing huge dramas.

Its also caused me (on more than one occasion) to explode tripoid joints in the gearbox.

SO .. the fix .. (we hope).

I have bought a coilover conversion kit, which consists of - an alloy threaded sleeve, with a spring platform, and locking ring, a top hat, some grub screws, o rings, and two different height springs.

I use early X19 rear shocks in the front of my 128 with KYB Inserts. The alloy collar slips over the original shock, which gives you a new base for the smaller diameter coilover springs.

After installing, my car has raised up about 65mm from its previous ride height (far less than desirable), so this weeks task is to figure out where we can get 65mm of ride height back.

Heres some pretty pics.

2007-09-19T17:15:00.000-07:00

Already Done Modifications ..

2007-09-19T16:28:00.000-07:00

Hey guys ..

I thought i'd tell you a bit about my car, as this is way late in the piece to be updating you on mods, as ive already been racing the car for several years. This is a list of a few of the things already done to the car that it is currently running ..

Engine:

1498cc Fiat X19 engine, overbored with 88mm Forged Iapel Pistons. - 1560cc.
Genuine Fiat X19 forged rods - crack tested, shot peened, balanced.
Genuine Fiat X19 Crankshaft - crack tested, balanced.
PBS Racing Oil Control Baffle Plate
Standard X19 Oil Pump, with PBS high volume relief spring (approx 80PSI)
200 X 280mm Oil Cooler, with thermostat.
Fiat 128 Tin Sump.
Custom graphite head gasket - enlarged fire rings.
Fiat Tipo 1600cc head, flowed by Lynn Rogers, with 40mm inlet valves, stock exhaust valves, ported & polished, flowed, valve guides trimmed, 3 cut valve grind.
12.8:1 compression on Avgas.
PBS Inlet manifold.
PBS double valve springs.
Twin Weber 42DCOE Sidedrafts.
PBS PH4 Hybrid Cam (430 thou lift, 290 duration)
Lynchbuilt performance equal length headers, 4 into 2 into 1, into 2" mandrel bent exhaust.
Urethane lower engine mount, solid steel top reaction strut (top mount).
Kent Cams adjustable aluminium cam gear.
Genuine Fiat steel idler gear.
Fiat uno bosch electronic ignition.
Malpassi Fuel Pressure regulator.

Brakes, Hubs, & Wheels:

Mazda Familia DOHC Turbo BP series front rotors (4X100) with centre hole machined to suit fiat hubs.
Custom 11mm steel plate adaptor brackets for calipers.
Mazda Familia DOHC Turbo BP calipers - single pot, with approx 55mm piston.
Hubs - redrilled to 4X100 PCD, with Toyota studs pressed through from behind, and wheel nuts.
Bendix Ultimate compound pads.
Fiat X19 Master Cylinder (larger bore than 128).
Standard Drums in rear.
TSW Razor 14 X 5.5" wheels, with 185/60/14" Dunlop D02G race rubber.

Suspension:

5 Leaf rear transverse spring - reset to lower the car.
GAB Shocks with heavy oil.
Front - work in progress.
Fiat X19 Rear shocks, with KYB Insert's, and a Jamex coilover conversion kit, with 300lb springs. (this is all set to change shortly).

Body:

Full rollcage with lots of extra bracing - links through to the strut towers in the front.
Jamex daytona fixed back bucket seats, FIA approved 5 point 3" harnesses.
No hoodlining, carpet, consols, or lower dash.
Rear doors gutted (no winders, or inside door skin).
Engine bay chassis rails plated with 2mm plates.
Strut tower faces plated with 3mm plates
Alloy strut brace.
2mm Plates over sway bar mounts - entire front end seem welded.

So this is how the car sits at the moment - currently having run 1.18.1's around Pukekohe circuit.

I have no doubt forgotten half the modifications that have been done, so will post them as i remember them.

Cheers.

Welcome

2007-07-29T14:40:00.000-07:00

Welcome to the blog place of both mine, and my father's Fiat 128 race cars.
We have been racing for many years in both these cars, and they are permanently being modified and improved ... so i thought i would start a blog to keep everyone updated on the problems and fixes that we find along the way with the 128's.

Cheers for visiting .. please keep coming back to this page.

Carl