That's great Trev, be sure to post a link here when it hits. Look forward to reading it!
Since it's been at the excellent Christian Lewis for a few weeks now i will be doing a big update very soon...
Here's the very latest video of my car at DC Valeting in Isle Of Man... Its waiting for its carbon spoiler back from re-laquering shop (hence if you watch carefully you can see the holes in the engine lid!) but the big news for me is that I've decided to go 'stripeless' after seeing the car after over a decade with a stripe on it makes a refreshing change (not to mention darker wheels suite the stripeless look I think). A huge update on this thread is way overdue but I wanted to get it to this point before I handed the car over to Supercar Driver for a video shoot and magazine feature (coming shortly). Watch this space..
Here's the before after photos showing what a good detailer can do! Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login
Without fully wading through the thread (which I will do for sure as time permits), what were the major weight reduction items and approximate associated weights of those items?
Hehe, well the wing is detachable with 4 bolts but it really does help me on the track days... My inspiration comes from this car... Image Unavailable, Please Login
Lots of different things each shedding kilos here, there and everywhere. Big items are exhaust system, headers, cats, backbox. Interior like sound deadening, roof lining, Seats, etc. I've recently she'd even more weight by using more Challenge car parts on gearbox and flywheel... I'll do an update soon with more details
Collection day.... Car looks Amazing! Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login
Looks great Trev! Would you happen to know the weight difference between a centerlock conversion kit and your route, (i.e.), full Challenge centerlock with hubs and so on?
Sorry I don't. I am happy with the factory SKF race centerlocks since they have uprated bearings so they can take more abuse but that comes at a price, they are not cheap so the conversion kit is a happy compromise.
So glad to see updates on this thread, along with a forthcoming video. One of the most understated, sublime builds out there.
I'll do a few updates which happened this year that I'm yet to document on here.. Trackday Lightweight Flywheel I recently had fitted an updated replacement flywheel manufactured by MD Clutches in the UK, this includes built in exciter ring. Its one of a short run of flywheel's originally designed for track cars so absolutely ideal for the Challenge Stradale spec type cars. MD produced a one off lighter flywheel for the 360 and they claimed comes in at around 4.5kg as opposed to the usual 6.2Kg model. I always weight everything so I've also included the real weights vs claimed weights of the final product. It started out that MD Clutches needed an alternative to the stock item to do Hillclimbing. He found it in a race flywheel specialist who had been looking for many years at getting the metallurgy right for producing new CNC machined flywheels. These are made of an extremely hard Chrome Moly Billet, as opposed to the original cast steel. It is more resistant to the heat and burning of the original, whilst retaining the same friction properties. IIt is more resistant to dishing and warping as well and comes in at very similar weights to the original. These qualities make it ideal to use with ceramic paddle friction plates, getting the best of all worlds without the damage. They are machined to an incredible accuracy on state of the art, computer controlled machinery. They believe, therefore, they have come up with a superior alternative that will give you longer life, incredibly at a lower price to the stock OEM flywheel. The actual item I supplied came in at 4.2kg's and the one I originally had fitted to the car (used) actually weighed 5.4kg so nearly a kilo lighter than what some 360's where apprently fitted with. Interesting huh? In the end my flywheel ended up being about 1.2kg's less mass. The result was that the car just rev's like a motorcycle, rev's rising and falling at a much more rapid rate than previously. Everyone always talks about the negatives on a lightweight flywheel as if they are gospel. However it really does vary from car to car. I'm not sure for instance if you'd need to recalibrate the F1 TCU to use a lowerweight flywheel than the stock one, I'm guessing this is probably the case but for the manual shifters this just means you can get back on the power quicker in the right sweet spot in the rev range (if your manually rev matching). It also sounds wonderful and makes the already exotic sound even better. The other noticeable feeling is that it feels like its had treacle removed from the engine, hard to really describe but it really does feel like this is the way the Challenge Stradale should have come from the factory. Just an amazing upgrade. Car genuinely feels quicker with it and certainly gets to the redline with more conviction. The other interesting thing is that I've never ONCE stalled with the lighter weight flywheel, which is always rolled out as a major pita for installing one. To be honest you cannot really tell the difference with modulation of the clutch pedal from before, the clutch biting point feels exactly the same with no harshness, you can still easily do a smooth get away. I'm guessing these kind of negatives only really come to play if you reduce it much more thank 1.2kgs but at this level it feels perfect. What a great upgrade! Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login
Lightweight CCM Brake Booster Had this in the garage for years and simply never found the time to fit it. Its a worthwhile weight reduction part... From 3.9kgs to 2.37kgs, another -1.5kgs deleted for minimal negatives. The only point worth mentioning here is that the old stock Modena booster provides less assistance so you actually get more brake feel. This means you apply less pressure for the same braking force on the CCM specific booster. I'm not sure if I feel I prefer the original Modena one in some ways despite having to press the pedal harder. I think brake modulation was ever so slightly better with the old setup, however having said all that we are splitting hairs here, it still feels great and stops the car like hitting a bollard (if you want it that way!) when you press the pedal! Also the extra -1.5kgs is worth it too... Free weight reduction. Image Unavailable, Please Login Image Unavailable, Please Login
360 Modena Challenge (Race car) Gearbox endcap. At the same time as getting a full clutch done I also opted to finally fit some more race car bits I had lying around in the garage (as you do, hahah). And this time in the way of the gearbox endcap (as used on all the race cars). This extra girth was added originally (apparently) to pass some of the US crash test regs. On the F430 they dropped doing it after seeing it was also an easy weight loss gain to be had off the engine/box.... 2.85kgs vs 1.93kgs, another 0.92kgs saved. So this basically saved near as dammit another kilo again for 'free'... I was told by a Master Technician that you can actually take your standard endcap to an lathe/cutting shop and they can simply cut the end cap off as its exactly the same part then once the weight has been removed. So if your happy to do this its an easy 1kgs deleted for little costs (again probably worth considering when your getting a clutch done and the box is already out)... Image Unavailable, Please Login Image Unavailable, Please Login
So just these 3 changes alone, lightweight flywheel, challenge gearbox endcap and ccm brake booster shed -4.7kg's. All without really trying... Shows what's possible if your thinking about weight as you do routine maintenance jobs!
Some more pics of the gearbox being worked on by Christian Lewis at their HQ. Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login View attachment 2573173
430 Scuderia Uprated Gearbox bush My gearbox bush really was END OF LIFE. Totally knackered is not the word... . Pictured are the Hills Engineering tool to remove the old one. . Heat being applied to make it easier to fit the new one. . Old one (really damaged!) . New one (430 Scuderia one) which has a wedge of metal to yield even better support than before. I'll post part numbers again here if anyone's interested. Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login
Couple more pics of the clutch and lightweight flywheel assembly being fitted. Image Unavailable, Please Login Image Unavailable, Please Login
Good job Trev! And thanks for sharing the info. Would you be able to let us know purchasing details or costs for the flywheel and brake booster upgrades? Also, have you ever considered a multiplate racing clutch bolted onto a custom flywheel, which would then act merely as a carrier for the starter ring-gear and sensor wheel?
Hey Trev360 I have been looking for at least two years for a Challenge gear box end cap ! do you know where I could find one ? I have the Challenge exhaust bracket already, Was thinking about fabricating Challenge exhaust bracket and make it in Titanium. What are your thoughts ? I even had my brake and gas pedals machine down and drilled out tho wholes and foot rest . I still think I can shave off allot more weight, it weights in at 2650 pounds now with stock under trays and standard Modena suspension . I have the Titanium springs and new rear CS shocks and anti roll bar for CS. I just have to buy the CS under trays next many thanks !! Love your post Sir !!! Image Unavailable, Please Login Image Unavailable, Please Login
Oh Trev360 I almost for got to ask you did you change out your ABS/ASR control unit ? I know they are different on the CS car Image Unavailable, Please Login
Randy I'm just on way out to catch food now but I'll come back to you on your posts later. On the ABS, read this background about Bosch Motorsport ABS M4 and I'll come back to you.. https://www.pistonheads.com/gassing/topic.asp?t=1047865 Quote, " The Bosch 'motorsport' ABS is really just there basic road car system in a snazzy box, cruicially you need to check what level of calibration access and support it comes with. To work properly the system needs to have correct values for wheel/tyre inertia, wheelbase, CofG, Mass distribution, Caliper volume etc etc. Speed target wheels obviously need to be correct in terms of tooth count and mark/space ratio and profile, (especially cruical as the wheel speed gets down close to zero). Fundamentally there would be nothing stopping you from taking the ABS from a car with similar physical layout (Ford GT maybe??) and using that, although obviously some reverse engineering may be required to get it to work in it's new home." Interesting huh?
What I was hinting at here is that via the K-Line serial link its possible to read/write the ABS flash software. If you use KWP2000 protocol you can also access the EEPROM and edit the settings to give you full access to settings to adjust its use for larger wheels, lower weight, etc. I'll come back to this soon.
