Milan's Clio 197 Tracktool

Hi all,

I've finally decided to make a build thread of my Tracktool project that I been driving since over a year.

I will start completely at the beginning :

So in January 2018 I've bought myself a Clio 197 that has been advertised for months. It has been used for autocross events here in switzerland, so thats why I assumed nobody wanted it, since it had a roll cage in it. But besides the roll cage, the seats, braided brake lines and steering wheel it was pretty much stock.
Because nobody wanted it, I got it for a really good price. But enough talking, here are the pictures when I got home :
IMG_20180203_153037.jpg IMG_20180203_151830.jpg IMG_20180203_151647.jpg After 1 week my Cup Spoiler came so I got it painted and mounted it on and deleted the Clio emblem :IMG_20180211_130257.jpg Then I ordered a some Renault Sport decals of eBay and a set of white 8j Cup Racer Speedlines and it looked so much better than the Megane wheels :IMG_20180325_100722.jpg After that I decided to change the Sabelt steering with a MK4 Cup Racer Sparco wheel, along with the MK4 bolt on seat subframe with the Sabelt Taurus seat. But the seats didn't last long as I couldn't see anything with it and they were illegal here in switzerland. I then put the old Sabelt seat back on, but with the Cup Racer seat subframe I was sitting a little bit lower, which was a bonus for me :IMG_20180414_140141.jpgIMG_20180511_193630.jpg I finally got to the point, to do some suspension tuning. I have ordered a set of Powerflex black series bushes and swapped them in. They were a pain to put it in but I felt a difference for sure, especially with fast steering inputs :IMG_20180526_183557.jpg So then I ordered a set of carbon door panels and have fitted them in. They weren't quite plug and play, as I had to cut holes for the windows switch, the speakers and the door lock. But the bigger problem was the door handle. I had to bend the inner door skin, weld the hole close and put a thread insert, so that the handle is aligned to the panel. Wasn't quite the best moment I had with the car...IMG_20180602_075000.jpgIMG_20180602_130638.jpg A friend of mine had a set of black 8j Speedline Cup Racer wheels, so I bought them to have a spare set. In my opinion I like the white ones more, but after a 10 min drive they are completely full with brake dust !IMG_20180623_200846.jpg I then finally started to do some proper performance mods and bought a set of 2 way adjustable KW Clubsport dampers with adjustable top mounts for the front. At the rear I first tried MK4 Cup Racer Coilovers from ZF, but the Mk4 dampers were quite a bit longer than the MK3 dampers, so I bought a set of Gaz Coilovers for a Lotus Elise at the rear and modified them to the Clio top mount.IMG_20180701_195233.jpg IMG_20180707_173129.jpgIMG_20180714_083108.jpg IMG_20180707_150938.jpg I then ordered a set of Nankang NS2-R's and put them on the white Speedlines. The car was then ready for its first Trackday. I booked a day at Anneau du Rhin in France for the German Renault Sport Event.IMG_20180722_121437.jpgIMG_20180722_121507.jpg The day finally came, I was so excited I only slept 3 hours but never mind. It already started bad as the VVT stopped working on the way there. It was because of a faulty cam position sensor. That was a loss of around 30 hp, but I still wanted to drive, and oh man was it good. I don't know how, but I was the fastest of the street Clios there (and there were around 30 including MK4's) and I was battling it out with a MK2 Cup Racer !! I was benefiting of short straights and high speed corners for my power loss. I also had the Clio 2 wheeling but sadly not there, where the photographers were. After the 4th session my throttle body went into limp mode. I then went home, the car only had a top speed of 90 km/h, so that was a really long drive home.. IMG_20180811_145730.jpgRWM_6526.jpg RWM_6181.jpgRWM_6121.jpgRWM_6098.jpg I then fixed my car after the Trackday, but I wasn't sure if I would keep it. I was thinking of getting a Honda Integra DC2 or a E36 , but I kinda fell in love with the Clio. I just couldn't sell it !! But I wanted a faster car, so I decided to do a complete rebuild starting again with the suspension. I wanted to put spherical bearings at the rear beam and on the front with a complete Cup Racer spec axle. I also wanted to put a better cage in it and maybe a Megane engine swap.
So I got then a little garage, where I can work freely on my car and started removing the rear beam :IMG_20181111_184152.jpg IMG_20181201_202650.jpg I have ordered a spherical bearing and a stiffening plate kit from Pure Motorsport. I then started to remove all parts from the beam that I don't need anymore, for example the spring plates.IMG_20181202_150652.jpg Then I got the beam all welded up thanks to my father :IMG_20181216_184928.jpgIMG_20181216_185247.jpg IMG_20181216_185301.jpg My beam was then painted and I then put studs on my stub axle to put camber and toe shims from the Cup Racer and started putting the beam together :IMG_20181225_144451.jpgIMG_20181225_164446.jpg I wasn't quite finished with the beam but I wanted to put the car on the ground with the Cup Racer shims to get some more motivation :grinning:: IMG_20181226_155306.jpgIMG_20181226_154255.jpgIMG_20181226_155500.jpg After that I finished up the rear beam with rerouted brake lines, new calipers and R26.R discs with PBS pads : IMG_20190105_141039.jpgIMG_20190105_141058.jpg IMG_20190124_162315.jpg I then ordered a rebuild kit for the front Brembos and painted it silver again to look clean again :IMG_20181228_125300.jpg IMG_20181230_161549.jpg After that I finally started tearing the front axle down and ordered used Cup Racer parts to complete the axle :IMG_20190127_155221.jpgIMG_20190127_172016.jpg Then i chopped up the front subframe for the water cooler same as the Cup Racer for easier access to suspension components : IMG_20190209_103645.jpgIMG_20190216_174425.jpg My new subframe and wheel hubs finally came, so I removed the dogbone mount of the stock subframe, since the Cup Racer subframes don't have them and again with the help from my father I got the dogbone mount welded on the Cup Racer subframe :IMG_20190224_121614.jpgIMG_20190224_132501.jpgIMG_20190224_174506.jpg IMG_20190224_174512.jpg 1 week later some more parts came for me : IMG_20190228_182320.jpgIMG_20190228_182342.jpg I also got these top mount adaptors from Sean at Jade Developments :IMG_20180522_183453.jpg After cleaning all parts with wheel cleaner and a lot of scotch pads I started to put the top mounts on. I had to modify the top mount on the car with a Dremel to fit the adaptors. I then put primer with a very tiny paintbrush on the ring and mounted all up :IMG_20190302_175459.jpg IMG_20190302_183613.jpgIMG_20190302_183619.jpgIMG_20190303_161733.jpg Also these look like new again thankfully :IMG_20190303_170125.jpg So thats how things stand now. It has been an awesome journey for me and I will keep this thread updated.

Cheers !
 
Some good grogress there. I think I've seen some pictures on Facebook.

What's the difference in the subframe?
 
The Cup Racer subframe has solid bushes, where stock one has rubber bushes. Its also raised up in the chassis by 4 mm and has other mounts for the front subframe link supports. It is also a little bit strenghtened because of the spherical bearings at the wishbones.
 
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great read and photos..really enjoyed it..this is what a proper progress thread should look like..
thanks for sharing:thumb:
 
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Looks good! Notice much difference in the bearing conversion on the rear beam?

Sent from my ONEPLUS A5010 using Tapatalk

I didn't drove the car since I started the rebuild, but it will make a huge difference thats for sure !

@Pav Thanks mate, it is my first build thread as the Clio is my first car I bought so everything is a little new for me !
 
I've made some progress on the Clio the past 2 weekends.
My subframe has been painted and I refurbished my steering rack and gave it a new layer of paint.
I also drilled 2 holes in the aluminum brace to have access to the dogbone.
I sadly only have this pic, because I broke my phone this evening and I can't upload any pictures from there.
54799281_876659975999168_8746419182809120768_o.jpg
But the subframe is now complete. I just need to refurb the dampers and fit the y-pipe on the manifold that hopefully comes next week.
Cheers !
 
Really good read and some quick progress going on.

May I ask where you got the cup racer parts from?
 
@Cullen Thanks mate, I got the Cup Racer parts from various places. The subframe is from apmotorsport, the rest are from local Clio Cup teams and some parts are even new from Renault. I've seen that apmotorsport is breaking a Cup Racer so he would be the best option I think.
 
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In the past weeks the progress wasn't really the fastest. It's all a bit step by step due to many reasons : No time, delivery delays and so on. But I did some things. I fitted a Supersprint Y-Pipe on the stock manifold, as I think the Toyosport manifold is a bit risky, and the rest is to expensive for me right now. It should be the best I can get for that price range.IMG-20190416-WA0001.jpgIMG-20190416-WA0000.jpg I also have got my hands into a brand new (!) TL4 003 gearbox. It was from a brand new 197 that's been converted into a R3 Access. It has been sitting for around 10 years but its now in good hands. :smile:
The reason is, the synchros on my current gearbox are gone and because it is a common problem, its better to keep one as a spare. In this case I will fix the broken gearbox and keep the old one as a spare.
IMG_20190420_192731.jpg For this gearbox I bought a Gripper diff and a lightened flywheel with genuine clutch from Pure Motorsport that should come hopefully at tuesday. I'll keep things updated.
Cheers !
 
So in the last weeks, I've been working on the car every weekend and made some progress.
I have disassembled my new TL4 gearbox and have fitted my new Gripper diff. Thank god i took photos of the shifting mechanism as this was the most difficult part for me on this operation :IMG_20190505_142525.jpgIMG_20190505_173255.jpgIMG_20190506_162621.jpg

After that, I removed my old gearbox out of the car, which was really a straightforward thing. I've never removed a gearbox out of a car, but it was quite easy for me. But I had always a small oil leak on the car and I didn't took time to look where it is leaking, as I had other things that broke down on the Clio.
It turns out that my rear crankshaft seal is leaking, which was very frustrating for me, as I planned to change the gearbox, flywheel and clutch last saturday and I didn't had that seal. I have ordered one now and will change it this weekend.
Also my slave cylinder was destroyed, which I didn't noticed, when driving the car:
IMG_20190601_092950.jpg

So for the rest of the day, I mounted up my CAE shifter, that I have ordered last week and it looks so amazing :
IMG_20190601_172100.jpg
I also decided to change plans with this car. I've always wanted to start doing some competitive racing and then came the idea for me to drive Time Attack with the Clio. It would perfectly fit in the Club NA class against BMW E36's, Toyota GT86's and Honda Integras. The concept of the car will remain the same, the only change will be instead of doing some Trackdays for fun, I will get a little bit into racing, where I can really progress as a driver.
My goal is set to attend the German Time Attack Series final at the 13th October at the Nürburgring GP course.
I will keep grinding till then :smile:
 
Man, thanks for great progress, your thread offers a refreshing take on modding the Clio. Keep it up, I will be following with interest! There is only one Clio and thats the Clio 3!
 
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