Vehicle development programme of my Corsa VXR Racing vehicle

images of my Corsa VXR Racing vehicle

On this page I have detailed the programme of development, upgrades and improvements undertaken on my Corsa VXR Racing vehicle. I have also detailed what future work I hope to do (funds permitting!!)

bluefin - Corsa VXR Racing

All of my Corsa VXR ECU remaps have been installed by Thorney Motosport using the Bluefin hand-held unit. Bluefin enables complete control over the remapping process, enables you to turn the remap on or off, has the option to immobilise the car (for extra security) and even a fault code reader and OBD data display!

Tesco Momentum 99 Octane fuel - Corsa VXR Racing

Thorney Motosport recommend using Tesco Momentum 99 Octane fuel. Engines with turbo chargers create extra heat in the engine. Hotter air contains less oxygen which means the engine must work harder to generate power, but the higher ethanol content in Tesco Momentum 99 Octane means the fuel is more resistant to this effect, so it can still generate power without requiring more of it. For those interested in my Corsa VXR Racing fuel consumption figures and CO2 emissions click here.

When describing the various upgrades clicking on the various images and links will open a new window which contains more detailed information.

Future Development Plans - last updated 2 September 2011

cam camber adjustment bolts | corsa vxr

2 September 2011 ...When setting up the Bilstein B14s on the Corsa VXR Racing we noted that the front camber was unequal (-1°18' on the NS and - 0°54' on the OS). To try and achieve equal camber on both sides we are going to fit cam camber adjustment bolts which will allow both positive and negative camber changes up to approximately 1.75°. These bolts replace the original upper strut/spindle bolt and should help us to further optimise handling and reduce uneven tyre wear. Not sure what camber we will set the vehicle up with (probably start with 1/1½° negative camber) and take it from there. More details to follow once the camber has been adjusted, road tested and we are happy with the setup.

bilstein b14s | Corsa VXR Racing | Geometry setup

18 August 2011 ...So the Bilstein B14's have been fitted and the full fast road geometry setup completed. The Corsa VXR was already lowered with the Eibachs fitted but with the Bilsteins fitted we have lowered the car by about an extra 5mm to about 40mm. The ride is much improved, however, thanks to the Bilstein B14 shock absorbers which offer much firmer and positive ride control compared with the standard Corsa VXR shocks. The Corsa was set up with 1.5mm toe out on the front and zero toe at the rear. Photos of the Bilstein B14s installation as well as the fast road geometry setup can be viewed on the gallery page.

10 August 2011 ...At last the Bilstein B14's have arrived and are due to be fitted by Thorney Motorsport on 17 August. A full fast road geometry set up will be carried out once the Bilstein B14s are fitted. As a result I have a set of Eibach Pro Springs as well as standard shock absorbers for the Corsa VXR for sale. See the for sale page of this website for more details.

5 May 2011 ...The Astra VXR engine conversion is progressing well on the TMS prepared race car. A new website has been created which will document the progress of development and future test/track days.

9 February 2011 ...As all future development work for the Astra VXR engine conversion will be carried out in the TMS prepared race car it is anticipated that no more upgrades will be forthcoming on my Corsa VXR Racing car. A new website specific to the Corsa race car is being created and will be available to view online soon.

3 February 2011 ...Having decided to purchase the TMS Corsa race car the Astra VXR engine conversion is progressing well. The engine/gearbox has been fitted successfully without any major problems. Some mods were required to engine/gearbox/diff mounts. Driveshafts line up ok. Next stage is to check out intercooler and air intake system to ensure there are no heat issues when running 400+bhp!

6 January 2011 ...Due to the heavy snow conditions just before Christmas the dry engine fit into the TMS race car was delayed. The good news is it's ongoing as we speak. Results and photos to follow.

21 December 2010 ...Thorney have released the engine performance figures for the stage 5 Astra VXR engine. Max power is up to around 375bhp @ 5880rpm with 360ftlb torque kicking in at 3780rpm. I'm still confident that with my stage 5 engine spec - uprated internals and injectors etc. - 400bhp+ is achievable! Click here to view power graph.

7 December 2010 ...A few pictures of the stage 5 Astra VXR engine available to view on the conversion gallery page. More to follow soon.

24 November 2010 ...Primarily to benefit engine bay cooling but also for visual effect I have decided to ask TMS to arrange to have a metallic black ceramic coating applied to the tubular exhaust mainfold, turbo housing and exhaust downpipe. We have approached Zircotec to carry out the ceramic coating. I have chosen to have the metallic black coating which I think will compliment and enhance the engine bay appearance. More info and pictures will be posted on the Astra engine conversion page. Also, TMS have announced the availabilty early next year of a carbon fibre bonnet for the Corsa VXR. This will help disperse heat build up in and around the engine bay - probably needed once the Astra VXR engine is installed. I certainly will asking TMS to fit one to my Corsa VXR Racing.

19 November 2010 ...Thorney Motorsports (TMS) have created a new webpage on their website to cover this project. To visit this webpage click here.

8 November 2010 ...The Astra VXR engine rebuild to stage 5 (380+ bhp) is complete. The next stage is to carry out a dry run for the engine installation into the Corsa to enable engine mounts etc. to be postioned ready for fabrication. This will take place this week.

3 November 2010 ...Looking to the end of the Astra VXR engine conversion and fitment of the Bilstein B14's I have decided to ask Thorney Motorsport not only to carry out their Fast Road Geometry setup but also to carry out a full Corner Weighting setup. Proper weight distribution is critical in setting up a well-handling car. For more info about Corner Weighting click here.

11 October 2010 ...Great news - the Astra VXR engine has arrived. I've decided to go straight for the 380+ bhp upgrade so work will start soon on preparing the engine. For more details click here or click on the button on the nav bar above at any time to follow progress of this exciting project. The Bilstein B14's have also finally arrived. Fitting of these will be delayed until the engine upgrade project is finished.

1 October 2010 ...My quest to achieve 300+ bhp has led to more discussions with Thorney Motorsport as to my options. Sticking with the Corsa VXR Racing engine (Z16LER) would require a bottom end and turbo upgrade, all possible but resulting in a more highly stressed engine. Another option, proposed by Thorney Motorsport, would be to replace the Corsa VXR engine (Z16LER) with the Astra VXR engine (Z20LEH). With the mods already carried out my car - larger front mounted intercooler and 3" stainless steel race exhaust power/torque figures of 300bhp/340ftlbs would be immediately available from the Astra VXR engine (with a suitable remap) in it's standard specification. Also, already having the Quaife LSD and AP Racing Brakes fitted will ensure that all this extra power can be safely handled on both the road and track. However, the exciting part of this option is that by further modifying the Astra VXR engine (upgraded turbo - GT28, equal length exhaust manifold, uprated pistons & rods and uprated injectors) it will be possible to achieve at least 380+ bhp. So, this is the route I have decided to follow - the brand new Astra VXR engine is on order from Opel - work will start later this month and take about 2 months.

So, this is the route I have decided to follow - the brand new Astra VXR engine is on order from Opel - work will start in October and take about 2 months.

2 July 2010 ...More bad news - the Bilsteins won't be available now until mid August (so much for German manufacturing efficiency). I'm still going ahead with the Forge RV fitment plus the car will have it's first service.

4 June 2010 ...Good news and bad news. Bad news is the Bilsteins won't be available for 4 weeks so the car is rescheduled for 6 July. Good news is the Forge RV is approved by Thorney and will be fitted at the same time. Also, Thorney asked if I wanted to put my car on their stand at the forthcoming PV Show at Santa Pod Raceway (12/13 June). Unfortunately I will be away on holiday that weekend - a big shame!

21 May 2010 ...Car booked in at Thorney Motorsport for June 15 to have the Stage 3 Handling Upgrade (Bilstein B14 PSS Coilovers). I may also have the Forge Recirculation Valve fitted - it depends upon whether Thorney Motorsport underwrite it's use on the Corsa VXR.

14 May 2010 ...Just purchased the black plastic front foglight surrounds to replace the standard silver/black ones currently fitted as standard. Pictures on gallery page.

23 April 2010 ...Not really vehicle development related but I have just purchased 2 cg-lock seatbelt devices. Apparently the cg-lock is a device that locks the seatbelt in place and offers some of the benefits of full harnesses without being as restrictive. Redline magazine recently used them during a feature on bucket seats and gave them a decent review. With my eye on possible future test track days it will be interesting to see how they perform. For more info from the cg-lock website click here.

16 April 2010 ...The next stage is to uprate the suspension with the Bilstein B14 PSS Coilover Suspension Kit.

14/15 April 2010 ...Engine remap completed successfully. See further down the page for details.

26 March 2010 ...The Corsa has been booked in at Thorney Motorsport for April 14/15 for the engine remap to try and increase the power to nearer 250bhp.

24 February 2010 ...Due to time restraints the engine remap planned for 23 February could not be completed. It is plannned to carry this out mid March 2010.

15 February 2010 ...The Corsa has been booked in at Thorney Motorsport for 23 February to have the front brakes uprated and braided hoses front and rear. An engine remap is also scheduled to try and increase the power to nearer 250bhp.

10 February 2010 ...With all the modifications and equipment upgrades already carried out there are still a couple of areas left to review to see what can be done.

The first area involves uprating the braking system - larger front discs and 4 pot callipers, as well as braided hoses front and rear. I may look at improving the chassis dynamics by way of installing an adjustable Bilstein suspension kit (more info to follow).

Secondly, although the engine is currently producing 230bhp it should be possible to achieve close to 245/250bhp with a more agressive engine remap. The larger injector maps for Thorney Motorsport own upgrades, allow for 250bhp+ power but injector levels remain well within their maximum.

Ultimately, after discussions with Thorney Motorsport, it seems it may be feasible to swap out the Corsa engine and replace with the 1998cc Astra VXR turbo engine, whereby 300+ bhp is easily achievable. Development work is still ongoing at Thorney Motorsport so this option will have to wait a little longer. Updates will be posted as soon as available.

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14/15 April 2010 - rolling road - stage 3 engine remap

stage 3 engine remap figures - Corsa VXR Racing - click for more info

Following discussions with Thorney Motorsports it was agreed to schedule a further rolling road session to try and achieve the anticipated max power of 250+ bhp which it was felt the stage 3 modifications made to the Corsa should achieve.

During the 2 day session a more agressive remap was produced by Superchips which resulted in figures of 255.2bhp @ 6335rpm and 280.75ftlb @ 3415rpm.

The car drives more smoothly, is more responsive with maximum torque being reached at lower rpm.

All in all a very satisfactory outcome.

 

 

19 January 2010 - Upgrade to stage 3 engine remap

stage 3 engine remap figures - Corsa VXR Racing - click for more info

Late December 2009 the long awaited fuel injectors arrived so the car was booked in for the stage 3 engine remap. I had also elected to replace the standard wheels with Team Dynamics race wheels, so as to achieve a modest (20kg) weight saving. They also looked good!!

 

 

 

 

 

 

 

 

19 November 2009 - Upgrade to stage 2 engine remap

stage 2 engine remap figures - Corsa VXR Racing - click for more info

After discussions with John at Thorney Motorsport I decided to go for the stage 3 engine ECU remap. Due to the long leadtime for the larger capacity fuel injectors required for this upgrade I decided to have all the other equipment upgrades carried out and the engine remapped to stage 2 specification.

Furthermore, on the advice of John I elected to have a Quaife ATB (Automatic Torque Biasing) differential fitted as well as having a custom fast geometry setup including lowered springs all round.

An ITG air panel filter was also fitted.

The equipment fitted in anticipation of the stage 3 engine ECU remap was:

27 July 2009 - Original vehicle specification

Delivery of the Corsa took place on 27 July 2009. As received the vehicle specification was as follows:

Engine

original engine performance chart - Corsa VXR Racing - click for more info

Transmission

Performance

Chassis, suspension and steering

Brakes

Wheels and Tyres

Vehicle Weight

For the complete Corsa VXR Racing specification and equipment highlights click here to read or download the official Vauxhall brochure (opens in new window).

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