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Discussion Starter #1
Greetings from Australia.

I am looking at running a 156 GTA in a local Production Car race series. We don't have a lot of leeway with putting in lightweight panels etc so having seen a lot lightweight (1000-1100kg) 156s in the various adverts over there, I was wondering whether it was all lightweight panels or are there some specific things that can be done to reduce weight. The race car currently weighs about 1380kg (has to maintain most of the interior trim)

Any and all ideas will be apprecitate.

Rgds (and have a wonderful Xmas and 2012)

Genghis
 
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what interior trim must you keep? seats? door cards? carpet?

seats are heavy, door cards, carpets, sound proofing, glass too
 

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Remember most of the race 156 over here will be 2.0TS, so will have started out considerably lighter than a GTA.
Most race in a production class too, so will have std panels & glass.
 

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Discussion Starter #4
Thanks for the answers guys. Yes have to keep standard panels and glass and did notice that most of the racing ones over there are based on the 2.0ltr. In answer to what can go and what can stay;

1. All seats are gone except for the racing seat.
2. Door trim is allowed to be replaced (except with CF) and this has not yet been done (how heavy are the standard ones?)
3. All carpet is gone,
4. Most of the sound proofing is gone from the car.

I am also going to replace the standard battery with a lightweight one.

The car weighs 1380kg now (with out driver) and the racing weight cannot be less than about 1386 (with driver). I weigh 75kg (with suit, boots and hat) so if can get around 70kg out of it then we will be looking pretty good. That weight is the target but any reduction will help. Some other intersting things that I am allowed to do with the rule changes are as follows.

1. Remove all cats (3)
2. Go from 305mm to 330mm brakes at the front.

So with a bit of weight reduction and the unknown increase in HP and the bigger breaks, the car should be more competitive than it was back in 2002 / 2003 when the original owner campaigned it.

Any tips, tricks or suggestions would be very much appreciated.

Cheers and hope everyone is having a great Xmas.

Rgds

Genghis
 

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Presumably you are going to have to add a roll cage? That'll add a fair bit.

I am assuming also that you can remove the carpets and sound deadening material, scrape back the bodyshell of any panel deadening and then put the carpets back on top?
 

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2. Door trim is allowed to be replaced (except with CF) and this has not yet been done (how heavy are the standard ones?)
Reasonably heavy.
Easy to replace with thin plastic sheet.

Don't expect massive weight reduction though, but every bit helps.

You can loose a fare amount from the wiring loom too, either by careful pruning(!) or a custom loom.
 

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Are you allowed to replace the glass ?
The rear plate, and the rear passenger glass wights a bit too.
 

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doh :)
 

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Can you remove the window winder mechanisms - they don't weigh a lot, but every little helps....

Have you removed the aircon compressor? - its a big heavy lump....You'll have to be a little creative with the auxiliary belt, of course - its easier on the TS as they can be supplied without aircon as standard. Lose all the aircon piping, condensor etc.

Small savings - the airbag ECU, airbags and all the associated wiring....I presume you've already binned the standard seat-belts. Ditch the huge screenwash bottle, or at least ensure there is very little in it.....

Getting 70Kg out of the car will be difficult, tho.....can you remove any of the bracing on the bonnet and bootlid? Maybe the side impact bars in the doors (although I'd leave the driver's side in).
Foglights ditched from the front bumper?
 

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Discussion Starter #11
Hi folks,

Some great suggestions there. Just to clarify the car is already a racing car so already has cage, safety gear etc. The things that I don't know about (as we have yet to purchase the car from the current owner) are;

1. Air conditioning units (most current rules don't need it although I am not sure about the 2002 rules)
2. Wiring loom
3. Any additional removing of sound deadening material

To give you all a bit of a background the car would be competing in a class against BMW 130i, Mazda MPS etc. The format for next year will be a lot of endurance racing 1hr - 8hr depending on the event so even though the 156 may not be the quickest tool in the shed I think it will go well against the others in endurance trim. Needless to say it will be the ONLY 156 racing (there was orginally 2 Production cars racing back in 02) so from a sponsors point of view it has both the Alfa appeal and a unique angle as well.

My current delima is that I race a Honda DC2 Type R that has a great chassis and is only 1120kg (with me in it!). I can match the lap times of the BMWs (and beat them) in sprint races. So even if I can get the Alfa up to around 280hp (no cats, good exhaust and tuning), the extra 260kg will make the car only as quick as the Honda and a lot more thirsty (3.2ltr V6 Vs 1.8ltr 4). But at the end of the day it's the difference between racing a Honda or an Alfa. From a sponsors point of view it's a no brainer.

Anyway, keep the suggestions coming because if I can get the car weight down (legally) then I think the car could be a bit of dark horse.

Cheers

Genghis
 

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Sorry if i cover old ground.
-Have you removed all speakers?
-Airbag systems
-change the alloys for some lighter OZ
 

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Discussion Starter #13
Hi Tomfromtelford,

It is still running the factory GTA Clover leaf pattern. I have been trying to source some Oz wheels. Do you know what the difference is in weight between the two?

Cheers

Genghis
 
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remove the following, some already covered:

speakers & door panels
air bag ecu, air bags, saftey belts
central air vent tunnel
remove the dash & then remove the sound proofing on the bulk head, thats worth at least 10kg
remove the heater matrix, another 12kg, fit an electric heater to de-mist the windscreen [ may no be an issue in Aus ]
As part of the rules can you cut the passengers side off the dash?
Striping back the wiring loom would reduce weight too
remove the standard fuel tank & fit a light weight version
lighter rims
racing suspension could be lighter than road parts
remove any trim from around the engine bay, bonnet carpet, bulk head lining, dump the washer system.

air-con pump is a hard one to work around on a V6 as its one of the systems driven by the AUX belt which in turn operates the water pump. simply removing the pump & fitting a shorter belt is not solution. HOWEVER you could remove the air-con rad & piping & wiring , that should also save a few kgs.

I wonder if you could ditch the power steering pump too & fit an electric module could that be combined into the one project with removing the air-con pump?????
 

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Discussion Starter #16
remove the following, some already covered:


central air vent tunnel
remove the dash & then remove the sound proofing on the bulk head, thats worth at least 10kg
remove the heater matrix, another 12kg, fit an electric heater to de-mist the windscreen [ may no be an issue in Aus ]
As part of the rules can you cut the passengers side off the dash?
Striping back the wiring loom would reduce weight too
remove the standard fuel tank & fit a light weight version
lighter rims
racing suspension could be lighter than road parts
remove any trim from around the engine bay, bonnet carpet, bulk head lining, dump the washer system.

air-con pump is a hard one to work around on a V6 as its one of the systems driven by the AUX belt which in turn operates the water pump. simply removing the pump & fitting a shorter belt is not solution. HOWEVER you could remove the air-con rad & piping & wiring , that should also save a few kgs.

I wonder if you could ditch the power steering pump too & fit an electric module could that be combined into the one project with removing the air-con pump?????
Thanks so much for these 'hidden' weight savings.

In answer to a couple of your questions.

1. We can't cut the dash (but I don't think they removed the sound proofing you mention behind the dash).
2. We do need the demister paricularly if we run the 12hr at Mt Panorama (at the same time as the GT Audi R8s. Bigger rear view mirror required!). I will check the regs as to whether a heated windscreen is allowed.
3. If we can find a solution to the AC pump then that would be good but we must keep the power steering pump.

One thing we are allowed to do to the engine is to fit lightweight pulleys to drive the ancillaries etc. This would certainly reduce some rotating mass and not only save some weight but perhaps free up some ponies. I say this without knowing how lightweight the factory pullies are.

It is starting to look very promising now. The important thing is that even if I get the weight below the minimum then I can put the weight back as ballast where 'I' choose.

As an aside, what sort of Hp have you guys been getting on a GTA engine with only removing cats, new exhaust (from first flange back) and re-tuning? One of the local specialists is an agent for AutoDelta so he has done all the 3.7 ltr conversions but has not got any benchmark info on the base GTA engine with no internal mods.

As always, any and all information is appreciated. At this rate I may have to put Alfaowner.com signage on the car!

Cheers

Genghis
 

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Discussion Starter #18
Thanks Cuore_Sportivo these are great. Looks like a very professional outfit and there may be some clues here as well. Increasing the plenum size is outside the rules but the lagging to contain the heat warming the air in the engine bay is not. :)

Love the front lip and rear spoiler but unfortunately our rules basiscally say that unless it was available as a factory option (through a dealer) we cannot run it. Besides we don't really have enough high speed corners here in Aus to warrant needing the extra downforce so really we only be creating drag (and adding some extra weight).

Thanks again for these I will pass them onto my engineer who is evaluating the whole project.

Rgds

Genghis
 

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Discussion Starter #20
That is a great weight that you have got the car down to. Unfortuneately we can't run the lightweight panels or replacement glass that I can see in some of your images there but it certainly shows me that with all the suggestions that have been given here that I could quite possibly get it down to 1382 (racing weight = driver + fuel although I never use fuel in the weight calculations).

But these images will certainly give me a great frame of reference.

Rgds

Genghis
 
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