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CCHMSC visit M-Sport - Thursday 6 October
Report & photos by Jim Paterson
Some of our group gathering in the Trophy Room with Monte Carlo trophy on the table
From all corners of the UK we met up at M-Sport
at Dovenby Hall near Cockermouth at around 1700hrs for the tour of the
M-Sport facility, to see and find out how they build rally cars, from 2
wheel drive clubman to full AWD WRC cars.
In the Trophy Room, which itself displays a very impressive collection
of silverware cups, our guide Roger introduced us to the new facilities
we would be seeing. The site map covered the main building we were in,
the new manufacturing building and the Test Track.
The new track is where cars are put through their final checks. We
asked Roger if he had ever 'had a go' in one of the rally cars, he
replied in 16 years with M-Sport he hadn't. We would see this later.
Note photographs were not permitted in many of the rooms we
visited, but I managed a few in the rooms we were allowed.
The major changes since we were last here in 2019 were the test track,
which was an empty building site last time, and the updated cars now
that we are in the 'Hybrid' era. After the introduction and
refreshments we started on our way.
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Flying Puma's flat out
On
our way to the first first port of call Roger told us that the new Ford
Puma car is the base model, taking over from the Fiesta, and is
predecessor the Focus. The Puma is a stronger car and to meet the FIA
regulations uses a lot of manufacturer parts. We arrived at the the
gearbox and differential build workshop. To meet the latest Hybrid
regulations these now have a drive input from the petrol engine and the
electric motor. For the four wheel drive cars the engine drive shaft
enters the front gearbox/diff with three outputs one to each front
wheel and a third to a prop shaft heading to the back diff unit. That
has three I/O ports, one for each wheel and the third to the electric
motor. This along with the associated battery pack is mounted behind
the front seats.
Which one will I try first?
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Now how do I get inside this one?
Our team in the showroom
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A bit like F1 cars the electric motor power is used as a 'boost', at
take off from the start line and in stage. Roger reported some 118bhp
added when this motor switched in. A lot of technology in there to
prevent the whole lot going out of sync. The driver has to learn how to
manage this boost energy so as to recharge the battery through
regenerative braking, acceleration etc. Finally rally cars driving
through built up areas, e.g. between stages, have to drive on electric
only. With only 15 minutes all electric capacity they have to drive
pretty frugally.
Here are a couple of links showing testing techniques
M-Sport Loeb tests Puma Hybrid on Gravel https://youtu.be/KK4uYChyygo
Hyundai Hybrid testing https://www.youtube.com/watch?v=6opfVuLd75s
On to our next area to view. This looked down on the car preparation
area, where several Puma's, Fiesta's,and we spotted one Focus, were
being built / rebuilt for customers. There were a few Bentley GT cars,
based on the Continental model, being rebuilt. Bentley we were told
have pulled out of the GT series as electric power is taking over from
big combustion engines as the Company way forward. They were pretty
impressive all the same.
It was noted there was not a hydraulic lift on site. Roger explained
that on stage you don't have that luxury, and as the technicians (they
don't call them engineers) who work on the M-Sport WRC cars in this
workshop get first refusal to travel to events with the car, they will
be used to working under long leg axle stands.
member Tom Niven eyes up this GT40
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or maybe this Ford GT?
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Time to head over the road to see the test track, before the light
failed. Most impressive with lots of turns and changes in altitude.
Roger told us that testing only takes place on certain days and times,
to meet their planning regulations, i.e. noise etc. So you can't just
drive on and press the loud pedal!
Back inside we visited the engine department. Most engines are based on
the stock Ford Ecoboost block, bored out and fitted with wet liners.
The WRC blocks are custom built. Several engines in varying states of
build were in the workshop. There is a limit of two engines per season,
and with many FIA scrutineer seals not a lot can be done if one goes
wrong. As Roger said, you can poke a camera into the sump and down the
spark plug hole to see what's up, but fixing it might not be possible
without dismantling.
In the next body build workshop we saw the custom made roll cages being
fitted into the body shells. All the pipe bending and welding is done
here. I noted the front cage links through the centre of the bulkhead
to the top of the coil over spring suspension (not unlike Macpherson
struts!) In a head on smash the energy goes through these bars into the
inside cage where it dissipates around all the bars in there. Whilst
some panels can be changed for carbon fibre, other have to be
manufacturer original. The doors however can and are filled with
compression retarding foam to slow a side impact down. So in effect the
crew are in a protective cocoon.
flight crates loaded and ready to fly
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anyone got the keys?
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As we headed to our final spot we passed the boxes of kit (spares,
tools, oils etc) that go out to each venue before the rally event. For
distant venues this all goes by ship, so set off months ahead of the
event. For closer venues they go by air. Remember the technicians
that built the car here at M-Sport usually fly out to service it on the
event.
Roger presents.... the finer points of the Bentley GT3 cars
Our
final stop on the tour was the showroom a stunning 557m2 space suitable
for functions, exhibitions, vehicle launches and other private events,
like our tour. From a very early Peugeot (never knowingly rallied!)
through GT3 Bentley's and a selection of M-Sport previous rally cars,
plus some exotic cars, we ended with Colin Mcrae's winning Focus. See
more at https://www.m-sport.co.uk/copy-of-conference-centre
We returned back to the main Dovenby Hall Trophy Room for the wrap up.
Many questions had been asked of Roger on the way round and his
experience added detail that only taking a tour can discover. Well
worth a visit and something everyone should have on their 'must visit'
list.
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Published 11 October 2022
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