dieselfan
A2OC Donor
1. Introduction of Letty
She is a LHD silver low spec 2003 model sold new in Germany 2002. Imported to Norway in 2005 by second owner. Letty had done almost 200' km when we bought her in 2010, not very well maintained but affordable. She was used as my second (solotrip) commuter and had passed 400' km when the servo, head gasket and AC compressor broke down same month and Letty was parked in 2018.
Letty is special for me, all the km we have had together and my personal commitment to not throw usable things into the bin just because I would like a new one... led to that it is natural for me to get her back on the road, in a reliable condition, ready to do a lot of km together with me...again
2. The objektive
And why is weight so important for me? Well... let's that be said very early in this project, weight and “drive-ability” are the main drivers and key words are: Weight-to-power, balance, simplification and consumption
A2 was never intended to be a race car, it was never intended to be a autobahn locomotive or a drift car. My intention is not to try to transverse Letty into something she never can become.
I would just like to help her a little to “dance on lighter feet’s”
(to be a bit more precise; 8.5kg to the hp....)
3. Balance
The weight of the car is important, though one must bear in mind that the “balance”, the actual weight on the front axle compared to the rear axle is a huge factor when it comes to whether I will be pleased with the handling or not... A2 1.4TDI's are to my opinion “nose heavy” and one of my major drivers for Project Letty is to bring this factor closer to 50/50
4. How to loose weight ?
4.1 Remove parts The intention is to strip off some of the components that are defect and actually not “needed” for my use of Letty. Some parts will be stripped solely to reduce weight.
The are also parts that are considered to make lighter versions of to achieve the goal of reducing the weight with 100kg...:All the listed parts do also reduce unsprung weight which again have a very positive contribution to handling and stopping distance
4.4 Items to be added (items that are added to achieve a non standard function even if it will add weight...)
*- modified ECU
**- weight reduced with 100 kg and modified ECU
5. Simplification
Based on a couple of assumptions, it is my opinion that by replacing the electro hydraulic servoassisted steering system/steering rack, with a manual manual steering rack I will reduce the risk of failure and that I would be able to repair the car my selves over night...
Same philosophy for removing AC system and reducing the size of the alternator
6. Aerodynamic Improvements (added Dec28 - adviced by @A2Dreamer )
I will study the aerodynamic details that is mounted to the 1.2TDI and implement on Letty. Proposals for further details will be very welcome since my ovn experience on this topic is very limited...
Would you like to contribute?
Content will be updated accordingly, new chapters might be added and corrections will be done to Post #1
(I had window seat with a very nice view at school so I never managed to learn proper English so please correct typos, misspellings, grammar and terminology issues so this thread can be possible to understand for all and so everyone can participate to, I will be happy for every correction) ???
Cheers
dieselfan
She is a LHD silver low spec 2003 model sold new in Germany 2002. Imported to Norway in 2005 by second owner. Letty had done almost 200' km when we bought her in 2010, not very well maintained but affordable. She was used as my second (solotrip) commuter and had passed 400' km when the servo, head gasket and AC compressor broke down same month and Letty was parked in 2018.
Letty is special for me, all the km we have had together and my personal commitment to not throw usable things into the bin just because I would like a new one... led to that it is natural for me to get her back on the road, in a reliable condition, ready to do a lot of km together with me...again
2. The objektive
And why is weight so important for me? Well... let's that be said very early in this project, weight and “drive-ability” are the main drivers and key words are: Weight-to-power, balance, simplification and consumption
A2 was never intended to be a race car, it was never intended to be a autobahn locomotive or a drift car. My intention is not to try to transverse Letty into something she never can become.
I would just like to help her a little to “dance on lighter feet’s”
(to be a bit more precise; 8.5kg to the hp....)
3. Balance
The weight of the car is important, though one must bear in mind that the “balance”, the actual weight on the front axle compared to the rear axle is a huge factor when it comes to whether I will be pleased with the handling or not... A2 1.4TDI's are to my opinion “nose heavy” and one of my major drivers for Project Letty is to bring this factor closer to 50/50
4. How to loose weight ?
4.1 Remove parts The intention is to strip off some of the components that are defect and actually not “needed” for my use of Letty. Some parts will be stripped solely to reduce weight.
- Webasto unit with brackets, hoses and fuel lines
- Air conditioning system with piping and houses
- Rear silencer
- Doble deck
- Rollo
- Rear bumper steel brackets and transverse bar
- Stereo and speakers will gain 3 kg (added Dec28 - adviced by @carbore ?)
- Oil filler and assy (added Dec28 - adviced by @carbore ? )
- Downpipe 60mm in stainless steel (will be designed and produced by author)
- Rear exhaust system (will be designed and produced by author)
- Servo steering system replaced with manual steering from A2 1.2TDI
- Rims will be replaced with lighter options
- AC and alternator bracket replaced with solely alternator bracket
- 80Ah battery replaced with 55 Ah (since AC, Webasto and servo are removed there are no need for 140Ah alternator and 80Ah battery)
- 140A Alternator will be replaced with 75A
The are also parts that are considered to make lighter versions of to achieve the goal of reducing the weight with 100kg...:All the listed parts do also reduce unsprung weight which again have a very positive contribution to handling and stopping distance
- Front axle brake calipers (aluminium/magnesium alloy) 4 kg gained
- Front axle wheel bearing hub (titanium)
- Drive shafts (titanium)
- Brake disks centre sections (aluminium/magnesium alloy)
- Suspension strut top mounts (added Dec29 - adviced by @carbore ? )
4.4 Items to be added (items that are added to achieve a non standard function even if it will add weight...)
- Towbar (is heavy and work against the weight loss, though very positive wrt balance. Towbar weight is equal to rear crash bar.
- FIA master key for battery isolation. (added Dec29 - adviced by @carbore ? )
| Weight kg | Power hp | W/P | |
AMF 75hp | 990 | 75 | 13.20 | |
ATL 90hp | 1030 | 90 | 11.44 | |
AMF 105hp* | 990 | 105 | 9.43 | |
AMF LW 105hp** | 890 | 105 | 8.48 | |
ANY 61hp | 855 | 61 | 14.02 |
**- weight reduced with 100 kg and modified ECU
5. Simplification
Based on a couple of assumptions, it is my opinion that by replacing the electro hydraulic servoassisted steering system/steering rack, with a manual manual steering rack I will reduce the risk of failure and that I would be able to repair the car my selves over night...
Same philosophy for removing AC system and reducing the size of the alternator
6. Aerodynamic Improvements (added Dec28 - adviced by @A2Dreamer )
I will study the aerodynamic details that is mounted to the 1.2TDI and implement on Letty. Proposals for further details will be very welcome since my ovn experience on this topic is very limited...
Would you like to contribute?
- Do you have proposals for how one can save weight ?
- Do you have arguments for why I should do different than planned ?
- Alternative technical solutions ?
- Improve balance ?
Content will be updated accordingly, new chapters might be added and corrections will be done to Post #1
(I had window seat with a very nice view at school so I never managed to learn proper English so please correct typos, misspellings, grammar and terminology issues so this thread can be possible to understand for all and so everyone can participate to, I will be happy for every correction) ???
Cheers
dieselfan
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