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Birth Of A Rally Car - Creation Of A Peugeot 307 WRC
Lego-Time, Anyone?
Photo Courtesy of WAKE UPP / G Planchenault - D Goubet. Peugeot.
The months of design work, the weeks of assembly and the hours of fine-tuning all seem a long way from the celebrations on the finish ramp. Yet without them... Peugeot Sport lifts the veil to give an exclusive glimpse of the secrets behind the creation of the 307 World Rally Car.
Click READ MORE for the full story and photos.
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 | It takes 45 days to prepare a WRC.
There's no question of just strolling into the workshops at Vélizy. You'll have to prove your identity and show your pass first. only when the formalities are completed do the doors to Peugeot Sport finally open. It's a hive of activity, yet everything is ordered.
Thanks to the unflagging pressure imposed by the World Championship calendar, there are always several 307 WRCs under construction at the same time. For there is always plenty of work to be done, what with the cars being prepared for the next rally, those being readied for the next test and the ones that need to be produced for the following month's fixtures.
A three-man team is wholly responsible for the preparation of each car. A new World Rally Car takes three to four weeks to assemble, and that doesn't include the fitting of the roll cage, a particularly important step since, as a coupe cabriolet, the 307 WRC lacks the stiffness provided by a fixed roof.
Don't Scratch It.
Photo Courtesy of WAKE UPP / B. Capdevielle. Peugeot.
Once the roll cage is installed, a tunnel is fitted from the engine bay to the rear axle to accommodate a propshaft for the conversion from two-wheel to four-wheel drive.
There's a brisk visit to the paintshop before assembly begins in earnest. Before the two coats of red are applied, the 307 WRC receives two coats of white to highlight the livery of Marlboro, the team's title sponsor. once that's done, the bare shell is fitted with suspension, engine, hydraulics, transmission, dashboard and electronics.
The work is ceaseless and the deadline for the first run creeps steadily nearer.The parts forming the standard 307 CC's roof are bolted on. To convert the 307 WRC to four-wheel drive, a tunnel is fitted to the bodyshell, housing the propshaft linking the engine bay and the rear axle.
Under Carriage.
Photo Courtesy of WAKE UPP / B. Capdevielle. Peugeot.
The installation of the wiring loom is a lengthy procedure that demands particular care. No fewer than 3600 metres of cable are used in a 307 WRC. In contrast, the pedal box - ultra-light and made in-house - consists of the bare essentials only. It's perfectly adapted for the dedicated left-foot brakers who will take the wheel of the n°6 307 WRC.
Thanks to the three designated mechanics, the 307 WRC gradually takes shape. Here they can be seen fitting the dashboard and the centre console. The onboard computer is situated in front of the co-driver.
Peugeot 307 WRC Cockpit
Photo courtesy of WAKE UPP / B. Capdevielle. Peugeot.
1. The 307 WRCs are designed and built in Peugeot Sport's Vélizy workshops in utmost secrecy. Access to the inner sanctum is tightly controlled.
2. once the car has been assembled, the next stage is a thorough check of the electronics. It's a vital step before the car's maiden run.
3. Before a 307 WRC leaves the workshop for the first test, it's topped up with oil and petrol, both supplied by Total.
4. Peugeot Sport's workshops are as spotless as a laboratory. Several 307 WRCs in different stages of preparation are under construction at any one time.Let's go!
Air-Time.
Photo Courtesy of DPPI. Peugeot.
Each car is naturally tested before it plunges into the cauldron of World Championship competition. The first stage is a shakedown session, often carried out by the 1993 Le Mans 24 Hours winner Eric Hélary, who is a keen rally fan. This first test is essentially a systems check to ensure the car is ready before it is entrusted to Marcus Grönholm.
Wiring loom: a modern World Rally Car bristles with electronics. No fewer than 3600 metres of cabling are used in a 307 WRC!
Engine: it's a turbocharged derivative of a four-cylinder unit used in the 406. The regulations limit it to 300 bhp via a restrictor.
Side window: as the regulations demand, a small pane of glass carries the car number, the national flag and the name of the driver.
Propshaft: connecting the engine to the rear axle, it's the link that makes the 307 WRC four-wheel drive.
Fuel tank: it conforms to strict safety standards to ensure it doesn't leak in an accident. It has a capacity of around 90 litres.
Helmet holder: once they've completed a stage, driver and co-driver remove helmets and hang them from the support provided.
Fine Tuning The Heart
Photo Courtesy of WAKE UPP/ B. Capedevielle. Peugeot.
Radiator grille: it has to remain the standard shape, while the radiator size itself is limited by the regulations.5-point harness: a vital safety feature, it holds the driver firmly in place by the shoulders, hips and crotch.
Spring: different springs are used for different conditions. Each spring has to withstand a force of up to three tonnes on a bump.
Shock absorber: has a separate reservoir and is made by Peugeot to Peugeot Sport's specific requirements.Brake disc: each ventilated disc is 370mm in diameter for tarmac rallies and just 295mm for rallies on dirt.
Brake caliper: four pistons in each caliper clamp the pads. However, there are eight pistons in each front caliper for tarmac rallies.
Gearbox: positioned transversely, in line with the engine, it has five speeds.rear differential: like the front and centre differentials, it is controlled electronically for optimum traction.
Electronic control unit: it controls all the car's electronic functions (chiefly the engine and chassis brains).
Windscreen wipers: essential not just in rain, but also when crossing fords. Operated by the co-driver who has a switch next to his... foot.
Steering wheel: is equipped with two metal rings for gear changing. The front ring is for down-changes, the back ring for up-changes.
Centre console: it houses the brake balance adjuster, and controls for adjusting the engine map and differentials.
Tool-kit: all mechanical assistance by a third party is forbidden outside service areas. The crew therefore carries tools on board.
Bucket seat: rigidly mounted and individually shaped, they keep driver and co-driver securely located during special stages.
Roof: consisting of two parts, as on the 307 CC, it is bolted to the roll cage. The folding mechanism is not fitted.
The Birth of Champions.
Photo Courtesy of WAKE UPP / B. Capdevielle. Peugeot.
PaddockTalk Perspective
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