[project] Sos Track 205 16v Turbo Project

[sounds of silence 2]

Ok going to do a build thread on my 205 we are in the middle of building for the beginning of next year.

 

Alot of folk will have seen it this year anyway but i have recently stripped it down to a bare shell to undergo alot of work due to the engine that will be going in it this time .

 

Going to start off when i first got it to the stage it is at now this will be a on going thread for the next few months as it gets built from start to finish and all in house.

 

A pic of the car first of all just a pretty std 1.9 gti .

 

 

then i converted it to a 2.0 8v turbo for the track.

 

 

at this time it was stripped out , a set of bucket seats and a safety devices multi point weld in cage

 

 

engine pretty much std except bigger exhaust and 14psi boost from the t25 turbo this putting out around 190 atf .

 

brakes were gti-6 285mm on the front and std 1.9 on the rear .

 

suspension was koni adj all round.

 

cosworth 2wd intercooler modified and fitted to the 205 .

 

End caps cut off and rotated 90 degrees

 

 

Factory !! :wink:

 

 

 

Edited January 21, 2009 by sounds of silence

[sounds of silence 2]

Next up a fancied a bit more power having owned a few high powered 205s in the past a wanted a play around with the engine alittle .

 

Biggest problem with the 2.0 8v engine is there has'nt been alot of them tuned in the past so we had to pretty much just make a spec up as we went alittle trial and error but was fun

 

 

sent my old turbo away to aet turbos to see what spec i could get made up for the std manifold and to my surprise they said could upgrade to a hybrid T3 (biggest i had heard of on a std manifold was a T28) so i gave them the go ahead and a week later .

 

old turbo against the new one

 

 

 

 

next up was an uprated cam shaft this car from CATCAMS a nice stage 3 cam

 

 

 

now with the bigger turbo and cam i knew i had to go for a stand alone management so i bought KMS management , to go with this i got my hands on a set of cosworth green 803 injectors at this stage the engine looked like this

 

 

after a bit off mapping with the new engine the inlet temp were alittle high so we went for a bigger intercooler this time i opted for a evo one

 

 

 

now at this stage i need to be able to get the power down so we went for a quaife diff and a set of toyo 888's cut slick tyres

 

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so now able to get the power down we now had to be able to stop so decided to upgrade for the gti-6 brakes to a set of hi spec 4 pots and still able to keep the 15" wheels

 

 

That was the car for a while and at that spec we managed to get 230 / 240 bhp at the fly a nice figure and defo good power increase

 

 

and not every day runs smoothly , burst water pipe :cry:

 

[sounds of silence 2]

Plans were made for the car to get stripped again this time for the proper build and a nice 2.0 16v turbo engine (same as t16 but better spec'd) and a good few body mods inc seem welding , new cage and light weight panels now hoping for roughly 750kg and 350 bhp.

 

So car goes in looking like this

 

 

to this in no time , engine stripped out

 

 

 

now right back to a bare shell with everything off

 

 

 

of course being stuck on one of the lifts is no good so was moved into its possition for the time being and for work to commence .

 

so as it is in the weld and prep area

 

 

now completely completely striped ready for the engine bay to be seem welded and strengthened

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This section will show how the engine bay has been seem welded and strengthened.

 

reason for this work is basically a 205 was never designed for hard track use and certainly not for high powered engines as this picture will show the strut top after a bit of hard cornering .

 

see how its started to dome.

 

 

so this is where the strength needs to be added

 

area gets prep'ed

 

 

now plates get tacked into position

 

 

everything gets checked making sure there 100% and then fully seem welded into position

 

 

now while preping the engine bay to seem weld i found a couple of rust patches so decided to cut them out and plate them up properly

 

 

section cut out and ready for a plate to be made and welded in place

 

[sounds of silence 2]

This section will show how the engine bay has been seem welded and strengthened.

 

reason for this work is basically a 205 was never designed for hard track use and certainly not for high powered engines as this picture will show the strut top after a bit of hard cornering .

 

see how its started to dome.

 

 

so this is where the strength needs to be added

 

area gets prep'ed

 

 

now plates get tacked into position

 

 

everything gets checked making sure there 100% and then fully seem welded into position

 

 

now while preping the engine bay to seem weld i found a couple of rust patches so decided to cut them out and plate them up properly

 

 

section cut out and ready for a plate to be made and welded in place

 

[sounds of silence 2]

now its not like you can just go out and buy in a section to replace it , so a section has to made up now for this all that was required was a bit of sheet metal , plasma cutter , square and a hammer :wink:

 

 

now a rough size is cut a shape can then be made to fit

 

 

now must be trial fitted

 

 

and when happy with the fit tack welded into place and then seem welded

 

 

and the rest of the engine bay seem welded

 

[sounds of silence 2]

we'll engine bay pretty much complete except the cage work which will follow , i moved on to seam welding the inside of the car .

 

For this to be done correct and the cage to be 100% spot on i had to strip the dash completely out and then had to dress up every seam on the car again to be able to start the welding pretty much the same procedure as the engine bay .

 

inside untouched except seats removed

 

 

dash starting to be removed

 

 

completely stripped

 

 

getting prep'd

 

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then seam welded

 

 

so now car completely seam welded its now time to move on to the new front cage to be made for this we are using 38mm cds tube and getting bent with out HUTH pipe bender.

 

reason for the new front cage is i was wanting it a bit tighter to the A piller and also wanting it to go straight on to the strut tops and cross braced at both doors and behind the seats.

 

first part of the cage in place

 

 

now a perfect fit to the A piller alot happier so now added the first part of the cage to go onto the strut tops.

 

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Another part of the cage complete but ran out of pipe so will have to get more ordered tomorrow to get the cage finished off .

 

 

 

 

 

and the strut tops completely braced

 

 

then seam welded the subframe , now ready to be powdercoated

 

[welshpug 1,657]

Good effort

 

now its not like you can just go out and buy in a section to replace it

 

 

er, yes you can...

[sounds of silence 2]

no you cant as there all back order for a month , its not like i didnt try

[sounds of silence 2]

was back on the cage again trying to get it finished off , now pretty much 90% complete just a few we bits left to go on .

 

centre bars to support behind the seats

 

 

 

then both doors crossed

 

 

 

then the final side supports triangulated

 

 

 

 

next up am going to build up a trial engine to fit it in and make sure everything is fitting before it heads into the bodyshop to get prep'd and painted before the proper rebuild

[sounds of silence 2]

well managed to make up a test engine today to try out positions for various parts and to make sure of clearance issues which i thought could be a problem , but after its in and everything tested its pretty much perfect to say the least 8)

 

a few teasing pics (now this will make me get the finger out)

 

 

 

 

 

and a pic to show the room to get in from the cage

 

 

[M@tt 77]

thats a fantastic effort mate!!!

 

simialr to what i'd like to do do my Dimma which will be my next project.

 

Out of interest what are material costs like to build a cage like that? also is your pipe bender one of them fancy programmable hydraulic efforts or a manual jobbie?

 

keep up the good work!

[taylorspug 7]

Proper effort there, well done that man! Its nice to see a track car being well thought out and nicely put together, rather than just a random bunch of 'fashionable' bits bolted in.

 

Be very interested in the engine spec when its done too.

[sounds of silence 2]

thats a fantastic effort mate!!!

 

simialr to what i'd like to do do my Dimma which will be my next project.

 

Out of interest what are material costs like to build a cage like that? also is your pipe bender one of them fancy programmable hydraulic efforts or a manual jobbie?

 

keep up the good work!

 

cost of materials for the cage were prob around £500 but the man hours is where it is at lol

 

its a proper programmable hydraulic pipe bender mate we use for our exhaust systems etc.

 

and thanks

[sounds of silence 2]

Managed to get the last pieces for the cage in place and thats now all the welding and cage done , next up is the car will be getting fully prep'd for painting this week and will hopefully be painted before the week is out depending on other work . Thought it would have been quiet first few weeks in jan but is not and we are actually fully booked so will just have to find time to squeeze my own in or ill end up running well behind.

 

strangthing plates welded to A pillers and roof

 

 

roof also braced

 

 

and the last piece was to brace the cage onto the rear suspension points

 

 

the rear beam now fixes up through the floor and the cage to stop any flex this will go nicely with the group A beam we are building for it .

[sounds of silence 2]

well today seen me in to start the preping the car , nothing to drastic needing done but few dents etc normal stuff for a car 20 years old

 

 

all filled and ready to prime

 

 

rest of the car stripped ready to start the paint work now all off the wiring loom , steering column and clutch and throttle cable oh and peddle box and servo

 

now this is total naked 8)

 

[sounds of silence 2]

and on that note a was back in today to start the painting so had to give a few of the boys a shout as the team are still off till monday , so cheers guys :wink:

 

first off moved the car into the booth and panel wiped it all

 

 

then on to the etch primer

 

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then started the high build primer

 

onit 8)

 

then full car primed

 

 

now ready to paint woohoo 8)

[M@tt 77]

so have you made you own exhaust manifold as well?

 

any pics??

[sounds of silence 2]

no mate got my hands on a new dp engineering one "welders nightmare" the design of that maniold is superb

[sounds of silence 2]

and for another little update ,

 

today seen the car go into paint , big ups to toffi nice job for first day back :wink: dont say a aint nice to ya

 

and on that note always bet on black

 

 

pictures really dont do it justice imo coz this really s to die for 8)

[sounds of silence 2]

a few pics from last year at the track

 

SOS 1

 

SOS 2

 

SOS 3