[project] 205 Cti T16

[nickaliath 22]

LOVING IT!!!!!

 

Im hoping to turbocharge my 205 in the future, so will be coming back for tips on the manifold!!!!

 

It will be the third turbo conversion ive done so have bit of experience, but lving your work!!

[richardjw 1]

Looks like the attention to detail i'm doing on my project, apart from the zinc plating.

 

Hopefully publish pics when i have somethign apart from stripping down photos.

 

Loving the colour too.

[qwerty 9]

Incredible work mate, hats off

 

cant wait to see more of it

[Miles 331 1 Cars]

Just having a look thru, Nice build.

The only thing I will say about the 307 P/S pump is on the 307 at least, it cavitates leaving you without the feeling of steering for a split second if you do a slalom for example

[Richy_cti 0]

truly amazin project whens the next update due

[Paulmac19 4]

Amazing work top marks for the commitment you must have to do a build like this

please get some youtube video of this running i would love to see it through the gears

[lemmingzappa 75 1 Cars]

Love this project, very clean work.

 

Only thing I don't like is that backbox....

[magic 1 1 Cars]

thx guys .

after a break i keep continue the car build with the goal to finish the car in less then 3 weeks

 

hx

 

After rewiring the car for the last 3 days and roughly 30 hours

 

My wiring work is nearly done, what is 23 relays , roughly 10 meter’s alone in power and earth cables, for battery and chassis..

 

Done so far

high speed and low speed wiring loom + AC

Turbo timer

Water pump timer .

Wastegate solenoid for boost

Intercooler spray (advanced)

Launch control for the 402 meter drag ..

Vehicle speed ( used a 206 Wheel speed sensor) and calibrated it to the haltech ecu..

Calculation of gearbox ratio (to have in the lower gears less power)

307 Power steering pump ( cuts of at 50 km/h via speed sensor signal )

Rpm signal for 205 Tacho

Nos 4 Small motorbike bottles in one line ..signal via tps sensor over 90% and switch gets triggered..

Oil presser sensor .(cuts the engine off, if the pressure drops ..

Boost trim ( so I can adjust the hole maps and boost inside the car, means cruise with 220 hp or flick the switch and 500+

02 wideband sensor

A/C request .. to lift up idle, when AC is on.+ cut of AC over 50% throttle position..

Air temp switch, for intercooler sprays and ice tank solenoid ..

Ecu diagnostic light, use the stock 205 one in the cluster, just triggered it via haltech ecu ..

 

Bought a bosch 044 fuel pump and (5) x 660 cc injectors

2 x oil coolers .

and 800$ in speed fittings and pipes

 

pluming part

 

 

 

pluming for water to air cooler is done, turbo water feed goes over the engine, water to air cooler gots a separate water pump and a 3 liter water/ ice tank

 

 

oil cooler build 2 x for the engine

 

 

after hearing so many drama story’s about external waste gates like surging, boost problems, etc .. I made a pressure test of the waste gate, and found a leak..!!! so I had to dismantle the waste gate, and recut the valve in a 3 angel valve cut, like I do on my engines . result is 1.0 bar negative pressure ..top sealed unit now ..

 

 

 

new over flow water tank

 

 

[magic 1 1 Cars]

 

all the pluming work is done, I used only speed flow fittings and braided hose’s 2100$ for the hole car!! auuuutshhh

 

 

dummy build I be happy how all looks so far ..

 

 

had to rewire again the Audi rs coils …

 

 

 

to make the cover fit nicely

 

http://www.aussiefrogs.com/~upload/9460/1284462287.jpg

 

fuel rail build, I cant use anymore the stock fuel pressure regulator, but I do not like the aluminum custom fuel rails, so I had to make my own system ..i run later over 35 psi boost in the overboost mode, so i need a variable fuel pressure regulator to 5 bar

 

 

more speed flow fitting’s and a new fuel pressure regulator up to 100 psi

 

 

[magic 1 1 Cars]

new fuel pressure regulator, just needs to be modified to suit my needs

 

 

 

made a new oil pressure adaptor

 

finished off the fuel lines

 

[DrSarty 90 1 Cars]

Great update Magic.

 

I was just down in Australia again, and spent some time in Hamilton Island so I wasn't that far away. Sorry I didn't get time to stop by and say hi again.

 

Can't wait to see this finished.

[Henry Yorke 269 3 Cars]

Looks great and will surpass the lazer green one for performance Nice to see all of this in a CTI still.

[un numero d'or 38 3 Cars]

So brutal!!!!!

[blessed6383 0]

this car just keeps getting better and better shame it will be your last 205 build. fantastic work mate big thumbs up

[magic 1 1 Cars]

New gear shifting system, no more worn out bushes and loose gear stick . my roller bearing system …

 

 

 

converted the turbo to struts

 

 

fuel set up

a bosch 040 pump inside the tank. And 044 outside the tank

I had to replace the fuel line as well. The dynamiter of the line is on 60 psi good for 400 hp maximal. So I had to go to dash 8 to get the fuel supply right ..

 

Took ages to build this set up ..

 

 

dash 8 new fuel lines.. return line stays stock

 

 

fitted a new black velour carpet for the boot

 

 

 

nearly done ..

 

 

 

@DRsarty shame that we didnt catch up any more .

 

@thx henry

[ultimatepug 0]

that is pureley awesome!

[magic 1 1 Cars]

New race car battery same as the nas car or V8 super cars have 1200 CCA is like 4 times more power full then a normal battery .. was a need for my car with all the fxxxk around in it ..

 

 

406 283 mm rear rotors

 

 

titanium and Teflon inside makes 1300 psi clamp pressure on 60 psi pedal pressure

 

http://www.aussiefrogs.com/~upload/9460/1285663505.jpg

 

red stuff

 

 

 

4 pod in the rears with out spacers or etc ..

 

 

 

just need to connect the hydraulic handbrake now, with bias valves+ a Mc inside the car ..

[magic 1 1 Cars]

Hydraulic handbrake set up

 

 

had to get rid of the handbrake plate what is welded to the floor panel

 

 

made the brake lines by my self speed flow Teflon version in –4

 

 

all done

 

 

old carpet

 

 

Overhauled

 

 

New handbrake and 23.8 MM Mc

 

 

 

 

all installed just needs now a adjustable bias valve a new line from the MC

 

thx guys

Edited October 5, 2010 by magic

[matty_gti 20]

Just read the topic and a lovely build!. How did you get the carpet so clean?!.

[Dj_mini 7]

Those brakes look awesome but way to powerfull for the rear of a 205!

[magic 1 1 Cars]

Just read the topic and a lovely build!. How did you get the carpet so clean?!.

 

washing, painting, and love:)

 

Those brakes look awesome but way to powerfull for the rear of a 205!

 

same as the engine, but is far more complicated as its looks right now, wait till you see the car is finish..

[bazil_205gti 22]

this is an amazing project! great effort! look forward to seeing the finished result

[whizzer71 0]

Pure Car Porn, I would have loved to been blessed with such ability to reach these dizzy heights of ingenuity and perfection !

 

[Brian M 0]

Is Aussie Frogs defunked? I can't find your thread on there any more and none of your pictures are showing on here??

 

"ANNOUNCEMENT - AUSSIEFROGS.COM and backups have been deleted by a godaddy error. AUS-CITY.COM is temporarily taking all traffic, so register here to post in AF General Forum."

[un numero d'or 38 3 Cars]

Come on Magic give us an update:)