[project] Sarty Evo II - Phase 2 Of Project Sarty

[Batfink 201]

I was down nr Exeter yesterday for work so popped over to Colin to drop off some parts. Had a good chat to him about this car and a few others

Its looking good. Will look very nice with its new coat of paint in the bay. Not sure that it will have no squeaks or rattles without a full cage but it will certainly be a lot better

 

K.

[Galifrey 1]

About time this got moved to "large scale and special projects" isn't it?

 

 

Any updates for us Rich?

[shalmaneser 26]

Any chance of some more pics?! I'd love to see the progress!

[Batfink 201]

I was just down there on wednesday and theres no real progress. I think its going down to the paintshop next.

I dont know if Colin will be working on Sartys car until he gets his mate in to help in about a week.

 

K.

[hexhamstu 9]

Someone take some more photos!

[DrSarty 90 1 Cars]

Colin's got swine flu!

 

But the next pics you should see will be the car in white, with the Xsara rack fitted and on its wheels.

[Galifrey 1]

WTB: Updates

 

[DrSarty 90 1 Cars]

Pictures coming from Colin soon. It's all painted now apparently.

 

Pico outer injectors and 'brand X' inner injectors ready to go in.

 

Saxo electric PAS pump en route, and maybe even a heated windscreen.

 

I'm home again in 6 weeks to put her on the road. Very excited.

 

[Batfink 201]

hows the weekend gone? I'm looking forward to how its turning out.

Edited January 31, 2010 by Batfink

[Galifrey 1]

hows the weekend gone? I'm looking forward to how its turning out.

 

Yeah come on, lets see it!

[Cameron 16]

Rich, how much longer than standard 205 wishbones are those 306 ones, and do they fit in the 205 subframe?

Sorry if this info is already in here, I just can't be arsed to try and find it.

[DrSarty 90 1 Cars]

Rich, how much longer than standard 205 wishbones are those 306 ones, and do they fit in the 205 subframe?

Sorry if this info is already in here, I just can't be arsed to try and find it.

 

^^ Plus the other comments above.

 

Don't be expecting anything radical this week. I started on it today, but it was in the air on the ramp with Colin meticulously ensuring the bump steer was minimised. He had to modify his modified 205 rack, to raise the steering rack.

 

This got it all sorted, but then meant different amendments to the CV joint shaft on the Xsara VTS rack to make it mate into the 205 column. It also means a minor bulkhead mod to ensure full clearance as it doesn't sit centrally in the original steering column bulkhead hole; it's right at the upper edge.

 

This rack is already modified (and strengthened) to fit the 306 'bones, and I'm afraid I'm not sure how much larger they are, although I think Colin has modified/built custom brackets to house the wishbone balljoint system. This could be where the extra length has been taken up.

 

He is fitting Kevlar bushed, rose-jointed steering arm ends, and tomorrow when we drop in the 2.2 engine (that I removed from my red car) he will be able to see how it all fits, giving M/C clearance, bulkhead clearance, subframe & gear linkage clearance etc, and most importantly, whether the Gaz springs are how he wants them. He has a sneaking suspiscion that the current once are a tad too long. All will become clearer once the power plant's in.

 

We have the Xsara 283mm discs fitted, which are actually a thinner variety than other 283s apparently, and also we have 406 calipers coming with the 51mm piston, which is the largest of 3 varieties apparently available. This thing should stop very well indeed, but not be overly heavy, easy to replace with OE parts and not silly expensive. K.I.S.S.!

 

The valance, grille and spoiler have all been painted, as has the entire engine bay, underside, wheel arches and boot. It's whiter than a white thing that just saw a ghost.

 

I'm sending all the 8 injectors away for cleaning tomorrow, and ordering some Magnecore 8mm custom HT leads to suit the new higher power Chevy coils.

 

Once the engine's in, I can also mock up the loom and make a peg board.

 

[DrSarty 90 1 Cars]

Mainly pics now. Car can go in its wheels on the ground (off the ramp) tomorrow. The engine is now fully prep'd.

 

Please remember the engine has over 8,000 miles under its belt, and hasn't missed a beat.

 

Cylinder head - exhaust port side.

 

I don't use a gasket, choosing instead Loctite 5920 which is the copper coloured stuff. However it needs heat to cure, and my engine sat cold for 6 months with the manifold fitted before it started, and hence a small blow (upper most) got worse.

 

Removing the PITA studs.

 

Nice and clean; all stud (exh) and screw holes (inlet) 'chased' and check-tapped. All swarf and removed carbon blown out.

 

New stainless, allen key head M8 x 50mm studs....and then with Aeronuts ready for fixing.

[DrSarty 90 1 Cars]

In the last pic you'll see I have the alloy S16 (+) water distribution housing/union on the back of the block.

 

This is more robust than the plastic ones, and has only 4 outlets: 1 lge to rad via captive metal side hose, and 3 (usually) for exp tank, heater matrix upper (with bleed screw) and oil heater exchanger (on the front of the block). I am doing away with the heater exchanger, choosing to assess the recently collected advice that like on a 1.6 GTI, in this country it's not needed for road use.

 

This saves plumbing, complexity (more to go wrong) and weight. To this end I found a PSA original union bung to use. This is a 2inch long closed-off/dead end rubber hose which you jubilee clip on. I could've had it TiG welded up but that would limit future changes/options.

 

The old clutch was FUBAR, especially the ends of the central splines. Here's the flywheel before keying and then the Techniclutch (varying reviews heard on these - I shall take the risk) fast road clutch fitted, courtesy of an input shaft loaned by Colin, who is next seen finishing the welds on the 'slugs' fitted to raise the Xsara I VTS rack.

 

The Xantia lightweight 283mm disks. Just a/w delivery of the 406 (51mm) calipers, to run Ferodo DS2500s.

[DrSarty 90 1 Cars]

Finally the inlet side of the engine, showing the remanufactured 70aH alternator (on its Audi tensioner) and lightweight alloy crank pulley fitted. The latter is very nice indeed. Thank you Miles.

 

The lightweight Valeo starter motor - which I tested as per Surgie's method - is quite different to a std starter motor.

 

The cam cover and 2 cam end caps are going away to be powder coated red to refresh the top end of the engine, and Magnecore are making a set of 8.5mm red HT leads to mate the coils to the plugs.

 

Throttle bodies are getting their Pico injectors in a customised rail, and a thermal barrier gasket (like a PTFE one but not) is being machined to go between the inlet manifold and head whilst I go back to 'the office'.

 

***

On a side note, many of you know I work in Afghanistan. When I was last having lunch at camp Bastion, I sat at a dining table only to find Mike Brewer - he of Wheeler Dealers and Ed China fame - sat opposite me.

 

Here we are after an enjoyable 2 hour chat in his tent. The photo was his idea. He was a really good egg, and I praise any TV personality (non typical journalist) who comes out and 'beds down' with the troops.

 

He was with Discovery making a new series on British military fighting/armoured vehs out there on ops.

 

He said he was insistent that the new, 1 hour-long Wheeler Dealer episodes currently in final production would be his list of 20 classics or none at all.

 

Expect to see a Sapphire Cosworth and a Jensen Interceptor. Apparently HD is very tough to film, as detail on everything shows up and lighting is even more critical.

 

He also gave me advice on how and where to find my goal car - a Lancia Delta Evo III. An Evo II (this Pug) and an Evo III will be enough from here on in.

 

This project will have to wait until April 15th when I finish in Afghanistan for good. Then it has to be ready for Ecosse 2010, to hoon them there Highlands.

Edited February 5, 2010 by DrSarty

[Daviewonder 533 3 Cars]

Did you mention "that" episode to him?

[DrSarty 90 1 Cars]

Did you mention "that" episode to him?

 

Yes. He said he'd never really noticed, although he said it was probably edited to make it look that way as a result of time constraints.

 

Extremely nice fella.

[Batfink 201]

its starting to take shape nicely. It will be interesting to see whether you need the heat exchanger. With your longer stroke do you rev as high as the standard engines?

Two things - did Colin get the brakelines? and is that my 205 in the background....its got doors!

Edited February 6, 2010 by Batfink

[SurGie 54]

I agree with the above ^ it is shaping up nicely there Rich.

 

Mike looks like he's put on some weight since the last time i seen him. The one hour episodes sound good enough to watch

when it pops on the TV.

 

George

[B1ack_Mi16 67]

its starting to take shape nicely. It will be interesting to see whether you need the heat exchanger. With your longer stroke do you rev as high as the standard engines?

Two things - did Colin get the brakelines? and is that my 205 in the background....its got doors!

 

It's not that much more stroke is it

 

I run 8000rpms on 94.5mm stroke, no problems with that so far

[DrSarty 90 1 Cars]

^^Agreed, It revs just fine, although you can feel the power tail off at about 6.6k. The remap on the staged injectors may find more top end, but I'm really interested in getting more area under the curve.

 

Engine: Going...

 

Going...

 

In...

 

(Lots of 1.6 GTI donor car parts available FOC if collected in a For Sale thread posted today.)

[welshpug 1,657]

Love the fan and radiator support, cant imagine why more people don't do that, I hate seeing cable tied fans!

[rubyna 4 1 Cars]

looking the nuts Rich..

[kyepan 291]

Colin meticulously ensuring the bump steer was minimised. He had to modify his modified 205 rack, to raise the steering rack.

 

Without asking colin to give too much away, even though asking this is essentially giving it away, roughly how much does he raise the rack to get rid of the bump steer? TBH I was not aware that the 205 suffered from much bump steer, not compared to the pulsar (a veritable plough) when it was lowered.

 

edit - Just had a bit of a read up on bump steer, can see why a lowered anything with mcpherson struts would be more prone to bump steer.

 

We have the Xsara 283mm discs fitted, which are actually a thinner variety than other 283s apparently,

307 Hdi 283mm x 26 brake disc-----6.9 kgs, i wonder how much lighter the xsara ones are?

 

 

nice to see things progressing sweetly.

 

cheers

 

J

Edited February 9, 2010 by kyepan

[Sandy 191]

I was aiding Colin with the rack location and it's not linear, the best height needs to be decided by testing with it all built up without springs and obviously with the necessary gauges. We narrowed it down to two quite different positions, then chose the best one. A small amount up or down wrecked it!