[project] 205 Turbo 8 Valve Build

[NickMi 0]

Hi all,

This 205 started its life as a phase 1 d-plate 1.6 gti non-sunroof. The car had been stood in a kids driveway for years as he wanted it for the engine. I did a deal with him and took the engine out and fitted it to his other car in exchange for the rolling shell.

I took the car back to my work, stripped it bare, spent hours removing all the underseal, had it sand blasted and welded in a rollcage,this is how it looked:-

[Galifrey 1]

Nice start, watching with interest

[pablo 0]

indeed, more soon please!

[NickMi 0]

After the shell had been blasted i set about stitch welding every seam and then seam sealing them.

Then i welded in a new front panel which i modified to lower the radiator and bring it back.

Also fitted two new front wings and cut them out as i plan to run 306 wide track and low ride height.

[cybernck 402 1 Cars]

Ooh, nice - more please!

[Galifrey 1]

Ooh, nice - more please!

 

Indeed

 

[NickMi 0]

Ok next thing was i welded in some door bars and primed the whole shell inside,outside and underneath.

Then i mock fitted the front wide arches and front valance

I also started mocking up my custom made manifold and downpipe to engine

I will update with full engine spec when i have more time as its boxing day and i have had a few beers!

[205freak 7 1 Cars]

Looking awsome, please post more pics???!!!!!

[NickMi 0]

Ok here is the shell after i applied opel 2k silver inside,outside and underneath followed by lashings of laquer. I painted it myself and considering i have only ever painted a few bits and bobs i think it turned out ok.

[tezza 0]

that looks amazing mate. great job on the paintwork as well. very impressive. what splitter is that on the front bumper? picture quality isnt the best

[cybernck 402 1 Cars]

Slightly reminds of pdd144c's old build:

 

http://projects.205gtidrivers.com/pdd144c

 

There's some inspiration for you .

[NickMi 0]

Slightly reminds of pdd144c's old build:

 

http://projects.205gtidrivers.com/pdd144c

 

There's some inspiration for you .

 

Funny you should say that as i have a picture of that car as my screen saver and it has been a big inspiration for this build.

Any idea what happened to that car?

I was going to do a 16valve turbo engine aswell but decided to go for something a bit different.

[danpug 1]

What's the engine spec?

[NickMi 0]

Here is an update with a few more pictures.

I have fitted my polycarb rear quarter lights with new genuine non opening seals which were a small fortune.

The OMP seat fitted has now been removed in favour of a side mount corbeau sprint and a corbeau pro race carbon/kevlar drivers seat.

For those interested the engine spec is as follows:

 

Citroen xm 2.0 turbo base unit,

Cylinder head stripped and acid dipped,all valve and guides replaved for new,lightly ported,CAT CAMS stage 3 turbo cam fitted and re-shimmed,Multi later steel head gasket.

Block stripped and acid dipped,Re-bored to 87mm with forged pistons, Rods shot peened and polished fitted with arp bolts,Crank checked Knife edged and balanced with rods,pistons,flywheel etc. All new bearings and seals fitted

Inlet ported and fitted with Cosworth cream injectors and FSE pressure regulator,Dta ECU with custom loom.

Stainless steel tubular exh manifold with T34 turbo and Stainless downpipe with 36mm external wastegate.

RS500 front mount intercooler

[dcc 855]

seriously impressive looking build!

[danpug 1]

Thats going to be an animal. Have you had it running yet? And its a home made manifold?

[pablo 0]

hi mate couple of Qs

 

1. is the air filter pipe safe that close to the timing belt?

2. do you need the filter on the filler bottle? Given its vented at the catch tank.

[NickMi 0]

Hi guys

To answer a few questions,

I have to run the air filter where it is unless you guys can think of a different routing?

The reason for two breather filters is that i have had past experience of these engines breathing quite hard.

And yes the manifold is "home made" but its not a bodge up,I have a guy who makes manifolds and custom motorbike exhausts for a living, He tig and mig welded the manifold and its a work of art. Shame to cover it with heat wrap!

[pablo 0]

aye my filter piping goes where your turbo is! Can you even fit the cambelt cover to stop them rubbing?

 

Know what you mean about the breathing, can feel mine phut phut phut out the pipe when idling.

[NickMi 0]

Hi guys,

Another quick update, I stripped the rear beam and the nearside inner stub was worn with bearing pitted marks. I knocked out the bearings and seals and cleaned everything up, Fitted new bearings abd seals and one new inner stub from GSF.

I have also fitted an 23mm ARB from a citroen saxo vts using some custom made end plates.

[pablo 0]

Slightly reminds of pdd144c's old build:

 

http://projects.205gtidrivers.com/pdd144c

 

There's some inspiration for you .

 

wow, looks amazing!!

[danpug 1]

Are you able to get the manifolds made up again and if so what sort of cost?

[taylorspug 7]

Are you going to use ballast resistors with the Cossie injectors, as they are low impedance IIRC?

[pablo 0]

cossie beige injectors (701s) are std on an XU10J2TE, if they are the ones you mean.

[NickMi 0]

Hi guys,

I have said they are cosworth injectors but they are cream in colour and have four needle holes, they are weber injectors and when i rang webcon he could not tell me what they fitted just that they had a huge flow rate. I will have to check the reistance when i get back to work but that is a good point made. I think i can change the resistance settings on my dta ecu. Might explain why when i had it running it overfueled badly and ran lumpy.