[project] Peugeot 205 Twin Turbo

[wracing 19]

i have started a new thread as the direction of my project has changed and im shelving that specific idea of twin charging an XU10 lump. to take its place i have decided to go for a twin turbo route, something i haven't seen done before on a 205.

 

just to catch up, the shell that will be used for this project started life as a 1.1, soon after it came into my possession it received a 1.9 8v which was rebuild. after a few track days a few issues where highlighted. handling and lack of power.

 

the 1.9 was turbo'd with a hybrid t3/tb25 turbo and ran very well on mega squirt managment.

 

the cars current spec is:

 

1.9 turbo megasquirt managment

avo gtx coilovers

266mm front brakes

compbrake brake bias box

309 rear beam with rear discs

diy cage

various other bits that ive forgotten.

 

over the next few weeks we are looking to achieve

 

2.05l twin turbo with forged pistons and rods, gt42 and t4/t3 hybrid on the turbocharger side and cat cams turbo billets. again on megasquirt management

custom cages multipoint (waiting on delivery)

seam welded chassis

custom dash

spec to conform with fia/msa regs for hillclimbs and rally

 

 

 

looking to crack on this weekend and get her ready for the new cage and lump.

 

thanks

 

james

[Daviewonder 533 3 Cars]

Sounds good, gonna be following this one (again)

[DanielKamar 0]

So twin turbo ahn.. Seems you take the "power is never enough" way too serious!

 

Good luck on the project, looking forward to the updates! Thumbs up m8!

[pablo 0]

really struggling to see the point mate but fair play and all the best

[wracing 19]

because i can really, an engineering challenge, bored of bolting shiny bits on, want to do something a little move involved. if you've driven a compound turbo before you would understand

 

 

thanks

 

james

[rescue dude 0]

If you intend to hillclimb, it would be classed as a Sports Libre due to the turbo's.

[Henry Yorke 269 3 Cars]

With such investment in expensive bits like Cat Billet cams etc is it not worth using a "proper" ecu as opposed to a Megasquirt? This means rolling road experts can map them better for the right power delivery you need as they tend not to like Megasquirt

[wracing 19]

ive built on my megasquirt to a point that it would be uneconomical and silly to change ecu. with a expanded feature set and integration to our navigation software i can't justify changing ecus. ive got a mapper over here in norfolk he is happy to use megatune.

 

thanks

 

james

[hcmini1989 16]

nice work mate .is it an 8v turbo now or is it an mi engine your using at the minute .should be a real weapon when your done

Edited February 13, 2010 by hcmini1989

[wracing 19]

more work today....

 

i finished the manifold

 

 

while simon set about removing the engine i started on the clearance issue we have been having.

 

 

once cut i rolled the edge to give the steel its strength back and increase space even more

 

 

and before you knew in the engine was out

 

 

bye bye 8v turbo....

 

 

hello 16v

 

 

 

 

this is the image im left with......

 

 

 

hmmm

 

and just for a laugh...

 

 

 

more work tomorrow, god knows how i got the missus to ok that one!!

 

thanks

 

james

[wracing 19]

i forgot we have had to edit the front end a little:

 

 

front cross member gone

 

 

more excess steel shed.

 

 

thanks

 

james

Edited February 13, 2010 by wracing

[hcmini1989 16]

looks absoloutley brilliant mate .how good a welder are you .i.e a proffesional .and what are you using to cut the manifold tubing at the right angles or are you buying them pre cut .

 

i take back what i said before about it being a weapon more like a monster

[danpug 1]

Fancy selling the exhaust manifold off the 8v engine?!

[wracing 19]

this first prototype that i have done, i've cut the manifold by hand with plasma or grinder, then welded together and finished and ported with a die grinder, oh i forgot i pack purge with a bit of argon to stop caking and slag.

 

im not a professional self taught taken advice along the way, welder. more than good enough for a prototype. any manifold that i may produce will be welded by a friend who is a qualified pipe welder.

 

for the moment im looking to keep the manifold but everything has a price pm me!!

 

thanks

 

james

Edited February 13, 2010 by wracing

[davey sprocket 14]

WOW, hats off to you fella, that's bonkers!! Look at the size of that new turbo against the old one .

 

It was a fairly unmistakeable machine before with the intercooler hung outside the front but now with that turbo sticking up there.... crikey!

[zebedy101 0]

Just looked through this topic and your manifold topic james I'm really very impressed it looks awesome and will certainly be mental. How will you put all that power down without spinning through every gear? I will have to come and have a butchers at some point. Nice work :-D

[wracing 19]

your welcome to pop round at any time mate, i would say you can come a muck in but we are working on her at work and only me and simon are covered by our public liability insurance

 

as far as power is concerned an lsd, 245 tyres and traction control will work for eurotrip if the powerplant proves reliable it will be going in the rear!!

 

unfortunately the trademark intercooler has to go behind the bumper to get her through an mot as there are to many sharp edges to cover. but i we will make up for it some how!!

 

thanks

 

james

[wracing 19]

more work today.

 

simon started cleaning the gearbox for refitting and mocking up, as well as the gearbox

 

 

i got on with mounting up the larger turbo

 

 

unfortunately we had to use a different type of bend which ment grinding off all of the galv inside and out all to make the turbo fit!!

 

 

once welded i made another merge collector out of 2" pipe to mate up with the t6 flange, we will be using a quick spool valve to half the a/r of the housing its currently 1.28 but we have a 1.01 on order!!

 

fitted both turbos looking really good i think. when the engine is off for rebuild im going to weld strengthening webs ontothe manifold to support such a large frame turbo.

 

 

 

trial if in the car highlights a few issues that will addressing,

 

 

the exaust side is going to be a pita to plumb!!

 

thanks

 

james

 

[pablo 0]

what on earth are you going to do with the bonnet?

[wracing 19]

auto bonnet lifted at the rear with a bulge in it engine will be 1" lower than what is shown.

 

thanks

 

james

[pugpete1108 62 1 Cars]

saw these pics on facebook, you are one craaazy mo fo james.

 

hat off to you fella, keep us updated

[wracing 19]

more work today. im particularly pissed off with custom cages, after been messed around with delivery dates, it turns out that my main hoop was over 40mm to tall. 800 pounds an it doesn't even fit, so i have had to modify the main hoop, in the process ive trashed my roof skin. that im pretty pissed about but ive got a friend that should be able to sort it. i guess every project has to have its hickups.

 

 

the cage all laid out im thinking this is going to be easy!!!

 

first rear foot in these are the only datum you have as there are no measurements

 

 

roped dad in two engineers better than one!!

 

 

second rear foot

 

 

the old cage was a bitch to remove, i must have done a good job!!

 

 

little bit more work on the turbos. covered the manifold in swarf don't worry that's not weld splatter!!

 

 

 

more updates tomorrow!!

 

thanks

 

james

Edited February 20, 2010 by wracing

[Daviewonder 533 3 Cars]

Hi james please excuse my ignorance but whats that thing with the cooling fins coming off the manifold?

 

Dave

[wracing 19]

its one of the waste gates ebay jobbie rebuilt with proper diaphragms. this 50mm one is used to bypass exaust in to the larger turbo, there will be another 38mm waste gate that acts as final boost control

 

thanks

 

james

Edited February 20, 2010 by wracing

[Batfink 201]

Most cages are supplied longer so you can fit them perfectly. My safety devices one was. It allows you to but the cage right up to the roof.