[engine_work] Its Not Size That Matters

[iamjackiechan 0]

Hi

Ive been on the forum a while now and never introduced my car so i think its time.

 

It started life as a standard miami 1.6 i bought off ebay for £600, not in great condition and the paint had faided badly on the bonnet and roof.

 

as i have abit of a fetish for matt black the first thing i did was paint the bonnet to cover up the bad paint.

 

Within a couple of months the engine decided to give up and i thought it was a great oppurtunity for a project. I was studying motorsport engineering at brooklands college and decided i was going to do an engine conversion and track prep the car for my end of year project.

 

This consisted of an s16 engine on carbs, cage, bucket seats, gti6 brakes etc etc.

 

This went great, pulled really well and was alot of fun to drive. But always felt like it was missing something.

 

After having it on the road for only 7 months i already wanted to move onto something different, prefferably boosted and i wanted to do something different to the usual conversions.

 

By coincidence, at the same point i was thinking about this a good friend of mine was breaking his s1 106 rallye track car which a few people may have seen before.

 

this car had soooo much time and money spent on it and went unbelievably well with a little something special under the bonnet.

 

It had been turbo'ed to a very high spec, dp engineering manifold, tiel external wasted, ceramic coated pistons, the list goes on.

 

There is a video of it on youtube:

[Paul_13 212 1 Cars]

Fair play good on ya, be good to see how it performs

[iamjackiechan 0]

I bought the engine off him for an amazing price that i couldnt turn down, so the task of fitting it now begins.

 

Before i took the s16 out i welded the middle box of my exhaust system out and when i wasnt looking, a friend welded something else on the exhaust.

I think it might make it abit hard to sell on lol

 

I wanted to make it into a more track orientated road car so i ditched most of the interior and made my own control panel in the centre consol.

 

I picked the engine up off my friend and i think it looks like a work of art.

[iamjackiechan 0]

I had a 309 beam on the car that had never been apart and was deffinatly not in good shape so after a few emails to anthony i part ex my beam for a freshly rebuilt beam that looks awesome, cheers anthony.

http://i766.photobucket.com/albums/xx306/i...an/IMG_0393.jpg

 

Im the type of person that randomly buys when i shouldnt, so the first thing i did even before the engine was in is to buy and fit an intercooler. i must have abit of pikey in me as ive always wanted a big intercooler sticking out the front of the car and i know a few of you will hate it.

 

you can see in the second picture how much i have had to modify the bumper and push it forwards for it to fit

 

I then purchased and fitted an air intake temp sensor off ebay and fitted that in the dash.

 

and yes that is actually how hot it was in my car.

[iamjackiechan 0]

I forgot to say that the engine made 155bhp at the wheels and is only running 15psi, once ive got the engine running im going to up the boost to 20psi and il be hoping for around 200bhp at the wheels

considering the engine weights nothing and two people can lift it, the handling should be considerably improved aswell.

 

the stage im at at the moment is trying to mount it, as you may know i got an xs top mount which was too short

i then bough the longer tu top mount and its way to long

so i have now decided im going to make my own mount and have started by making the bottom plate of it

 

cheers will

[calvinhorse 870]

i think your gearbox mount is wrong, the longer of the two mounts should fit, you need a tu 205 gearbox mount

[iamjackiechan 0]

oooooh really

ive got a 106 gti box on it, is there a difference?

can i bolt the mount onto this box?

cheers will

[calvinhorse 870]

yes the mount will bolt on but your driveshaft seal needs to be left sticking out to make it seal. im not sure how much but its been covered before

[welshpug 1,657]

driveshaft seals should stick out by 1.5mm r so IIRC anyway.

[calvinhorse 870]

D ne ne ne ne ne D ne ne ne ne ne WELSHPUG!!

[iamjackiechan 0]

fanny tastic

so what model tu do i need the mount off?

anyone got one they want to sell?

 

cheers will

[welshpug 1,657]

I'd guess any TU engined 205...

 

 

and on checking servicebox, any Tu engined 309 and 405 too, its part number 181324 and costs £28.34.

[iamjackiechan 0]

Cheers for the help welshpug, I'm gonna give this a go, hopefully sort my problems.

 

Will

[miamichris 9]

I'd guess any TU engined 205...

 

 

and on checking servicebox, any Tu engined 309 and 405 too, its part number 181324 and costs £28.34.

 

Ignore me, i'm talking bollocks got confused and thought you were talking about the rubber mount, not the metal bracket!

Edited June 23, 2010 by miamichris

[All Praise The GTI 3]

thats a fairly awesome engine mate, keep us posted

[iamjackiechan 0]

Bit more progress today.

 

Firstly a big thankyou to calvinhorse about the gearbox mount you were spot on.

I went to the scrapyard this morning and got a tu gearbox mount and after alot of jiggery pokery i got it in

 

I then fitted the manifold, turbo and downpipe.

The turbo sits out quite far and so the radiator doesnt fit, i think i will have to bring the radiator all the way forwards and mount a fan on the back (which hopefully wont get melted by the turbo).

the slam panel and bonnet will also need chopping to allow the wastegate to stick through or il re-direct the wastegate, havent decided yet.

 

It kind of feels like ive done alot of work to find out ive got even more to do lol

 

cheers will

[welshpug 1,657]

nice to find the solution, just think if you had carried on with fabricating the right hand mounting you'd have had issues with the driveshafts further along the line because the engine was shifted over to one side.

 

Once you get it running, I'd get looking to do a TU-BE4 conversion, the MA won;t last long with a turbo.

[iamjackiechan 0]

This is very true, if I would have made that mount I'm sure I would have had plenty of problems along the way.

 

I'm not to sure on the codes for the gearbox's, but I don't really want to run this 106 gti box as I've heard they are weak and the ratios aren't very good, my friend that ran this engine said the best box was the Rallye one as it made the car feel frantic but lower top speed which I'm not fused about.

 

Which is this gearbox you mention

 

cheers will

[iamjackiechan 0]

Hi

Bit more progress today only to encounter more problems to add to the list.

I began by trying to fit the drive shafts only to notice a massive difference in size on the hub end.

Im using gti6 brakes and hubs which i was using 1.9 driveshafts with and the shafts i bought which i pressumed would work are 205 xs. Obviously something isnt right.

 

Would i be right in saying that the splines on 1.6 and xs shafts are the same and what i need to do is by 1.6 hubs?

Also, will my gti6 brakes fit onto 1.6 hubs.

 

Ater that i fitted the inlet manifold.

There is huge amounts of space all around the inlet manifold which im sure will come in handy.

 

Another problem i came across is that my friend was using rose jointed gear linkages with this gearbox so the ball joints have been drilled off which you can kind of see from the picture.

So my next question is, does anyone know were i can by bolt on ball joints for standard style gear linkages.

 

cheers will

[welshpug 1,657]

re-driveshafts, yes indeed, base model hubs and shafts required if you want to run gti6 brakes with that engine and box combination.

 

Miles does some linkage balljoints.

Edited June 28, 2010 by welshpug

[Paul_13 212 1 Cars]

Good to see you hammering on with this, would be good to come over and see it.

 

As WP says Miles sells these. If not i've got one spare.

 

Sorry about not getting back to you about gearbox. Turned out I didn't blow mine up

[iamjackiechan 0]

Hi

I do spend most of my spare time cracking on with it as there is alot to do.

Well money is the only thing slowing me down so hoping that I can get enough money to finish it soon il be bringing it along to ace cafe and all the meets I can.

Cool, il send a pm to miles.

Not a problem about the gearbox.

Cheers will

[allanallen 528 2 Cars]

This should make a cool little car. Is that a screamer pipe pointing outof the grill?

[iamjackiechan 0]

Technicaly not the same thing but very similar, it's an external wastegate that likes to pop flames and sounds very much like a screamer pipe.

[GLPoomobile 958]

So what is a screamer pipe exactly? I always thought it was just a fancy name for what is essentially the exhaust pipe from the wastegate, but simply not plumbed back in to the exhaust system so it's completely unsilenced