[rally_prep] My 205 Constantly Evolving 205 Xs Road Rally Car Project

[welshpug 1,661]

xs already has the sport gear cluster doesn't it?

[tdr_1976 41 1 Cars]

Hi Mei,

 

I think it does. I used to have an excel file with all the ratios on it, including the XS's one, but I lost it.

 

The one I found on Google hasn't got the XS ratios on it

 

It would be good to find another as I can compare the ratios between the GTi/VTS and the XS clusters.

[And 15 1 Cars]

I am sure there is only 2 gear sets in the ma both have the same 1st and 2nd? Just different 3-5th and final drives the xs should have a 4.2fd and lower gear set the final drive is also found in a 5dr saxo 1.1 but the poor ratios some 1.1 206s have a 4.5fd

[tdr_1976 41 1 Cars]

Checked my striped down XS gearbox earlier on this evening, the FD is a 4:2

[samthornton1990 23]

Just a heads up, the JP4 cam covers fowl the bonnet, best off sticking with the metal J4 ones. Ended up grinding one of the braces of the bonnet on my GTI and it still rubs.

[welshpug 1,661]

the one place where an 'auto' bonnet probably helps !

[samthornton1990 23]

the one place where an 'auto' bonnet probably helps !

Well said that man! I'm just a stingy bugger!

[tdr_1976 41 1 Cars]

Thanks for the heads up mate!

 

My mate's got a J4 converted 205 Rallye with the JP4 covers, and he's got an auto bonnet on his for clearance.

 

I'm not a 100% sure what to do yet, but it's likely that I'll stick with the J4 ones - Are they really a bugger to seal up? Heard they are a problem!

Edited December 8, 2016 by tdr_1976

[welshpug 1,661]

they are a pain in the arse, no replaceable seal, just a bonded silicone strip, thats why the JP4 covers are much better with the replaceable rubber seals.

[tdr_1976 41 1 Cars]

I've decided to go with the JP4 covers and leave the coilpack cover off for now.

 

I do have a question though - Relating to the oil filter heat exchanger, I've noticed that some of the J4 engines don't have them, an the JP4's dont? Can I run without it?

[welshpug 1,661]

you can run without just fine, i prefer to keep them as they aid warmup, if oil temps become an issue you can always add sn air-oil cooler on top and use a half height filter, found on early 90's renaults.

 

a common arrangement to find on peugeot and citroen sport rally cars.

[tdr_1976 41 1 Cars]

Thanks for the info Mei, much appreciated!

 

I'll keep it on, I've already got a new seal for it, just need to get a pipe with the offtakes for it

[tdr_1976 41 1 Cars]

Some progress photos from the last few days

 

GTi Gearbox cleaned and painted

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I got lucky last Saturday and got my hands on this Genuine Peugeot 1.9 Brass Radiator

 

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I also got the cylinder head back

 

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Catcams 708's Fitted

 

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Exhaust stud kit fitted

 

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Covers on to keep the dust out !

 

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[tdr_1976 41 1 Cars]

Just took one of the new head bolts out of the box and found that there's no spacer on it.

 

It's exactly the same length from the base of the spacer, I think it's ok but could do with a second opinion before I go ahead with the job later on.

 

[tdr_1976 41 1 Cars]

Another update.

 

Got the engine rebuilt, after I decided against using the cylinder head bolts without the friction washers on.

 

A few progress photos of the weekend before last;

 

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[trogboy 17]

Looking tidy!

[East_Hud 7 1 Cars]

Engine and box look great!

[tdr_1976 41 1 Cars]

Cheers chaps

 

A few more photos to add from last weekends progress;

 

Engine and box bolted together, on the engine hoist ready to go in

 

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That's where it's up to at the moment. Got a lot to do still, sort the wiring loom out, make an exhaust manifold, replace the xs tank with a GTi one, run a return line from the engine bay to the tank, oil catch tank etc etc.... will keep updating this as I go along

Edited December 21, 2016 by tdr_1976

[Graz 1]

Does the lightweight crank and alternator pulley gear down the alternator so it produces less power? Not exactly what you want with a big pair of spots or have you figured out its not a probelm?

I always come to your thread for inspiration for mine.

[tdr_1976 41 1 Cars]

Does the lightweight crank and alternator pulley gear down the alternator so it produces less power? Not exactly what you want with a big pair of spots or have you figured out its not a probelm?

I always come to your thread for inspiration for mine.

 

Hi matey, I'll find out when the project is completed and have the spots fitted for testing

 

In the meantime, I have the small matter of sorting the wiring loom out...... not going well at all at this stage.....haha!

 

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[toolie72 67 1 Cars]

Looks standard-well done that man

[tdr_1976 41 1 Cars]

Thanks mate!

 

Made some good progress today, modified a 106 induction kit to fit, and fitted the new oil catch tank and pipes;

 

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[opticaltrigger 52]

Very,very nice Dyl.

 

O.T.

[welshpug 1,661]

no breather on that can? I think you will need to tee the two hoses together and add a breather filter to one of the two ports.

 

 

far too shiny for a rally car

[tdr_1976 41 1 Cars]

Hi Mei, I'm going to add a offtake for a filter on top of the tank :-)

Edited December 31, 2016 by tdr_1976