[engine_work] White 205 Gti6 Conversion

[chipstick 382 1 Cars]

So then it was off to Combe. A great day out with no issues at all with the car. Didn't miss a beat.

 

 

 

 

 

 

 

 

 

 

 

Edited July 21, 2012 by chipstick

[chipstick 382 1 Cars]

 

 

 

 

 

 

 

[chipstick 382 1 Cars]

Cocking the ole leg

 

 

 

 

 

[wilyoldave 0]

Looking good Dan,

[chipstick 382 1 Cars]

Back to present progress, Today I removed a few bits from the engine bay ready for some new additions.

 

 

Started to feed the DTA ECU loom through

 

[CaptainK 11]

Awesome work Dan, and I'm so pleased to see some of "her" bits being used as intended (I assume the GTi6 brakes were the ones off mine?)

 

Look forward to pictures (and videos) of when the "other" new additions are fitted

[chipstick 382 1 Cars]

No, the GTi6 brakes were off one of the ones I broke last year. Your's had a siezed slider so Russ_T had them to rebuild and put on his 205.

 

I finished wiring the DTA in yesterday. Fingers crossed I haven't messed it up. I did spend a fair amount of time writing down wiring numbers, pin locations and traced them back to my car - so hopefully it should work. If not, I wouldn't know where to start as I purely mirrored how it was when I removed it.

 

The only issues I have come across are some of the loom plugs fitting on to some sensors. I think there may be a chance that some of the sensors need the locating lugs smoothed off so the universal plugs can slide onto them fully and clip home. They are labelled so it's not as if I have them in the wrong place (but I wouldn't put it past me).

 

Made the mistake of starting to polish the Colin Satchell inlet and will have to polish the whole bloody thing now

 

Off to pug shortly for an inlet manifold gasket so I can get the bodies on over the next few days

 

Just have to somehow straighten the filter backing plate out then. The trumpets aren't budging out the way to remove the plate, but I'l have more purchase when it's bolted to the head. May be a job for Sandy. I will need a couple of replacement trumpets anyway, so may leave it for when it's mapped to be done at the same time.

[chipstick 382 1 Cars]

 

Finished wiring. Obviously needs a tidy up. I am going to leave that for when it's running incase I need to swap any wires over.

 

 

Fitted the single coil pack and leads. Noticed the servo looks a state in that pic, so that will be painted at some point - probably when I change the master cylinder over. The bolrs that hold the pack on will also be changed for stainless items when I have a sec.

 

 

Spent a bit more time polishing the inlet. I will have to sort that throttle cable bracket also. I didn't really want it shiny, but the ali was oxidised and very dull. It was either that or try and improve it - so I'll live with it. Will dull back down after a while anyway.

[chipstick 382 1 Cars]

It runs!

 

Will jot some more details down later.

[CaptainK 11]

It runs!

Hurrah! Videos and pics please.

 

Talking of pics, I'm very surprised to see the ITBs in that state (all oxidised and stuff). I guess the various "storage" places kept it with the bonnet open and the elements have all got in. I guess the sitting around was what also affected the brake calipers as I didn't have any problems with the brakes prior to the accident - she "anchored on" very well upon seeing a lorry come towards her

Edited July 27, 2012 by CaptainK

[chipstick 382 1 Cars]

So where did we get to..

 

I had the car up and running with the bodies on so that was a relief when it fired into life for the first time without any head scratching over wiring. I am suprised to be honest

 

I had a few little jobs to do, so I started by removing my front bumper and looked at lowering the rad. The radiator was forcing against the filter and blocking a lot of air flow. I initially grabbed some 6mm thick steel brackets and got them bent, but after many 'WTF 6mm' comments I decided to go to plan C and had some bits of ali cut and bent up which are ideal for the job.

 

 

 

Popped in some rubber grommet whatsits with a metal bobbin in just the right size. I figured if it needed to lean slightly I would have the adjustment there.

[chipstick 382 1 Cars]

 

The existing backing plate was 'slightly' bent, so I purchased a new one along with a new ITG JC40/40 as the existing one had a rather large chunk missing from it.

 

[chipstick 382 1 Cars]

No pics of the radiator in it's new lower position. I would say it's been lowered a good 100mm or so. The top of it is about 5/10mm away from the bottom of the filter. I popped the fan cowling back on and cut the slam panel around the filter.

 

I then realised the bonnet bracing was pushing on top of the filter. I cut part of the top bracing out and it now clears. It has weakened the bonnet slightly - but luckily the Aerocatches keep it firmly closed. I certainly wouldn't want to run this setup with a standard catch, yet I wouldn't really want the filter being forced down either.

[chipstick 382 1 Cars]

So after my trackday earlier in the year I caught the bug. Unfortunately due to taking the car off the road during the summer to sort these bodies out, and other commitments I haven't actually got back out there, but will book a day for next month or perhaps Oct.

 

My intial thoughts after taking it out for the first time that the power was good, braking very good but the let down was the suspension. I was going to live with it for a while, or perhaps long term and just use the thing. After all, I don't usually keep my weekend cars for very long and get more enjoyment out of making changes rather than driving them, but figured after investing a fair bit on it - I may as well do what I wanted to it. I knew that I couldn't justify spending serious money on it chasing big power etc, so decided to effectively go for a 'mild' track setup.

 

I came across the Gaz group buy on here. I know Gaz don't always get the best feedback quality wise - but I have always heard good things about their customer service and for what I want, they should be more than up to the job.

 

 

I did contemplate getting the car up on axle stands, fit the fronts and then source a beam and rebuild it over time. I have become a bit of a realist over the past year or so with this car, so figured it wouldn't be done in a short time period - and the 'summer' would have been and gone by the time it was back on it's feet. So I have decided to get the thing mapped, enjoy it for the next couple of months and then go all out on it over the winter. I have a cage and some seats stored away waiting to go in, so they can be done at the same time so that next spring, I can actually get in the thing and use it without having several wish lists.

 

So that's where we are. It's off to Sandy on Wednesday to be put through it's paces. Hopefully some enjoyable sunset coast runs to follow shortly

[Wes 86 1 Cars]

looking good mate. give me a shout when you get it back and we can go for a blast somewhere.

[chipstick 382 1 Cars]

looking good mate. give me a shout when you get it back and we can go for a blast somewhere.

 

I'l hold you to that. I'm surprised there's been no local meets arranged over the summer.

[allye 530 3 Cars]

Looking Dan, so much for selling it! If you arranged a meet shortly I would attend, selling the XS soon though off to the land of Aus for the winter, got my heart set on a laser GTI when I get back!

[chipstick 382 1 Cars]

 

I suppose it's just the right time for me to do it. I never intended to keep it forever, but lifes too short eh. I'l pop a meet up.

[CaptainK 11]

So that's where we are. It's off to Sandy on Wednesday to be put through it's paces. Hopefully some enjoyable sunset coast runs to follow shortly

Good luck with it mate, hope it goes well

 

Apologies I forgotten to mention about needing the bonnet braces chopped a bit with the bodies installed. I used the standard catch and it worked fine (except for the time I forgot to close the bonnet correct, and consequently why my 205 ended up with a blue bonnet on it )

 

Gotta say though, that picture of the ITBs makes them look very sad. Can't believe that just a few months sat in an insurance yard has deteriorated their look so quickly.

 

Oh and we need videos of the "brappage" when its all done

[chipstick 382 1 Cars]

Well today Sandy Brown worked his magic.

 

Clearly a very talented gent who fuels himself on just Popcorn and Smokey Bacon Jacobs Oddities.

 

Photobucket video:

 

http://img.photobucket.com/albums/v318/blueovalspanker/5F5C95A3-530C-4795-9F00-BD6CDF97CDCC-1740-000001AC92A8981D.mp4

 

The way it drives compared to the existing map on the DTA is unbelievable.

 

Also top work from Colin Satchel sorting out a new filter backing plate for me.

[Wes 86 1 Cars]

fancy a run around town tomorrow evening?

[chipstick 382 1 Cars]

Yeah get on then Wesley!

[CaptainK 11]

http://img.photobuck...1AC92A8981D.mp4

Thankyou ever so much for the video - I miss that sound immensely

 

What power did you make on the rollers then ?

[chipstick 382 1 Cars]

178 ATW on the dyno, but I'm going to take it back to where I had it rolling roaded several months ago as a comparison more than anything.

[stef205 92 1 Cars]

Nice power that dan, certainly sounds like it anyway.

 

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