[car_upgrade] Stef's 205 Gti6 Conversion And Tidy

[stef205 92 1 Cars]

M62?

 

Just one suggestion which would aid your cooling would be to block up all the open space next to the radiator, given air takes path of least resistance etc, no doubt there will be a fair bit of heat to deal with given a blower of that size

m90.... tbh i dont suffer one bit with air temps i have a probe on the inlet to the filter and a temp sensor in the inlet chamber and it ranges from 8-20deg. i have a reduced crankpulley with a larger charger pulley. it is nearly a 1:1 pulley ratio so the charger is barely doing much work. Once its mapped i will start to fine tune the car but i will certainly look into what you have suggested.

Your engine bay gets more and more ridiculous.

Thanks buddy!!

[Goliath 94]

Your rad definitely looks like a possibility for my bay. I would definitely like to take you up on the offer of your dud one to trial fit!

 

Oh and happy birthday

[stef205 92 1 Cars]

No problem george just give me a message at some point and let me know when you want it.

[stef205 92 1 Cars]

Ive recently been suffering with belt slip since changing to a smaller s/c pulley as i did with the m45 charger. I bearly had 180 deg of belt to pulley contact, so after trawling through a few yank forums about the issue i found that they add various extra idlers to give more contact. I had a idler pulley laying about from the m45 setup which i decided to use. After a few hours i made a bracket up that would bolt to the main mounting and give the s/c pulley a few more deg of belt coverage.

This is what the coverage was like before the extra idler.

 

 

After the extra idler.

 

 

It seems to have worked very well and i dont have to have a massive belt tension now as i did without.

 

 

 

 

[stef205 92 1 Cars]

I visited sandy on the 4th for mapping down at srd in launceston. I arrived at 9.30am and met sandy, as last time the day began with a nice chat and a few questions. We then got the car on the rollers and strapped down and i then left sandy to do his magic. We started to suffer with a flickering tps signal which was playing around with the idle, it was later traced down to a dicky tps plug. By the end of the day the car was sounding good and making clean power with no hesitations. We started to suffer with wheelspin as sandy worked the higher points of the map. Sandy then wanted to fine tune it on the road with showed the engine wanted more fuel and then he nicely added a few of his party tricks to the exhaust. I dont know a official fiqure but it pulls very well and runs smooth and clean.

 

 

 

This is a light pull during mapping.

 

http://vid10.photobucket.com/albums/a129/skyline_999/205%20gti%20project/205%20mapping_zpsv3hzps6z.mp4

 

A big thank you to sandy again for his excellent work, i returned with a big smile and grin.

[johniban 59 1 Cars]

what an animal or a car, would love to see what this goes like

[stef205 92 1 Cars]

Thanks John, i will be at pugfest again and hopefully doing a few hill runs as normal.

[johniban 59 1 Cars]

ill have to get you to build me one of them axles soon

[stef205 92 1 Cars]

you might be in luck ive a few coming up soon.

[stef205 92 1 Cars]

Update,

 

Some of you may know that the car was in Performance French car mag back in december. I had the shoot done on the late sunday evening on my way home from pugfest.

 

Here are some of the photos

 

 

 

 

 

Ive been suffering with fuel surge at time despite changing the in tank pump from a walbro 255 to a walbro 360. So i had my good friend fabricate me a under boot floor swirl pot, I had it made from stainless mainly to protect it from the road debris etc naturally its slightly heavier than a ali version but im not weight obsessed.

 

 

The inlet to the pot has been swirled so it does as it should along with a pick up pipe and i opted for jic fittings too as im not a fan of clips.

My seat rails have been damaged for some time now and was starting to effect the seats. I decided to start fabricating some weld in rail along with some harness points. Around the handbrake was servilely cracked as with the inner seat mounts.

 

 

i decided to use some 25mm cds tubing that i had in the workshop cut some 50x50mm support plates for them. I got some threaded inserts made for both the seat mounts and the harness eyes.

 

 

 

I have also now change my harnesses to a set of RSA 6 points which are aot better than the ebay crap that i had previous. Im also in the stages of fitting a bias valve and a refurbed set of rear calipers along with braided hoses.

 

Stef

 

 

 

[stef205 92 1 Cars]

Havent updated this in over a year lots has changed so ill try my best to do it in order.

 

I decided to fit a bias valve and a hydro handbrake, i found i was locking the rears easy in corners nothing special a compbrake valve and a kode handbrake.

 

 

A plated diff has been on the cards for awhile and after speaking with miles he did a cracking deal on a 3j along with new diff bearings. Fitted it to the box along with new crown wheel bolts.

 

 

 

Been looking at better boost control and with dump valves from a turbo car the spring setup wasnt suited with a supercharger so with alot of research and various question i found a bov from tial that is 50mm and has specific supercharger springs.

 

 

The difference was night and day its now like driving a normally aspirated car with out the sudden surge of boost i had to alter the map abit to suit.

 

Next i upgraded to a 2.4 rack from a xsara and converting to power steering using a saxo pump, Wired it so it only works when engine runs as it would in a saxo. Rebuilt the motor and the rack at the same time as it would be silly not to.

Managed to mount the pump and motor behine the battery in a up right position.

 

Next i got my friend to make me a new rad but alot thicker and some proper fan brackets, very happy with how it turned out and car runs alot cooler.

 

 

It was only going to be time but i visited colin for one of his lovely satchshifts. Money well spent imo and what a lovely feel it gives, considering 2nd used to be under my arm pit!

 

 

More to come.....

 

 

[stef205 92 1 Cars]

managed to get my hands on a genuine zender valance ive been looking for one for years, managed to get this one from holland. Got it test fitted to the car didnt fully go due to intercooler.

 

Got my friend to make me a new intercooler and new boost pipes, My previous cooler and pipe work was in a right state and was well over due and change.

Cooler is a little ott but never mind.

 

 

 

Been meaning to fit my auto tensioner setup for awhile now and i finally got around to it, With a dummy pulley on the sump to divert the belt then using a standard 6 tensioner.

 

 

 

Works much better than the rallye setup i had and no longer get any belt slip or squeal! I had to make up a new bottom water pipe to clear the pulley nothing a bit of stainless didnt sort and managed to mount it to one of the holes in the sump.

 

 

more to come....

[stef205 92 1 Cars]

finally made a start with the swirl pot! car has been surging more and more.

 

 

 

Used 8mm aluminum tubing from the tank to the pot to keep things neat. Ive yet to finalize the feed to the engine.

 

Got my pro race 3's blasted and powdercoated fancied a change for abit will probably had the 1.2's done at somepoint

 

 

This really take me up to date with the car i apologize its abit short with description but im sure the pictures speak for them self.

 

Stef

[calvinhorse 870]

Awesome work Stef! What a car!

[stef205 92 1 Cars]

Thanks Calvin

[j_turnell 137 3 Cars]

Looks awesome, bet that's great fun to drive. Where did you get your bonnet from out of interest?

[stef205 92 1 Cars]

bonnet is from ramsport

[stef205 92 1 Cars]

done abit of interior work over the last few weeks mainly seat rails. I did them about a year ago but the tunnel gave way and my seats became crooked and the seating position wasnt right. So i cut the rails out and some of the tunnel and began to strengthen it using 2mm plate along with 30mm box for the rails.

 

 

 

Just to give everything a paint then i can start refitting everything.

 

Stef

[stef205 92 1 Cars]

It been awhile.... Done a fair bit to the car again in my absence.

 

Painted the zender valance and fitted a splitter

 

 

Got the dash flocked by a local firm turned out well.

 

 

Had to remove the aps 360 pump from the tank as it was appearing to pressurize the pot so it was replaced with a 5psi lift pump from glencoe.

 

 

Been doing abit of thought and research into my injectors and their spray pattern mainly due to my current ones were nearly on 100% duty. I decided on a set of bosch 490cc injectors normally found in the vauxhall vxr's. Give off a nice pattern and are a much better design. Previous injectors being some lucas 380cc from a old rover tomcat turbo. Fitted a new 3 bar weber fpr aswell as i was using a ebay cheapy haha.

 

 

 

Gave the car back to sandy to map them in. Saw a good improvement across the map along with mpg improvement.

 

 

took it to a local car show not normally my thing but was a good day.

 

 

Pugfest was a good crack as always, good to catch up with people, but im sure i killed the clutch haha.

 

 

 

 

 

[stef205 92 1 Cars]

i finally decided to sort out my air filter or lack of one after my previous one was sucked in! Got on the phone to k&n and they were very help full and provided me with a few options. Settled on a filter with a slight taper around 6"x6" this one didnt restrict the charger as others i have tried did.

 

 

Got a clutch made up by a local firm which sandy was kind enough to recommend. Sent them a near new luk unit and they returned it to me as a 4 paddle. They have generally "beefed" it up with various stronger springs etc. Found the oem flywheels had plenty of stress cracks to got a ttv flywheel.

 

 

Clutch feels nice, its not heavy as such, bites alot harder as expected. I some times forget its there its nice to drive with. Flywheel i should have changed years ago what a difference engine really comes alive with it.

 

Been in the market for some new suspension for awhile now, been toying with many options but i settled with some new bilstein coilovers which miles was very kind to sort for me. Left miles to decide on springs, ive yet to fit them. Ive got allan on the case of making some top hats and mounts for them once they arrive ill get them fitted.

 

stef

[changingman 7 1 Cars]

That's a lot of work mate, looks good though.

Did you have any issues with dials and clocks because I've just picked up a 205 with a gti6 lump and mi16 box with lsd and all the clocks and dials either don't work or read wrong , except the fuel gauge!!!!!

Cheers

Liam

[allye 530 3 Cars]

Are you going to update this thread with the new Jap news then Stef!

[stef205 92 1 Cars]

That's a lot of work mate, looks good though.

Did you have any issues with dials and clocks because I've just picked up a 205 with a gti6 lump and mi16 box with lsd and all the clocks and dials either don't work or read wrong , except the fuel gauge!!!!!

Cheers

Liam

 

no issue with dials as the car runs off omex, the aux gauges are wired separate with no issue and work as they should.

 

 

Are you going to update this thread with the new Jap news then Stef!

 

Are you trying to get me banned? Not sure this forum wants to hear about jap scrap.

[changingman 7 1 Cars]

no issue with dials as the car runs off omex, the aux gauges are wired separate with no issue and work as they should.

 

 

 

 

Are you trying to get me banned? Not sure this forum wants to hear about jap scrap.

Ok cheers!

[stef205 92 1 Cars]

Nothing to report on this lately other than reliability.

Cleaned the floor up abit hasnt been touched in 6 years.

 

Deep clean

 

 

Will be reducing to weekend work due to the new arrival.

 

Stef