Project "peugeot 375"

[Reebmit 51 4 Cars]

Looking good some nice work there, look forward to seeing the end result....

[Ron_Jaegers 12]

The ISIS power management system has arrived!

Box with goodies.

A MasterCell and a PowerCell with a two-euro coin for size reference (not so relevant on this forum, I know ). The two euro depicted there is also all the money I have left after buying all this fancy stuff.

All package contents spread out.

The units themselves are pretty large, but luckily very light. The PowerCells are a bit heavier because of the (passive) cooling of the MOSFETs. The MasterCell weighs next to nothing.

Globally determining the position of the PowerCell's. The front one I will hide under the scutle panel. This gives me two nice exits on either side of the car. This position also makes it easier to provide power to the heated windscreen and to the dashboard on the inside of the car.

Next up the cabling on the inside, what you see is what you get in this picture. This is (almost) everything necessary to wire up all electrical circuits in the car. The rear PowerCell will be placed near the location where normally the passenger seat-belt bolts to the chassis (opposite to where it is shown on the following picture since it is a LHD car). The MasterCell will be fixed where it is shown, all the way towards the back of the exhaust tunnel. This way I can easily wire in the buttons to a panel that will be at the location normally the hand-brake assemby resides. This should allow me to controll all electrics when strapped in my seat.

Loom-to-be...

Because I have glass-fibre doors I need to cut about 10 cm from my lexan windows, so mocking up with cardboard to determine the right size.

The cat is "helping".

Tonight will continue making the windows the right size.

[johniban 59 1 Cars]

love this

[Ron_Jaegers 12]

Spent some time on the car again during the week-end. Trying to shorten the to-do list.

Installing the Satchshift...

Testing the seating position and trying out if everything is within reach.

Lastly a mock-up of the console that is going to house the buttons, since I can not reach the normal dashboard position when fully strapped in I will re-locate the buttons to the position of the original handbrake. Like so:

[Kane 34]

Liking the idea with the centre console. Looking great, keep up the good work!

[Ron_Jaegers 12]

Got the electric system up-and-running yesterday! It's very preliminary but it works, following a short description of what I did:

First up; creating battery cables. Stripping back the wire and inserting it into the connector such that the connector is filled and a minimum of copper is exposed.

Created the crimps with this tool.

Which looks like this.

Afterwards applying glue lined shrink-tube with the heat gun until the glue comes out. This creates a water-tight seal that will hopefully prevent corrosion.

Last step is adding rubber boots over the exposed connectors.

All the above mounted to the car looks like this. Also note the Cartek battery isolator.

Repeat for positive side and presto, we have a circuit.

Pretty happy with the results. I also got the ISIS (or InfinityBox as it is called now) system to come to life, but will post about that later.

[johniban 59 1 Cars]

whats the four fuses for ?

[pip470 61]

The doors look like good copies and also a good fit especially around the top of the door. Where are they from? Loving the project by the way.

[Ron_Jaegers 12]

The four fuses protect the main wiring that provides power to the front and back power distribution modules.

 

All the GRP stuff is quite good! It's from "those French guys" at MC Racing. A b*tch to do buisiness with if your French is so-so, but they provide quality goods.

[Ron_Jaegers 12]

Given myself a birthday present for my 30th birthday.

 

Hopefully will arrive soon so I can wire it up together with the ISIS system. Now only the VEMS ECU must be bought to complete the entire electrical side of things.

[SwedishBob 24 1 Cars]

Globally determing the position of the battery (thanks to SwedishBob for the inspiration).

 

No problem.

 

Had totally missed this project. Really like it!

[Ron_Jaegers 12]

After some life-changing-events; couple of kids, (moving)homes, (changing)work, a break-in where they nicked most of my more expensive 205 stuff, I have finally found time and renewed energy to start working on this car again. It is now inside my heated garage inside of my house, so working on it for 30 min. is possible. So while it's not going at top-speed, stuff is moving again! Yay!

 

My most recent achievement was re-wiring the back of the car, namely the light-clusters, washer bottle (that is servicing the front wipers) and the fuel-pump.

 

Mounted the rear PDU.

 

 

Mounted the battery and the main +12v fuses along with the solid-state kill-switch.

 

 

The +12v firewall gubbin was a bit too small for the hole it needed to fit (that's what she said), so I printed a small adapter.

 

 

That now goes from here.

 

 

To here.

 

 

Making up a new loom for the backside.

 

 

 

Almost done.

 

 

Up- and onwards!

[Ron_Jaegers 12]

At the moment I am busy building a center-console button panel. Since I have no stalks around the steering wheel anymore, only a couple of buttons on the steering wheel. And since I plan on leaving the complete dash out, I needed a suitable place to mount some buttons.

 

Printing the front panel.

 

 

Something like that.

 

 

Position(ed) in the car.

 

 

All buttons have an individually addressable multi-color LED onboard, and the microcontroller servicing this panel is connected to the CAN bus. So it can directly switch the loads. The plan is to have them on dim white after the ignition is on. And depending on the function of the button light them up an appropriate color.

 

 

Still need to do some wiring and print the surround of the box.

 

To be continued.

[cybernck 402 1 Cars]

Wow! Can we get an update please?

[Ron_Jaegers 12]

Will do an update soon. In the meanwhile life happened (again).

 

Nice to see you drop by here Nikica. Its a lot more quiet here than a couple of years ago. I believe most relevant content has moved to social media these days. Which is unfortunate for me since I have no presence there.

[Thijs_Rallye 87 4 Cars]

11 hours ago, Ron_Jaegers said:

Which is unfortunate for me since I have no presence there.

You aren't missing out tbh. Facebook is utter sh*te compared to a forum, expect to see the same questions a thousand times over.

[Ron_Jaegers 12]

Hi Thijs! Nice to see somebody from around the block.

 

It’s too bad for the forums. But good to see some people still pass by here once in a while. The Dutch forums are pretty much dead.

 

Anyway I am doing some work on the 306 at the moment. That needs doing before I can continue on the 205.

[Thijs_Rallye 87 4 Cars]

20 hours ago, Ron_Jaegers said:

The Dutch forums are pretty much dead. 

Yep. Quite a shame really. I still check it from time to time, but the glory days have long been past.

[wicked 105 3 Cars]

I think that is valid for many forums nowadays...    I think this forum is still relevant as it contains some much good info, which you won't find on social media. 

 

Good to hear that you picked up the spanners again Ron! Looking forward to the end result of your car!

 

/Rolf 

[Ron_Jaegers 12]

I was about to throw the towel in the ring on this one. Still not 100% sure on the future of the car but I have found some renewed energy to work on it.

 

Currently trying to figure out what the "minimal thing that could possibly work" is. Go to the planning table and start executing.

 

It's not like I did nothing, but progress is slow and when I see the previous dates in this topic it brings tears to my eyes ;).

 

Anyway, some progress:

 

Satchshift handbrake extension

 

 

Re-built the fuel pump with a high-flow Walbro 255 l/h one

 

 

 

Got some more Satchell goodies; eventually will switch to a GTi6 head, but for now get it running first on the LFY one

 

 

 

Bit of loom stripping, think I will not need the stuff from the second picture (almost a kilo worth of wire and crap)

 

 

 

Position of ECU and PDU

 

 

Wires!

 

 

Part of steering wheel buttons and dash position

 

 

Exhaust prep

 

 

That's it for now, I am currently building a new alternator tensioning bracket and will start fitting the exhaust manifold to back.

 

 

 

 

 

Edited January 15 by Ron_Jaegers

[welshpug 1,666]

nice to see more work on this, does the gti6 exhaust manifold fit without changing the angle given the Aluminium XU block is 11mm shorter?

 

My own 205 has not been on the road in about 12 years, was even stored in a real 1800's Barn for a while but is now sat outside at work as a rolling shell/shed

[Ron_Jaegers 12]

I really hope the exhaust will fit because of the reduced height; exhaust trial fit is the next thing on the list. I will report back once I have found out. I might have some more clearance because of the v-band coupling, but I have an un-butchered manifold as well. Will also test-fit that one.

 

And you at least had your ZX Mei, I had a Fiat Multipla :). But the love for the 205 has shifted a bit to the collectors I guess, insane prices on them don't help either. Anyway, good to see you are still around!

[wicked 105 3 Cars]

Hi Ron, good to hear you're still working on it. Don't throw the towel! 

 

In fact, when I was at your place to pick up some S16 stuff, you did put some ideas in my head with the 3D printing also started on some small side projects, next to the other car projects. 

 

One of them is a VEMS retrofit display for my trackday car (not installed yet)

 

 

 

 

[Ron_Jaegers 12]

Thats pretty damn cool Rolf, nice to see there is still people working on 205’s.

 

I did a trial fit of the exhaust today. The good news is that it fits and sits quite nice in the tunnel. This is on VibraTechnics mounts so that might play a role next to the reduced block height.

 

The bad news is that the water pipes are in the way. They extend, and loop around, towards the bulkhead. No way that is going to fit. GTi6 gear won’t fit. Any ideas on what would?

[petert 598]

Dump all that and find an aluminium XU10J4 entry block. Cut off and block the ports you don’t need. Then you can use the oem 205 pipe(s).