Back On The Road After 11 Years.

[205turbo 32 2 Cars]

Longtime forum members might remember my 205TT. It was last seen prowling the streets in 2004 as a stripped out track-car.

 

 

 

 

 

 

 

The car developed a misfire and was took of the road. A new engine was built and its internals were lightened and balanced i already had a Autosprint full race cylinder head and was impressed by the quality and proformace so they parts were shipped off to them.

 

I need a new Turbo Manifold so ended up getting a batch made up at the local foundry. I nice shiny manifold needed a nice shinny turbo so this was also upgraded with a GT2560 Garrett.

 

 

 

 

this was around 2006 and then the project stood still for a few years. Anthony very kindly built me a 309 Rear Beam with 23mm torsion bars and 25mm Arb.

 

The car was semi put back together and again moth balled.

 

Enter Tom. i asked tom if he would get the car piped up for me but he offered to do more than that. I hope Tom will jump in with some follow up.

 

needless to say he sorted all of the bits and im back on the road

 

 

 

 

 

 

 

 

[Phil Gti 11]

It's good to see yet another 205 back on the road, especially when it is turbo'd !

 

Mine is mechanically done, off to paint in the next few weeks

Edited June 25, 2015 by Phil Gti

[Paul_13 212 1 Cars]

I remember reading that magazine

[Alastairh 47]

Great to see this back on the road. I know most people would of just sold it as spares or repairs within 11 years.

 

Looking forward to the passenger ride.

[welshpug 1,657]

wasn't there another 205 there that Day? or am I thinking of another similar mag feature, possibly one of the classic mags.

[j_turnell 137 3 Cars]

Bout bloody time heheh. Glad it's back on the road. Look forward to seeing it. Last time I saw it it was on axle stands covered in dust.

[Mikey S 29 1 Cars]

wasn't there another 205 there that Day? or am I thinking of another similar mag feature, possibly one of the classic mags.

I remember the feature. Pretty sure there was an mi16 there as it was a Peugeot vs Renault thrash but, if memory serves me correctly, wasn't it held on a really hot day so the Renault turbos suffered quite a lot.

 

Mike

[205turbo 32 2 Cars]

I think on this one I was the only 205 we had a 309/106/206/405 there.

 

The 5 turbos were 1/4 mile cars, they paced out a 1/4 mile and cut them off just passed the marker as they feared they would blowup.

 

I took my car over yesterday to store in my mates garage for a few weeks as my garage is full with another project and I have to say 250bhp is not nice in light rain.

 

I'm looking forward to take it up the hill at pugfest this year

[Wes 86 1 Cars]

same bonnet as mine, do you know anything about it? was it done by cool louvers?

[205turbo 32 2 Cars]

yeah it was bought new from cool louvers many years ago (the name Brendon rings a bell with me)

Edited June 27, 2015 by 205turbo

[Tom Fenton 1,542]

Well I could go on forever and a day here and make everyone rather bored so instead I'll keep it brief and allow pictures to do the narrative.

The brief in the beginning was that it "just needed a bit of pipework" which in reality turned into quite a lot of stuff to sort out. As with any custom install it's not really just a case of buying things and bolting them on, so a lot of stuff needs either making it thinking about to do a half tidy job. In addition due to being out if service for quite some time there were also a few things to rectify due to age, for example both master cylinders were dry and seized solid!

 

So photos;

 

Paul wanted the brake lines done in aeroquip so this little lot was ordered from Speedflow.

 

Same for the fuel hoses in the engine bay so Torques supplied this

 

Next up was doing a nice job of mounting the various radiator oil cooler and intercooler. It all had to be concealed by the bumper as anything showing is a failure in my book!

[Tom Fenton 1,542]

Boost pipes next. First I tried the Pete Quigley throw them in from afar method

 

 

But that was utter s*ite so instead I had a better go with the tig and some alloy pipe. This is the air inlet to the turbo to clear the pedal box.

 

 

I made a tool to allow me to roll a bead on the alloy pipe then set about the pressure side boost pipes

 

[Tom Fenton 1,542]

Enclosed air filter mounted on the battery tray

 

Recirc dump valve for extra stealth, starting to get quite busy in there now

 

 

So skip forwards a bit, after making an exhaust amongst other jobs, and fitting a vernier cam pulley

 

So the next job was an MOT test. After a good few hours beforehand sorting out electrical niggles (quick way of saying removed old wiring fitted new loom) the car was ready for its first road use.

[Tom Fenton 1,542]

So once working it was mapping time. John Sleath Race Cars near me did the honours, what a top guy by the way.

Anyway the first session ended short at circa 190bhp after fuel pressure issues. New filter and a Walbro pump sorted that once I made an adaptor to fit the pump in the housing.

 

 

Quick pic at that stage, on the 16" Raceline RL7's

 

 

Before it went back for finish mapping it was the PSCUK Curborough day so it was rude not to make the trip, although only on a measly 8psi boost pressure. Paul met me there with the new SL434's which suited it much better.

 

 

After that in preparation for final mapping I made an air deflector plate to get plenty of air from the front grille through the intercooler

[Tom Fenton 1,542]

Whilst I waited for a rolling road slot I had a go at sorting the front bumper out. Respected the front balance and added driving lights, really finished the front of the car off, I hate 205's with nothing there they look unfinished to me.

 

 

So it then went back for final mapping, we settled on 18psi boost which yielded a solid 252bhp. More important is how it drives, totally tractable, you can poodle about at 30mph in 3rd or 4th gear without any coughing spluttering or hesitations. In addition on a longer run drive gently and the fuel

Economy is good too.

Only niggle was the breathers were no sufficient so I added a catch tank.

[Tom Fenton 1,542]

So at that point it was pretty much finished but I wanted to get some hours on it to be able to iron out any teething faults before it went back to Paul.

 

A trip out to a local ish car show one Saturday with the Yorkshire Bastards

 

 

With a sister car as Bims 205 TT also came in for some jobs doing

 

 

And then really the most important picture

One man and his car

 

Hopefully Paul will really be able to enjoy it. I have to say it's been a lot of work but the end result is ace. It's a good all round package with the suspension, brakes, LSD, all make a great match for the motor. The roller bearing turbo combined with a relatively large cam profile for a turbo motor means the power delivery is awesome, no going flat higher up here, it pulls like a train right round to 7000rpm. I have to say I' missing it already but plans are now afoot for a few choice extra mods as I'm fairly sure there's another 25 or 30bhp to be had before we are done yet.

[Tom Fenton 1,542]

Brief spec

XU9 8v 1905cc

Low comp machined std Pistons

Std crank/rods etc

Auto sprint St 3 head and cam

GT2560 roller bearing turbo

2.5" stainless exhaust

Aem wide and lambda and Truboost controller

Emerald M3D ECU

 

252bhp/250ftlb@18psi

 

306 TD gearbox with Tranx plate LSD

 

309 wishbones

GAZ front legs 275lb springs eccentric top mounts

309 rear beam 23mm bars 25mm roll bar

AST rear dampers

Hi-Spec billet4 calipers 4 pots

Twin master cyl bias pedal box

Sparco suede steering wheel

Sparco EVO2 seats

3" 4 point Safety Devices belts

Safety Devices C12 cage

Plastic side and rear windows

[Paul_13 212 1 Cars]

Nice little write up. Impressive figures from a 1.9!

[RossD 44]

18psi through standard pistons and rods, wow. Are they really that strong, especially revving to 7000rpm? I'm guessing that with a well setup ECU calibration its not so much of an issue.

Very nicely done though!

[Tom Fenton 1,542]

My 1600 XU 8v turbo also runs similar peak boost pressure, it made 204bhp as opposed to 252bhp which is pretty consistant with the fact that its 300cc down on capacity. (132bhp/l on the 1.9, 129bhp/l on the 1.6)

However the rods on the 1600 crank have a smaller big end than the 1900 rods and have survived the same 7000rpm rev limit. To my mind its mega high revs that will hurt rods, 7000rpm is not out of the way as the standard limit is 6500rpm or thereabouts. The standard pistons seem to be perfectly up to the job also. As you allude to, so long as the fuel and ignition control is correct then it should last OK.

[welshpug 1,657]

is it the standard TT turbo or something that flows a bit more air?

[Tom Fenton 1,542]

Its a GT2560R, so it is bigger in terms of flow, a newer GT series turbo which are superior to the old T series in many ways, roller bearing which makes a big difference to the dynamic response, but still will bolt up to the Turbo Technics exhaust manifold and downpipe. Its all WIN! There are some mods needed to the air intake and boost outlet, but those are perfectly surmountable issues nothing too difficult is required.

[speno 239 2 Cars]

To sum it up . Tom Knows his s*it and knows how to build a proper car :0)

Nice work our kid