Xmt - Sarty's Xsara GTI6 Turbo

[allanallen 528 2 Cars]

5 minutes ago, DrSarty said:

Quite a lot of weight for the runners to support. It also means the turbo or manifold can be removed independently. Plus it all moves together, which overall means it should all last longer.

Fair enough, different ways to skin a cat and all that! Was more curious as there’s obviously 2 sealing faces/gaskets now but it’s fair reasoning. 

We made a bolt on affair to the manifold flange. 

Looks a hefty turbo, really looking forward to the results with the twin scroll set up, crack on!  

[petert 586]

1 hour ago, welshpug said:

the the support bracket.

https://en.wikipedia.org/wiki/The_The

 

Great band too.

[johniban 59 1 Cars]

Very nice manifold! you'd do well to mock up a few  more of them for sale! 

[wicked 103 3 Cars]

Nice progress!! 

Must say you have a lot of space under the hood (being a xsara and RHD).

I've been working on a similar setup and don't think this manifold will fit in a LHD 205 (smaller engine bay, break booster and steering column taking space).

Regarding the lambda bung; seems to stick out a bit far? Will the sensor be long enough? 

 

Edited March 26, 2018 by wicked

[DrSarty 90 1 Cars]

Mike's assured me the lambda bung is fine.

 

One reason I went Xsara (or considered a ZX or even BX for that matter) was giving me space to work in versus a 205. It's luxuriously cavernous in there!

 

When I get the manifold out I'll measure it so you can consider it for a LHD 205. Be aware that it cost £1,200 before you get excited though. Type/grade of steel used, inclusion of downpipe, matched runners with pairing etc contributed to price BTW.

 

Thanks for your comments.

Edited March 26, 2018 by DrSarty

[wicked 103 3 Cars]

If Mike checked it, it will be ok. Would be a pity if it was overlooked and you would end up with strange behavior because of bad AFR readings. 

Don't bother measuring it; from the pictures/down pipe routing it will be a big no-no for LHD. Keep it a your DrSarty's one-off manifold. 

[DrSarty 90 1 Cars]

Zorst porn!

Edited March 29, 2018 by DrSarty
Added pics.

[Andy 105 1 Cars]

Never mind your car. Straight to Tate Modern. Pure Art.

 

[DrSarty 90 1 Cars]

Things have moved along; I'll post some pics later. Jobs away from home have caused delays, but I keep picking at it.

 

16" Oz Superturismo x4 (ET16) found for £100. Professionally refurbished for £200, and fitted with Toyo Proxes all for less than £450. Big saving on new. (In white of course)

 

Leather interior fitted. Bonus find for £90, considering cloth bolster repair may have cost £50.

 

XU7 engine out from underneath, saving £100 on crane hire. Took head off, but 1x head bolt started rounding. I banged in a M10 'Ribe' bit - a lucky find - which got it out. Slightly smaller than a Tx55 but with squared spines. Sphincter moment averted.

 

New discs fitted all round; new pads on rear; GTI6 calipers going away for a refurb to suit new 288mm front discs. Ferodo DS2500s ready to go in.

 

Now getting engine 'kit' ready to go away. Have a local builder but now messaging Sandy Brown to see if he has capacity to build my hybrid (XU7 block; 10RS crank; 9J4 rods & low comp pistons; 9J/4 block stiffener; 9J4 oil spray jets; 10RS sump, cams & head; Piper vernier cam pulleys; alloy crank pulley). *Crosses fingers*

[Andy 105 1 Cars]

You have been busy . Photographs when you have a moment. We are all keen to see the progress

[DrSarty 90 1 Cars]

It's been a while since I've posted and I apologise. Right now I'm just just planning a move from Peterborough to Hull based on a new job.

 

I've kept this project creeping along, doing bits here and there. But I have to confess; whilst I actually work in IT, I find the whole 'take pictures - put the pics somewhere - upload to a hosting site - type on here and add hosted pictures' piece a real ball-ache.

 

It's not the system I'm moaning about here; it's just maybe how easy it is to give project updates in balance with real life. It's not that I don't wish to tell you what's happening - even if it's at quite a slow pace, giving that I'm now 47 years old - but it's finding the time within my lifestyle as it stands, almost regardless of the technology available to us.

 

It's either that I had more time when I was younger, updates were easier (unlikely, but appeared to be as I had more time), or that I overlooked the effort because (I thought) the updates were more important to give. Whatever the reason, I hope you see that I DO want to show what I'm doing, for everyone's information and (I hope) benefit, but it's not that practical on a regular basis.

 

In case you think I've become a tech-pr1ck, I'm typing this watching The Matrix in 4k on a 55" UHD TV in my 'man cave', with a 7.2 Bowers & Wilkins sound system and a rather nice gin and tonic.

 

So: if you are interested....watch this space:

[DrSarty 90 1 Cars]

(And BTW: the 7.2 B&W sound system includes 2 x PV1 subs. If you haven't experienced that degree of sub-bass then you haven't lived!)

 

Anyway: Let's start with a few pics showing the Xsara on stilts, the wheel swap and ripping the XU7JP4 engine out.

 

 

The 15" standards were ditched, despite them having pretty good tyres (shame). I found some Oz alloys and had them re-furbed, adding some Toyo R888s. It looks terrible dangling in the air but I'm sure it will sit realy well later, or lend itself to a degree of 'drop':

 

Edited August 17, 2018 by DrSarty

[DrSarty 90 1 Cars]

So out came the XU7JP4 engine....from underneath:

 

 

The beer was essential - near the cam pulleys - as the head bolts were a bugger; one in particular. One stud started rounding, and a RIBE drive banged into the Torx head was needed to get it to undo. This left a huge engine bay; much bigger than a 205 (so hats off to anyone who turbos or supercharges one), which gave inspiration for my project in terms of space for intercooler piping, general engine cooling, and having room to work.

 

 

 

So the engine bay is big and pretty clean, and I'll clean it fully before installing the hybrid PSA engine that it's destined to receive.

 

This yielded a rather pleasant XU7JP4 block and head; the latter of which is available to buy for a reasonable £20 collected:

 

Edited August 17, 2018 by DrSarty

[DrSarty 90 1 Cars]

With this apparently generous amount of space for intercooling...I set to work:

 

 

I researched intercooler calculation theories and formalae until my head hurt, then looked on eBay for something about right.

 

What I found was a V6 (Audi or Nissan) air-to-air intercooler which wasn't overly large (or so I'm led to believe), fitted in the space I'd liberated and wasn't too much dosh (£130 delivered).

 

Before ordering it, I mocked the Front-Mounted Intercooler (FMIC) up using some fruit and veg boxes: 

 

 

...and it seemed/seems to work.

 

Edited August 17, 2018 by DrSarty

[DrSarty 90 1 Cars]

This is the eBay FMIC; a mental projection of my digital self...delivered in 2 days.

 

 

The FMIC is already away with an engineer to 'bung' 1 of the 2 'hot side' 2.5" inputs - so that input and output are on the same (passenger side) end - and also merge the 2 radiator matrices with 1 feed, by cutting and plating the obvious 'V', i.e. making the FMIC 1 input and 1 output.

 

This will deliver a single hot FMIC input to be fed by the turbo output, which itself points upwards where the battery used to be. I need to make the piping for that.

 

With liberal cutting and hammer work around the headlight surrounds, I have made plenty of room to mount the FMIC - slightly biased to the driver's side - and allow the FMIC hot and cold piping to fit.

 

The lower/larger (3") FMIC fitment will take cool air to the Throttle Body (TB) housing. All this 'cold' feed piping will be wrapped/shielded - per some recent and common sense suggestions from Jackherer - to gain maximum benefit from the FMIC, i.e. why ask it to cool air then allow that air to pick up engine bay heat on its journey to the TB (?). So in short: turbo hot out > FMIC hot in (2.5" top spigot) > FMIC cold out (3" bottom spigot) > 76mm (I think) GTI6 TB on my modified GTI6 inlet.

 

I'll post some pics of the FMIC once modified and fitted, onto the braces/spars/brackets that I attached between the front chassis bar and the valance. These are just simple aluminium strips that have holes in for some new 10mm dowels/spigots that I have had fitted to the bottom of the FMIC. The sides of the FMIC will have additional brackets fixed to the shell behind the headlights.

 

The rest of the pics show the XU7JP4 bottom end 'tear down'. It'll soon get new shells and seals to suit a balanced bottom end of XU10J4RS crank with Mi16 rods and low-comp Mi16 pistons. I'm also trying to have Mi16 under-piston oil sprayers fitted to the XU7 block, but the block currently doesn't seem to contain the same 'real estate' as the alloy Mi block to fit them. I'd like the cooling from these sprayers, but this is a work in progress.

 

BTW: I bought a replacement radiator, but I altered the sprung top brackets to sit further back, i.e. tilting the radiator backwards. There's enough room, after ditching the front-mount cooling fan, for their to be a large (90mm!!!) FMIC, then a 10mm gap, then the (tilted) rad, and fit a pull fan or fans to the back of the radiator, still leaving space between the rad/rad fans and the inlet manifold.

 

 

 

Edited August 17, 2018 by DrSarty

[DrSarty 90 1 Cars]

I'll finish for tonight, but basically the old engine is out and stripped (to get what I need, including the engine bay space), and an intercooling mock-up has been made.

 

The hybrid engine components now go away, and I get to play with the new Emerald K6 ECU and loom I'm building.

 

Meanwhile, I'm still consulting and refining the design, such as how to oil and water-cool the Subaru Legacy GT turbo i.e. water feed and drain with respect to the thermostat and where to pick up and drain the oil, and also re the fuel system.

 

Even with the house move, I'm suspecting a 300bhp result before Xmas.

 

FINAL EDIT:

My 205 was previously 203bhp, and running well, if a little rich. After a visit to Emerald (and John) today, I've ended up with re-balanced ITBs, and light throttle remap which has improved idle smoothness and normal driving characteristics beyond belief. It should improve fuel economy too, as it was definitely over-juicing, so it smells cleaner and gives me the confidence to boot it even more. It feels amazing.

 

The fact I've jumped 14bhp from 203 to 217 today is probably just a sign of Emerald reporting a previously under-reading rolling road at the first mapping; but it seriously feels a different car now based on low range tractability and smoothness, so I've had a very good day. When one can push decently-sized motorbikes up the road when they know you're there, and they try to give it the beans and can't get away from you, you realise what a beast you have!

 

 

 

Edited August 17, 2018 by DrSarty

[petert 586]

Bugger third party hosting. Why not upload the pics straight to the forum? Since the recent upgrade, the process is far easier and more generous in file size.

[DrSarty 90 1 Cars]

I asked Jackherer about that (direct uploads) earlier, but perhaps he, I and others aren't aware/missing a trick. Maybe we need some help to at least make it easier to get pictures posted. Excuse my ignorance, but how is it done?

 

P.S. Just adding Emerald RR graph(s) to previous posts.

[petert 586]

I just drop the file on the paper clip.

[DrSarty 90 1 Cars]

I'll try it next time. In fact I'll try to post the previous RR results now.

 

Maybe it works differently for those who are 'upside down'....... 

[DrSarty 90 1 Cars]

Here goes, old map....

(P.S. After posting: unfair test, as this was already hosted and just dragged in. I need to see if it will post/show in-line with text without prior hosting, i.e. an image on my PC. Watch this space.)

 

Edited August 18, 2018 by DrSarty

[DrSarty 90 1 Cars]

Pete: I'll PM you, as I'm thinking that while I'm at this I might as well have an extended oil pickup. Hopefully I can send you one for modification/exchange.

 

P.P.S. Big fight now in The Matrix between Neo and Agent Smith. Finger chop to the throat scene!

Edited August 18, 2018 by DrSarty

[jackherer 543]

20 minutes ago, DrSarty said:

I asked Jackherer about that (direct uploads) earlier, but perhaps he, I and others aren't aware/missing a trick.

That's what I meant when I was talking about attachments but we must have been talking at cross purposes because I thought you said it didn't work for you.

 

 

[DrSarty 90 1 Cars]

Hope I didn't misquote or portray you K. Probably cross purposes as you say.

 

I've always been fine with attachments, i.e. they can be local (to my PC) and of a certain size, attached (via the 'paperclip'), then other users have to download.

 

What I meant was pictures that show in the thread. Have I got to host them elsewhere then get a 'IMG' code from the hosting site? Can I not display images local to my PC without the external hosting b*ll*cks?

[jackherer 543]

You can put them inline e.g.:

 

 

There should be a + icon on the thumbnail once it is attached, click that and it will put it inline with the text.