[trackday_prep] Mi16 Track Car

[Henry 1.9GTi 36]

Having bought Dino's old engine some time ago I have been itching to start the project, but having uni and funds get in the way. With easter hols I couldn't resist and started, helped along by the fact the insurance ran out

 

First stage was to strip the engine of all hoses and manifolds and give it a good clean up. Most of the grime and dirt has been removed which is good enough for me:

http://geocities.com/noob_with_attitude/Cl...g_up_engine.JPG

 

Then onto the cam belt side, replaced the belt whilst the engine is out is its alot easier to get to things. Taking off the covers revealed some fancey looking pulleys which I was unaware of so locking the camshafts was goning to be a little harder, as Im lazy i didnt bother and yes one of them moved when the belt was taken off! But I had it all marked up and soon had a nice new belt on (pic is of old cambelt)

http://geocities.com/noob_with_attitude/Pulley_side.JPG

 

Taking the sump off revealed the current cump baffle which is a peugeotsport item i think. Most of the welds were breaking away and it had a massive crack down the middle. Also made taking the oil pickup off a pain in the arse. The whole setup looked a bit messy and added another layer to the sump/baffle/spacer setup. Looked like it was leaking a little aswell. So im glad to have it all cleaned up.

The GTi-6 sump is on temporarily whilst my oil pump pickup is away having an extender fitted. It was done today and when i get it back ill put some pics up.

Before pic

 

I started ripping open the front of the car today. Drained oil and coolant and set about removing things. Of the 6 bumper bolts/nuts 5 sheared gota love old cars. So all will be replaced with new, will also be cleaning up the brackets and freshly painting, pics to follow when i get round to it.

But for now:

 

Next job is to drop the gearbox out and have it sent away for an Mi16 final drive and a minor refurb.

The car is partially stripped out on the inside and being used as a parts shed atm but will post some more pics up when all the front stuff is out. Will be painted as well closer to finishing time.

 

And the parts collection so far;

 

http://geocities.com/noob_with_attitude/Parts_collection.JPG

 

Cam cover to go over cam left open when removing power steering pulley.

Sump,inlet,exhuast gaskets and a fuel filter from pug.

Racetech oil pressure and temp gauge to keep an eye on the Mi. + fittings.

XU10J4 higher pressure oil pump spring (£2.70+vat) Cheaper than a GrpA alternative.

Motronic 1.3 ECU

Poweflex ARB bushes to fit the 309GTi ARB in my garage

Some BBM hard rubber GrpN engine and gearbox mounts.

 

Plug and play loom from PRD to save hassel with wiring. Gonna take some proper pics of the loom tomorrow and post some info up.

 

http://geocities.com/noob_with_attitude/Loom.JPG

 

Thats it for now, more to follow soon I hope!

 

Henry.

 

Can I have a project page please admins?

[sutol 0]

LUVELY

[Henry 1.9GTi 36]

Update:

 

Spent yesterday stripping out the interior. The rear seats were already out a long time ago so the fronts were next onthe list. Front seats came out along with the stereo, speakers and a jumble of wiring.

 

Then out came the carpet and roof lining. Made a hash of the trim around the rear windows and snapped a piece in half but managed to get one side out without breaking anything.

 

The underlay was a bit damp but not as bad as I thought came out in clumps and was very messy, weighed in at 10kg+

Finished but still v untidy: Total removed ~ 55kg + 35kg from when the rear was done. Bathroom scales are not all that great though.

 

 

 

Today I spent my time getting ready to lift the engine out. Disconnected the loom and all hoses. Took off the exhaust, speedo cable and gear linkages. Drained gearbox oil then set about taking off the driveshafts. Thanks to JonMurgie for his giude was very helpfull. Passeneger side came out easy enough; disconnecting the wishbone ball joint allows the hub/upright to be pulled back and the drive shaft can be pulled out of its housing. The driver side was more tricky; ended up removing the caliper and trackrod end and then taking the shock absorber off the upright and pulling the whole lot out along with the drive shaft. Then reassembled with driveshafts cable tied and bagged up.

 

Tomorrow the engine is coming out and the gearbox will be off, will then rest the engine bk in the bay for storage. Pics tomorrow.

 

Henry.

Edited April 14, 2007 by Henry 1.9GTi

[smckeown 1]

nice to see another lightweight track car in the making. What are your objectives/goals ?

[Miles 331 1 Cars]

You'll be surprized what rubbish can come out of the car, If you looked at the loom you'll loose allot more too, But looking good

[Henry 1.9GTi 36]

hopefully nearer to paint time the dash will be out and can take out more sound deadening to get that -100kg And will be able to have a good look at the car loom aswell, its a mess im not looking forward to, especially as its got an alarm fitted that doesnt work, so will try and get rid of all associated wiring!

[Miles 331 1 Cars]

Just trace the wires one by one if you havn;t done it before, Thankfully the 205 is very simple, You should see the rubbish I've taken out my 306!!, I recon near 200kg's

[Henry 1.9GTi 36]

Objectives are a road leagal track car. Wont be entering and competition with the car, not in the forseeable future anyway. Just a fun project for me as I have never done anything as major as this so its all fun and games, for the moment anyway. No time scale to meet although I want it ready for TRAX seeing as I bought some track time

On the weight issue though I might remove 100kg but then the Mi is going to be ~25kg more. Bucket seats and harness' ~ 17kg and a roll cage ~ 35kg? So car wont actually be much lighter untill i start earning some proper money and can buy fibreglass bits and remove the electric windows. But for now I just want to get this stage finished and get it out on track to have some fun.

[changingman 7 1 Cars]

And have some fun you will!!

 

Ive a few pugs and my MI16 is a corker so ive no doubt your will be too and youll love it

 

Itll be even better for you as it look as though youve done the lot yourself!!

 

Well done.

 

Liam

[Henry 1.9GTi 36]

Thanks Liam

 

 

Small update:

 

After the prep work yesterday the engine came out easily, only thing to do was undo the engine mounts and hoist it out.

 

Then set about removing the gearbox which was so filthy compared to the engine. Messy box out:

 

Then put the engine back in the car for storage untill its sold.

 

I took the ECU out of its jungle of wiring but the loom will have to wait untill the dash is out as its a right mess.

Thats it for now, top priority is shifting the bits I don't need now and stripping the engine bay down ready for some rust removal and paint.

 

Henry.

 

Engine and iterior is up for grabs, search for "Interior, ICE and engine sale"

[Henry 1.9GTi 36]

Geocities sucks so pics wont be viewable for a while and then will proably overload itself again. Sorry.

 

Henry.

[Henry 1.9GTi 36]

small update:

 

got my oil pickup back from my mate Chris at www.neilgarner.co.uk (plug plug) with the extender welded on. Big thanks as its perfect

I drilled out the back plate thingy and used the allen bolts supplied with the extender to secure it all up. Was messy getting the gauze to fit but got there in the end.

 

The dash came out yesterday along with the loom. I started taking out unwanted wires such as my not working alarm! Already got a massive pile of wires on the floor, I hope it will still work when its all back together pics to follow later once its all done.

 

Next on the list is to completey strip the engine bay and start looking at the rust, hopefully its just surface, it doesn't look all that bad but can't be sure really.

 

Henry.

Edited April 22, 2007 by Henry 1.9GTi

[petert 588]

Luckily I haven't seen many guaze mesh pickups. They mostly seem to be a perforated plate over here, which makes it a breeze to drill through. Hope it all goes well!

[Henry 1.9GTi 36]

thanks peter. and thanks for the parts. I didn't use the baffle in the end though; couldn't justify £120 for the GTi-6 oil pump. So I bought the spring instead for £3

[Alan_M 66 1 Cars]

Looking good fella, must get my arse in gear and start mine

[Henry 1.9GTi 36]

Been a while but I finally have got an update on this project!

 

After my rush to get it all apart over easter, putting it back together proves more difficult

After uni finished I went on a spending spree and got some of these:

 

 

Got 2 of each, the harnesses were more expensive than the seats!

I also got 10L of silkolene 10-W50 oil and an purolater oil filter off opie oils. Spent about £40 on bolts from peugeot as well

Finally got round to putting the GTi-6 sump on but taking it out to garage I remembered my oil temp gauge is mechanical and will need to sit in the sump somewhere. Thanks to my mate Marc at subaru4you for sorting this one out! Got the sump plug hole drilled and tapped to the same size as the guage fittings, which is PTFE'ed and gasket gooed in, hopefully wont leak as I was too dumb to check before I bolted the sump up Extended pickup is on, sumps on along with gauge fittings and T-piece for the oil pressure line.

 

If anybody is thinking of using a GTi-6 sump with a spacer plate don't bother buying the longer bolts from pug that are needed for the GTi-6 sump, they are too short! I got 10 as they only sold them in packs. Bloody 7mm bolts! Anyway after drilling out the wholes I still got to use the longer bolts.

 

I have rubbed down the front of the car with a wirebrush attachment for a drill to get rid of surface rust, thank god thats all it was (I hope) Front end is now painted with hammerite. Big thanks to Chris at Neil Garner Engineering again for sand blasting and painting vario9us parts including my slam panel \o/

 

Got some flush locking bonnect cathes as well - pics to come when installed.

 

Next bit of spending was on a 4-2-1 Pugracing manifold and a gearbox rebuild + Mi16 final drive fitting.

Thanks to Miles for sorting this, very good price from Miles on this, or I thought so anyway. Also picked up a gear rod set and silicone breather hose to replace a dodgey looking one. Nice clean box and other parts:

Edited June 23, 2007 by Henry 1.9GTi

[Henry 1.9GTi 36]

Next up I decided to change over the anti-roll bar for the 309 one I purchased a while ago on this forum.

3 of the 4 Nuts on the ARB studs came off. The other one decided to turn the stud along with itself after trying to file a flat edge onto the ROUND!?! stud/bolt and jamming screw dirvers under the brakcet to get some friction me and my dad decided to drill the but off. Big thanks to my dad here as after 5 secs of drilling (with no goggles) i got something in my eye off the drill! So I sat there with my left eye streaming whilst my dad drilled the nut off and after alot of banging and swearing we got the stud/bolt out.

Thanks to the forum user i got the ARB off as he had supplied it with the much better 309 brackets as well meaning I could ditch the 205 ones and use the 309 which are threaded to take a bolt from underneath.

Also thanks to jonmurgie for the ARB removal guide, following this I took off the 4 rear subframe bolts which came off suprisingly well seeing how everything else seemed to have snapped. The ARB could then be pushed through the gap created. The 209 one was slotted intoplace unfortuantly without bushes as powerflex supplied me with ones which are too big and one does not have a groove to take the 'hump' on the ARB. they also do not have a round bottom part to sit nicely in the indentation in the subframe. so the bushes will go on later!

weedy vs beefy ARB:

subframe bolts out:

 

and to finish off, after reading a post by smckowen I got one of these from pug for £13.99 to replace the mankey old one.

[Henry 1.9GTi 36]

next up is cleaning more of the engine bay and making sure everything is ready for the egine. Then on goes manifold clutch and gearbox and the engine can go in v soon hopefully. will update when i remember

 

cheers.

Henry.

[Alan_M 66 1 Cars]

Whereabouts in Reading are you?

 

Must know where the other Mi's 205 is in the area

[Guest Cally]

Looking good.

[Henry 1.9GTi 36]

South of reading Alan, Spencers Wood.

 

thanks cally

 

engine is in will post pics and report of the fun and games in a few days time.

[Trick 1]

thanks peter. and thanks for the parts. I didn't use the baffle in the end though; couldn't justify £120 for the GTi-6 oil pump. So I bought the spring instead for £3

 

 

ive got an old gti6 oil pump...whats the diff between that an an mi one?

Edited June 26, 2007 by Trick

[Henry 1.9GTi 36]

im not exactly sure on all the differences, but the GTi-6 pump has mountings for a chain gaurd and pump baffle which is what I wanted it for. In the Xu10 cars it also uses a longer chain and bigger sprocket I think. But they are ~ £120 from pug so if you were selling you might be able to get a fair bit for it.

[Henry 1.9GTi 36]

Some updates:

 

With the parts back from miles I had a final stare at the engine bay to see if id missed anything obvious then set about putting the engine in. Got it onto the crane and on went the Mi clutch and then the rebuilt box.

Got the BBM hard rubber mounts on the car then put the exhaust manifold on the engine. When lifting the engine up and pointing it in the cars direction it soon became obvious it wasnt going to go. Just couldnt get the rt angle to slot it all in. Especially as there were no hoisting points on the engine. So off came the manifold and after alot of banging and bumping against bodywork and dropping the engine on the master cylinder! oops! it was in and starting to look car like again. But in order to get it in the lower strut brace had to come off as it was fouling the sump. (GTi-6 wings :|) so off came the sump and 5 hours of on and off hacksawing began. With the wings chopped off and grinded flush with the sump it just about clears the brace. In my haste to get the engine in i forgot to put the alternator bolt through, so off came the strut brace again and I undid the lower engine mount and pulled the engine foward as far as it would go and the bolt could just be hammered in. phew. But putting the sump bk I managed to strip one of the threads and put a crack in the block yay, really am not gonna type about it, been a bit of a nightmare.

 

Today I got the driver side hub off to feed the driveshaft bk in. New strut clamp bolt and wishbone bolts later its all back together. Track rods done bk up and caliper bolts done up 74ft lbs seemed tight as Ive never had the calipers off before so is all new to me . Both driveshatfs are bk in new gear rods are on manifold is now on but with limited if no clearance atall. Attacked speedo and clutch cables, on went the alternator and starter motor.

Started to make up brackets for the rad to be lowered but by 11pm i was nackered and called it a day!

 

Beast read for engine:

engine in with rad mock up:

16vs!!!

[Henry 1.9GTi 36]

Its been a long time coming but the car has been on the road for 2 months now.

 

Had problems with the loom which had to taken off again and stripped to have a conection re soldered as it was badly corroded, so it showed continuity but not enough current was getting through to run the fuel relay and injectors etc...

DES developments sorted this for me as I had to scamper back of to uni. They aslo refitted the front end and fitted the seats properly.

 

Once up and running I had a big list of things to do! The front end came off again for a rethink as the oil filter was touching the rad, all bk on now with a new filter and oil, plus there is now enough room to change the oil filter without taking the radiator out! Pug fan came out as it was blowing over the top of the radiator and a slimline fan just squeezed in to the opposite side as a pull type. Also saved a bit of weight. Next up is to remove fan cowling completely as its only holding the oil cooler now.

 

Alarm fitted, fire extinguisher fitted, although may rethink fitment, general tidying up done, screenwash now working! horn wiring sorted so horn now works switch to dash put in for the fan, just need to add an inline fuse.

 

Various other things done to make it just generally more tidy / roadworthy.

 

Trackday at bedford on the 26th Jan - need to fit 2 new water/oil temp gauges, bleed the brakes, fit new gearbox mount nut and hopefully get the exhuast sorted as its fallen off twice! But thankfully DES are on to the exhuast and should be all good for bedford.

 

So thought Id give the beast a clean, first one in 9 months! Made me smile seeing it polished up ticking over on its lumpy cam with the side lights on