[trackday_prep] Project 150

[Sandy 191]

Excellent

[RossD 44]

I've got the modified GTi subframe in, with polybushed wishbones. The engine bay is clean and has been sprayed, so it looks better than new! I've started putting the wiring loom back in place too.

 

Another new addition is my Emerald K3 which will be controlling the whole shebang. A really nice bit of kit and a real bargain in my eyes for the features it offers. Thanks to Paul at Xsport racing for the ECU deal.

Still got to source a gearbox before the engine can go back in. Anybody got an MA gearbox (post 1992) they want shot of?! Ideally from a 106 XSi or Rallye?!?!

 

Pictures to follow, but I've updated my website with a few pics for the time being.

[DaveW 6]

Ax gti is the same as the xsi if you can find one..

[Sam 4]

I have a Quaife box that needs a rebuild? Don't want mega money but of course it needs the rebuild and possibly a new fifth but it is by far the best option for a beefy TU.

 

I have given Rob Thompson first refusal but he hasn't come to pick it up yet.

[RossD 44]

I have a Quaife box that needs a rebuild? Don't want mega money but of course it needs the rebuild and possibly a new fifth but it is by far the best option for a beefy TU.

 

I have given Rob Thompson first refusal but he hasn't come to pick it up yet.

 

Thanks for the offer Sam, but I'd prefer a box that I can just shove on without it needing any work! MA's aren't exactly the toughest things, so if I get through a few £50 ebay jobs....

 

Website now updated with pics of the engine rebuild

www.rossy.org.uk

[RossD 44]

Right, update time:

Engine bay has been stripped and now painted. A couple of before and after shots...

 

Before:

http://img.photobucket.com/albums/v727/ros...ld/STA71443.jpg

 

After:

http://img.photobucket.com/albums/v727/ros...ld/STA71654.jpg

http://img.photobucket.com/albums/v727/ros...ld/STA71645.jpg

[RossD 44]

Front panel, clean and shiney!

http://img.photobucket.com/albums/v727/ros...ld/STA71659.jpg

 

New subframe is in (CHeers Jrod!) which has been modified for the TU engine and also has 309 polybushed wishbones

http://img.photobucket.com/albums/v727/ros...ld/STA71653.jpg

 

This weekends jobs include replacing the track-rods and TRE's on the steering rack as they are past their best, and cleaning and protecting the front wheelarches. Also got to rub down that rusty 'orrible looking brake servo and make it look presentable. Years of brake fluid seeping onto it has stripped the original paint off and its gone rusty.

 

Thats it for now

Edited February 25, 2008 by cybernck

[Boris 0]

Cheers RossD, you'v done one verry intersting progect.

205 is a lovely car and combination with 1600cc new generation 8v engine is that take me to think - it will be one verry fast and less weight road car.

cheers

[RossD 44]

Thanks Boris, glad you're enjoying it!

 

Quick update:

My suspension bits have been arriving over the last few days, Bilstein Gp N shocks and Eibach 7001 springs.

A few pics below:

 

New Eibach spring compared to old base model spring

http://img.photobucket.com/albums/v727/ros...ld/STA71683.jpg

 

Eibach close up

http://img.photobucket.com/albums/v727/ros...ld/STA71684.jpg

 

New Bilstein Gp N shock vs original

http://img.photobucket.com/albums/v727/ros...ld/STA71665.jpg

 

Thats it for now, have ordered some Gp N top mount rubbers from BakerBM and will put up some more pics when the suspension is on the car :-)

[Sandy 191]

Nice. The standard springs are unbelievably long aren't they!

[welshpug 1,661]

I didnt realise the diameter of the piston on the Yellow billies, that should stiffen things up a fair bit on its own.

 

I'm really tempted to get some Yellows on my 405 now, but I cant afford it!

[Jrod 7]

Nice. The standard springs are unbelievably long aren't they!

 

I was worried my spring compressors wern't going to open up enough when I was undoing them.

[Sandy 191]

I didnt realise the diameter of the piston on the Yellow billies, that should stiffen things up a fair bit on its own.

 

I'm really tempted to get some Yellows on my 405 now, but I cant afford it!

It's actually the body of the damper itself that slides inside the strut casing. But yes, stiffer and better heat dissipation.

[RossD 44]

Nice. The standard springs are unbelievably long aren't they!

 

Yup, just a bit. Its amazing how much they are compressed to fit when the strut is assembled.

 

 

I was worried my spring compressors wern't going to open up enough when I was undoing them.

 

LOL, Mine didnt actually, I had to remove them just as I undid the top nut. Que one spring flying across the room. Was actually quite amusing :-)

Edited November 22, 2007 by RossD

[RossD 44]

Right, thought it was about time I gave this thread an update!

 

Lots has been going on since the last update. The front suspension is all on now and I started work on the rear.

For the rear, I've stayed with the standard torsion bars for now (Weedy 18.1mm items) but put some Bilstein Grp N rear dampers on. I've also got some hard rubber rear mounts from PTS. I've replaced the very weedy 14mm rear ARB with a 19mm item from a GTi. Suspension now much stiffer!

 

The new PTS hard rubber mounts:

http://img.photobucket.com/albums/v727/ros...ld/S1051782.jpg

 

 

14mm vs 19mm Anti-roll bars

http://img.photobucket.com/albums/v727/ros...ld/S1051778.jpg

 

 

Axle remounted onto car; I've been putting underseal on vunerable areas underneath.

http://img.photobucket.com/albums/v727/ros...ld/S1051786.jpg

 

 

A rare outing out of the garage! The first time in about 3 months its had 4 wheels. Engine and gearbox now ready to be dropped in.

http://img.photobucket.com/albums/v727/ros...ld/S1051788.jpg

Edited February 25, 2008 by cybernck
heavy pictures

[Sandy 191]

Good work

[RossD 44]

More pictures of progress:

 

http://img.photobucket.com/albums/v727/ros...ld/S1051785.jpg

http://img.photobucket.com/albums/v727/ros...ld/S1051781.jpg

http://img.photobucket.com/albums/v727/ros...ld/S1051772.jpg

 

I've got a new gearbox to go with the engine as the old gearbox doesnt have the cut-out in the casing for the crank sensor. It's interesting to note the evolution of the MA gearbox....

 

 

The later boxes have proper bronze selector forks instead of the steel forks with plastic tips the old boxes had. (Later box below)

http://img.photobucket.com/albums/v727/ros...ld/S1051765.jpg

 

 

 

Also this box has an uprated diff, the crosspins are 16mm instead of the standard 14mm; It seems all 1.6 models had the uprated diff.

 

Also this pic shows the reinforcements made to the casign on the later boxes. Note the area around the starter motor mounts and around the bottom of the box where it mounts to the engine has been redesigned. (Old box on left, later box on right)

http://img.photobucket.com/albums/v727/ros...ld/S1051794.jpg

 

 

 

 

Next job on the list is to hopefully frop the engine and box in. After that I need to put new fuel and brake lines on the car. Then maybe strip the rear brakes down.... The list goes on!

[RossD 44]

Booked the day off work today so that I could spend some time on the 205. Managed to get the engine and box in

 

http://img.photobucket.com/albums/v727/ros...on/STA71830.jpg

 

More pics of todays work can be found here:

More Pictures.....

[cybernck 402 1 Cars]

good work, but please insert thumbnails linked to main pics from now on.

 

thanks.

[Teacher 0]

I'm really keen to see the outcome of this project. I used to enjoy my old xs and the gt before it but with the power of both combined you will grinning wider than Lewis Carroll's Cheshire cat

[christopher 5 1 Cars]

Looks nice. Really looking forward to hearing about the result. Why was it you didn't use the 1,4 flywheel actually?

Edited February 25, 2008 by christopher

[RossD 44]

Looks nice. Really looking forward to hearing about the result. Why was it you didn't use the 1,4 flywheel actually?

 

Because the 1.6 takes the bigger clutch and I dont think the 1.4 clutch would last long with the expected output and also the 1.6 flywheel has the 60-2 trigger teeth already on it which I require for the Emerald ECU I'm going to run. Otherwise, I would have used the lighter 1.4 flywheel

 

Next job is to do all the plumbing... (Fuel lines, brakes) and then the wiring....

Edited February 26, 2008 by RossD

[christopher 5 1 Cars]

Which bottom engine mount are you using Ross?

[Rippthrough 98]

Because the 1.6 takes the bigger clutch and I dont think the 1.4 clutch would last long with the expected output and also the 1.6 flywheel has the 60-2 trigger teeth already on it which I require for the Emerald ECU I'm going to run. Otherwise, I would have used the lighter 1.4 flywheel

 

Next job is to do all the plumbing... (Fuel lines, brakes) and then the wiring....

 

 

306 1.4 flywheel has a 60-2 trigger wheel on it, is lighter than the 1.6 and can be easily machined for a 200mm clutch

 

Just a thought

[RossD 44]

Which bottom engine mount are you using Ross?

 

Standard mount for the moment. I'll see how it goes and maybe think about changing it if needs be!

 

Thanks for the encouragement so far