[engine_work] 205 Gti 6 Supercharged

[Garry 1]

I enjoy reading the numerous project threads so I thought it is time to start my own.

 

I am currently supercharging my Gti 6 engined 205, I have run the mainly standard 6 lump for about 4 years now and decided I wanted a bit more oomph!

 

The car used to produce 187bhp and 137lb/ft as tested at PTS in Luton (which admittedly seems a little optimistic) but I will get a post conversion test there for consistency. My best SQM was 14.7 with a 96mph terminal.

 

I have bought the Kit from a guy called Richard Walker who has designed and developed the kit for his own 306, which is currently running over 400bhp and 280lb/ft at 14PSI of boost.

I have opted for a low boost version (7PSI) which has been proven to produce 260bhp and 218lb/ft, which I think you will agree will be plenty for a stripped out 205! Although there is always potential for a little more boost…..

 

So, first things first I decided to clear out the garage and paint the floor white (I used the remains of an old tin of Dulux!) but it has turned out alright so far.

 

 

 

I bought a Forge intercooler and Swirl pot from the autosport show in January for a considerable saving over the rrp:

 

 

and a couple of weeks ago I received the heart of the conversion, as Rotrex C30-94 supercharger:

 

 

This is what the car looked like Pre op:

 

 

I made my own lifting frame from some scaffold borrowed from work, same design as a garden swing I used to have when I was little but much bigger!

 

 

Engine and box on the way out, this is the first time I have removed or even seen an engine be removed, it took me all weekend! I was also surprised at the angle it had to go at in order for the gearbox to clear the wing too.

 

 

The engine and Box were then taken down to Miles Horne of Pug racing for a gearbox rebuild, as I broke it at Spa last year (it kept popping out of gear, which made Eau Rouge a little more exciting!) and to have the belts and water pump changed.

[Garry 1]

This is what my trusty fiesta looked like with an additional engine, two gearboxes and a pair of trailing arms in the boot. It has made me question the logic of twin engined conversions, so much extra weight!

 

 

 

Last weekend I jet washed the engine bay ready for taking to the body shop for re painting, I uncovered some pretty nasty rot on the near side wing, which will need replacing

 

Pre Wash

 

 

Post wash

 

 

Rotten wing, I was actually able to push a screwdriver through it!

 

 

 

I have also mounted the supercharger bracket and supercharger to the block

 

 

I am currently waiting for the new inner wing from Peugeot and then it can hopefully go to the body shop next weekend.

 

Target completion is the 10th of May when I am heading over to the Nurburgring for Sunday TF and then a track day at Spa on the Monday.

 

Will keep you posted as work progresses.

 

Garry

[Miles 331 1 Cars]

Glad you got the engine out the boot OK!!, Look foward to seeing it done

[Garry 1]

It was quite interesting actually, I made a see-saw out of the scaffold and lifted the engine whilst it was in the boot, I then got the wife to drive forwards, removing the engine. The only trouble was that it was quite hard lowering it without the scaffold slipping forwards, got there in the end though.

[DrSarty 90 1 Cars]

Good thread and nice project our Gazza. Was nice to meet you at our last curry bash as well. Keep it up eh.

 

Rich

[dean 0]

have you got any closer to finishing yet

[Garry 1]

Progress has been quiet of late due to waiting for a new inner wing to be imported from France:

New panel

 

And then on to the body shop for engine bay painting.I collected the car on Saturday, I am pretty pleased with the results, nice and clean:

 

From this:

 

To this:

 

Saturday morning me and my brother rebuilt my scaffold lifting frame and collected the car, he kindly towed me back from the bodyshop. it was only 2 miles along country lanes, but I always find it unnerving knowing I have little control and no brakes!

 

 

Engine going in. Is that safe?

 

I bought and fitted new spark plugs, these are R8 rated which are colder than the standard R6 plugs:

 

I also fitted my new 440cc Injectors:

Edited April 14, 2008 by Garry

[Garry 1]

You may have seen previously that the inlet manifold was too long, thankfully Richard Walker took it back and shortened the inlet tracts by 30mm and now it fits!

 

 

Engine installed and 205 TD radiator mounted, although I will not be able to use this rad as I need to change the charger outlet rotation. In its current configuration the bonnet, yet again, will not close!

 

 

This is my intended Intercooler setup, although the charger has now been rotated one notch so the outlet is lower down. To solve this I intend to get radtec rad which is designed for running bodies/ carbs, therefore lower.

 

[Super Josh 4]

Oooh that's coming along nicely Gary The intercooler and pipework look nice and neat too.

 

 

Josh

[dean 0]

how much did you drop the rad in the end

[Garry 1]

The current set up doesn't work Dean, I need a Radtec radiator, as i have rotated the charger downwards. It doesn't look like the photos anymore. Same principle, but the Rad is too high.

 

Have a look in the group buys and you will see what I mean.

[dean 0]

ok why didnt it work like it is can you not just lower your standard rad

[Garry 1]

You may have noticed on the last picture the charger outlet pipe was sticking up quite alot and subsequently the bonnet wouldn't close. To solve this I have rotated the charger outlet, but this meant that it clashed with the New TD radiator :angry.

 

So to solve the problem and spend even more money on the project I bought another radiator from Radtec (Via Daz C's group buy, thanks mate). This has been designed to suit 205's running carbs or bodies and is about 75mm shorter than the standard one but has a 60mm core so its twice as thick.

 

 

The quality is excellent and it fits perfectly. Anyway, must get back in the garage and solve the next problem!

[easypug 0]

Keep up the good work matey, I'll have to come have a butchers once your done. I'm slowly still getting bits together for mine...

[Daz_C 8 1 Cars]

Glad to see its done the job Garry

Keep battling on mate. Its looking good.

[Garry 1]

Another weekend spent tinkering with the car. My lower back is killing me!

 

I fitted the power steering pump brackets on Saturday, I needed some bushes which I got from Peugeot in order to fit them. The design of the kit requires the pump to be relocated down by the sump where the A/C pump normally sits (on the GTI6).

I don’t run power steering on the 205, but the route of the supercharger drive belt requires the pulley, I had tried getting around it but the bolts that hold the supercharger brackets in place fouled my non pas route.

 

 

 

I had considered running a PAS pump dry and unconnected, but I am not sure if the fluid acts as a lube and helps cooling. So instead, Rich Walker has offered to make a Dummy PAS pump with a pulley which would solve the potential problem.

 

Rich had planned to make the dummy pump circular but it would have fouled the radiator, so now it will have a slice taken off like this:

 

 

I have had to change the lower valence too, I had planned to run the original, to keep it looking stealthy , but there isn’t room for the intercooler and the new rad. So now the cooler will be on full display hanging out of the front, very Fast and the Furious I know, but this way the rad and the intercooler will get plenty of air.

I plan to fit the engine oil cooler and Supercharger fluid cooler behind the two circular cut outs (originally for spot lamps), I added another couple for good measure too! I also managed to round off the thread whilst trying to fit one of the outlet fittings to the charger cooler, more money to spend!

 

 

I have also made a plate to mount the swirl pot and external fuel pump, I have cut through the bulkhead to allow the ECU to be placed in the passenger foot well. I am pretty pleased with the results:

 

 

 

[welshpug 1,657]

just a suggestion garry but could the charger etc be mounted with countersunk bolts to allow a different belt routing?

[Garry 1]

How do you mean? To space it out a bit? If so, no.

The belt needs to line up with the crank and alternator pullies. Its really annoying, the head of the bolt that holds the charger bracket sticks out a bit, which stops my short cut.......... hang on, I think I know what you mean!

 

I suppose you could do, but there wouldn't be much plate left if you did counter sink. Its too late for me, to fit the bolts into the bracket you need to remove the engine as there isn't enough clearance between the wheel arch and the bracket. I don't think Rich can reinforce from behind as that would push the bracket out again.

 

Thanks for your input.

[tidypug 5 2 Cars]

Good to see you making progress with this.

If i was to use a thin rad would there be room to run pas as i want to retain mine if possible.

[smighall 1]

Liking the swirl pot setup, given me a few more ideas for mine now

[Garry 1]

Good to see you making progress with this.

If i was to use a thin rad would there be room to run pas as i want to retain mine if possible.

 

I think so, yes. Although I havent tried a real PAS pump!

 

If it was close, you could always move the rad forward a bit.

[tom_m 0]

Good to see you making progress with this.

If i was to use a thin rad would there be room to run pas as i want to retain mine if possible.

 

switch to ePAS using a 106/saxo pump, that way you get to keep the PAS but aren't tied to keeping the pump on the sump.

[base-1 17]

now the cooler will be on full display hanging out of the front, very Fast and the Furious I know, but this way the rad and the intercooler will get plenty of air.

If you want to tone down the barry aspect, paint the cooler black for maximum stealthyness

[Garry 1]

I like that idea, any suggestions on the type of paint to use?

[James_R 3]

matt stove paint, matt finish transfers heat better, black does too.