[engine_work] Project 205 8v To Gti6

[djinuk 2]

somes pics of the engien bay second time round.

 

Opinions welcome.

 

seam sealer spec brush

 

 

guide coat after high build ready to flat

[djinuk 2]

 

And just to show , i havnt got massive funds, nor have i got a garage (not one for my car to go in anyway, the weather was bad so we improvised.

 

[djinuk 2]

Turned attention today towards the engine, stripped it down and gave the main block and oil cooler a lick of engine paint, its halfords gloss black stuff and i must say hats off , fast drying easy to apply and great coverage, spot on for £5 or so. Also i replaced copper washers for all the senders, fitted Sandys Tpiece adapted and fitted a genuine pug oil filter to the engine. Also whizzed of the cambelt cover to check condition, it all looks about new but ill be changing it anyway for piece of mind.

 

 

 

 

[djinuk 2]

Well i attacked the brake servo and master cylinder with hammerite spray paint , first thing i will say is this stuff is a nightmare to paint and goes on like piss, seams the lightest coat ever is needed to give the paint something to stick to once its gone tacky, anyway here are a few pics.

 

 

quick pic of first coat on the master cylinder *just shows how thin the paint is*

 

then gave my gearbox a lick of paint to tidy it up.

[205freak 7 1 Cars]

Looking very nice, more pics please.

[djinuk 2]

bit of an update, firstly i brought and fitted a 1.9 mi16 push clutch to the gti6 engine and bolted on the gearbox.

 

Then i reseamsealed the eghaust tunnel where the heat had caused the o/e stuff to all crack of.

 

shutzz the front arches

 

Gave the driving light cases a lick of paint as they were battered after only 4 months of use (denji/bad quality)

 

Then fitted Various brackets, subframe and brake servo back into the engine bay.

along with a pair of new pug arb bushes

[SurGie 54]

Are they pug bush's, as i heard you carnt get them anymore?

Iv heard that poly bush's dont fit very well if that is what they are?

The project is looking good, nice shiny engine bay!

[SteveW 6]

top work your doing there, looks really good fair play

[djinuk 2]

nah , they are certainly genuine bushes mate, around £15 i think they were, the ones i removed were pretty much new funny enough. Thanks for the kind comments i do try .

[djinuk 2]

Well i decided to have a shot at bolting up the engine today, the big ass heavy thing it is. Ignore the unpainted battery tray , that will be coming off at a later date for paint.

 

 

so at the moment its bolted in under the gearbox and the front drivers side top mount, fork mount isnt bolted as i need to adjust the manifold before it will fit. So far ive sliced the manifold across the bottom ready to bend it however my grinder could not get far enough into it so i fear i made need 10 mins with a hack saw.

 

 

I managed a few scuff marks but there were kept at a minmium

[marksorrento205 80]

Looking sweeeet Good job fella

[Spiky 37]

welded the manifold yet?

 

getting there matey

[djinuk 2]

thanks folks, nah , ive just cut halfway thru but the manifold isnt possible to bend by hand so going to have to get a torch to heat it up some.

[djinuk 2]

is it possible to fit a clutch the wrong way ? reason i ask is today ive been doing a clutch on the ford ka (my 2nd clutch ever) and noticed that there is a specific side to face the flywheel. Just wondering as i cant remmber seeing this marking on my gti6 clutch.. If it can be fitted the wrong way how do i go about checking this ? .. i.e is there an easier way then taking off the gearbox and pressure plate.

[djinuk 2]

got the engine in today , with the manifold cut and bent (still needs welding up) good clearance all round, not tried it with the master cylinder yet.. really happy though, here are the pics.

 

[2052006 10]

My conversion is at about the same stage as your's. Do you know how you're doing the downpipe / rest of the exhaust yet?

[djinuk 2]

not relaly looked into it yet, but ill probably get a 306 xsi or similar down pipe, and cut/modify it to fit my magnex system

[djinuk 2]

Got the manifold all welded up and threw a die grinder around the inner edge to get it smooth.

 

Also scotched up the thottle body and gave it a coat of paint.

 

And also preped up the inlet manifold with some scotch , and chucked some etch primer on the areas where i had gone through the original paint to metal.

[djinuk 2]

theres been a delay in updates as the things ive been doing include

 

fitting genuine cambelt kit

replacing nuts and bolts from the subframe,

fitted engine and loom and fired it up for the first time and it all works.

collected a pair of new front wings

 

and now ive just stripped the manifold back down for paint and im working out the route to take with regards to plumbing the engine in.

 

[Tom Fenton 1,542]

Take your time with the wings to make them fit, if you just bolt them on they are usually awful. As a guide you will probably need to trim the top back edge near the windscreen, and bend the bottom near where it meets the door to make it line up.

[djinuk 2]

Take your time with the wings to make them fit, if you just bolt them on they are usually awful. As a guide you will probably need to trim the top back edge near the windscreen, and bend the bottom near where it meets the door to make it line up.

 

 

yea mate, i will be doing, in that pic they are just bolted these so that they are out the garage, and out the way of people who will probably bend them.

[djinuk 2]

Ive also been plumbing in the gti6 using some of the 8v hosing aswell as the thermostat adapter (curtoisy of baker bm) and some random hosing from scrapyards.

 

 

Ive not plumbed up the oil cooler housing as im going to get a remote oil cooler (mocal or similar)

 

Only thing ive realised now is the only bleeding point i have is the one on the thermostat, any ideas if i will manage to bleed the system ok.

[djinuk 2]

well, i gave the inlet and cam covers a pruce up with some fresh paint, after scothing and panel wipe, they came up ok so thats all back on now.. Also i found a carvan shop that does 8mm fuel line and all the ends i need so on wednesday night ill be fitting new fuel lines to the car throughout and a 106 gti fuel filter underneath the car.

 

 

 

Also i took a video of the car running up to temp. (no manifold)

 

and the section i needed to cut for clearance

 

Also i have two redundant plugs hanging about the throttle body area.. do i need them ?

[djinuk 2]

bit of an update, cars now on 4 wheels, with new wheel bearing etc, theres clearance with the borbets on the gti6 calipers, but only just, Ive fitted new fuel lines and opted for using the 306 fuel filter and mounting it below the rear brake compensator, i used the original barbed plastic connections etc to fit the fuel filter using the original quick release fittings and all seems well.

 

 

I guess ill soon be at a stage to look at the bodywork to some degree and get help from friends

 

[Spiky 37]

plugs

 

there is normally a black plug just hanging around

 

the blue,

 

could be oil temp?

you probably got a white one too, whixh was connected to the air con