[car_restoration] Alien Vs. 205

[B1ack_Mi16 67]

Also as a downpipe for the 309 GTi16 exhaustmanifold was impossible to get anywhere, I got a mate to make me a 321 stainless 2.25" pipe with a 45 degree flare on it.

 

Not perfect so I had to clean it up in the lathe.

 

 

Made an backing plate to fix it to the exhaust flange

 

 

 

[B1ack_Mi16 67]

1 minute ago, wicked said:

Nice work!

 

How did the pizza taste like, after baking the calipers... ?? 

My other half does not allow me to use the oven for baking parts.....

 

 

Not too bad after some venting... my other half already left me....

[B1ack_Mi16 67]

Sorting out messy stereo and speaker wiring in the loom

 

Put the bottom end together (though I had pics of that too but couldn't find them now), and then lifted it into the bay just by my hands. A bit of a struggle but easier than I had thought. Then mounted the clutch.

 

Gearbox next to get in

 

 

[B1ack_Mi16 67]

Then started to work on the engine loom, had a 3 ROW Mi16 ECU and a couple of engine looms from 405 Mi16 with CAT. Took the loom in worst condition and started on that as a basis.

Put manifold in place and tried to find a nice path for the wiring. Relay box will sit where the jack is orginally located.

 

On the inside of the bulkhead I modified the car side of the orginal loom with some other plugs so I got 3 plugs instead of 2 (didn't wanna destroy the orginal 205 loom I had so did it this way, also possible to add some wires if needed now).

 

 

[B1ack_Mi16 67]

Also continuing a bit on the exhaust, trial fitting downpipe flange.

 

And attacked the inlet manifold with the angle grinder for shortening. Don't wanna chop the rad cowling.. think I took it down approx 4-5cm.

 

Ready for welding... made sure to keep the coil mounting points to still have as OE look as possible.

[B1ack_Mi16 67]

Inlet was then welded by a good friend of mine.

 

 

More or less completely smooth transition on the inside of all ports.

 

Had to put a T16 fuel rail on it as the orginal Mi16 one didn't fit anymore, the fuel pressure regulator would foul the coil. Anyway the more modern one with the small central FPR looks much better.

 

[B1ack_Mi16 67]

Had to get a rather small battery to have any chance of fitting an air-filter between the headlamp, battery and washer bottle.

 

Also recieved the exhaust mufflers so started putting them into place.

 

 

 

[B1ack_Mi16 67]

A big thank to Hilgert for getting me a Phase2 / Diesel? expansion tank!

 

However, even though it fits much better than the orginal oval one, it didn't clear the exhaust manifold from the 309 GTi16.

 

So needed to start modifying the manifold a slight bit, out with the angle grinder.

 

[B1ack_Mi16 67]

Started working more on the exhaust after I recieved my mandrel bends

 

 

Off the car, finished spot welding

 

Finished downpipe with cat.

[B1ack_Mi16 67]

After trying a few different air-filter solutions, and thinking of making a smaller hose from the throttle body etc. to make better space, I managed to get this filter that seem to fit in there.

I might try to spray it black later on.. at least it fits in the limited space.

 

 

Also notice I moved the servo steering reservoir as there was no possibility keeping it in the standard location. Now it sits close to the orginal Mi16 servopump and also the steering rack.

[GLPoomobile 958]

I didn't have a problem getting a decent sized Green Filters jobbie squeezed in between the headlight and washer bottle. Well, I say squeezed, but actually there was space to spare. And by decent size I mean it was one that was rated for the appropriate BHP for an Mi. On mine I moved the washer bottle back about an inch. If you move the loom that runs around the shock tower and behind the washer bottle (just needs moved a bit, not totally re-routed) and then modify the bracket for the bottle, you can push it right back towards the shock tower. Seems insignificant but that's all that mine required to give more than adequate space.

 

No disrespect meant here, but do you know if that filter is going to be any good (will it flow well enough)? I only ask as it looks a bit cheap and cheerful 

[B1ack_Mi16 67]

It is cheap indeed. But I'll test it, it is only 160bhp it's gonna flow and I actually think it will be ok. Impressive how little air is needed for this power levels

[B1ack_Mi16 67]

Exhaust manifold was slightly reshaped and TIG welded
 

 

 

And I started to make a bracket for the fusebox and a stereo power cable fuse holder

[B1ack_Mi16 67]

Bought some speakers for the rear and the doors and started mounting those

 

And the new modern EV14 injectors arrived for the engine

 

And picked up the head from the machinist after a small porting job and freshly ground valves and cut seats.

 

 

Refurbed some lifters using Petert's method and started assembling head

 

 

[B1ack_Mi16 67]

Exhaust manifold in place on head

 

Block ready for head

 

Bolted down

 

Also finally recieved the correct type of pigtails/connectors for the injectors

 

[B1ack_Mi16 67]

Started on the injector wiring. had to use spacer hats on top of the injectors to make them fit though, they are a bit shorter than the standard ones.

 

And also started working on the interior now, trying to figure out how the dash comes together

 

First trial fit of the dash

[B1ack_Mi16 67]

Bolted down the rockercover after the seal kit arrived from Spoox.

 

And got some steering wheels to chose from in the mail from a mate

 

Found out I had orginal headlights from Valeo in my own stock, after I had ordered some new cheap headlamps as Valeo seemed to be unavaliable these days... How much one forgets that are in stock when projects takes 10years ish!

 

Also started fabricating a stainless coolant pipe to go from the matrix outlet down to the waterpump inlet/distributor on back of engine.

[B1ack_Mi16 67]

Engine bay starts to look quite complete now

 

Had the waterpipes TiG welded and made de-airing screws on them both. Also had a 321 stainless pipe cut at an slight angle to use as exhaust tip.

 

Exhaust outlet

[B1ack_Mi16 67]

Got the 306 GTi fuel rail in the post, cleaned it and painted it.. then added the fuel hoses. Nicer hose layout with this one compared to the S16/T16 one I had there before.

 

After messing around with filling engine with water, it had some leaks here and there. Even from the thermostat outlet... I found another one that was much thicker and more rigid, which seemed to fix the weeping...

 

In addition after faffing about with different injectors and some diagnostics related to fuelling, the paint was gone and fuel rail a mess... decided to paint it with 2pac black and then add some 2pac clear for gloss.. now it will not get messy by petrol spillage..!

[B1ack_Mi16 67]

A small video of first startup attempt

 

Incredible different in noise level with and without the exhaust tip in place

 

 

[B1ack_Mi16 67]

Exhaust tip welded into place

 

And I machined a small de-airing nipple to connect to the top radiator de-airing outlet. Can't be arsed having a hose from the rad to the tank, as it looks messy.

[B1ack_Mi16 67]

Some more progress on the dash

 

Managed to fit the ECU in the roof of the glove box with the amount of wiring that accidentally was avaliable after the loom was placed as it should in the engine bay.

 

And continued with some more assembly work.. starting to look like a car again now.

 

[B1ack_Mi16 67]

Updates coming to an end. Last progress from yesterday now.

 

Just engine bay more or less finished. You can see the radiator bleed nipple there too.

 

And more complete interior, CD player with DAB+ radio in place and started putting in the rear seat bottoms and side covers etc.

 

[Aroton 19 2 Cars]

Impressive work!

[bluesleeper 3]

This is looking nice dude! Keep us posted!