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Forums › Tuning, Modification & Legal › Project Cars › Project sleeper |
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 Posted: Sun May 01, 2011 7:28 am |
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Joined: Feb 08, 2010
Posts: 7045
Trade Rating: +5
Location: In the garage
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Well it's all back together now. Plenty of coolant added this time and there are no leaks either. All the wiring is secured and I've added some more convoluted tubing to tidy the wiring up further.
I went through my tool cabinet and I was amazed at the amount of little parts I've got left over. Most of this is because of Peugeot only supplying parts in minimum quantities. Best bit is often when if I order two parts they just give me the rest of the parts for free. So I end up with a pile like this.
I've still got loads of little wiring bits left over too.
I also priced up the cost of a Jenvey throttle linkage, 42x90mm air horns, air filter back plate and sausage filter (not sure if this will fit alongside the PAS pump though) and it's all rather expensive. I need this lot to be able to measure the available space for a new shorter radiator. Getting rid of the air conditioning will mean the radiator can sit further forwards (the alloy rads tend to be thicker than standard) and without the A/C condensor etc the radiator can be made a few inches wider than it currently is meaning the surface area and coolant capacity can be maintained. Radiators are about £500 with a fan. I might specify two fans if there is space. The original Peugeot fan will be removed and the standard radiator housing will be trimmed to allow more air to flow through it to the radiator.
This is all that's exposed to the airflow as standard.
Not sure what country this is from but I think that's the sort of opening I will try to use on mine.
Not sure if I've specified the correct air filter back plate but I just wanted to see roughly how much it would cost. So I need about £900 for new radiator, fans and the parts below. Bargain.
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| 2001 GTi 138, Bilstein Sprint dampers, H&R springs, 21mm Peugeot Sport torsion bars, 22mm rear ARB, Peugeot Sport Group A wishbones, 283mm discs, Goodridge stainless hoses, Maniflow 304 grade 4-2-1 2.5" manifold and system, 200 cell cat, Richard Longman head, 45mm Jenvey throttle bodies, 9.5mm TB spacers, 90mm air horns, Jenvey throttle linkage, Jenvey fuel rail, Aeromotive and Goodridge fuel fittings and braided hose, ITG sausage filter, Radtec custom radiator, Piper Ultimate Road cams, Piper vernier pulleys, Omex 600 ECU. Saxo electric PAS pump, Vibra Technics engine mounts. Samco coolant hoses, TTV steel flywheel, 4.76 final drive ratio, 307 CC 180 ratios. 2019 BMW 530i. 2017 Mercedes C300 convertible. | |
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Posted: Sun May 01, 2011 5:56 pm |
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Joined: Feb 08, 2010
Posts: 6055
Trade Rating: +53
Location: Salisbury / New Forest
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Still looks good but you have a rusty bolt on the bonnet latch 
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Posted: Mon May 02, 2011 12:55 am |
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Joined: Feb 08, 2010
Posts: 7045
Trade Rating: +5
Location: In the garage
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That picture was from years ago. It's a lot cleaner now.
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| 2001 GTi 138, Bilstein Sprint dampers, H&R springs, 21mm Peugeot Sport torsion bars, 22mm rear ARB, Peugeot Sport Group A wishbones, 283mm discs, Goodridge stainless hoses, Maniflow 304 grade 4-2-1 2.5" manifold and system, 200 cell cat, Richard Longman head, 45mm Jenvey throttle bodies, 9.5mm TB spacers, 90mm air horns, Jenvey throttle linkage, Jenvey fuel rail, Aeromotive and Goodridge fuel fittings and braided hose, ITG sausage filter, Radtec custom radiator, Piper Ultimate Road cams, Piper vernier pulleys, Omex 600 ECU. Saxo electric PAS pump, Vibra Technics engine mounts. Samco coolant hoses, TTV steel flywheel, 4.76 final drive ratio, 307 CC 180 ratios. 2019 BMW 530i. 2017 Mercedes C300 convertible. | |
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Posted: Sat May 07, 2011 5:29 am |
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Joined: Feb 08, 2010
Posts: 7045
Trade Rating: +5
Location: In the garage
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This is what makes it all work...Much better sat in here away from the elements.
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| 2001 GTi 138, Bilstein Sprint dampers, H&R springs, 21mm Peugeot Sport torsion bars, 22mm rear ARB, Peugeot Sport Group A wishbones, 283mm discs, Goodridge stainless hoses, Maniflow 304 grade 4-2-1 2.5" manifold and system, 200 cell cat, Richard Longman head, 45mm Jenvey throttle bodies, 9.5mm TB spacers, 90mm air horns, Jenvey throttle linkage, Jenvey fuel rail, Aeromotive and Goodridge fuel fittings and braided hose, ITG sausage filter, Radtec custom radiator, Piper Ultimate Road cams, Piper vernier pulleys, Omex 600 ECU. Saxo electric PAS pump, Vibra Technics engine mounts. Samco coolant hoses, TTV steel flywheel, 4.76 final drive ratio, 307 CC 180 ratios. 2019 BMW 530i. 2017 Mercedes C300 convertible. | |
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Posted: Sat May 07, 2011 5:49 am |
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Joined: Feb 08, 2010
Posts: 7045
Trade Rating: +5
Location: In the garage
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So who knows anything about Jenvey linkage kits?
Apparently to fit the linkage I do also need to buy a new lever for the bodies. So on top of the £130 for the linkage kit a new lever will cost £30. These levers are fitted as standard so when Ecosse fitted a linkage that wasn't specified it also meant a different lever was fitted. Thanks!
So the drawing below shows the inner throttle cable is double ended. I.e. there is a barrel/nipple at both ends of the cable. The bottom photo shows the barrel being at just one end of the cable. So how is the cable clamped???
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| 2001 GTi 138, Bilstein Sprint dampers, H&R springs, 21mm Peugeot Sport torsion bars, 22mm rear ARB, Peugeot Sport Group A wishbones, 283mm discs, Goodridge stainless hoses, Maniflow 304 grade 4-2-1 2.5" manifold and system, 200 cell cat, Richard Longman head, 45mm Jenvey throttle bodies, 9.5mm TB spacers, 90mm air horns, Jenvey throttle linkage, Jenvey fuel rail, Aeromotive and Goodridge fuel fittings and braided hose, ITG sausage filter, Radtec custom radiator, Piper Ultimate Road cams, Piper vernier pulleys, Omex 600 ECU. Saxo electric PAS pump, Vibra Technics engine mounts. Samco coolant hoses, TTV steel flywheel, 4.76 final drive ratio, 307 CC 180 ratios. 2019 BMW 530i. 2017 Mercedes C300 convertible. | |
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Posted: Sat May 14, 2011 2:58 pm |
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Joined: Feb 08, 2010
Posts: 7045
Trade Rating: +5
Location: In the garage
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Did some more fiddling today. I took the front bumper and headlights off to access the fan wiring.
Previously the relay contacts have been a bit crusty so they were cleaned up. The fan was working when the engine got warm. When removing the cover with the relays lots of green dust was falling out of the lower relay block...the picture below shows why.
When I joined the two power wires from the relay to create the circuit the fan kicked in at full speed. It was a lot louder than I've ever heard before so I don't think the high speed fan has been working for a long time.
To connect the fan to the Omex I'm going to keep the existing standard power (the fuse too) and earth wiring and connect the Omex trigger straight to the original relay. I'll only have the high speed fan so it won't switch on when the A/C is switched on but that's no problem. I'll also get the strip out lots of redundant wiring to the low speed fan relay.
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| 2001 GTi 138, Bilstein Sprint dampers, H&R springs, 21mm Peugeot Sport torsion bars, 22mm rear ARB, Peugeot Sport Group A wishbones, 283mm discs, Goodridge stainless hoses, Maniflow 304 grade 4-2-1 2.5" manifold and system, 200 cell cat, Richard Longman head, 45mm Jenvey throttle bodies, 9.5mm TB spacers, 90mm air horns, Jenvey throttle linkage, Jenvey fuel rail, Aeromotive and Goodridge fuel fittings and braided hose, ITG sausage filter, Radtec custom radiator, Piper Ultimate Road cams, Piper vernier pulleys, Omex 600 ECU. Saxo electric PAS pump, Vibra Technics engine mounts. Samco coolant hoses, TTV steel flywheel, 4.76 final drive ratio, 307 CC 180 ratios. 2019 BMW 530i. 2017 Mercedes C300 convertible. | |
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Posted: Sun May 15, 2011 6:20 am |
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Joined: Feb 08, 2010
Posts: 7045
Trade Rating: +5
Location: In the garage
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All finished now. Fitted with a new relay (could have used the originals but can a 10 year old relay be 100% trusted?), a new relay holder and new convoluted tubing.
There are two tubes, one for the +ve's to power the fan and to switch the relay, the other tube for the earths one straight to the fan and the other one is the trigger to the relay from the Omex.
A lot neater than before and manage to remove a few surplus wires, two relays and the resistor. Think of the weight savings!
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| 2001 GTi 138, Bilstein Sprint dampers, H&R springs, 21mm Peugeot Sport torsion bars, 22mm rear ARB, Peugeot Sport Group A wishbones, 283mm discs, Goodridge stainless hoses, Maniflow 304 grade 4-2-1 2.5" manifold and system, 200 cell cat, Richard Longman head, 45mm Jenvey throttle bodies, 9.5mm TB spacers, 90mm air horns, Jenvey throttle linkage, Jenvey fuel rail, Aeromotive and Goodridge fuel fittings and braided hose, ITG sausage filter, Radtec custom radiator, Piper Ultimate Road cams, Piper vernier pulleys, Omex 600 ECU. Saxo electric PAS pump, Vibra Technics engine mounts. Samco coolant hoses, TTV steel flywheel, 4.76 final drive ratio, 307 CC 180 ratios. 2019 BMW 530i. 2017 Mercedes C300 convertible. | |
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Posted: Sun May 15, 2011 10:46 am |
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Joined: Jan 25, 2010
Posts: 3497
Trade Rating: +31
Location: VVT Land, Fife
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Looking good! You could probably get away with chopping more out of the fan surround than the standard one shown too?
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Posted: Sun May 15, 2011 1:31 pm |
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Joined: Feb 08, 2010
Posts: 7045
Trade Rating: +5
Location: In the garage
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I'm leaving the fan housing as it is for now. I have an extra little hole for air to flow through where the resistor sat!
When I get the custom radiator with two smaller fans I'll judge how much fan housing needs trimming. I've already ordered all the wiring bits for the two fans. i.e. another relay and holder with terminals etc.
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| 2001 GTi 138, Bilstein Sprint dampers, H&R springs, 21mm Peugeot Sport torsion bars, 22mm rear ARB, Peugeot Sport Group A wishbones, 283mm discs, Goodridge stainless hoses, Maniflow 304 grade 4-2-1 2.5" manifold and system, 200 cell cat, Richard Longman head, 45mm Jenvey throttle bodies, 9.5mm TB spacers, 90mm air horns, Jenvey throttle linkage, Jenvey fuel rail, Aeromotive and Goodridge fuel fittings and braided hose, ITG sausage filter, Radtec custom radiator, Piper Ultimate Road cams, Piper vernier pulleys, Omex 600 ECU. Saxo electric PAS pump, Vibra Technics engine mounts. Samco coolant hoses, TTV steel flywheel, 4.76 final drive ratio, 307 CC 180 ratios. 2019 BMW 530i. 2017 Mercedes C300 convertible. | |
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Posted: Thu May 19, 2011 9:40 am |
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Joined: Feb 07, 2010
Posts: 3085
Trade Rating: +12
Location: Essex
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Very interesting Ed. I was looking at the problem of re-locating the ballast resistor today. If the fan is only used on full power it could be removed completely....this would allow more room for an oil cooler radiator in front of the cowl.... didnt think of that. Nice one mate... thank you
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Posted: Thu May 19, 2011 12:42 pm |
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Joined: Feb 08, 2010
Posts: 7045
Trade Rating: +5
Location: In the garage
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I thought you'd have done it already. I could have kept the two speed arrangement but it's gone now! I could have just wired the Omex to trigger the high speed fan instead. Much tidier now.
It's quite good fun sitting at the front of the car with the laptop connected to the Omex and switching the fan on and off.
Also spent £18 on new bolts. Minimum order quantities again so a good stash of spares in the garage.
New earth bolts for rad fan earth and those on the inner wings too.
Old
New
New nuts and bolts for where the wings bolt to the bumper. Mine had been off before but were still a little seized. So new ones were ordered and fitted with plenty of copper grease on them.
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| 2001 GTi 138, Bilstein Sprint dampers, H&R springs, 21mm Peugeot Sport torsion bars, 22mm rear ARB, Peugeot Sport Group A wishbones, 283mm discs, Goodridge stainless hoses, Maniflow 304 grade 4-2-1 2.5" manifold and system, 200 cell cat, Richard Longman head, 45mm Jenvey throttle bodies, 9.5mm TB spacers, 90mm air horns, Jenvey throttle linkage, Jenvey fuel rail, Aeromotive and Goodridge fuel fittings and braided hose, ITG sausage filter, Radtec custom radiator, Piper Ultimate Road cams, Piper vernier pulleys, Omex 600 ECU. Saxo electric PAS pump, Vibra Technics engine mounts. Samco coolant hoses, TTV steel flywheel, 4.76 final drive ratio, 307 CC 180 ratios. 2019 BMW 530i. 2017 Mercedes C300 convertible. | |
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Posted: Thu May 19, 2011 12:46 pm |
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Joined: Feb 07, 2010
Posts: 3085
Trade Rating: +12
Location: Essex
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mine has all gone.... its for another car that is getting an oil cooler but the plug was in the way
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Posted: Thu May 19, 2011 12:49 pm |
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Joined: Feb 08, 2010
Posts: 7045
Trade Rating: +5
Location: In the garage
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Is it fitted with an aftermarket ECU too?
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| 2001 GTi 138, Bilstein Sprint dampers, H&R springs, 21mm Peugeot Sport torsion bars, 22mm rear ARB, Peugeot Sport Group A wishbones, 283mm discs, Goodridge stainless hoses, Maniflow 304 grade 4-2-1 2.5" manifold and system, 200 cell cat, Richard Longman head, 45mm Jenvey throttle bodies, 9.5mm TB spacers, 90mm air horns, Jenvey throttle linkage, Jenvey fuel rail, Aeromotive and Goodridge fuel fittings and braided hose, ITG sausage filter, Radtec custom radiator, Piper Ultimate Road cams, Piper vernier pulleys, Omex 600 ECU. Saxo electric PAS pump, Vibra Technics engine mounts. Samco coolant hoses, TTV steel flywheel, 4.76 final drive ratio, 307 CC 180 ratios. 2019 BMW 530i. 2017 Mercedes C300 convertible. | |
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Posted: Thu May 19, 2011 12:53 pm |
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Joined: Feb 07, 2010
Posts: 3085
Trade Rating: +12
Location: Essex
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no.... it has the standard set-up at present....
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Posted: Thu May 19, 2011 2:43 pm |
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Joined: Apr 25, 2011
Posts: 70
Trade Rating: 0
Location: Earth.
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If you get stuck on anything get in touch with Scott at SP-Developments i'm sure he can help you out with stuff. 
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| In SlowMotion Motorsport. | |
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