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Project sleeper
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#1: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Feb 08, 2010 1:42 pm
    ----
Just start a new topic off...the car goes in this Saturday to Ecosse for the throttle bodies to be fitted.

So from the beginning...way back in 2004...

 


Suspension got fitted...
Eibach Pro Kit springs, Bilstein Sport dampers, Peugeot Sport 21mm torsion bars (gravel rally spec).

 


Then some GTi 180 front brakes

 


Then some Goodridge braided hoses...

 


Then the 22mm GTi 180 rear roll bar

 


Then a Richard Longman cylinder head

 


Then a Maniflow 4-2-1 manifold and 2.5" system with 200cell cat.

 


During the summer I fitted some Peugeot Sport GP A wishbones and various other new suspension parts.

 


So this weekend it's going to Ecosse for the throttle bodies to be fitted which means I've had to do some shopping to prepare for the job.

Jenvey inlet manifold

 


Then an ACT products/ Jenvey/ Longman carbon airbox.

 


I also bought a new water pump, rocker cover gaskets, hydraulic lifters and a GTi 180 inlet manifold gasket. A new clutch has been fitted too.

 


 


It's also had a new dipstick fitted (Recommended for any older style 138 GTi)

 


In the last few weeks it's also had some new front discs and pads.

 


It all looks completely standard.
 

Last edited by Edward on Mon Feb 08, 2010 1:55 pm; edited 2 times in total

#2: Re: Project sleeper Author: AJS, Location: Scotland PostPosted: Mon Feb 08, 2010 1:45 pm
    ----
Cant wait for the work to be done at Ecosse Smile

Will you be up over a weekend at all? Im only down the road from there...

Oh and great to have you back Edward!

#3: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Mon Feb 08, 2010 1:46 pm
    ----
<3

#4: Re: Project sleeper Author: nakednakeddave, Location: aberdeen PostPosted: Mon Feb 08, 2010 1:46 pm
    ----
looks like its goin to be a bit of a beast, id love the suspension setup youve got

#5: Re: Project sleeper Author: Lecktorious, Location: Scotland PostPosted: Mon Feb 08, 2010 1:47 pm
    ----
Might pop along and say hello on Saturday Smile

#6: Re: Project sleeper Author: Cr4zYb0y, Location: Salisbury PostPosted: Mon Feb 08, 2010 1:47 pm
    ----
Looking forward to seeing this all done and dusted mate..!

#7: Re: Project sleeper Author: twed207, Location: borders, near carlisle. PostPosted: Mon Feb 08, 2010 2:04 pm
    ----
Shocked car looks ace edward! i think that's the first time i've ever seen it! lol

it's gonna sound orgasmic once the TB's are in!! Twisted Evil

#8: Re: Project sleeper Author: mattievrs, Location: Leicester PostPosted: Mon Feb 08, 2010 2:26 pm
    ----
First time ive seen the car ever! lol

What power you hoping for Edward?

#9: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Mon Feb 08, 2010 2:27 pm
    ----
Major love for the car, the man and the thread!

#10: Re: Project sleeper Author: Alan_206HDi, Location: Hatfield Heath, Herts PostPosted: Mon Feb 08, 2010 2:33 pm
    ----
Very nice indeed! What year is the car?

#11: Re: Project sleeper Author: misskayleigh, Location: Kings Lynn, Norfolk PostPosted: Mon Feb 08, 2010 2:48 pm
    ----
i love your car! look forward to seeing everything done to it!

#12: Re: Project sleeper Author: =ZiAn=, Location: Slovenia PostPosted: Mon Feb 08, 2010 3:09 pm
    ----
Very very nice, I see you've been spending quite some money as those are some of the best if not the best parts for modification (eibach, bilstein jenvey, etc.) Thumb Up . Will you be changing the cams as well? If so, which ones will you use? Also what ECU will you install?

#13: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Mon Feb 08, 2010 3:11 pm
    ----
Ecosse seem to like Omex/Emerald iirc

#14: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Feb 08, 2010 3:20 pm
    ----
Yes it's getting 42mm Jenveys, Piper Ultimate Road cams and Piper verniers fitted. Ecosse use Omex ECU's.

#15: Re: Project sleeper Author: Ruffy_206, Location: Bristol PostPosted: Mon Feb 08, 2010 5:25 pm
    ----
i love what you have done to it mate. keep up the good work

#16: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Mon Feb 08, 2010 5:28 pm
    ----
Wey hey,

Welcome back Paul.

I'd have popped along too for a blether but sadly, i'm working! It'll be a cracking car when its done.

#17: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Mon Feb 08, 2010 5:29 pm
    ----
Edward wrote:
Yes it's getting 42mm Jenveys, Piper Ultimate Road cams and Piper verniers fitted. Ecosse use Omex ECU's.

Which is weird because Sandy/Colin swear by DTA on PSA engines

#18: Re: Project sleeper Author: Dillon, Location: Kent PostPosted: Mon Feb 08, 2010 5:34 pm
    ----
Good to hear it's all going smoothly with the GTI seeing as it has to be the cleanest most pampered 206 ever!

#19: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Mon Feb 08, 2010 5:37 pm
    ----
Dillon wrote:
Good to hear it's all going smoothly with the GTI seeing as it has to be the cleanest most pampered 206 ever!

Really is!! When all the chavs crash their gti 138's, this will be worth a fortune one day Laughing

#20: Re: Project sleeper Author: EdCherry, Location: Wiltshire PostPosted: Mon Feb 08, 2010 5:40 pm
    ----
Jamie wrote:
Edward wrote:
Yes it's getting 42mm Jenveys, Piper Ultimate Road cams and Piper verniers fitted. Ecosse use Omex ECU's.

Which is weird because Sandy/Colin swear by DTA on PSA engines

Thats because Sandy is familiar with it and thats what he likes to map. It's down to the choice of who is mapping first and foremost of what ECU you should buy, then secondly what application it is for.

#21: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Mon Feb 08, 2010 5:46 pm
    ----
I agree, and by the sounds of it you know Sandy too. However he said DTA is the easiest, which is why it's his preference for TB on PSA engines...

#22: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Mon Feb 08, 2010 5:46 pm
    ----
Bonson's gti-6 uses omex management and he's over the 200bhp mark without cams... ok, it required a bit of tweaking with the exhaust, outlet manifold and so on, but it's still very impressive.

#23: Re: Project sleeper Author: Chi, Location: North London PostPosted: Mon Feb 08, 2010 5:53 pm
    ----
Can't wait for the completed article!! It's been a long time a coming!

#24: Re: Project sleeper Author: andyG, Location: Arbroath, Scotland PostPosted: Mon Feb 08, 2010 5:54 pm
    ----
and rapid as he blasted past me after university in Dundee last year

#25: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Mon Feb 08, 2010 6:02 pm
    ----
Yup, TB's certainly do make a car shift! He took me and graham out in it when he first got it done, we met him at ecosse when he went to collect it. He was a very happy lad! lol.

#26: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Mon Feb 08, 2010 7:28 pm
    ----
Will be me soon enough Very Happy

#27: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Mon Feb 08, 2010 7:48 pm
    ----
Nice one Paul, good to see you back.

#28: Re: Project sleeper Author: Austin, Location: Telford PostPosted: Tue Feb 09, 2010 6:00 am
    ----
Stunning GTi, what BHP will you be running with all the mods done? also what is the standard GTi torsion bar? as i see you have upgraded to a GTi 180?

#29: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Feb 09, 2010 6:12 am
    ----
No idea what the car will be running at...any guesses anybody?

The 138 GTi as standard has 19.5mm torsion bars and a 21mm rear ARB. I have 21mm torsion bars and a 22mm rear ARB.

#30: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Tue Feb 09, 2010 6:24 am
    ----
I'm gonna guess somewhere in the region of 175-185bhp

#31: Re: Project sleeper Author: Austin, Location: Telford PostPosted: Tue Feb 09, 2010 6:27 am
    ----
Edward wrote:
No idea what the car will be running at...any guesses anybody?

The 138 GTi as standard has 19.5mm torsion bars and a 21mm rear ARB. I have 21mm torsion bars and a 22mm rear ARB.

Cheers, are both these parts off a GTi 180? also are they a straight fit?

#32: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Tue Feb 09, 2010 6:39 am
    ----
I'd probably think the same as Jamie, around 185 ish.

#33: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Feb 09, 2010 6:49 am
    ----
So people don't trust the Longmans figures of 190bhp then?

#34: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Tue Feb 09, 2010 7:34 am
    ----
Bear in mind he has a longman's head folks....

#35: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Tue Feb 09, 2010 7:42 am
    ----
185 is close enough to 190!

I hate predicting figures, it's so hit and miss. Like my own project, could come out at 250, could come out at 275. Who knows!
It's all down to the exact conditions the engine has been under, the stress/strain put on it. And also the condition and production methods of all the parts that are being put on!

It could be miles out.

I'm just giving a rough figure, would be great to get over it yeah, and it most likely will. Just like to play it safe personally Smile

#36: Re: Project sleeper Author: =ZiAn=, Location: Slovenia PostPosted: Tue Feb 09, 2010 7:43 am
    ----
including the cams I'd be guessing in the region of 200. Judging by macj's rally 206 running at 183 with just ITB's mapping and exhaust iirc..+ comparing it to Spike's 206.

#37: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Tue Feb 09, 2010 7:50 am
    ----
Good point actually!

#38: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Tue Feb 09, 2010 8:31 am
    ----
The ManiPorn exhaust system is going to be able to work its wonders now as well. Am i right in saying though Tedward that you'd never put it on the rollers? Surely you'll be a little bit more curious now? Smile

#39: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Tue Feb 09, 2010 8:37 am
    ----
I was thinking that too Bri, I wouldn't be surprised if this broke the 200bhp barrier...

#40: Re: Project sleeper Author: Guy, Location: Solihull, Birmingham PostPosted: Tue Feb 09, 2010 8:41 am
    ----
Seb wrote:
185 is close enough to 190!

I hate predicting figures, it's so hit and miss. Like my own project, could come out at 250, could come out at 275. Who knows!
It's all down to the exact conditions the engine has been under, the stress/strain put on it. And also the condition and production methods of all the parts that are being put on!

It could be miles out.

I'm just giving a rough figure, would be great to get over it yeah, and it most likely will. Just like to play it safe personally Smile

I agree you there seb!

Loving that project! Will keep following this Wink

#41: Re: Project sleeper Author: Ross, Location: West Midlands PostPosted: Tue Feb 09, 2010 9:05 am
    ----
Cracking example, in some ways I wish I had the same sort of dedication to keep a car that long and get it to the sort of level you have. It'll be in another league when the TB's are on!

One thing though... first your username was Teddy, now Edward, and now I find out your name is actually Paul..... confused Laughing

#42: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Feb 09, 2010 3:10 pm
    ----
Brian wrote:
Am i right in saying though Tedward that you'd never put it on the rollers? Surely you'll be a little bit more curious now? Smile

They just show numbers...it's never had any mapping done and the throttle bodies and cams had always been planned so I never bothered wasting money on remaps etc. Therefore it has never been run on any rollers.

#43: Re: Project sleeper Author: Addaz, Location: Suffolk PostPosted: Tue Feb 09, 2010 3:18 pm
    ----
Predicting fiqures is like trying to guess the lottery numbers, only a few are ever correct Wink

But in my honest opinion i would be guessing 160 mark, sorry to be harsh but i dont want to get your hopes up if i say 180 and you come out with 140 Laughing

It all really depends on the actually construction of the engine, it could have been a friday afternoon job for all you know...

Example A
Ford main dealers way to constructing an engine
No labeled pistons, bung them in any order and see which fits best Rolling Eyes

Say the factory document say X one factory could make the fiqure Y while another Z

But anyways
I do like that about your car, simple yet effective Wink

#44: Re: Project sleeper Author: Ruffy_206, Location: Bristol PostPosted: Tue Feb 09, 2010 3:23 pm
    ----
comes with 138 standard would think it would be over 160 mate

#45: Re: Project sleeper Author: Addaz, Location: Suffolk PostPosted: Tue Feb 09, 2010 3:26 pm
    ----
Ruffy_206 wrote:
comes with 138 standard would think it would be over 160 mate

Well you say that....

But who says it still has 138? Or even left the factory with 138 to start with Wink

#46: Re: Project sleeper Author: Ruffy_206, Location: Bristol PostPosted: Tue Feb 09, 2010 3:30 pm
    ----
well just going by what they say and a few people have had these at rs tuning last year and seem to perform arounf their unlike the 180

#47: Re: Project sleeper Author: Addaz, Location: Suffolk PostPosted: Tue Feb 09, 2010 3:31 pm
    ----
Ruffy_206 wrote:
well just going by what they say and a few people have had these at rs tuning last year and seem to perform arounf their unlike the 180

Who knows mate, who knows.... Laughing

But im still going with the 160 mark Sad

#48: Re: Project sleeper Author: macj, Location: Essex PostPosted: Tue Feb 09, 2010 3:32 pm
    ----
Can I have a little prediction.......198-203HP Wink

#49: Re: Project sleeper Author: Addaz, Location: Suffolk PostPosted: Tue Feb 09, 2010 3:36 pm
    ----
macj wrote:
Can I have a little prediction.......198-203HP Wink

Thats with camshafts/other wierd and wonderful shiny things though? Laughing

I thought Ed wasnt going that far Confused

#50: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Feb 09, 2010 3:39 pm
    ----
Full spec will be...

Piper Ultimate Road cams (I think they are actually a 276 degree duration)
Piper vernier pulleys
42mm Jenvey bodies
Omex management
Richard Longman head
Maniflow 4-2-1 manifold and 2.5" system

#51: Re: Project sleeper Author: macj, Location: Essex PostPosted: Tue Feb 09, 2010 3:41 pm
    ----
addaz wrote:
macj wrote:
Can I have a little prediction.......198-203HP Wink

Thats with camshafts/other wierd and wonderful shiny things though? Laughing

I thought Ed wasnt going that far Confused

what you think now you seen the spec Very Happy
If I know edward he will opt for a good torque curve rather than all out BHP.... I love verniers

Last edited by macj on Tue Feb 09, 2010 3:45 pm; edited 1 time in total

#52: Re: Project sleeper Author: Addaz, Location: Suffolk PostPosted: Tue Feb 09, 2010 3:45 pm
    ----
Till i know the condition of the engine i wont hold my hopes high, sorry Sad

But if it was full spec 138 i would say near the 175 to 185 mark, as....

The only way to truely determine the torque/horsepower is to put it on the rolling road in which the factory car was tested on

As ALL rolling roads are different in one way or the other, or could even be space or conditions. So no one output will be the same, hence why you see increase/decrease from different comapnies Wink

Also i prefer to go by BHP on the wheels, so you will be looking at the 130 mark Wink

#53: Re: Project sleeper Author: WilkyGTi, Location: Cumbria, UK PostPosted: Tue Feb 09, 2010 3:51 pm
    ----
Well i think i'll just give in now! All this stuff looks mint, not to mention the car!

Did you get the lifters from Peugeot (obviously there genuine but could've been from a diff company)? I'm wanting to rebuild the top end and wanting to replace the lifters. Just wondering how much they set you back.

#54: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Feb 09, 2010 3:51 pm
    ----
It's all just a game of numbers. At the end of the day it's got the best parts with the right compromises for a road car. The power will be what it will be...If it doesn't make power than that's how it will stay.

Piper camshafts once told me the engine is a bit of a wet lettuce!

WilkyGTi wrote:

Did you get the lifters from Peugeot (obviously there genuine but could've been from a diff company)? I'm wanting to rebuild the top end and wanting to replace the lifters. Just wondering how much they set you back.

Yes I got the Peugeot lifters and list price is £380 I think. I asked for a discount and paid about £330.

#55: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Tue Feb 09, 2010 4:00 pm
    ----
Edward wrote:
It's all just a game of numbers. At the end of the day it's got the best parts with the right compromises for a road car. The power will be what it will be...If it doesn't make power than that's how it will stay.
And it'll most likely still be awesome to drive Smile

Numbers are numbers, I don't care what mine will make. I used to, with my 206, as I was led down a line of thought that 1bhp actually makes a difference. I've long since been rid of that thinking.

It makes what it makes, and unless it feels like something is up, then it's good enough for me.

#56: Re: Project sleeper Author: WilkyGTi, Location: Cumbria, UK PostPosted: Tue Feb 09, 2010 4:02 pm
    ----
Edward wrote:

Yes I got the Peugeot lifters and list price is £380 I think. I asked for a discount and paid about £330.

Wow! i didn't expect that price! may have to rethink my plans! for you its a must as its a performance engine, but mines only standard, got a sticky lifter atm so was just gonna buy another head and replace lifters and stem seals for a little project and peace of mind!

#57: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Feb 10, 2010 1:53 am
    ----
Mine splutters on start up and that happened as soon as the head was fitted. It might be something else but seeing as new cams are being fitted I thought it would be an ideal opportunity/excuse to replace them.

Euro Car parts do lifters for less money.

#58: Re: Project sleeper Author: t1mmy, Location: Reading PostPosted: Fri Feb 12, 2010 7:41 am
    ----
It's looking as good as ever, will be even better once the TB's are fitted.

#59: Re: Project sleeper Author: Luke, Location: Leeds PostPosted: Fri Feb 12, 2010 7:54 am
    ----
I'll be very disappointed if you never put this on a RR just for curiousity. I don't believe in them really, but graphs are nice to look at and give a ballpark figure.

I bet it'll shift some though. Wink

#60: Re: Project sleeper Author: jimmyfloydreturns, Location: Sittingbourne PostPosted: Fri Feb 12, 2010 8:09 am
    ----
Nice to see this thread again, it was one of my favourites before. Hopefully the weather won't stop you this time round Smile

#61: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Feb 12, 2010 11:58 am
    ----
Luke wrote:
I'll be very disappointed if you never put this on a RR just for curiousity. I don't believe in them really, but graphs are nice to look at and give a ballpark figure

It will be going on a rolling road to do the mapping.

#62: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Fri Feb 12, 2010 12:00 pm
    ----
Why are you using 42mm bodies Paul?
ie any particular reason? Sandy has sold me 45mm jobbies, and I double checked with him to make sure they're right... Did you opt for the CF air horns are standard aluminum ones?
Very Happy

#63: Re: Project sleeper Author: MattyP, Location: Plymouth PostPosted: Fri Feb 12, 2010 3:48 pm
    ----
Your engine mods sound mental mate, can't wait to see the finished result. The longman cylinder head, can it be fitted without the need for TB's?

#64: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Feb 12, 2010 3:58 pm
    ----
Jamie wrote:
Why are you using 42mm bodies Paul?
ie any particular reason? Sandy has sold me 45mm jobbies, and I double checked with him to make sure they're right... Did you opt for the CF air horns are standard aluminum ones?
Very Happy

The inlet manifold is 42mm so it makes sense to use bodies of the same size. There's no need to go any bigger. Smaller bodies give better throttle response too. The Jenvey website says 42mm is ideal for up to 56bhp per cylinder.
A 2 litre would be fitted with 45mm carbs and bodies tend to be smaller because they don't have the narrowing that a venturi in the carb has.

#65: Re: Project sleeper Author: t1mmy, Location: Reading PostPosted: Sun Feb 14, 2010 5:10 am
    ----
Did you drop it off ok yesterday?

#66: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Feb 14, 2010 6:45 am
    ----
Yes it was a great run to Ecosse. Took 4 hours including picking up my hire car in Glasgow. It's the longest drive I've done in the car for a couple of years. Avis gave me a VW Jetta 2.0 TDi 140...I booked a 90bhp Golf 1.6 TDi...

#67: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Feb 14, 2010 11:20 am
    ----
They gave me this...

 


It's got a handy ski hatch too...

 

#68: Re: Project sleeper Author: Ruffy_206, Location: Bristol PostPosted: Sun Feb 14, 2010 11:21 am
    ----
ha thats cute.

#69: Re: Project sleeper Author: Chi, Location: North London PostPosted: Sun Feb 14, 2010 11:29 am
    ----
How long will Ecosse have your car for? How does the VW compare to the GTi?

#70: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Feb 14, 2010 12:19 pm
    ----
It was booked in for the week. They couldn't promise it would be just a week though. I just hope they have actually ordered all the parts in ready to get on with the job. I paid them enough money up front to buy 90% of the parts required!

The Jetta is a nice car. It's very comfortable, well built with lots of low down punch but ultimately it's a bit boring. It's not supposed to be exciting though but would be a great family car. I want an everyday car so was looking at what they cost these days. I think it looks quite smart with the silver front grille and 17" wheels. What I can't work out is why is has no remote control for the stereo. If a basic 206 can have one why can't a Jetta that costs £18k ish?

#71: Re: Project sleeper Author: Austin, Location: Telford PostPosted: Sun Feb 14, 2010 1:13 pm
    ----
Your dog is well cute, the missus has just said she wants it lol. Good luck with the TB's. Wink

#72: Re: Project sleeper Author: Chi, Location: North London PostPosted: Sun Feb 14, 2010 1:30 pm
    ----
Fingers crossed for you Paul regarding Ecosse getting your car sorted in a week as agreed.

I vaguely remember you also buying a Vauxhall Signum a while a go? Have you sold that since?

#73: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Mon Feb 15, 2010 6:43 pm
    ----
Hope it all goes well, and following on from an old conversation we had, would be good to finally see you at a track day.... Smile

#74: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Mon Feb 15, 2010 6:57 pm
    ----
PANTS! I was there today too. I expect i'd politely be told to "just bolt pal" if i asked how it was getting on etc Razz

A week would be a pretty quick turnaround!

#75: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Mon Feb 15, 2010 8:03 pm
    ----
Did you buy your head direct from Longmans?
Can't wait for this to be done Very Happy

#76: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Feb 17, 2010 1:57 am
    ----
Brian wrote:
PANTS! I was there today too. I expect i'd politely be told to "just bolt pal" if i asked how it was getting on etc Razz

A week would be a pretty quick turnaround!

You were at Ecosse? Did you see it ?

They told me originally it would take a week although since then they wouldn't 100% commit to a week just in case...it is a big job but a week isn't impossible if they've ordered all the parts in advance (they had enough time and I paid them enough up front!)


Jamie wrote:
Did you buy your head direct from Longmans?
Can't wait for this to be done Very Happy

I bought it second hand. It was very clean though and had been finished off at a machine shop. It's a shame they can't be bought new anymore.

#77: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Wed Feb 17, 2010 4:07 am
    ----
I see, I'm interested because there is a cylinder head machinist opposite my house, only a little operation though which is why I'm a bit dubious to use them...
I have a spare GTi180 engine, so if it doesn't sell I'll be building that up and then stick that in all at once.

What kind of work should I ask to be done by the machine shop, ie in mm etc?

#78: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Wed Feb 17, 2010 4:28 am
    ----
I seem to vaguely remember something like 6/9 that I had off mine but don't quote me on that as I lost my thread with the site Sad

#79: Re: Project sleeper Author: Jon, Location: 666ft Below PostPosted: Wed Feb 17, 2010 4:31 am
    ----
Sometime little companies are better Jamie. See if you can find anyone they have done work for before?

#80: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Wed Feb 17, 2010 4:36 am
    ----
I've been in there a few times, asked to do work experience, only 2 men work there as far as I can tell!
I've never seen anyone trying to brick the place so it can't be that bad!
And thanks Seb but yours was a TU wasn't it Sad

#81: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Wed Feb 17, 2010 4:48 am
    ----
Yeah it was but afaik it will all be relative and even 6/9 is a fairly conservative amount. It's mostly to up the compression slightly and give the gasket a flat surface to sandwich with. As for porting I'd guess there are no definitive measurements for that as it will mostly be done on a case to case basis.

#82: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Wed Feb 17, 2010 6:24 am
    ----
Edward wrote:
You were at Ecosse? Did you see it ?

Nah, i didn't dude, it would have been hidden away in the workshop. I was literally just in and out of the place as I had other places to be Very Happy

#83: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Feb 17, 2010 6:35 am
    ----
Jamie wrote:

What kind of work should I ask to be done by the machine shop, ie in mm etc?

All depends how big the combustion chamber is in the head. Don't forget skimming the head changes the valve timing...which is where verniers come in handy to correct the timing again.

#84: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Fri Feb 19, 2010 4:34 am
    ----
will you be at fcs ed?

#85: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Feb 19, 2010 12:09 pm
    ----
spike_202 wrote:
will you be at fcs ed?

Naah.

#86: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Fri Feb 19, 2010 12:24 pm
    ----
Sad

#87: Re: Project sleeper Author: Iain, Location: Aberdeen, Scotland PostPosted: Fri Feb 19, 2010 12:31 pm
    ----
Edward, i think you have my favourite sig on the site.

#88: Re: Project sleeper Author: t1mmy, Location: Reading PostPosted: Fri Feb 19, 2010 1:16 pm
    ----
Are you getting it back tomorrow or do they need it for longer?

#89: Re: Project sleeper Author: wooders_09, Location: Cheshire PostPosted: Fri Feb 19, 2010 1:24 pm
    ----
Gorgeous mate. Would love to one day do a car to the standard you have on this.

#90: Re: Project sleeper Author: Andy_VXR PostPosted: Fri Feb 19, 2010 1:31 pm
    ----
To much talk of figures. At end of the day the figures are just down to the conditions at that time and as you know, all RR are different. As long as it drives right and feels like it should then thats what you should want.

#91: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Feb 20, 2010 2:19 am
    ----
Will get the car back next weekend.

Exactly, numbers are boring. It's got every part fitted that's best suited for road use. I've done my best in terms of spec so it will be what it will be.

Told my insurance yesterday about the changes and it only went up by £55 for the remaining 7 months of the policy. That's with Adrian Flux. It does make me worry when the person on the phone doesn't know what an ECU is though.

#92: Re: Project sleeper Author: Chi, Location: North London PostPosted: Sat Feb 20, 2010 5:21 am
    ----
Hahahaha @ Adrian Flux person!!

You will be driving back from Ecosse with a big grin on your face!

#93: Re: Project sleeper Author: Bailey, Location: Finding Dr. Robotnik PostPosted: Sat Feb 20, 2010 5:35 am
    ----
Even i know what an ecu is not that I know where it is under the bonnet thy guy must have been a ruhtard!

#94: Re: Project sleeper Author: Dave, Location: Birmingham PostPosted: Sat Feb 20, 2010 5:56 am
    ----
Looking forward to the pics mate!

#95: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Sat Feb 20, 2010 8:16 am
    ----
My insurance is cheaper next with the TB's than it is this year!
It's crazy!

#96: Re: Project sleeper Author: gti180boy, Location: Stafford PostPosted: Sat Feb 20, 2010 10:51 am
    ----
Edward have have to say that your car is very very clean lol Smile i love it

#97: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Feb 20, 2010 10:56 am
    ----
Couldn't justify spending thousands of £'s if it was in average X reg condition!

#98: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Sat Feb 20, 2010 11:01 am
    ----
Edward wrote:
Will get the car back next weekend.

Exactly, numbers are boring. It's got every part fitted that's best suited for road use. I've done my best in terms of spec so it will be what it will be.

Told my insurance yesterday about the changes and it only went up by £55 for the remaining 7 months of the policy. That's with Adrian Flux. It does make me worry when the person on the phone doesn't know what an ECU is though.

Do you have an agreed value on the car?

#99: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Feb 20, 2010 11:08 am
    ----
That's what I want to sort with them. I asked them what 'like for like' means on modifications and the response was a bit vague when I asked if the car was completely destroyed would I get back the value of the parts paid.

These insurance companies want everything declaring in writing by me to cover their backs but when I want clarification of something they can't give it

The base car can be replaced with another as there is no shortage of 206 GTi's around but the parts aren't available 2nd hand. Realistically it would cost £10k to build another of the same spec and there's no point in having fully comp insurance with everything declared if it came to the crunch and I couldn't build an identical car.

#100: Re: Project sleeper Author: Geoff, Location: Evesham, Worcestershire PostPosted: Sat Feb 20, 2010 12:20 pm
    ----
Its quite an issue in getting things declared. Endsleigh had a fit over fitting a towbar - they weren't sure whether they could insure me! I've read over a few forums now that some people are having there insurance cover void because they are fitting winter wheels! A friend of mine rang up his insurance and the woman didn't know what a steel wheel was! Rolling Eyes

#101: Re: Project sleeper Author: Lecktorious, Location: Scotland PostPosted: Fri Feb 26, 2010 1:14 pm
    ----
Picking the car up tomorrow then Paul? Thought you might also get that scuff on the front O/S SP arch sorted while the car was in getting the TB's fitted.

#102: Re: Project sleeper Author: Ruffy_206, Location: Bristol PostPosted: Fri Feb 26, 2010 1:17 pm
    ----
G. wrote:
Picking the car up tomorrow then Paul? Thought you might also get that scuff on the front O/S SP arch sorted while the car was in getting the TB's fitted.

lol stop being picky.

#103: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Feb 26, 2010 3:18 pm
    ----
G. wrote:
Picking the car up tomorrow then Paul? Thought you might also get that scuff on the front O/S SP arch sorted while the car was in getting the TB's fitted.

Err...no and I like the scratch gives it some individuality.

#104: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Fri Feb 26, 2010 3:42 pm
    ----
I have a spare moonstone offside rear arch extension if you want it?

#105: Re: Project sleeper Author: Lecktorious, Location: Scotland PostPosted: Fri Feb 26, 2010 3:52 pm
    ----
Edward wrote:
G. wrote:
Picking the car up tomorrow then Paul? Thought you might also get that scuff on the front O/S SP arch sorted while the car was in getting the TB's fitted.

Err...no and I like the scratch gives it some individuality.

Laughing is it to add to the sleeper look? Just thought you would have got it tidyed up considering how well looked after the rest of the car is.

#106: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Feb 26, 2010 4:08 pm
    ----
It's my version of Cindy Crawfords Mole...

#107: Re: Project sleeper Author: carl123uk, Location: Nuneaton PostPosted: Sun Feb 28, 2010 1:36 pm
    ----
any updates?

#108: Re: Project sleeper Author: AJS, Location: Scotland PostPosted: Sun Feb 28, 2010 1:40 pm
    ----
Hes probably out having too much fun to be posting on here Very Happy

#109: Re: Project sleeper Author: carl123uk, Location: Nuneaton PostPosted: Sun Feb 28, 2010 1:48 pm
    ----
lol anyone would. i bet he's gone through a few tanks of petrol since having it done.

#110: Re: Project sleeper Author: Dillon, Location: Kent PostPosted: Sun Feb 28, 2010 2:27 pm
    ----
AJS wrote:
Hes probably out having too much fun to be posting on here Very Happy

If it where me you wouldn't get a peep out of me for weeks..

#111: Re: Project sleeper Author: SAB206, Location: North West PostPosted: Sun Feb 28, 2010 2:36 pm
    ----
He'll be enjoying the drive back from Scotland and binning the VW Laughing

#112: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Feb 28, 2010 2:50 pm
    ----
It isn't back yet...

#113: Re: Project sleeper Author: twed207, Location: borders, near carlisle. PostPosted: Sun Feb 28, 2010 3:02 pm
    ----
so i've heard...

#114: Re: Project sleeper Author: carl123uk, Location: Nuneaton PostPosted: Sun Feb 28, 2010 3:16 pm
    ----
Edward wrote:
It isn't back yet...

what's happening with it?

#115: Re: Project sleeper Author: vanman_foci, Location: Barry, South Wales PostPosted: Sun Feb 28, 2010 3:18 pm
    ----
thought Flux insurance was supposed to get cheaper with mods?

#116: Re: Project sleeper Author: WilkyGTi, Location: Cumbria, UK PostPosted: Mon Mar 01, 2010 3:25 pm
    ----
So Mr Scissor Hands? whats the stage with this weapon?

#117: Re: Project sleeper Author: gti180boy, Location: Stafford PostPosted: Mon Mar 01, 2010 4:49 pm
    ----
edward what bhp and torque you reackon it will pump out???

#118: Re: Project sleeper Author: WilkyGTi, Location: Cumbria, UK PostPosted: Tue Mar 09, 2010 2:29 pm
    ----
Is this still not done?

#119: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Mar 09, 2010 2:41 pm
    ----
At the moment it's still not finished...Should be back this weekend though...

#120: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Tue Mar 09, 2010 4:17 pm
    ----
Goooood Smile

#121: Re: Project sleeper Author: WilkyGTi, Location: Cumbria, UK PostPosted: Tue Mar 09, 2010 4:19 pm
    ----
Whats the issue if you dont mind me asking? Just someone biting off more than they can chew? or general issues?

#122: Re: Project sleeper Author: Dillon, Location: Kent PostPosted: Wed Mar 10, 2010 1:41 pm
    ----
never mind, only got to the end of the week with the Jetta

WilkyGTI wrote:
Whats the issue if you dont mind me asking? Just someone biting off more than they can chew? or general issues?

What He Said

#123: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Mar 11, 2010 2:36 pm
    ----
I really like the Jetta. It's so comfy and refined...might need to invest in one someday...

Anyway a few pictures have arrived from Ecosse...It's not finished and from the pictures it's evident there is still all the wiring to do, cambelt needs fitting, the camshafts need timing, airbox needs fitting, throttle linkage needs fitting...mapping...a lot of still to go work. What's been done so far looks good though. I like the vernier pulleys. Should the cambelt covers be cut so the pulleys are on view all the time?

 


 


 


 


 


 


 


 

#124: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Thu Mar 11, 2010 2:40 pm
    ----
How come your bodies are red? Is it because they're 42mm?
Keep the pulleys on show Cool
Are they doing the mapping in house or taking it somewhere else?
Do you have pictures of the VT engine mounts? I want to make sure they are the same design as the Baker ones before I buy them Very Happy

#125: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Mar 11, 2010 2:47 pm
    ----
All bodies come in a choice of black or red don't they? I'm not sure where Ecosse do the mapping.

I've posted pictures of the VT engine mount on another post earlier in the week.

#126: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Thu Mar 11, 2010 2:52 pm
    ----
The new search feature is less than good, so can't find it Sad
I feel conned, I was never given that option Sad

#127: Re: Project sleeper Author: WeeDel, Location: fife, scotland PostPosted: Thu Mar 11, 2010 5:48 pm
    ----
jesus wots with using vise grips on the shiney new cams??!!

#128: Re: Project sleeper Author: SAB206, Location: North West PostPosted: Thu Mar 11, 2010 5:50 pm
    ----
WeeDel wrote:
jesus wots with using vise grips on the shiney new cams??!!

I cringed at the grips on cams too Sad

#129: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Mar 12, 2010 1:34 am
    ----
They are only used on the shafts not the cam lobes so won't do any harm.
These cams don't appear to have anywhere for spanners to sit so maybe the grips are the only option.

#130: Re: Project sleeper Author: gti180boy, Location: Stafford PostPosted: Fri Mar 12, 2010 2:59 am
    ----
Edward wrote:
They are only used on the shafts not the cam lobes so won't do any harm.
These cams don't appear to have anywhere for spanners to sit so maybe the grips are the only option.

this is the same as the gti 180 cat cams.

on standed cams there a 24mm nut apart of camshaft so can turn camshaft on the cat ones there's nufin so cant turn it unless you molegrips or put bolt in end.

Smile

#131: Re: Project sleeper Author: no_offences, Location: Leeds PostPosted: Fri Mar 12, 2010 4:25 am
    ----
addaz wrote:
Ruffy_206 wrote:
comes with 138 standard would think it would be over 160 mate

Well you say that....

But who says it still has 138? Or even left the factory with 138 to start with Wink
before my gti died it had 144, it was remapped to 146 in 2001 so engines can keep there bhp and its will p**s well over the 160 seriously

#132: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Fri Mar 12, 2010 5:53 am
    ----
Wey hey Smile

That head looks stunning Cool

#133: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Fri Mar 12, 2010 6:11 am
    ----
looking good ed, my pullys are on show,↲Did you not opt for a oil catch tank? As when you open it up it could get a bit messy in the air box if thats were there feeding the breather pipe to.

#134: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Fri Mar 12, 2010 7:03 am
    ----
It's safer to have the cam covers on i suppose. How would you cut the cover Paul?

#135: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Mar 12, 2010 7:49 am
    ----
There are little circles already moulded into the cover. I'd just cut them out.

#136: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Mar 13, 2010 8:05 am
    ----
I'm picking the car up on Monday...Spoken to Ecosse and the power figures if genuine should provide some amusement.

#137: Re: Project sleeper Author: burga_hdi, Location: Goole East yorks PostPosted: Sat Mar 13, 2010 8:18 am
    ----
bet you cant wait

looks good though

#138: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Sat Mar 13, 2010 9:22 am
    ----
Edward wrote:
I'm picking the car up on Monday...Spoken to Ecosse and the power figures if genuine should provide some amusement.

Please elaborate Very Happy

#139: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Mar 13, 2010 9:49 am
    ----
Well they says it's into the 200's and they are going to try some GTi 180 injectors to see if it will give some more. If the standard 138 injectors are good enough for 200bhp why would Peugeot change them for the 180?

#140: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Sat Mar 13, 2010 10:00 am
    ----
Maybe something to do with changing the spray pattern?

#141: Re: Project sleeper Author: Austin, Location: Telford PostPosted: Sat Mar 13, 2010 11:25 am
    ----
Edward wrote:
Well they says it's into the 200's and they are going to try some GTi 180 injectors to see if it will give some more. If the standard 138 injectors are good enough for 200bhp why would Peugeot change them for the 180?

Shocked Holy Crap! 200bhp, that would be awesome.

#142: Re: Project sleeper Author: Lecktorious, Location: Scotland PostPosted: Sat Mar 13, 2010 11:28 am
    ----
I was expecting near 200 but over 200...bloody hell!

#143: Re: Project sleeper Author: Ruffy_206, Location: Bristol PostPosted: Sat Mar 13, 2010 11:30 am
    ----
yeah looking at others i wasnt expecting over fair play but this is one special car.

#144: Re: Project sleeper Author: GazRG, Location: Bournemouth/Cardiff PostPosted: Sat Mar 13, 2010 11:31 am
    ----
Watching with baited breath! Over 200bhp is going to be tasty!

#145: Re: Project sleeper Author: tomd0801754, Location: Moscow PostPosted: Sat Mar 13, 2010 11:32 am
    ----
Hmmm.. I wouldn't be able to wait, I gotta be honest.

#146: Re: Project sleeper Author: henryb102, Location: West Wales PostPosted: Sat Mar 13, 2010 11:34 am
    ----
amazing project!! Will this be at the fast show?

#147: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Mar 13, 2010 2:12 pm
    ----
Well I always take power figures with a pinch of salt.

Spikes car apparently made over 200bhp...chances are I have a better cylinder head and I've certainly got a better exhaust manifold and system.

Car won't be going to any shows. I find standing round looking at cars a bit boring.

#148: Re: Project sleeper Author: Lecktorious, Location: Scotland PostPosted: Sat Mar 13, 2010 2:15 pm
    ----
Not even PugFest? Smile

#149: Re: Project sleeper Author: Ruffy_206, Location: Bristol PostPosted: Sat Mar 13, 2010 2:18 pm
    ----
it would be a show i could see you attending if any

#150: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Mar 13, 2010 2:18 pm
    ----
Not a chance...it's never been my scene.

#151: Re: Project sleeper Author: Antix, Location: Worcester PostPosted: Sat Mar 13, 2010 2:23 pm
    ----
Edward wrote:
Not a chance...it's never been my scene.

RS Tuning meet then?
Good chance to show the mods to fellow 206 enthusiasts?

and a chance for us all to meet you too [finally!] Very Happy

#152: Re: Project sleeper Author: GtiTom, Location: Halifax West Yorkshire PostPosted: Sun Mar 14, 2010 4:41 am
    ----
Hats off to you Edward. Will be superb with those sort of figures very good!

#153: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sun Mar 14, 2010 6:02 am
    ----
Whats next Edward.... LSD to correct the cronic torque steer Laughing

#154: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Mar 14, 2010 6:35 am
    ----
macj wrote:
Whats next Edward.... LSD to correct the cronic torque steer Laughing
Im with you on that mac,also ed my 138 injectors are on full cycle and are limiting the power as they cant keep up lol, next month i'll be finaly getting my jenvy c/f air box and some lovely 415cc injectors,then i want to do a few more bits then back down to the RR for a remap,that will do me for now until i can aford the forge internals.

#155: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Mar 14, 2010 2:33 pm
    ----
macj wrote:
Whats next Edward.... LSD to correct the cronic torque steer Laughing

Err...naah if the 304mm 2 piece AP Racing discs and 4pot calipers will really fit behind Nimrods I'll be getting some of those!

#156: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Mar 14, 2010 2:34 pm
    ----
spike_202 wrote:
next month i'll be finaly getting my jenvy c/f air box

Have you ordered it yet? They take a month of so to be made...because they are a bit lazy at ACT products.

#157: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Sun Mar 14, 2010 2:46 pm
    ----
Glad all now seems to be going very very well. It'll be a bit of an animal Smile

#158: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Sun Mar 14, 2010 4:25 pm
    ----
Not tempted by the Peugeot Sport 4 pots? Razz
(I know they're AP too)

#159: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sun Mar 14, 2010 5:05 pm
    ----
Edward wrote:
macj wrote:
Whats next Edward.... LSD to correct the cronic torque steer Laughing

Err...naah if the 304mm 2 piece AP Racing discs and 4pot calipers will really fit behind Nimrods I'll be getting some of those!

Kind of knew you would think one better Laughing

#160: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Mon Mar 15, 2010 4:21 am
    ----
Edward wrote:
spike_202 wrote:
next month i'll be finaly getting my jenvy c/f air box

Have you ordered it yet? They take a month of so to be made...because they are a bit lazy at ACT products.
Haha i orderd it before xmas and its only just arived.↲What will you be doing with your 180brake set up ed? As id have them off you as i want to stay on 15s for now

#161: Re: Project sleeper Author: =ZiAn=, Location: Slovenia PostPosted: Mon Mar 15, 2010 3:42 pm
    ----
well Edward is it home yet? Very Happy

#162: Re: Project sleeper Author: tomd0801754, Location: Moscow PostPosted: Mon Mar 15, 2010 3:45 pm
    ----
=ZiAn= wrote:
well Edward is it home yet? Very Happy

He probs has his foot down on a motorway seeing how fast he can get from Scotland to Lands End and then to his house Wink With a large smile on his face. Wink

(Speed limits of course. Smile )

#163: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Mar 15, 2010 4:56 pm
    ----
It is home...as for motorways they aren't the best thing for this car...3k rpm in fifth gear = noise and not much action. To say the power band is high up is an understatement!

It sounds like a little rally car even at idle and sets car alarms off when just tootling along at 30mph which I didn't expect.

Final figures from Ecosse are 214bhp and looks like 157lb ft at 6640rpm. I'm always very suspicious of rolling road figures so lets just ignore them and let's just say it's quick once it's over 5.5k rpm.

#164: Re: Project sleeper Author: t1mmy, Location: Reading PostPosted: Mon Mar 15, 2010 5:02 pm
    ----
Glad you are enjoying it. Don't worry about the rolling road readout, it's just a figure on a piece of paper.

#165: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Mar 15, 2010 5:07 pm
    ----
I completely disregarded it as soon as I saw it....it might be real...so I'm not going to rubbish it, I'm just not paying any attention to it. Same with the 160bhp before the work was done.

#166: Re: Project sleeper Author: gti180boy, Location: Stafford PostPosted: Mon Mar 15, 2010 5:47 pm
    ----
edward get some picture up of the engine bay now its all completed. Smile

#167: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Mon Mar 15, 2010 5:52 pm
    ----
He'll be cleaning and polishing it for a week before he posts pictures Kyle! haha.

Glad it's all working! Bonson's car's loud - i could only imagine what that sounds like. My 180 at 70 on a motorway is at 3600rpm!

Makes me want to do stuff to engines now. I have a gti-180 crying out for a supercharger and a 309 crying out for a supercharged gti-6 engine or a T16 should i be so lucky Rolling On The Floor Laughing

A lottery win would go down very well indeed! Very Happy

Hope the car was worth the wait buddy...

#168: Re: Project sleeper Author: Dave, Location: Birmingham PostPosted: Mon Mar 15, 2010 6:29 pm
    ----
Glad your happy, guessing you dont like the attention that comes with the noise though! lol!

Looking forward to seeing pics!

#169: Re: Project sleeper Author: macj, Location: Essex PostPosted: Tue Mar 16, 2010 1:56 am
    ----
Your setting car alarms off because its trying to suck the fluffy dice out and triggering the sensors Laughing

#170: Re: Project sleeper Author: DJ-, Location: UK PostPosted: Tue Mar 16, 2010 2:01 am
    ----
Wicked glad to hear its back and completed! Been great following this project thread. Cant wait to see some piccies! Razz

#171: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Tue Mar 16, 2010 6:37 am
    ----
mint ed v.happy for you buddy i was suprized at the power at 5.5k? Mine starts at 4.5k, and i try to stay off the motor ways as even with the tunes on you can still hear it rawring away lol.↲Did you get my message about your brakes?

#172: Re: Project sleeper Author: GazRG, Location: Bournemouth/Cardiff PostPosted: Tue Mar 16, 2010 6:45 am
    ----
Sounds great mate, hope you're enjoying it, nice healthy BHP reading too if it's accurate!!

#173: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Mar 16, 2010 7:24 am
    ----
spike_202 wrote:
mint ed v.happy for you buddy i was suprized at the power at 5.5k? Mine starts at 4.5k, and i try to stay off the motor ways as even with the tunes on you can still hear it rawring away lol.↲Did you get my message about your brakes?

It actually feels a bit gutless partly because of the noise it makes. I.e. it makes more noise than thrust.

A PM about brakes or what you wrote above somewhere?

#174: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Mar 16, 2010 7:26 am
    ----
Brian wrote:


I have a gti-180 crying out for a supercharger

I actually think going forced induction would be a good idea.

#175: Re: Project sleeper Author: Seabook PostPosted: Tue Mar 16, 2010 7:28 am
    ----
got any new pics? Smile

#176: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Tue Mar 16, 2010 7:29 am
    ----
Any pictures?
Adding up all the costs I don't think supercharging would cost that much more, ie maybe £1-£2k but that's relatively small considering what's already been spent?

#177: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Tue Mar 16, 2010 7:30 am
    ----
Edward wrote:

I actually think going forced induction would be a good idea.

Now you say! All that talk of wanting me to go N/A (and while there's nothing wrong with N/A tuning at all - it's just not as cost effective for my engine), now you say forced! Smile

#178: Re: Project sleeper Author: Geoff, Location: Evesham, Worcestershire PostPosted: Tue Mar 16, 2010 10:18 am
    ----
If its gone from 160 to 214bhp on the same RR then that is still very impressive.

The tricky question is whats next?!

#179: Re: Project sleeper Author: macj, Location: Essex PostPosted: Tue Mar 16, 2010 10:31 am
    ----
Edward wrote:
Brian wrote:


I have a gti-180 crying out for a supercharger

I actually think going forced induction would be a good idea.

Something dont sound right Edward.... that HP should hit you in the back. where does the power start making?

#180: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Mar 16, 2010 10:42 am
    ----
I'll see tonight but the power all seems high up with no real sudden step in acceleration...

#181: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Tue Mar 16, 2010 12:37 pm
    ----
i'll pm you mate, i agree with macj as soon as mine hits 4.5k thats it its like a turbo kicking in and pins you to the seat below the cam it doesnt feel to bad just like before i had any work done 2bf. Maybe you just need to get used to the 'power band'?

#182: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Mar 16, 2010 1:07 pm
    ----
 


 


 


 

#183: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Tue Mar 16, 2010 1:21 pm
    ----
Looks very OEM I must say! Only thing that gives it away is the Longman box and silicon tube to the untrained eye!

#184: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Tue Mar 16, 2010 2:03 pm
    ----
Very nice! Any chance of the engine cover going back on? How is the air drawn into the trumpets? Through the origonal air intake, I take it the filter is out of there?

#185: Re: Project sleeper Author: Ape, Location: Clipping the Apex! PostPosted: Tue Mar 16, 2010 2:41 pm
    ----
Edward wrote:
Brian wrote:


I have a gti-180 crying out for a supercharger

I actually think going forced induction would be a good idea.

Shocked

#186: Re: Project sleeper Author: macj, Location: Essex PostPosted: Tue Mar 16, 2010 2:48 pm
    ----
Are you getting a torque steer on acceleration from standstill and trouble stopping it wanting to light up one wheel

#187: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Tue Mar 16, 2010 2:52 pm
    ----
mint i actualy like mine with out the air box i may have to fabricate it so it can be removed easely.
I also didnt realize you had the red tb's

#188: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Tue Mar 16, 2010 3:17 pm
    ----
That looks absolutely stunning Tedward! As mentioned, that head is crying out for a cover...Ecosse do a nice carbon fibre one which would go with your airbox and would look yummy. Cool

Edward wrote:
Brian wrote:


I have a gti-180 crying out for a supercharger

I actually think going forced induction would be a good idea.

Are you saying you're not happy with the power delivery? I believe Bonson said his TB's really opened up once they got worn in a little.

#189: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Tue Mar 16, 2010 4:14 pm
    ----
2bf im with edward on that brian, if i was to do mine again i would go for a charger rather than the tb's.
Also as i said before ed keep an eye on that oil breather pipe as when you open it up it will throw oil out

#190: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Tue Mar 16, 2010 4:15 pm
    ----
Thing is though...you guys will just be craving more power now you have the bug Razz

#191: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Tue Mar 16, 2010 4:28 pm
    ----
Just noticed your strutbrace is off the car as well?

#192: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Tue Mar 16, 2010 5:50 pm
    ----
Oh, a little red hose between the longmans box and the standard one would look nice too!

#193: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Tue Mar 16, 2010 5:58 pm
    ----
Were there any issues with the radiator?

#194: Re: Project sleeper Author: JDave, Location: Airdrie, Scotland PostPosted: Tue Mar 16, 2010 6:16 pm
    ----
The bay is looking cracking. Have you taken the engine cover off? Is that not risky?

#195: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Tue Mar 16, 2010 6:36 pm
    ----
JDave wrote:
Is that not risky?

No it's just a plastic cover pal Smile

#196: Re: Project sleeper Author: tRiCk, Location: Mitcham PostPosted: Tue Mar 16, 2010 6:47 pm
    ----
Been watching this for a while I dunno what to say other than its amazing. But a real shame that it wont be at a car show so i can have a real good look.

#197: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Mar 17, 2010 2:39 am
    ----
macj wrote:
Are you getting a torque steer on acceleration from standstill and trouble stopping it wanting to light up one wheel

It will light them up if i try but after that it doesn't seem to pull a great deal harder than it did before. Yes it revs higher but there's no step in the torque and no clear power band. Basically it feels a bit flat at times.

Brian wrote:
That looks absolutely stunning Tedward! As mentioned, that head is crying out for a cover...Ecosse do a nice carbon fibre one which would go with your airbox

They offered me one and I didn't want it.

Steve206 wrote:
Just noticed your strutbrace is off the car as well?

It gets in the way of work and doesn't do anything anyway.

JDave wrote:
The bay is looking cracking. Have you taken the engine cover off? Is that not risky?

It doesn't do anything and it's been off for the last 3 years...

Jamie wrote:
Were there any issues with the radiator?

There is about 5mm between the radiator and airbox. I've seen Longmans cars with the radiator housing moved forwards to provide clearance. With the uprated engine mounts the engine doesn't move too much so it's not an issue. I'd be a bit concerned if the mounts weren't fitted though.

Last edited by Edward on Wed Mar 17, 2010 2:50 am; edited 1 time in total

#198: Re: Project sleeper Author: tomd0801754, Location: Moscow PostPosted: Wed Mar 17, 2010 2:42 am
    ----
I'm confused, so are you happy with it or not?

Does look good, but the main reason for it is the power, 'so if its feeling flat'...

#199: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Mar 17, 2010 2:49 am
    ----
I'll post up the rolling road print later for you guys to analyse...

#200: Re: Project sleeper Author: jimmyfloydreturns, Location: Sittingbourne PostPosted: Wed Mar 17, 2010 3:20 am
    ----
Looks amazing Edward! I love how you have kept the whole car standard, same as what I would do Thumb Up Man I miss my GTi Sad

So.... whats all this about disappointing power delivery?

#201: Re: Project sleeper Author: vanman_foci, Location: Barry, South Wales PostPosted: Wed Mar 17, 2010 4:33 am
    ----
I must say I have been watching this from the start and I love how it looks standard now Very Happy

Bit gutted for you as you don't seem happy with it! Hope you sort it out soon.

#202: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Wed Mar 17, 2010 4:59 am
    ----
I'd like to see the graph, whether the figures are accurate or not means nothing, I just want to see the shape, see if it looks like there's anything up with it.

#203: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Mar 17, 2010 1:08 pm
    ----
One rolling road print out...

 

#204: Re: Project sleeper Author: Geoff, Location: Evesham, Worcestershire PostPosted: Wed Mar 17, 2010 1:27 pm
    ----
Thats a bit of kink at 4500rpm!

I've just had a look at the longmans spec:
Max power: 190bhp @ 6750rpm
Max torque: 170lb ft @ 5500rpm

From the impression from reading the above you don't seem totally happy. I would be interested in what the others say when they see the above graph. Very Happy

#205: Re: Project sleeper Author: Mattie-RS, Location: A Track near you ;) PostPosted: Wed Mar 17, 2010 1:36 pm
    ----
is there a graph for air/fuel ratio??

#206: Re: Project sleeper Author: macj, Location: Essex PostPosted: Wed Mar 17, 2010 1:41 pm
    ----
Power curve is the wrong way and you should see at least another 10ft/lb of torque with those cams.

I need more time to study the graph but I think you have a torque curve issue. My only thoughts are that they have mapped it with 14.7lambda but have not fuelled it enough at the top of the rev range. The MOT test would not reach that sort of RPM. They also set the rev limiter too high in the RR session.

Give me a PM if you want to discuss it further

#207: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Mar 17, 2010 1:43 pm
    ----
Geoff wrote:

From the impression from reading the above you don't seem totally happy.

I'm quite underwhelmed by it to be honest. There is no mid range as such either, it pulls but doesn't feel quick. Looking at the before and after charts it appears to have less torque at 4500rpm than before.
It is fast higher up the rev range but it doesn't exactly blow your socks off.

Mattie® wrote:
is there a graph for air/fuel ratio??

Nope.

#208: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Mar 17, 2010 1:45 pm
    ----
macj wrote:
My only thoughts are that they have mapped it with 14.7lambda but have not fuelled it enough at the top of the rev range.

Which they would have to do in order to keep the cat working long term? I believe such cams dictate the need for richer mixtures but those and cats don't go together.

#209: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Wed Mar 17, 2010 2:05 pm
    ----
It's a shame you're not so pleased with it Edward. After the time and effort that has gone into it Sad

#210: Re: Project sleeper Author: SAB206, Location: North West PostPosted: Wed Mar 17, 2010 2:53 pm
    ----
Work that's done looks very neatly done, I like the OEM subtle look of it all.

It's a shame you're a bit dissapointed with it, I once went out In Bonsons car, and that felt MUCH different to the power delivery of the 180. It did knock me and throw me back in the seat, even mid-range it packed quite a punch.

I'm with you on the RR results too, all of them are a bit peculiar, but your torque is showing VERY similar to that of a 180 (mines 154ibft 0, should it not 'theoretically' be somewhat higher?

#211: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Wed Mar 17, 2010 7:49 pm
    ----
Yup, my 180 torque is 151lb/ft on the same RR. Ok the 180 already has slightly more uprated cams than the 138 but not by much. Tiz a funny kink, perhaps tha'ts where you're losing the "OOMPH" you're expecting?

 

#212: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Wed Mar 17, 2010 8:18 pm
    ----
Very disheartening I must say seeing as I'm about to shell out for the conversion Sad
Maybe the cam choice was a bad one and you should have stayed with the fast road cams?

#213: Re: Project sleeper Author: tRiCk, Location: Mitcham PostPosted: Wed Mar 17, 2010 8:28 pm
    ----
maybe you need to 1/4mile race a gti , 180 and then a type r (not the latest 1 theyr s**te) that will put a smile on your face if you win and you should win.

#214: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Wed Mar 17, 2010 8:46 pm
    ----
lol at tirck remember.... 206 take over, my pug wips my mates type-R all day long hes power it way to far up the rev range and buy that time he hits it im long gone haha.

#215: Re: Project sleeper Author: twed207, Location: borders, near carlisle. PostPosted: Thu Mar 18, 2010 2:00 am
    ----
abit sad to see that you're not 100% happy with it ed. Sad the setup does look the sex though! lol.

i'd say that those RR figures are bob on as all of the RR day's we've had at eccosse have been spot on and i've never heard of them tinkering with RR results. the operator is sound too, really nice guy. Smile

hope you get to the bottom of it. Wink

#216: Re: Project sleeper Author: macj, Location: Essex PostPosted: Thu Mar 18, 2010 2:03 am
    ----
look at the wheel drag between the two charts.... one is 30 odd HP and edwards is 50HP... someone is fiddling results

#217: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Mar 18, 2010 2:43 am
    ----
The original print out on mine has 39bhp wheel drag! The car actually feels slower than it was at times. There is no sweet mid range torque at all and the only time it really shows benefit is really high up the rev range. I knew the power band would move further up the rev range but I did expect it to be stronger in the mid range too.

The whole experience of this conversion has been very negative and I actually regret spending the best part of £4.5k. If necessary I will share my experience and hopefully somebody will benefit and not get caught out like I did.

#218: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Thu Mar 18, 2010 3:35 am
    ----
macj wrote:
look at the wheel drag between the two charts.... one is 30 odd HP and edwards is 50HP... someone is fiddling results

I used to love rolling roads, thought it was great being able to see the power increases from what you did. Now I'd like to think I know better, and would go on exactly how the car feels, rather than some numbers on a piece of paper done by someone trying to sell you something.

If Edward says it doesn't feel as powerful as he'd expected, then perhaps it isn't Surprised

I don't think he'd lie about it, so either there is something wrong with the actual car, or maybe throttle bodies really don't give so much oomph.

#219: Re: Project sleeper Author: Schumi, Location: Istanbul / Turkey PostPosted: Thu Mar 18, 2010 5:24 am
    ----
Once iam glad to see complete. But. I suggest you buy a wideband. Mount it on car. Because I didnt like your power curve. Its co crackign (i cant find true word sorry my english). You have a real gold. Your gold is standalone ecu. I think your problem is your mapping. With a standalone your power curve must be smooth.

In example. Its my friends car. C2 VTS. Stock ecu, Stock DBW. PT52 cams. Thinker gasget (for little higher compression ratio) 106gti header, filter, exhaust. But Turkey best mappers make his mapping. And the resoults.
 


Install a wideband. Watch when full accelerate. After this disable your stock O2 sensor and connect wideband to ecu. Go for better mapper.

#220: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Mar 18, 2010 5:28 am
    ----
It's running with an Omex ECU now.

#221: Re: Project sleeper Author: Dave, Location: Birmingham PostPosted: Thu Mar 18, 2010 5:36 am
    ----
Are you not tempted to take it somewhere else like RS Tuning to get a check over and a 2nd opinion?

#222: Re: Project sleeper Author: Quarmbo, Location: Bristol & Leicester PostPosted: Thu Mar 18, 2010 5:46 am
    ----
Or go back to Ecosse and explain why your not happy? Did they warn you/tell you to expect the power band to be higher in the revs? You've spent a lot of money on your car, they should recognise that and try and accomodate you as much as possible.

#223: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Thu Mar 18, 2010 5:52 am
    ----
If you want a wideband sensor give Tour-de-Force (a subsidiary of RS tuning iirc) a ring, they had a huge batch in, and are selling them at £100.

Why have you changed to Omex? Is it the 600?

#224: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Thu Mar 18, 2010 6:32 am
    ----
Thing is even I noticed the difference in my 206. I went from a 1.4 to 1.6. With ph3 cams. The power band in the mid and low range honestly felt like it was still a 1.4 but over about 3250 rpm it got a little better, truly coming in at about 4000. Now that wasn't even a lairy cam. You can't get an amazing power band with higher spec cams throughout the whole range, it's just not possible.

#225: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Mar 18, 2010 7:07 am
    ----
I did expect a flatter low rev output but i did expect the mid range to be better than it is. It seems to pull at 6k rpm like it used to at 4k rpm. The drop at 4k rpm isn't made up for by the improvement at 6k rpm.

#226: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Thu Mar 18, 2010 7:11 am
    ----
What did ecosse have to say about it? Do you think going back to the fast road cams may wield better drivability?
Last edited by Jamie on Thu Mar 18, 2010 9:07 am; edited 1 time in total

#227: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Thu Mar 18, 2010 9:04 am
    ----
Jamie wrote:
Do you think going back to the fast toad cams may wield better drivability?

Rapid amphibians is not something I'd like in my car Razz

#228: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Thu Mar 18, 2010 9:06 am
    ----
Go die.

#229: Re: Project sleeper Author: jimmyfloydreturns, Location: Sittingbourne PostPosted: Thu Mar 18, 2010 9:12 am
    ----
Seb wrote:
Jamie wrote:
Do you think going back to the fast toad cams may wield better drivability?

Rapid amphibians is not something I'd like in my car Razz

Laughing

#230: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Thu Mar 18, 2010 10:41 am
    ----
what degre cams have you got ed?

#231: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Thu Mar 18, 2010 10:43 am
    ----
285

#232: Re: Project sleeper Author: Geoff, Location: Evesham, Worcestershire PostPosted: Thu Mar 18, 2010 2:16 pm
    ----
Jamie wrote:
What did ecosse have to say about it? Do you think going back to the fast road cams may wield better drivability?

I would suggest as Jamie, go speak to Ecosse and say your not happy. I would also take the car to another Rolling Road and get another run done.

#233: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Mar 18, 2010 2:21 pm
    ----
It's all money, money, money though....I'm bored of spending money on this car.

#234: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Thu Mar 18, 2010 2:42 pm
    ----
Surely Ecosse have to offer some form of after-sales service?
I'm gutted for you, I can imagine how much you had been looking forward to this and how long you had it all planned Sad

#235: Re: Project sleeper Author: Dave, Location: Birmingham PostPosted: Thu Mar 18, 2010 2:55 pm
    ----
You'll know how it feels in August Jamie. Wink lol!

#236: Re: Project sleeper Author: macj, Location: Essex PostPosted: Thu Mar 18, 2010 2:56 pm
    ----
Edward wrote:
It's all money, money, money though....I'm bored of spending money on this car.

Take a deep breath........PMed

#237: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Thu Mar 18, 2010 3:00 pm
    ----
The thing is though Paul, are you really getting the chance to give the cars the berries? Aren't cams/tb's all high end power band stuff? ie you'll need to rev the nuts off it (like any 138 or 180) to get the power out of it. You ain't gonna get the torque with N/A engines as i tried to point out with my RR read-out.

#238: Re: Project sleeper Author: macj, Location: Essex PostPosted: Thu Mar 18, 2010 3:21 pm
    ----
I have put several experienced drivers in my car.... thay all say the same thing..... massive difference and get a LSD

#239: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Thu Mar 18, 2010 3:50 pm
    ----
Jamie wrote:
285

285s...thats what i've got??
so how does your power band differ to mine??
as yours kicks in at 5.5k and mine is at 4.5k
is that how they have done the timing??

#240: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Thu Mar 18, 2010 3:52 pm
    ----
Jamie wrote:
285

285s...thats what i've got??
so how does your power band differ to mine??
as yours kicks in at 5.5k and mine is at 4.5k
is that how they have done the timing??

#241: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Thu Mar 18, 2010 3:54 pm
    ----
My RR Results, from a different RR, standard GTi :
 


 


145bhp(flywheel)@6400rpm
137ft.lb@5000rpm

I know its from a different RR, but just setting standard figures. Do you have a standard RR printout before the work?

My 2.0 HDi was remapped to 115bhp but had 195lb.ft of torque, that would pull you back! I'm really dissapointed for you Edward. Despite the RR figures, i would have thought you would be able to 'feel' the difference.

#242: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Mar 18, 2010 3:57 pm
    ----
You can feel the difference at really high revs i.e. between 6k rpm and 7k rpm. Waiting for the engine to get to those revs though is slower than standard!

#243: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Thu Mar 18, 2010 4:09 pm
    ----
So odd, doesnt really make much sense?! Like you say, you would really expect it 4k onwards, its nice to have that power, but not much use unless your planning to drive around revving the engine so hard.

#244: Re: Project sleeper Author: Schumi, Location: Istanbul / Turkey PostPosted: Thu Mar 18, 2010 4:24 pm
    ----
Do you want to use this car every day ? How is your idling ? Isnt it to lumpy for daily use ? I think with 285 cams power come at 4500-5500 rpm. Its so normal. Maybe it can be a little changable with cam timing. And I suggest you 17-77 (4.53) short ratio gear set. Its from 307 HDI. It will complete change your cars acceleration.

#245: Re: Project sleeper Author: gti180boy, Location: Stafford PostPosted: Thu Mar 18, 2010 5:00 pm
    ----
iv been reading this post now for a while and i love your car edward you know, looks oem from out side and even undoor bonnet just how i like mine.

i agree with dave you should take it to paul @ rs tuning and get him to check the map or even remap it him self am sure he will push some more torgue lower down out of it he can do wonders. Smile

and i would get your cams timing check, and see if you are getting the most out the verniers?? i just had a cat cams vernier pulley fitted to my gti 180 that was ment for the gti 138 exhaust camshaft and slightly retarded it 3-4 deg and mine now from 4500 -to- 6500 pull like a bit-ch cant belive iv been driving round with cat cams wasnt getting the best out them intill now.

kyle

#246: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Mar 19, 2010 2:48 am
    ----
I do wonder if use has been made of the vernier pulleys. I was never asked if I wanted good torque or big headline bhp figures. I checked again earlier and it goes quite nicely at 6.5k rpm to 7k rpm but it should be pulling like that lower down the rev range too.

Look at the time the print out was made. 6pm on Sunday night. Could it be there wasn't enough time to do a thorough job or mapping the whole rev range?

It idles about 1000rpm so sounds like a big motorbike when they are idling. It's quite a smooth idle.

#247: Re: Project sleeper Author: gti180boy, Location: Stafford PostPosted: Fri Mar 19, 2010 4:11 am
    ----
Edward wrote:
I do wonder if use has been made of the vernier pulleys. I was never asked if I wanted good torque or big headline bhp figures. I checked again earlier and it goes quite nicely at 6.5k rpm to 7k rpm but it should be pulling like that lower down the rev range too.

Look at the time the print out was made. 6pm on Sunday night. Could it be there wasn't enough time to do a thorough job or mapping the whole rev range?

It idles about 1000rpm so sounds like a big motorbike when they are idling. It's quite a smooth idle.

it should start pulling aleast 4500 on ward early whats the point in pulling for 6500 to 7000 revs it useless i would get your cams adjusted by the verniers on the dyno to see if can get more low on power.

and 1000 idle is abit high really no need for this. i dont think they done the idle map properly or it wont idle at 750-800 and they rised it to cheat.

#248: Re: Project sleeper Author: macj, Location: Essex PostPosted: Fri Mar 19, 2010 1:50 pm
    ----
Asd I said to you before. This is a muddled mapping job. I think they bit off more than they could chew and ended up rushing it through for your collection on the monday. The fuelling in the midrange is probably way too lean and they have not utilised the valve timing to move your torgue curve around at all. It should be a mirror image of the graph and smooth.

You will get a shock when you get it back on a decent RR with an experienced tuner.... take my word for it... You will smile again then Smile

#249: Re: Project sleeper Author: Tarmac-Terrorist, Location: West Yorkshire PostPosted: Fri Mar 19, 2010 3:13 pm
    ----
If ecosse havent provided an AFR graph then I would be suspicious about the state of the map. As said, 1000 RPM idle speed and the timing of the graph all indicate a rushed job I believe.... Id have a word with Paul @ RST and see if he can shed any light on the subject...

The power band can also be tuned with different length trumpets.... Perhaps the box arrangment might have something to do with this?

#250: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Fri Mar 19, 2010 3:34 pm
    ----
I've already asked if he's tempted to go down and let Sandy get his hands on it!
Paul, this is one of the many engines Sandy has built;

www.106rallyeforum.com...p?p=649714

#251: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Mar 20, 2010 6:20 am
    ----
I'm going to keep the car as it is. The chances are the map is password protected anyway so a remap would require a total mapping session from start to finish. There is nothing to suggest the map is wrong in any way it is probably just the nature of the engine now.

It was playing up yesterday, when driving the car cut out very briefly (for 0.5 seconds) like a really big flat spot and then when rolling to a junction I saw the rev counter drop to zero then flicked back to normal. I didn't feel a change to the running this time.
When I got home it wouldn't idle and when restarted would run for two or three seconds then cut out. It then wouldn't fire up at all.
After leaving it a few minutes it ran again and I noticed when the high beam was switched on the engine would cut out. There is plenty of power in the battery otherwise it wouldn't turn the engine over.

I got fed up with it and left it overnight. This morning I switched the car on and it ran fine, no cutting out with all the electrical equipment switched on. It did give an interesting crack from the airbox when i pressed the throttle though...looks like it spat back for some reason.

#252: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Sat Mar 20, 2010 6:24 am
    ----
Please give ecosse a ring, they have obviously messed something up! Ask them to pay for a mapping session at rst for you?

#253: Re: Project sleeper Author: gti180boy, Location: Stafford PostPosted: Sat Mar 20, 2010 7:12 am
    ----
i would take it back it does not seem right and its just gona make you hate your car.

am sure ecosse no what they doing i would take it back and tell them you aint happen and tell them how you wont it to drive.

#254: Re: Project sleeper Author: GazRG, Location: Bournemouth/Cardiff PostPosted: Sat Mar 20, 2010 7:17 am
    ----
For the money you've spent shouldn't you be happy with it?

Why don't you complain to Ecosse? That's the first thing I'd have done.

#255: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Sat Mar 20, 2010 7:51 am
    ----
Definitely, think how much money you spent with them!
If you bought a sofa from DFS and when you got it home it was ripped or stained you'd take it straight back wouldn't you!
There are so many signs that it was either rushed or bodged, give them a ring!

#256: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Mar 20, 2010 7:59 am
    ----
I spoke to Ecosse about it yesterday and they put it down to an alternator or battery problem.

The problem is that they are 200 miles away from me!

#257: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Sat Mar 20, 2010 8:05 am
    ----
Yeah but if something is wrong then you deserve to have it put right!
Ask them to come get your car with their transporter?
It didn't have an alternator or battery problem when it went in did it?
Don't let them fob you off, at the end of the day you pay their wages with the work you give them, and they should be doing every thing in their power to make sure cars are of a standard the client would expect before they let them out of the workshop!

#258: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sat Mar 20, 2010 8:07 am
    ----
The ECU requires over 9volts at cranking to fire up the engine.... when you are running it is easy to see if the alternator is charging by checking with a meter at the battery. 13-14.5 volts is good. But I am sure I am teaching you how to suck eggs mate.

Please insist on them taking it back for look see. That graph is all I need to see the map is wrong. If you want some back up... I will ring and speak to them as well. I hate it when companies take your money and run Evil or Very Mad

#259: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Sat Mar 20, 2010 8:27 am
    ----
Looking at the graphs it is obvious it was rushed/bodged. Eg the time it was mapped, the wheel drag, the kink.
It produces the same torque as a standard GTi180 now...
Seems they've sacrificed torque for "peak bhp" figures...

#260: Re: Project sleeper Author: GazRG, Location: Bournemouth/Cardiff PostPosted: Sat Mar 20, 2010 8:32 am
    ----
Edward wrote:
I spoke to Ecosse about it yesterday and they put it down to an alternator or battery problem.

The problem is that they are 200 miles away from me!

Don't let them fob you off. As someone else mentioned, did it have this problem when it went in? I doubt it, knowing how meticulous you are.

They had a duty of care over your vehicle, not to even mention the amount you spent on it! I'd be kicking up a gigantic fuss. Don't just leave it as it is, especially as you were so looking forward to getting it done.

Do something about it mate.

#261: Re: Project sleeper Author: Austin, Location: Telford PostPosted: Sat Mar 20, 2010 8:59 am
    ----
Have been looking forward to seeing the results of this and tbh i am gutted for you mate Sad , was expecting big. I'm not really in the know with all this engine mapping stuff but something doesn't sound good or look right.

At the end of the day you've spent alot of money with ecosse and i think they should take another look at it until your happy. They've got a good reputation and i doubt they'd risk it over this tbh.

#262: Re: Project sleeper Author: t1mmy, Location: Reading PostPosted: Sat Mar 20, 2010 10:47 am
    ----
My concern is that if you leave it you could damage something, clearly it isn't running right.

#263: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Mar 20, 2010 11:33 am
    ----
Took it out earlier this afternoon and all was fine. I just needed it to build my confidence with it playing up yesterday...can't explain what it was doing yesterday.

I've been looking at new cars already. Looking at a 56 plate Golf...

#264: Re: Project sleeper Author: Ruffy_206, Location: Bristol PostPosted: Sat Mar 20, 2010 11:37 am
    ----
its such a shame i bet you wish you never got it done now.
as people have said before tho ecosse sould be helping you out here its not like its a £20 on the side job.
its alot of money and its not what your expecting.

if everything is right you sould really be able to tell 160bhp to 216bhp surly

#265: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Sat Mar 20, 2010 11:42 am
    ----
Edward wrote:

I've been looking at new cars already. Looking at a 56 plate Golf...
Not tempted by something more fun? Smile

As a succesor to the 206?

Read: My pm Razz

I had an '07 golf for about 4 months, 2.0 TDi version, then the '06 1.9TDi, and now have use of an '09 GTD. None of them particularly impress me or stand out at anything. Just more of an everyday standard car! The kick of the GTD is fairly hard though admittedly....

#266: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Mar 20, 2010 11:48 am
    ----
I just want a dull car to go to work in. It just needs to be smart and comfortable...(I do like VW build quality though...) doesn't need to be fast either.

My experience of 200+bhp cars have all had turbos which give big mid range torque. What does a N/A engine with over 100bhp / litre feel like?
Half the problem is the noise it makes. Pulling away from lowish speed in 2nd gear just results in slow acceleration and lots of noise from both the exhaust and engine. Then it starts to pull better with even more noise...and it's giving me a headache!

#267: Re: Project sleeper Author: t1mmy, Location: Reading PostPosted: Sat Mar 20, 2010 12:04 pm
    ----
Are you going to sell it?

#268: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Mar 20, 2010 12:07 pm
    ----
I was thinking about it this morning!!! I dunno. I would like to keep it in the garage all winter and let it just come out in the summer. I might just not need it though...so who knows what will happen long term.

#269: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sat Mar 20, 2010 12:10 pm
    ----
like you said ed keep it for summer and get it on the track and use that higher up power.

#270: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Sat Mar 20, 2010 12:17 pm
    ----
Edward wrote:
I just want a dull car to go to work in. It just needs to be smart and comfortable...(I do like VW build quality though...) doesn't need to be fast either.

The quality inside is good yeah, occasionally things to go tits up in them, but so do all cars.

Edward wrote:

My experience of 200+bhp cars have all had turbos which give big mid range torque. What does a N/A engine with over 100bhp / litre feel like?
Half the problem is the noise it makes. Pulling away from lowish speed in 2nd gear just results in slow acceleration and lots of noise from both the exhaust and engine. Then it starts to pull better with even more noise...and it's giving me a headache!

Turbos are nice, not my cup of tea personally but still. I'm not entirely sure I've ever driven an N/A engine with more than 100/litre.

Mine only has a measly 68/litre as N/A. How loud really is the car? I can imagine the exhaust note is now amplified by the fact it's bringing in more air and giving a louder bang, which isn't great as I remember you saying it was already loud enough in the first place!

I can also say I've only ever driven or been in 2 cars with TB's, and they were loud, one was a 2.2, and the other a 2.0, and not that I don't like the noise, but at least with forced induction you can turn the noise off and on with the loud pedal, with the TB's it felt more like it was loud ALL the time and you had no choice with regards to harshness of acceleration at all.

#271: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Mar 20, 2010 12:23 pm
    ----
Even at idle if you know what a big motorbike is like at idle it's like that. Multiply that for when the thing is running...
I've no idea what it sounds like from the outside!

#272: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Sat Mar 20, 2010 12:23 pm
    ----
I think I have a good idea! It's just a real shame that you're not happy about it I think.

#273: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Mar 20, 2010 12:31 pm
    ----
I'll make a video one day...

#274: Re: Project sleeper Author: gti180boy, Location: Stafford PostPosted: Sat Mar 20, 2010 12:41 pm
    ----
i cant belive you thinking bout selling it now after just spending that amount money one it.

to me they seemed to really made you lose all interest in your 206.

i just got my 180 running perfect now it idles at 750 with 4901804 cat camshafts with no lumpy idle and from 1000 to 3500 drive just like standed gti180 but from 4500 to back 7000 revs pulls like a bit-ch and was running 195.5bhp on dyno and since fitted vernier pulley last week and slightly retarded the timing most be over 200bhp as it pulls really well now, but it feel very nice car to drive and this should be what yours should drive like.

so take it back and get it sorted or take to rs tuning you wont regreat it am telling you.

kyle

#275: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sat Mar 20, 2010 1:22 pm
    ----
whats your torque out put kyle?

#276: Re: Project sleeper Author: gti180boy, Location: Stafford PostPosted: Sat Mar 20, 2010 2:02 pm
    ----
@ rs tuning on th 6-5-2009 it made 185.1 bhp @ flywheel and 160ldft but wasnt running right and would not idle.

on 2-3-2010 @ hi-tech motorsport it made 195.5bhp @ flywheel and 167.3ldft and was running fine due to me playing with it for mouths. alot hours spent on it due to these bloody cat cams Smile

i have just fitted a vernier pulleys and @ mo its has been retarded bout 4 deg's and now it pulls alot better so soon back to hi-tech in couple weeks.

Smile

#277: Re: Project sleeper Author: gti180boy, Location: Stafford PostPosted: Sat Mar 20, 2010 2:05 pm
    ----
arww and hi-tech motorsport use's same dyno type as red-dot and ecosse

#278: Re: Project sleeper Author: Quarmbo, Location: Bristol & Leicester PostPosted: Sat Mar 20, 2010 3:42 pm
    ----
Edward, hope whatever you do your happy with. However, I personally wish that you'd go back to Ecosse (with the supporting comments/evidence from macj & others) and get them to sort it out for you. You've spent a hell of a lot of money on your car. They made you fall out of love with it within 2-3 weeks. Likewise, they could make you fall back in love with it by doing their job correctly. Or by someone else correcting what appears to be their mistakes.

Anyway, best of luck with whatever you plan to do.

Sam

#279: Re: Project sleeper Author: vanman_foci, Location: Barry, South Wales PostPosted: Sat Mar 20, 2010 5:13 pm
    ----
After catching up, i agree. something needs to be done. You don't know what damage it could be doing to the car.

With regards to the rev range who would have a road car which you would have to rag around all the time?

Also with sound can't you put socks or filters on the end to quiten the sound and maybe add another silencer?

#280: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Sat Mar 20, 2010 5:14 pm
    ----
Socks aren't the greatest design as the bodies tend to suck the ends in

#281: Re: Project sleeper Author: vanman_foci, Location: Barry, South Wales PostPosted: Sat Mar 20, 2010 5:16 pm
    ----
Jamie wrote:
Socks aren't the greatest design as the bodies tend to suck the ends in

I haven't got a clue when it comes to TB. I am just happy to read and try and learn. Just remember seeing them before Very Happy

#282: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sat Mar 20, 2010 5:18 pm
    ----
it should be alot quiter with the air box on its when you take it off and open it up it hurts your ears haha

#283: Re: Project sleeper Author: Geoff, Location: Evesham, Worcestershire PostPosted: Sat Mar 20, 2010 5:29 pm
    ----
Edward wrote:
Half the problem is the noise it makes. Pulling away from lowish speed in 2nd gear just results in slow acceleration and lots of noise from both the exhaust and engine. Then it starts to pull better with even more noise...and it's giving me a headache!

Should have just bought a 1.1. For £4.5k you would have had change to spare as well. Rolling Eyes

Quarmbo wrote:
Edward, hope whatever you do your happy with. However, I personally wish that you'd go back to Ecosse (with the supporting comments/evidence from macj & others) and get them to sort it out for you. You've spent a hell of a lot of money on your car. They made you fall out of love with it within 2-3 weeks. Likewise, they could make you fall back in love with it by doing their job correctly. Or by someone else correcting what appears to be their mistakes.

Anyway, best of luck with whatever you plan to do.

Sam

What He Said

I agree with Quarmbo 100% It just reads a bodge remap to get the car ready for you in time. Take it back to Ecosse, I would bet the running issues are related as well. Ok so it is a 400mile round trip but when the car is running properly then it will be worth it. Wink

#284: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Sat Mar 20, 2010 5:33 pm
    ----
400 miles would be roughly £70 in a GTi? Maybe bit more due to the new engine setup, but it would cost you more than that in mapping at RST...
Ring up and give Ecosse an ultimatum;
Either they pay for your fuel (or pick the car up) for the car to be taken back to Ecosse, or they refund you for whatever work Paul does at RST.
That's the least they could do, and it could make you love the car again!

#285: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sat Mar 20, 2010 5:36 pm
    ----
Edward wrote:
Even at idle if you know what a big motorbike is like at idle it's like that. Multiply that for when the thing is running...
I've no idea what it sounds like from the outside!

Thats because the fuelling is too lean at idle and the butterflies are partially open to keep it running. you will get a slight deep warble when this occurs. Mine ticks over like a standard car apart from the exhaust note.

#286: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Mar 21, 2010 2:37 am
    ----
Let's stop the Ecosse bashing for now...
There's no evidence to me to suggest the mapping is actually wrong. It just doesn't pull that strongly which could be down to the nature of the cams.
Part of the problem could be my combination of TB's, cams and the exhaust. Nobody has an exhaust like mine and the combined noise makes it feel like there's lots of noise but no action at lower revs.

It does drive smoothly apart from a hiccup at the same 2nd gear corner I go through when the car is still warming up where it has a hiccup every morning.

The car won't be going back to Ecosse as I couldn't stand driving 400 miles in one shot. With my own family I don't have time either. As mentioned chances are the map will be password protected to stop other people getting hold of the map and using it themselves. So that will mean only Ecosse can change it. So I don't have the option of changing to shorter duration cams either.

#287: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Sun Mar 21, 2010 3:28 am
    ----
I've read all the comments, and to be fair, Eccose have done a great job fitting etc, so the map cant be that bad, but maybe needs tweaking.

What i cant understand, is that apart from a few people who kow what there talking about, everone has become an expert!

#288: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Mar 21, 2010 4:46 am
    ----
Steve206 wrote:
I've read all the comments, and to be fair, Eccose have done a great job fitting etc, so the map cant be that bad, but maybe needs tweaking.

What i cant understand, is that apart from a few people who kow what there talking about, everone has become an expert!

Haha well said steve

#289: Re: Project sleeper Author: gti180boy, Location: Stafford PostPosted: Sun Mar 21, 2010 5:34 am
    ----
Steve206 wrote:

What i cant understand, is that apart from a few people who kow what there talking about, everone has become an expert!

lmao Smile

#290: Re: Project sleeper Author: gti180lover, Location: Kent PostPosted: Sun Mar 21, 2010 6:37 am
    ----
Can you request that Ecosse send you the copy of the AFR graph via email ?

You will have an idea of fuelling then.

The job they done looks fantastic but if it was me i would be requesting they pick it up and check it out after the money you spent.

#291: Re: Project sleeper Author: SAB206, Location: North West PostPosted: Sun Mar 21, 2010 7:17 am
    ----
In fairness, a lot of members on here actually do respect you, your car and what you do to it a lot Edward, so just want your car to run how it should be after the amount of time and money you have put into it!

Got to be worth a quick phone call to see what they can offer you?

#292: Re: Project sleeper Author: Quarmbo, Location: Bristol & Leicester PostPosted: Sun Mar 21, 2010 7:27 am
    ----
Yeah, my apologies if my two pence worth is a bit out of order. I don't know you at all, I will probably never meet you, just wanted you to be happy (sound like a disgruntled ex!).

#293: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Mar 21, 2010 9:57 am
    ----
Let me just clarify a few things.

I have never said Ecosse have done anything wrong to the car, it's just not as I expected it to be. It could be just the same if somebody else built the engine.

Others have suggested the mapping may be the problem, that is their opinion. I've not in any way suggested they may be correct.

It starts fine and accelerates smoothly. It's just very linear between 2k rpm and 5k rpm. Whether it has full throttle or part throttle applied between these revs it seems to have no effect on the power output. I can see why this would happen though because it just suggests the engine is taking in as much air as it can and the butterfly is not a restriction.

It is faster than it was as high revs but it arrives at such high speeds that 200bhp at 60 mph has a lesser effect that it would if it was delivered at 40mph.
My opinion of fast may be different to other peoples and yes it does go well but it needs to be on the right road to feel quick.
This is why manufacturers pretty much limited tuning to 180bhp from 2 litres and if they wanted more they fitted a turbo.

I'm becoming happier with the car and appreciate it's not a car for motorways running at 4k rpm or pottering round town at small throttle openings.
I always wanted another everyday car as the 206 was becoming a bit too much and that will just arrive sooned than original expected.

I've taken some more pictures today with the engine cover back in place. I also gave it a bit of a clean to get rid of any oil etc. It's still a nice little toy to have sat in the garage.

 


 

#294: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Mar 21, 2010 11:36 am
    ----
is that it for now ed?
Whats to come?

#295: Re: Project sleeper Author: gti180lover, Location: Kent PostPosted: Sun Mar 21, 2010 2:18 pm
    ----
Got to admit it does look the absolute nuts ! Very Happy

#296: Re: Project sleeper Author: vanman_foci, Location: Barry, South Wales PostPosted: Sun Mar 21, 2010 2:36 pm
    ----
You going to make a call to them or trust them and get on with it?

#297: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Mar 21, 2010 2:45 pm
    ----
They already know all about it.

#298: Re: Project sleeper Author: vanman_foci, Location: Barry, South Wales PostPosted: Sun Mar 21, 2010 2:45 pm
    ----
Edward wrote:
They already know all about it.

Whats going to happen now then?

#299: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Sun Mar 21, 2010 3:41 pm
    ----
I think that they may have rushed it a little, but all in the name to meet a deadline unfortunately. I'm sure given the timescale the questioned map might be better? However, if it was such a terrible map would it be running 214bhp? I was expecting the torque figure to be higher but N/A engines aren't well known for their torque outputs i suppose!

Yet a few things don't stack up but it's hard to put a finger on it, there's clearly little niggles, mis-fires etc that you're experiencing too which need sorted!

All will be well on a dry road in the summer. It's cams and TB's..it's a high revving affair. Surely though Edward that with cams and TB's the noise level was bound to increase it's not a willy nilly crap exhaust either?

I'd give it time Smile You've spent far too much time on money on this cracking car to throw it all away now.

But if you could get ecosse to improve things then and if you could make it up it would be worth it. They're not pricks when it comes to after-sales service, they'd be more than happy to help, much opposite to the opinions which seem to have been stirred up on this thread. Pretty unfair on them too considering they can't explain/defend themselves too.

#300: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Sun Mar 21, 2010 4:50 pm
    ----
Good to see Edward. Without wanting to sound harsh, but perhaps you may have been anticipating too much from the mods. Either way it looks great, and a very nice project for someone like me to read.

I hope you retain your enthusiasm for performance cars and tuning and perhaps come back and show us all something new one day Smile

#301: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Sun Mar 21, 2010 4:53 pm
    ----
Seb wrote:
I hope you retain your enthusiasm for performance cars and tuning and perhaps come back and show us all something new one day Smile

...like whacking a turbo on the end of that longman's box Laughing

#302: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Mar 21, 2010 5:13 pm
    ----
i've had ideas of a super charge in front of the TB's but then thats just creating a restrictive inlet manifold so the TB's would just be in the way and a waist of money lol

#303: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Sun Mar 21, 2010 5:17 pm
    ----
I'm not entirely sure that would work particularly well with a roots charger!

#304: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Sun Mar 21, 2010 5:32 pm
    ----
I think it needs to be a rotrex/blower style supercharger! Hence why i just said turbo Smile

#305: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Sun Mar 21, 2010 5:36 pm
    ----
Yep rotrex can work Smile

I've seen it somewhere but can't put my finger on where....

The best thing about supercharging is that it needs less electrical customisation than turbo'ing.

Almost doubling the power and I can still keep the standard ECU, right up to the limit of that charger which is about 310bhp.

#306: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Sun Mar 21, 2010 5:39 pm
    ----
There was a guy called Cannonball on the forum before it died, he had a turbo'd & TB'd GTi!

#307: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Sun Mar 21, 2010 5:40 pm
    ----
There was a guy on here who had a TB'd and turbo'd gti-180 done by DP engineering i think. He was on here before the site went down.

#308: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Sun Mar 21, 2010 5:45 pm
    ----
Is there an echo in here?

#309: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Sun Mar 21, 2010 5:46 pm
    ----
Besides, turbo's are for show offs who like whoosh whoosh noises. /end thread Razz

#310: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Sun Mar 21, 2010 5:47 pm
    ----
haha! that's the one Jamie! I do prefer a supercharger myself Seb. I do want so all donations to Brian please...£5/6k is the target Laughing

Sport relief for Brian!

#311: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Sun Mar 21, 2010 5:57 pm
    ----
Lol! You can have mine when I'm finished with it... for a fair bit less than what I paid for it Razz

#312: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Sun Mar 21, 2010 6:23 pm
    ----
lol Razz If i win the lottery i'll be after an opcon jobbie.

#313: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Mar 22, 2010 2:53 am
    ----
Seb wrote:
Good to see Edward. Without wanting to sound harsh, but perhaps you may have been anticipating too much from the mods. Either way it looks great, and a very nice project for someone like me to read.


Looking at the reviews in both EVO and Cars and Car Conversions I expected the car to be great on the road but the cam choice obviously left the engine a little more peaky than expected.
I would like to think a little bit of the top end power could be sacrificed in order to gain more torque low down though by changing the cam timing.

#314: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Wed Mar 24, 2010 8:54 am
    ----
Ah I'm sure some of it can be reclaimed yes, all completely dependant on the cams though I would guess! Though I'm not in the know on those specific ones.

#315: Re: Project sleeper Author: Mattie-RS, Location: A Track near you ;) PostPosted: Wed Mar 24, 2010 12:59 pm
    ----
Seb wrote:
Besides, turbo's are for show offs who like whoosh whoosh noises. /end thread Razz

Cool Razz

#316: Re: Project sleeper Author: Ape, Location: Clipping the Apex! PostPosted: Wed Mar 24, 2010 1:44 pm
    ----
Mattie® wrote:
Seb wrote:
Besides, turbo's are for show offs who like whoosh whoosh noises. /end thread Razz

Cool Razz

Something you'd expect a whiner boy to say Laughing

#317: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Wed Mar 24, 2010 1:51 pm
    ----
AHA no.

#318: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Mar 25, 2010 2:38 am
    ----
Been thinking if I'd have to do this job again I'd definately not have gone for these cams. I'd have stuck with the standard exhaust cam and the Piper inlet cam.
That would have saved about £1k too.

What use on a road car is peak torque at over 6k rpm? Even then it's less than 170lb ft.

The car might be faster overall than standard but that's just because it continues to make power where the previously power would drop off. Acceleration might be stronger but it's no night and day difference, it just continues further up the rev range.

#319: Re: Project sleeper Author: Quarmbo, Location: Bristol & Leicester PostPosted: Thu Mar 25, 2010 3:15 am
    ----
Is there anything you can do to adjust the peak power band? Weren't you thinking of adjusting something?

#320: Re: Project sleeper Author: gti180boy, Location: Stafford PostPosted: Thu Mar 25, 2010 3:23 am
    ----
you could play around with the timing with the verniers to get the power band kicks in @ lower revs

#321: Re: Project sleeper Author: macj, Location: Essex PostPosted: Thu Mar 25, 2010 1:50 pm
    ----
would need another RR sessioon to map a new fuelling curve if you mess with the cam timing Crying or Very sad

#322: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Mar 25, 2010 3:39 pm
    ----
I guess if any re-mapping is needed a total map from scratch would be needed as well.

#323: Re: Project sleeper Author: Quarmbo, Location: Bristol & Leicester PostPosted: Thu Mar 25, 2010 3:39 pm
    ----
But like you said, the ECU would be locked now? So would have to go back to Ecosse? In Scotland. Bummer.

#324: Re: Project sleeper Author: vanman_foci, Location: Barry, South Wales PostPosted: Thu Mar 25, 2010 3:46 pm
    ----
could you just try to access the map? Obviously from there if it's locked/unlocked then you know a bit more what you need to do.

#325: Re: Project sleeper Author: macj, Location: Essex PostPosted: Thu Mar 25, 2010 3:49 pm
    ----
Ecosse will tell you if it is locked... they should let you unlock it as you own it and paid for the map it contains... also the map is useless to anyone else unless they have exactly the same mods. they could use it as a base map though

#326: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Mar 26, 2010 11:27 am
    ----
Took the car home through the scenic route today...it does go quite nicely and it does make a nice sound, you can't go fast discretely though...
It is a bit unruly for everyday use but it is fun once it has some revs on the engine. It's quite good fun and I actually like it again. I do think for sustained hard use an oil cooler would be a wise move. It does run hotter than it did before.
I'm still buying another car though!

#327: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Fri Mar 26, 2010 11:40 am
    ----
Edward wrote:
Took the car home through the scenic route today...it does go quite nicely and it does make a nice sound, you can't go fast discretely though...
It is a bit unruly for everyday use but it is fun once it has some revs on the engine. It's quite good fun and I actually like it again. I do think for sustained hard use an oil cooler would be a wise move. It does run hotter than it did before.
I'm still buying another car though!

I totally agree with you ed its hard to give it some without looking/sounding to suspicious haha.
what are you thinking of as a daily driver then??

#328: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Mar 26, 2010 11:43 am
    ----
I really liked the Jetta hire car I had so going for one of them. Got to be the right spec though...

#329: Re: Project sleeper Author: CD-B3, Location: Salisbury / New Forest PostPosted: Fri Mar 26, 2010 11:44 am
    ----
Glad you like it again Smile

#330: Re: Project sleeper Author: Quarmbo, Location: Bristol & Leicester PostPosted: Fri Mar 26, 2010 1:25 pm
    ----
Edward wrote:
Took the car home through the scenic route today...it does go quite nicely and it does make a nice sound, you can't go fast discretely though...
It is a bit unruly for everyday use but it is fun once it has some revs on the engine. It's quite good fun and I actually like it again. I do think for sustained hard use an oil cooler would be a wise move. It does run hotter than it did before.
I'm still buying another car though!

Positive news, glad you enjoyed the drive!

#331: Re: Project sleeper Author: macj, Location: Essex PostPosted: Fri Mar 26, 2010 2:10 pm
    ----
You will be fitting a roll cage and joining me on a rally stage soon Very Happy Very Happy

#332: Re: Project sleeper Author: tRiCk, Location: Mitcham PostPosted: Fri Mar 26, 2010 2:31 pm
    ----
spike_202 wrote:
Edward wrote:
Took the car home through the scenic route today...it does go quite nicely and it does make a nice sound, you can't go fast discretely though...
It is a bit unruly for everyday use but it is fun once it has some revs on the engine. It's quite good fun and I actually like it again. I do think for sustained hard use an oil cooler would be a wise move. It does run hotter than it did before.
I'm still buying another car though!

I totally agree with you ed its hard to give it some without looking/sounding to suspicious haha.
what are you thinking of as a daily driver then??

Same here. Slightly annoying. Power that im not allowed to use.

#333: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Fri Mar 26, 2010 3:00 pm
    ----
lol at trick oh i make good use of it haha i just have to choose my times carefully as its like a rally car.

#334: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Mar 26, 2010 4:07 pm
    ----
macj wrote:
You will be fitting a roll cage and joining me on a rally stage soon Very Happy Very Happy

That would mean getting it dirty.

#335: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sat Mar 27, 2010 5:14 am
    ----
Edward wrote:
macj wrote:
You will be fitting a roll cage and joining me on a rally stage soon Very Happy Very Happy

That would mean getting it dirty.


Shocked Shocked Shocked Shocked Shocked

#336: Re: Project sleeper Author: Antix, Location: Worcester PostPosted: Sat Mar 27, 2010 6:01 am
    ----
Edward wrote:
macj wrote:
You will be fitting a roll cage and joining me on a rally stage soon Very Happy Very Happy

That would mean getting it dirty.

'All show and all go' now, Edward Wink

#337: Re: Project sleeper Author: Dave, Location: Birmingham PostPosted: Sat Mar 27, 2010 6:19 am
    ----
'Detailed, not driven' ? Laughing

#338: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Mar 27, 2010 9:19 am
    ----
I did some fiddling today. I wanted to know what was in the airbox as I noticed Ecosse hadn't used 5 of the bolts to hold the bottom of the lid onto the airbox (making it easier for me to take the lid off!).

It's the five bolts on the lower row of the box that haven't been used.

 


This is what's inside the box.

 


 


The bottom of the airbox behind the radiator isn't held together and therefore isn't perfectly sealed. I fully understand why they haven't bolted it together simply because there is just no space for tools etc. There is about 5mm between the airbox and radiator so it's impossible to get access. Either the radiator and fan housing would have to be removed to fit the bolts or the whole inlet and bodies removed to do the airbox bolts up.

So I though of an alternative. Some simple cable ties to hold the lid onto the box are better than nothing. They are a bit fiddley to fit but they don't need tools to do them up. They also just need some cable cutters to remove them.

There is also a bit of oil in the airbox from the breather pipe. It's not excessive but I might look into buying an oil catch tank. Anybody know how they work? Do they still use air going into the inlet to pull the vapours out of the engine?

Even though I don't think the strut brace does anything to benefit the handling of the car I thought I might as well fit it. It does finish things off nicely.

 


 


 


Also had a bit of 'help' from the dog.

 

Last edited by Edward on Sat Mar 27, 2010 9:24 am; edited 1 time in total

#339: Re: Project sleeper Author: Nick, Location: Birmingham PostPosted: Sat Mar 27, 2010 9:23 am
    ----
thank you Edward you just brought loads of smiles into my day

#340: Re: Project sleeper Author: Antix, Location: Worcester PostPosted: Sat Mar 27, 2010 9:24 am
    ----
did the dog also make the mess in your yard? Wink Laughing

I like the red strutbrace - it goes with the other red thing in your engine bay, by the Longman carbon box

#341: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Mar 27, 2010 9:29 am
    ----
I did the mess of the driveway. I decided to finally fix the bathroom drainpipes to the walls hence the need for ladders etc. I only finished the bathroom last June!

#342: Re: Project sleeper Author: Antix, Location: Worcester PostPosted: Sat Mar 27, 2010 9:34 am
    ----
what's next on the 'to do' list? [car-wise I mean]

#343: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Sat Mar 27, 2010 9:35 am
    ----
It doesn't really matter which catch tank you go for, they are very basic in design, but I imagine the branded ones are made better, ie stick to Mocal/Forge/Baileys.
Have it set up so it drains back to the sump if you can, rather than having to empty it every so often!
What have Ecosse done in the way of a "breather"?

#344: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sat Mar 27, 2010 11:56 am
    ----
i said you would need one,espesh when your in the cam it will push more oil out i had mine custom made, and they are a good idea with a return like what jay said but if the pump packs in and it sifenz it will contaminate the engine,
And it was spot on what they did with the air box, thats what im doing with mine when i get round to it lol.

#345: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Sat Mar 27, 2010 12:18 pm
    ----
Watch the catch tanks sometimes, they can fill up with water for some reason!

#346: Re: Project sleeper Author: Ape, Location: Clipping the Apex! PostPosted: Sat Mar 27, 2010 12:22 pm
    ----
Seb wrote:
Watch the catch tanks sometimes, they can fill up with water for some reason!

Thats just condensation mate. I'm getting one for mine soon, but I got a PCV system to sort out too for it. they need periodic cleaning out as well, you don't want a catch tank getting full or blocked Laughing

#347: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sat Mar 27, 2010 12:25 pm
    ----
Seb wrote:
Watch the catch tanks sometimes, they can fill up with water for some reason!

I know seb ive had water in mine and also ive had like a throfy gunk in there, its when warm oil vapors react with the cold tank. But i empty mine every friday and i do not re use it.

#348: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Sat Mar 27, 2010 12:29 pm
    ----
Ape wrote:

Thats just condensation mate. I'm getting one for mine soon, but I got a PCV system to sort out too for it. they need periodic cleaning out as well, you don't want a catch tank getting full or blocked Laughing
Yeah indeed, was just saying if it's in a hard to reach area, then a catch might not be the best idea! I debated one for mine, but in the end they just get too much condensation in (slightly more on S/C's than ITB's for some reason..).

#349: Re: Project sleeper Author: gti180boy, Location: Stafford PostPosted: Sat Mar 27, 2010 12:58 pm
    ----
i just think that this just looks really nice and oem, proper job i have to say. Smile


 

#350: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Mar 27, 2010 1:00 pm
    ----
This had one fitted. Looks like it's in the only place to put it.

 

#351: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Mar 27, 2010 1:03 pm
    ----
gti180boy wrote:
i just think that this just looks really nice and oem, proper job i have to say. Smile


And not a single bit of colour coded plastic in sight...just goes to show, less is more.

#352: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Sat Mar 27, 2010 1:19 pm
    ----
Really is Smile ^^

Glad you're warming to it now Paul Smile

#353: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Mar 27, 2010 1:29 pm
    ----
Anybody know what an optimum oil temperature is? At what temperature would it be classed as being too hot?

#354: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Sat Mar 27, 2010 1:36 pm
    ----
If you can get a coolant -> oil cooler that would be better ideally.

Should be running at 90ish, maybe hitting 100. Anything over 140ish fully synth will start to fail. Though evidently hotter = better for vicsosity, just not TOO hot.

#355: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Sat Mar 27, 2010 1:38 pm
    ----
I'd have thought 120ish would be classed as pretty hot as well?? Still, I couldn't put my finger on a good and constant temperature for optimum performance.

#356: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Sat Mar 27, 2010 1:40 pm
    ----
Yeah, 120 is fairly hot. I'd be worried if it went over 110ish. It should be within 15 degrees of coolant temp at a push, and ideally 10 degrees.

#357: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sat Mar 27, 2010 2:16 pm
    ----
you can see mine there, but like what ed said its hard to find a place as i don't think I'll be using the standard air box yet i may get a bmc canister yet i haven't made my mind up yet.

 


have you got a new air feed to your box ed or is it still that horrible piping??

#358: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Mar 27, 2010 3:49 pm
    ----
The piping into the bottom of the standard air filter box? It's actually very good and the fabric inside is very good at soaking up and holding any moisture that could get into the intake.

#359: Re: Project sleeper Author: Dave, Location: Birmingham PostPosted: Sat Mar 27, 2010 4:23 pm
    ----
Can someone educate me here, i thought having TBs meant there was no need for the standard air filter box?

#360: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Sat Mar 27, 2010 4:25 pm
    ----
Dave, you should have some form of filter, you don't want dust/particles/insects etc going into your trumpets! A lot of people run the risk and use the bodies without a filter.

#361: Re: Project sleeper Author: Dave, Location: Birmingham PostPosted: Sat Mar 27, 2010 4:30 pm
    ----
Doesnt the standard air box go nowhere near the trumpets though.

I realise you should have the ''socks'' on the trumpets, although the long version that covers all four rather than the individual trumpets, but i thought TBs acted as (As shocking as this sounds) A Super super induction kit?

#362: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Sat Mar 27, 2010 4:32 pm
    ----
They do, but you still need to use some sort of filter! I would have thought the standard air intake pipe was a bit restrictive?

#363: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Sat Mar 27, 2010 4:33 pm
    ----
The standard air box has nothing to do with the filtration apart from "housing" it.
The standard air box is for silencing & delivering cold air. Something like the ACT/Longmans/Jenvey airbox is good for silencing, looks smart & can house a single filter for all the trumpets. The socks aren't an ideal solution as the bodies literally suck them in!

#364: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Sat Mar 27, 2010 4:35 pm
    ----
Also, unless that airbox around the trumpets isnt air tight, its going to be sucking a lot of the air coming of the radiator.

#365: Re: Project sleeper Author: Dave, Location: Birmingham PostPosted: Sat Mar 27, 2010 4:35 pm
    ----
So as Edward has the Longmans box, he wouldnt need the other one? Buuut he has, this is where im getting lost!

#366: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Sat Mar 27, 2010 4:38 pm
    ----
Because it looks OEM and is effectively a cold air feed. I think it's designed to be used like this

#367: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sat Mar 27, 2010 5:02 pm
    ----
Edward wrote:
The piping into the bottom of the standard air filter box? It's actually very good and the fabric inside is very good at soaking up and holding any moisture that could get into the intake.

i see... good point, do you have an after market panel filter in the standard box?

as im torn between using the standard system like you have or use a filter canister say like the BMC??

as at the moment im just using a very fine mesh that i have fabricated witch i do want to get rid of lol hence i me asking as i want to do this asap really.

#368: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Sat Mar 27, 2010 5:12 pm
    ----
What filter are you using Edward?

#369: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Mar 28, 2010 2:58 am
    ----
If you don't use the Longman airbox (or similar) you'll just suck in hot air from the engine bay. You also need to filter the air.

There's nothing wrong with the standard Peugeot airbox and it allows a filter to be used. I have a K&N panel filter in there.

A cone filter could go on the end of the Longman box but wouldn't solve the hot air issue. If my set up was good enough for Longmans then it's good enough for me.

#370: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Mar 28, 2010 3:59 am
    ----
i was thinking more on the lines of an enclosd induction say from the fog to the canister then to the trumpet box, i don't no what to do atm as its just ideas im looking into for a less restrictive intake.

#371: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sun Mar 28, 2010 4:36 am
    ----
Edwards solution to filtering is very good. The K&N filter has a good flow rate and the standard airbox solves the hot air issue. It looks neat and the cold air is fed into the system as Peugeot had designed. If the airbox wasnt in the way of the gearbox I would have gone this route....Good one mate Cool

#372: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Mar 28, 2010 4:58 am
    ----
lol. When i had a look at my cold air intake it was pointing backwards towards the wheel arch grate way to get cold air, i could use the standard box as i already have a k&n filter isn't it, but i was wondering what outher options there are?
Sorry to thread jack paul if u want to reply to help me could you do it in my thread
Rich

#373: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Mar 28, 2010 7:29 am
    ----
Spike, are you happy running no filter?
I wouldn't risk running without one.

As it's a road car I'd just stick with the standard Peugeot air filter box. It works fine. It's tidy, tough, durable and it's free!
It might be a little restrictive in terms of air flow (compared to having nothing) but I really wouldn't worry about it. It has more advantages than disadvantages. Power is great but not when it comes at the cost of ruining your engine!

I really don't like the look of using fog light holes to provide an air intake. They look a bit 'I'm desperate for 1 bhp' and the air pressure can vary as the car changes speed. That will confuse your engine nicely. They also suck in water too. and flies.

#374: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Mar 28, 2010 9:03 am
    ----
im not happy paul as ive had to wait since december for my carbon air box, and your right its free as its under my bed doing nothing atm with the k&n already in thanks lol, i think i may vent it behind the grill,

#375: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Mar 28, 2010 9:46 am
    ----
It is a little worrying if the airboxes take so long to build. I was thinking that yesterday when I had mine off the car, if I broke it what would I do?
I'd find a local aluminium or stainless steel fabricator and get them to build one. Hotels need stainless bits making so I'd approach whoever does this kitchen equipment etc.

So what are you going to do about moving the injectors into the manfiold and going back to the original fuel rail?

#376: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Mar 28, 2010 11:06 am
    ----
i think so yes paul as its easyer also i think the black 1 looks better. Also the loom can be just moved back, its just the throttle linkage what will need tinkering,
Thats my next step ill be down pug1off having my brakes dun,injectors,air box then go down the RR to have the map tweeked and get a print out az i have lost mine.
All that before fcs hopefuly so im doing loads of over time atm to pay for it all lol,

And to what you said about the waiting time i no it does take the pi** but im sure you agree its worth it.

#377: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Mar 28, 2010 11:52 am
    ----
It's certainly the best (only) airbox made to fit the 206 GTi so it's worth buying. Does yours have the inlet pipe made to the same size as the standard Peugeot airbox pipe?

#378: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Mar 28, 2010 1:36 pm
    ----
i havent collectd it yet ed, i'll get it when i get chance this week it should be im also going to get some smaller trumpets as mine are 60mm and am i right in saying you need 30mm? To fit in the box?

#379: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Mon Mar 29, 2010 6:26 pm
    ----
I have 45x90mm trumpets, I've been told mine will fit

#380: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Tue Mar 30, 2010 12:26 am
    ----
mine are 65mm or 60mm i cant remember and they will just fit but they will be to close to the side so limeting air intake.

#381: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Apr 01, 2010 1:12 pm
    ----
The trumpets need to be something like 30mm or 40mm deep. I'll measure them at the weekend.

You picked up your airbox yet?

#382: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Thu Apr 01, 2010 1:27 pm
    ----
chaers buddy that would be a grate help, nar im getting it on the 15th when i get paid as they are doing a deal on some pico 330cc injectors as well hopfully if you want in that would be 4 of us that want there products??

#383: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Apr 02, 2010 1:01 pm
    ----
Well today i completed the project with another purchase...

A VW Jetta 2.0 TDi Sport on a 56 plate...

 


 


 


 

#384: Re: Project sleeper Author: CD-B3, Location: Salisbury / New Forest PostPosted: Fri Apr 02, 2010 1:03 pm
    ----
Keeping the 206 as a weekend toy then?

I borrowed my dads Passat last summer for a few days.
Nice cars those VW's Smile

#385: Re: Project sleeper Author: Ruffy_206, Location: Bristol PostPosted: Fri Apr 02, 2010 1:14 pm
    ----
nice colour. i bet you never thought you would own a dirty durv.

#386: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Apr 02, 2010 1:37 pm
    ----
I could never have one as my only car. It's just there to do a job which a Jetta does quite nicely. The last one averaged about 42mpg and they cost £155 a year to tax and the insurance is relatively cheap too. I can't use my existing NCB on this car so it's on a new separate policy.

As for the colour yes I like it...silver is nice but hides the Jettas chrome grille and trim on the doors. Black looks like a taxi and this graphite grey will look really nice when polished too.

#387: Re: Project sleeper Author: Antix, Location: Worcester PostPosted: Fri Apr 02, 2010 2:08 pm
    ----
Nice VW Paul [but I would say that though!] Very Happy

Who did you get your insurance with?
I have just swapped my policy to Direct Line multiple car policy, my NCD is 'mirrored' from the Golf to the 206, so essentially I get max discount on both (except ONE [the 206] can't be NCD-protected). Total was £800 [ins grps 16 and 17 from memory]

#388: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Apr 02, 2010 2:18 pm
    ----
206 is with Adrian Flux and the Jetta is with Tesco who give a discount with the wife having a policy with them and me being a named driver etc.
It's harder to do a multicar with the 206 because it's so modified. 206 is £450 with protected NCD (hopefully will reduce as it will only be doing about 1k miles a year now) and the Jetta is £500.

#389: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Fri Apr 02, 2010 2:26 pm
    ----
nice buy mate when you going to mod this haha o.j nice colour to.

#390: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sat Apr 03, 2010 4:08 am
    ----
Pipercross panel filter part no. PP1621...£34.11 inc vat


Well.....its a start Laughing

#391: Re: Project sleeper Author: Geoff, Location: Evesham, Worcestershire PostPosted: Sat Apr 03, 2010 4:15 am
    ----
macj wrote:
Pipercross panel filter part no. PP1621...£34.11 inc vat


Well.....its a start Laughing

Over 200bhp is possible out of these engines Razz

#392: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Apr 03, 2010 4:55 am
    ----
macj wrote:
Pipercross panel filter part no. PP1621...£34.11 inc vat


Well.....its a start Laughing

Might invest in a K&N panel filter only because it can be cleaned...

Geoff wrote:

Over 200bhp is possible out of these engines Razz

I will not be doing any diesel tuning that's for sure! This one certainly has a stronger mid range than the Peugeot though!

#393: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Apr 03, 2010 5:03 am
    ----
Did a bit more fiddling today. The breather pipe was always popping off the attachment on the airbox which sometimes meant oil could be smelt inside the car. The airbox attachment is actually that off the original airscoop that sits on the standard throttle body. It was cut off the scoop and used on the new airbox. It was slightly loose in the airbox which mean't the standard hose couldn't be pushed on all the way hence it kept jumping off.

 


So I went on Ebay and bought some silicone tubing for less than £6. I cut the hose to release the original clip that attaches to the rocker cover.

 


Then I attached the hose to the original clip and the airbox attachment with a jubilee clip to make sure the hose doesn't come off.

 


 

#394: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sat Apr 03, 2010 6:53 am
    ----
what size is that tubing edward?? as i've been after some samco hose since day1, to go right to the head as its only half way atm

#395: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Apr 03, 2010 7:02 am
    ----
It's 13mm internal diameter. It's not Samco but does the job fine. You got any pictures as to where you want hose for?

Also does your car use an inlet air temp sensor? Mine seems to only have sensors for coolant, throttle position and the crank sensor.

#396: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sat Apr 03, 2010 7:43 am
    ----
I have an air temp sensor in the airbox

#397: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sat Apr 03, 2010 8:18 am
    ----
from the oil catch tank to the head breather as mine pipe has gone brittle so half is standard pipe and the other half is samco hose but i want the hole lot done properly lol.
you can see here
 


mine uses the crank,air,coolant,tps,oil temp sensors

#398: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Apr 03, 2010 8:53 am
    ----
Just get on Ebay then. For a breather pipe any brand of silicone will do.

I just can't find a air temp sensor at all on mine. Spike, where does your sit?

Can't stop taking pictures while the sun is out...

 

#399: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sat Apr 03, 2010 10:03 am
    ----
if you look closely paul its that little gray thing on the right hand side of my fuel rail, it will go in the box 'i think' im not sure i'll leave that to pug1off as they've goto move the rail back.

And nice 1 for the heads up on the hose paul i'll get some, i dont supose you could pm a link could you?

#400: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Apr 03, 2010 11:38 am
    ----
Yes I can see your sensor now. Either mine isn't fitted with one or it's nearer the inlet behind the arch liner somewhere.

I've had a couple of things from this place. Pretty quick postage too.

cgi.ebay.co.uk/13mm-1-...4399b2fe7e

#401: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sat Apr 03, 2010 12:24 pm
    ----
nice 1 paul, yourz is looking pristine as always.

#402: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Sun Apr 04, 2010 12:34 am
    ----
What does your trip computer say now Edward/Spike, has there been any difference on fuel consumption?

#403: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Apr 04, 2010 1:39 am
    ----
I'm not sure what it's doing mpg wise. It runs hotter so that will mean it's using more fuel. I've not put fuel in it for 2 weeks.

#404: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Sun Apr 04, 2010 3:03 am
    ----
Have you reset the trip computer? I know its not totally accurate, just wondered if it would notice!

#405: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Apr 04, 2010 4:01 am
    ----
It's not a multiplexed car so doesn't have one. I'm not sure one would work anyway with the way the car has been wired up. Not sure if Multiplexed cars are able to be wired the same as mine.

I always thought the original sensors had to keep being used in order to fool the original ECU into thinking it was still controlling the engine. On mine all the redundant stuff has been disconnected and the plugs can be seen in the first picture on the previous page. Disconnecting stuff would put the ECU light on so mine has had the bulb removed.

The original ECU now just measures coolant temperature for the guage and oil temperature. Another coolant sensor is fitted for the new ECU to read. I guess the original flywheel sensor still sends the signal via the ECU for the rev counter too.

My car uses the original flywheel sensor for the new ECU too. Longmans used a separate trigger wheel and crank sensor but that might just have been because of the EFi ECU they used. .

#406: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Apr 04, 2010 4:46 am
    ----
Steve206 wrote:
What does your trip computer say now Edward/Spike, has there been any difference on fuel consumption?
Mine is pre-plexd so i havent got any fancy suff like that lol

#407: Re: Project sleeper Author: Shodoku, Location: West Yorkshire PostPosted: Fri Apr 09, 2010 12:01 pm
    ----
Is that a strut-brace I see? Smile

#408: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Apr 10, 2010 2:35 pm
    ----
Well it turns out Ecosse haven't fitted an air temp sensor. If 99% of all other companies feel the need to fit one then why don't Ecosse? If they were such an unimportant sensor then why would all TB and ECU kits come with an air temp sensor?

The green and white wire at the bottom of the picture is the one that should be connected to the temp sensor and it's not connected to anything.

Put it this way every standard car uses an air temp sensor so the ECU can adjust the fuelling to account for the decrease in air density with increased air temperature. For every 10 degree increase in temperature a 3% reduction in fuel is needed as warm air is less dense than cool air. Without any correction this will mean the car is running richer than is ideal in warm weather.

Will be interesting to see how the car performs on an MOT emissions test.

 

#409: Re: Project sleeper Author: Ruffy_206, Location: Bristol PostPosted: Sat Apr 10, 2010 2:39 pm
    ----
uuummmm looks like a rushed job to me. im glad your happy with it again and the new edition is a good choice keep this one a minter.

#410: Re: Project sleeper Author: MattyP, Location: Plymouth PostPosted: Sat Apr 10, 2010 3:03 pm
    ----
Looking sweet mate!! 1 question though and I apologise for being slow haha, whatever happened to your 206 with the cyclones? Or is this the same car? Keep up the good work mate

#411: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Apr 10, 2010 3:15 pm
    ----
It's never had any wheels on it other than the Nimrods in the picture.

#412: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Sat Apr 10, 2010 3:57 pm
    ----
Out of interest Edward, what are you doing with all tohhse wires out. Shame about the set up.

#413: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Apr 11, 2010 12:44 am
    ----
What am I doing with those wires out? I'm looking to see if the wire that would go to an air temp sensor is actually connected to anything. Those loose unused wires are normally bundled together in insulation tape. I've just removed the tape.

#414: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Apr 11, 2010 6:25 am
    ----
is that your standard ecu under the omex??
mine has been completely replaced by the emerald is there a reason for the omex needing the standard ecu??

#415: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Apr 11, 2010 9:44 am
    ----
The Omex just runs the engine. The original ECU is kept as it controls everything else from the dimmer on the interior light to the speedo.

You sure yours has been removed?

#416: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Apr 11, 2010 10:18 am
    ----
lol yer i think so, well i cant find it any were

#417: Re: Project sleeper Author: t1mmy, Location: Reading PostPosted: Sun Apr 11, 2010 10:21 am
    ----
What made you think in the first place that they hadn't connected the wires?

#418: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Apr 11, 2010 11:40 am
    ----
I couldn't find the temp sensor anywhere so I went looking for confirmation by checking the wiring. I got the manual from the OMEX website to check what each wire did on the connector block.

#419: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Apr 11, 2010 12:56 pm
    ----
was you not given a hard back copy??
i got lots of stuff with the k3 i got a comms lead,hand book,cd software,loads of stickers and a catalogue

#420: Re: Project sleeper Author: Addaz, Location: Suffolk PostPosted: Sun Apr 11, 2010 1:12 pm
    ----
You would have thought they could have insulated the connectors, and put better wire covering, ie OEM

That is for the price you paid Neutral

But then again, installing TB's isnt brain surgery, as the OMEX should supply a copy of how to install, so technically you could do everything apart from the mapping Confused

#421: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Apr 11, 2010 1:16 pm
    ----
addaz wrote:
You would have thought they could have insulated the connectors, and put better wire covering, ie OEM

That is for the price you paid Neutral

But then again, installing TB's isnt brain surgery, as the OMEX should supply a copy of how to install, so technically you could do everything apart from the mapping Confused

true mate the manual i got even shows you how to operate the pc software to set them up but at the end of the day i much rather a respectable company do it as well...if i messed it up it would be my fault lol.

#422: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Apr 11, 2010 3:10 pm
    ----
Yes I thought wiring up the ECU would be quite hard but it seems amazingly simple really. Just disconnect everything, remove the ECU bulb and give the new ECU the minimum of inputs it needs to run the engine.

Emerald software is given away with the Dave Walker Engine Management book (which I have) but I don't think the Omex stuff is as readily available to all. I'm going to find out though because it's my map and I want to know everything I can about it.

#423: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Mon Apr 12, 2010 3:35 am
    ----
2 right paul thats what you have paid for and also have that book lol

#424: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Apr 12, 2010 5:06 am
    ----
All the software and owners manuals can be downloaded from the Omex website. When an ECU is ordered it is optional for the PC cable and manual are ordered with it.

#425: Re: Project sleeper Author: Lewis., Location: Bucks PostPosted: Tue Apr 27, 2010 5:15 pm
    ----
Hello mate, is there any way on earth I could persuade you to part with that carbon airbox, as I need another one! Smile

#426: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Tue Apr 27, 2010 5:21 pm
    ----
They're available from act products lewis Wink

#427: Re: Project sleeper Author: Lewis., Location: Bucks PostPosted: Tue Apr 27, 2010 5:41 pm
    ----
Ah good man - thanks very much for that mate Smile

Car is looking sweet too mate. Did you get the air sensor thing worked out in the end?

#428: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Apr 28, 2010 1:16 am
    ----
Ecosse are going to send me an air temp sensor and the wiring for it.

The airboxes are about £210 delivered this time last year. ACT Products have a website so you can see the sort of stuff they do.

#429: Re: Project sleeper Author: Lewis., Location: Bucks PostPosted: Wed Apr 28, 2010 6:17 am
    ----
Ah cool. It's a nice car mate - what sort of power is she making then? Will you need a remap after you've fitted the air sensor, i'd say you would?

Apprecaite the tip on the airbox mate that's really helpful ta Smile

#430: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Apr 28, 2010 12:29 pm
    ----
Apparently 214bhp ish...

We shall see if anything needs adjusting once the sensor is attached. The OMEX instructions suggest the ECU needs to be told the temp sensor is fitted so I imagine that also requires me to have access to the settings i.e. a password if it requires one.

Everything else has been thoroughly sorted on this car so I'm not going to settle for the engine not being set up perfectly.

Would you believe the car has done less than 500 miles since I picked it up. That includes the trip back from Scotland!

#431: Re: Project sleeper Author: t1mmy, Location: Reading PostPosted: Thu Apr 29, 2010 12:28 pm
    ----
So you're out enjoying it then Laughing

#432: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Apr 29, 2010 1:09 pm
    ----
Of course! I always wanted a toy in the garage and that's what I've got!

I don't really need to go out in the car and I don't see the point in going out just for the sake of it! Maybe I'll take it for a run this weekend. I also have the move the Modus out of the way to get the Peugeot out of the garage.
I actually started it up earlier and left it running to warm it up enough for the fan to come on. I varied the revs every now and again and it makes some scary spitting sounds from the bodies when plipping the throttle!
Since I got the car back I could smell oil in the garage but there was no sign of any leaks other than the night I got it home and there was a bit on the driveway and today there was a spot on the garage floor.

As the car was running I put it up on the ramps and had a look and it's on the sump at the cambelt end of the engine. I'll have a look this weekend to see where it's coming from but it's not too serious. I have never had cars with oil leaks and I don't intend to start now.

I also bought some clips that hold the PAS pipes under the engine. These are broken and so the pipes aren't very secure. I needed two but they come in a bag of five. The dealer couldn't find them when I first ordered them and when they ordered them again the originals turned up. They gave me the extras for free so I now have enough for five cars!

#433: Re: Project sleeper Author: t1mmy, Location: Reading PostPosted: Thu Apr 29, 2010 1:14 pm
    ----
I remember with my 206 I often had to move three cars off the drive to get it out the garage! It makes it worthwhile though once your out for a blast.

#434: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Apr 29, 2010 1:40 pm
    ----
I might take it for a run rounds the lanes above Lancaster sometime...If I can be bothered.

Seeing as I like pictures I took some...

Broken clip...it was always broken but the pipes were at least hooked where they belong once upon a time. Should have bought some new clips ages ago.

 


 


A bit of oil. No idea where it's coming from but it's as high as the water pump housing. It could have blown upwards though. Of course it shouldn't be there but I'll clean it up this weekend and keep an eye on it.

 


 

#435: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Thu Apr 29, 2010 1:43 pm
    ----
I have some interesting news on that airbox Paul, I'll find the prose from Sandy now!

#436: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Thu Apr 29, 2010 1:46 pm
    ----
In relation to using that airbox and shortened trumpets over using 90mm trumpets and a sausage filter. The last section refers to putting the airbox on after it has been set up with 90mm trumpets;

I can't say I like the idea of shortening the tract and enclosing the trumpets without testing to establish the effects and re-mapping if necessary (quite likely to be necessary). I'm sure it'll still be a quick engine, but potentially not as good as it could be and if the map is off, it won't drive as well and could be over-fuelling. Not being negative or anything, just trying to be informative.

#437: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Apr 29, 2010 3:01 pm
    ----
1) You can't fit 90mm long trumpets as they'd hit the radiator
2) It's a road car so needs filtered cool air
3) The airbox is the only way of achieving that
4) It's designed to fit the space in the 206 so it's the best there is
5) I'm sure it is compromised compared to having no airbox and maybe moving the radiator but with the aircon still fitted so that's not an option.

#438: Re: Project sleeper Author: t1mmy, Location: Reading PostPosted: Thu Apr 29, 2010 3:06 pm
    ----
I remember when TMS were still in business there was an option of a lowered rad which a few people had. This is what they used so the could use a sausage filter rather than the airbox.

#439: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Apr 29, 2010 3:10 pm
    ----
Is that actually the cheaper option though? It the filter is getting air straight from below the bonnet it will also suck up rain water.

Everything on a road car has some sort of compromise and I'm not going to trade safe cool, dry air for a little more power.

#440: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Thu Apr 29, 2010 3:10 pm
    ----
So I need shorter trumpets? Or need to get a new rad?

#441: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Apr 29, 2010 3:13 pm
    ----
What's to say the inlet length isn't perfect as it is? Longmans designed it and I very much doubt they would have settled for anything with serious downsides.

There is only limited space at the front of the engine bay and you have to do the best with what's there.

#442: Re: Project sleeper Author: t1mmy, Location: Reading PostPosted: Thu Apr 29, 2010 3:24 pm
    ----
I have no idea which is better to be honest. I know Longmans did a lot of work on their 206 and if they went with the airbox then it was a pretty good option in my eyes.

The difference between airbox or lowered rad and sausage filter could be negligable. I know the people with lower rads also fitted a kind of metal airscoop above the rad which also reduced heat soak from the rad.

#443: Re: Project sleeper Author: quiksilverRY, Location: West Yorkshire PostPosted: Thu Apr 29, 2010 3:43 pm
    ----
Hi, dont want to trail through all 30 pages but how much BHP and torque do u have now and how much has the ecosse mods set u back?

#444: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Fri Apr 30, 2010 2:07 am
    ----
i think that eds set up is spot on thats the way it was made to be thats why im doing that air box mod as its the easyest way in my eyes

#445: Re: Project sleeper Author: macj, Location: Essex PostPosted: Fri Apr 30, 2010 10:45 am
    ----
Yuo have the best option for road use Edward. I have had to fit a Toyota Corolla radiator as it is longer and lower but retains the same pipe setup. I had to modify the vent pipe header tank though.
Bear in mind that I deal with dust and water ingress on a stage so I have several options of filtering available. I have an airbox for potentially wet venues with a cold air feed and a 600 series filter with Jenvey deep backplate to take the longer trumpets.
Fitting shorter trumpets usually only alters the torque figures a bit

#446: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat May 01, 2010 8:35 am
    ----
Got the air temperature sensor yesterday from Ecosse.

 


I just have to decide where to fit it. I'd like to fit it in the side of the airbox just near the PAS pump because it would need really short wiring to the ECU...

 


...but Ecosse have wisely advised me to install it downstream of the breather pipe, I guess to stop it oiling up. So I think the best place might be inside the standard air filter box under the air filter. It's a bit further downstream than I want but it's the ideal place where there is plenty of space and a flat surface to drill in t.

Before I fit it though I want to order some wiring bits such as the braiding I've fitted to the temperature sensor wiring because I want to replace these connections that go to the throttle position sensor. They are the sort of thing I'd use to wire a stereo with.

They're not waterproof and while the car isn't going to be used in wet weather, I'm going to fit a 3 way Superseal connector like all other engine bay connections use. No I won't be removing the TPS sensor to fit it as this will ruin the settings in the map.

 


I also gave it a clean underneath. There was quite a bit of oil underneath and was on both front and back of the engine. I also used the new clips to fix the PAS pipes back in place. Looks much neater now.

 


 


A quick look up at the bottom of the throttle bodies shows how tight it is between the airbox and radiator. I also fitted some cables ties to the bottom of the airbox to hold the lid in place. The bolts used elsewhere are impossible to fit without removing the radiator.

 


I also noticed this extra lambda boss on the exhaust before the cat. What's this been used for? Has a wideband lambda been fitted while the mapping was done? Is this normal?

 

#447: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Sat May 01, 2010 8:47 am
    ----
I'd say it's pretty normal to fit a wideband for the mapping!

#448: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat May 01, 2010 9:07 am
    ----
I thought they'd have used the signal from the standard lambdas via the ECU into the mapping PC to set it up.

#449: Re: Project sleeper Author: Austin, Location: Telford PostPosted: Sat May 01, 2010 12:12 pm
    ----
looking good edward, need to give mine a good clean underneath, had a look today and its abit oily Smile

#450: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat May 01, 2010 3:40 pm
    ----
Oily can prevent rust though!

Went for a bit of a run today in it and it's got to be said it's a quick little car. It's just a shame the gearing is as tall as it is. Some shorter gearing would give better access to the power band while doing sensible speeds.

Also the clutch seems to feel rough through the pedal when it gets hot. It's a brand new Sachs clutch that's only been on the car since November. I'm wondering if the release bearing has got too hot while on the rolling road.
I might invest in an engine support bar and whip the gearbox off myself. No sign of oil underneath either.

#451: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun May 02, 2010 12:02 pm
    ----
im realy pleased that you have grown to love it again paul, just watch the faces of the type r drivers when you power past them lol it makes it all worth while haha

#452: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed May 05, 2010 3:06 pm
    ----
Took the car out again tonight and it was playing up again, just like it was doing when I first got it back.

I Drove it ten miles then switched it off for 45 minutes.

Then when it came to restarting it the engine fired up for 15 seconds then cut out. I started it again and again it ran for 5 seconds then cut out. It continued to do this for 6 or 7 times. It drove about 30 yards down the road then cut out again. I pushed it back to where I started and opened the bonnet for a minute then the engine started normally but as soon as I put the lights on it died. The next restart it kept running and stayed running with a brief stutter about 100 yards up the road. It ran fine after that all the way home.

Each time it cut out while driving the rev counter could be seen dropping to 0 when the engine was running in gear still.

I checked the battery and it had 12.75V with the engine off and 14.25V with the engine running. If there was a lack of power from the battery it wouldn't be able to start the engine so many times.

Any ideas anybody? All I can say is the car never misbehaved like this before the conversion and I'm very glad I've bought another car.

#453: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Wed May 05, 2010 3:08 pm
    ----
An earth? The map? A sensor?

#454: Re: Project sleeper Author: Mr_Cellexe, Location: Hertfordshire PostPosted: Wed May 05, 2010 3:10 pm
    ----
something like that must be a dodgy earth/termination, even a 'clipped or pinched cable. cant think of anything else at all.

#455: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed May 05, 2010 3:11 pm
    ----
It must be heat related because each time it's just after the car has sat for a bit after being run for a while.

It normally just gets driven and then parked either all day long or is put back in the garage for a few days. It's when it's done a hot run then is restarted after a short while that it won't start.

#456: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Wed May 05, 2010 3:18 pm
    ----
EGR? ICV?

#457: Re: Project sleeper Author: Mr_Cellexe, Location: Hertfordshire PostPosted: Wed May 05, 2010 3:19 pm
    ----
Edward wrote:
It must be heat related because each time it's just after the car has sat for a bit after being run for a while.

It normally just gets driven and then parked either all day long or is put back in the garage for a few days. It's when it's done a hot run then is restarted after a short while that it won't start.

its gotta be electrical. even if its heat related. could be split/corroded sheathing?

might be an idea to find a good auto electrician that can cable test, as i doubt its anything you will be able to see.

EDIT: reason i say this is the engine runs but you lose electrics (with no power to the ECU it surely must cut out)

#458: Re: Project sleeper Author: mattievrs, Location: Leicester PostPosted: Wed May 05, 2010 3:25 pm
    ----
Jamie wrote:
EGR? ICV?

one of these or cts

#459: Re: Project sleeper Author: mattievrs, Location: Leicester PostPosted: Wed May 05, 2010 3:26 pm
    ----
hmm actually if the rev counter drops to 0 whilst running it could be an issue with a cam or crank sensor also?They also govern spark and fuelling dont they?

#460: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed May 05, 2010 3:34 pm
    ----
Jamie wrote:
EGR? ICV?

You of all people should know it doesn't use those!

Mr_Cellexe wrote:

EDIT: reason i say this is the engine runs but you lose electrics (with no power to the ECU it surely must cut out)

Something along those lines yes...

mattie wrote:
hmm actually if the rev counter drops to 0 whilst running it could be an issue with a cam or crank sensor also?They also govern spark and fuelling dont they?

It's a shame aftermarket cams don't run with timing marks for a camshaft sensor because then if the crank sensor fails it could have a chance of running with just the cam sensor.
I think the crank sensor is the favourite here. That could explain why the tacho drops to zero when it's still running. Who knows, the whole ECU might be losing power.
Only thing is I think the only reason the standard crank sensor is being used is to run the rev counter. So both rev counter and Omex ECU are losing the signal. Has the wiring been cocked up when splicing in the Omex?

Why would the engine sometimes cut when I put the lights on?

Last edited by Edward on Thu May 06, 2010 11:56 am; edited 2 times in total

#461: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Wed May 05, 2010 3:35 pm
    ----
I thought the GTi did have EGR and the preplexed did have an ICV?

#462: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed May 05, 2010 3:37 pm
    ----
The EGR is plumbed in but with throttle bodies the exit from the head is blanked off. So it doesn't breathe in exhaust gasses. Throttle bodies don't use an Idle control valve.

#463: Re: Project sleeper Author: mattievrs, Location: Leicester PostPosted: Wed May 05, 2010 3:38 pm
    ----
Edward wrote:
Jamie wrote:
EGR? ICV?

You of all people should know it does use those!

Mr_Cellexe wrote:

EDIT: reason i say this is the engine runs but you lose electrics (with no power to the ECU it surely must cut out)

Something along those lines yes...

mattie wrote:
hmm actually if the rev counter drops to 0 whilst running it could be an issue with a cam or crank sensor also?They also govern spark and fuelling dont they?

It's a shame aftermarket cams don't run with timing marks for a camshaft sensor because then if the crank sensor fails it could have a chance of running with just the cam sensor.
I think the crank sensor is the favourite here. That could explain why the tacho drops to zero when it's still running. Who knows, the whole ECU might be losing power.
Only thing is I think the only reason the standard crank sensor is being used is to run the rev counter. So both rev counter and Omex ECU are losing the signal. Has the wiring been cocked up when splicing in the Omex?

Why would the engine sometimes cut when I put the lights on?

Ahh didnt realise you had aftermarket pulleys on the cams. Id definately suspect the crank sensor in this case.

#464: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Wed May 05, 2010 3:40 pm
    ----
Ah I see what you mean now... *facepalm*
Apparently the EGR valve acts like a 5th branch from an exhaust mani when unplugged and not blanked off properly?

#465: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed May 05, 2010 3:48 pm
    ----
mattie wrote:


Ahh didnt realise you had aftermarket pulleys on the cams. Id definately suspect the crank sensor in this case.

The pulleys are nothing to do with it. The trigger is part of the cam. These are 180 cams below, the X on the end of the cam is the trigger for the sensor.

I wish the Piper cams did have a cam sensor because I like the idea of a thorough set up like standard cars have.

 

#466: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed May 05, 2010 3:52 pm
    ----
Jamie wrote:
Ah I see what you mean now... *facepalm*
Apparently the EGR valve acts like a 5th branch from an exhaust mani when unplugged and not blanked off properly?

Ity just bleeds air off one exhaust port and feeds it back through the head into the inlet.

It's in this picture just at the left hand edge.

 

#467: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Wed May 05, 2010 3:54 pm
    ----
It's a much worse design on the EW rather than the TU then from what I can muster together. The 106 GTi has a pump to feed clean air into the cylinders.

#468: Re: Project sleeper Author: macj, Location: Essex PostPosted: Wed May 05, 2010 11:26 pm
    ----
Can you ring Omex Paul.... I have seen this with as coil driver issue

#469: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed May 05, 2010 11:33 pm
    ----
Why doesn't it do it when running though? Why does it only do it when it has sat for a while? Or is it just heat build up?

#470: Re: Project sleeper Author: macj, Location: Essex PostPosted: Thu May 06, 2010 12:37 pm
    ----
Mine would run from cold.... then would not start again till cold until it gave up all together and needed new coil drivers fitted.... they packed up shortly after as well.... Found the cause to be a loose earth on the ECU side and it was earthing through the drivers

#471: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu May 06, 2010 1:35 pm
    ----
When the car started briefly If I put the high beam lights on it causes it to cut out. Does that back up your theory?

After that it ran fine...all the way home...I really shouldn't be having to put up with problems like this especially so soon after picking it up.

#472: Re: Project sleeper Author: macj, Location: Essex PostPosted: Thu May 06, 2010 4:01 pm
    ----
The lights would load the circuits but not on a related circuit. interesting though... I think it is an intermitent earthing fault

#473: Re: Project sleeper Author: =ZiAn=, Location: Slovenia PostPosted: Fri May 07, 2010 8:23 am
    ----
Edward wrote:
Suspension got fitted...
Eibach Pro Kit springs, Bilstein Sport dampers, Peugeot Sport 21mm torsion bars (gravel rally spec).

 



Do you know the reference number for those torsion bars? I can't seem to find them on the Peugeot Sport website...thanks

#474: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri May 07, 2010 8:48 am
    ----
Look under 206 XS at Train Arriere

CC17010-21
CC17011-21

€194.65x2=€389.30 + approx €50 for postage (They charged that for my GP A wishbones) = €439.30
Which according to the Financial Times is about £378.59.

Bargain!

#475: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri May 07, 2010 1:37 pm
    ----
Took a little video earlier and I noticed something unusual. The idle speed wasn't where is once was and the revs are surging slightly too. When I got it the idle speed was spot on 1k rpm and something seems to have changed.

I've noticed this slight surging when driving too.

 

#476: Re: Project sleeper Author: macj, Location: Essex PostPosted: Fri May 07, 2010 1:49 pm
    ----
Classic symptom of fuel starvation..... or weak running

#477: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Fri May 07, 2010 2:57 pm
    ----
Thats my idle speed when i start up, soon settles to 950k revs after a few mins. Odd that your revs are bouncing though. Can you tell through the engine?

Have you conected your air temp sensor yet?

#478: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri May 07, 2010 3:02 pm
    ----
I'm not touching the air temp sensor until the problems are sorted. It doesn't need any added complications!
From the video the main thing you notice is the rev counter, when sitting in the car though the rev pick up is more sudden and can be felt through the car.

#479: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Fri May 07, 2010 3:26 pm
    ----
What does the AFR look like at idle? It's meant to be leaner on idle to keep it going, as too rich would cause stutters (partly due to the fuel cooling the mixture so much it almost chokes itself cold), but not so lean as to cause it to potentially do what you're seeing there.

#480: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Fri May 07, 2010 3:29 pm
    ----
Edward wrote:
I'm not touching the air temp sensor until the problems are sorted. It doesn't need any added complications!
From the video the main thing you notice is the rev counter, when sitting in the car though the rev pick up is more sudden and can be felt through the car.

Is that not just the case because of the throttle bodies?

#481: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Fri May 07, 2010 3:34 pm
    ----
Not if he says it wasn't first like that.

#482: Re: Project sleeper Author: quiksilverRY, Location: West Yorkshire PostPosted: Sat May 08, 2010 8:51 am
    ----
sometimes the ecu can loose its map and i know my car is no longer a pug but i had the same problems on my mondeo v6 and it turned out to be the EGR Valve and pipes, i dont know if your car has them but its worth a thought

#483: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat May 08, 2010 9:50 am
    ----
The EGR system isn't linked to anything anymore. In fact I might remove the EGR valve and blank it off using the plate from a GTi 180 if possible.

#484: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Jun 14, 2010 1:19 pm
    ----
I've been talking to Omex today and they've come up with the goods. They've told me how to access the ECU in order to help diagnose the hot start problems. All I wanted to view is the data that the various sensors are sending out when the engine is running.

The first picture is what everything looks like when the engine is switched off from cold. You can see the % the throtle is open, the engine speed, coolant temp and stat sync'd tell you whether the crank sensor is picking up anything. There is also a run time which tells you how long the ECU has been on for. If the engine cuts out and the timer says a low number you know the power supply has been interupted. It also shows you the battery voltage too.

 


This is the data from when the engine is running. All I need to do now is be able to plug the ECU into a laptop when I get the cut out problem. Thankfully it's is rare because I never do hot starts as the car doesn't do stop - start driving.

 

#485: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Mon Jun 14, 2010 1:40 pm
    ----
Excellent news, are you going to get the engine re-mapped/calibrated ( Wink ) when you have the air temp sensor installed? Any ideas where you'd take it?

#486: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Jun 14, 2010 2:12 pm
    ----
No plans to change anything yet. I just need to see whether the emissions are good enough to get it through an MOT and then I might fit the air temp sensor.
As you'll know, I am going to think about rewiring the Omex. The connectors to the original ECU are very close to the underside of the headlamp housing. On top of these coinnectors is the wiring to the Omex which is very tightly squeezed in resulting in them rubbing on the sharp headlamp housing.

The Omex is much better inside the car away from heat and also if the car was ever in a bump there's the best part of £600 worth of ECU sat in a vulnerable location. I'd like to put a really nice loom on it and also fit one of the Omex coolant temp sensors too. It would take time to make a nice loom so I might wait until the winter when the car is off the road.

#487: Re: Project sleeper Author: Ruffy_206, Location: Bristol PostPosted: Mon Jun 14, 2010 2:21 pm
    ----
Edward wrote:
No plans to change anything yet. I just need to see whether the emissions are good enough to get it through an MOT and then I might fit the air temp sensor.
As you'll know, I am going to think about rewiring the Omex. The connectors to the original ECU are very close to the underside of the headlamp housing. On top of these coinnectors is the wiring to the Omex which is very tightly squeezed in resulting in them rubbing on the sharp headlamp housing.

The Omex is much better inside the car away from heat and also if the car was ever in a bump there's the best part of £600 worth of ECU sat in a vulnerable location. I'd like to put a really nice loom on it and also fit one of the Omex coolant temp sensors too. It would take time to make a nice loom so I might wait until the winter when the car is off the road.

sounds like you thought it outwell. id wait to the winter and not rush it Smile

#488: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Mon Jun 14, 2010 2:27 pm
    ----
That sounds like a good idea to be honest!

#489: Re: Project sleeper Author: Schumi, Location: Istanbul / Turkey PostPosted: Mon Jun 14, 2010 11:09 pm
    ----
Is your omex is connected to your stock O2 sensor ? Standalone ECU's didnt like narrow band o2. Its might be better to use wideband sensor.

#490: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Jun 19, 2010 2:19 pm
    ----
Can I just stick a wideband in as a substitute for the standard lambda?

Anyway, more problems tonight. I'd not taken it for a proper run for a few weeks simply because it lets me down and it takes a few weeks for confidence to return to convince me to take it out. It gets started up every week and does a few miles to blow the dust off it.

At first it did the normal surging when driving on a constant throttle i.e. 3k rpm in 3rd gear. It does it in 2nd gear when driving in traffic and reminds me of a learner driver kangarooing away from traffic lights.

It did something different tonight though. When lifting off the throttle the car didn't slow down. It felt like I had cruise control as on occasions it held the car at 3k rpm. Even when I got home and blipped the throttle at standstill it held 3k rpm for a few seconds then dropped back to the normal idle speed.

There was also sometimes a slight hesitation when I floored the throttle too. After spending so much on the best kit why am I having so many problems????????

#491: Re: Project sleeper Author: Schumi, Location: Istanbul / Turkey PostPosted: Sun Jun 20, 2010 7:13 am
    ----
Edward wrote:
Can I just stick a wideband in as a substitute for the standard lambda?

Wideband sensors requed its controllers. You must buy kit. Not only sensor.

Edward wrote:
After spending so much on the best kit why am I having so many problems????????

Ask your installer. Ecosse. Its maybe very good in mechanice works but i didnt think is good in electronic and mapping. Missing IAT sensor and paralel ECU installation is enough argument for me. And your endless problems. Go real Omex certified tuner.

#492: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sun Jun 20, 2010 7:23 am
    ----
Edward wrote:
Can I just stick a wideband in as a substitute for the standard lambda?

Anyway, more problems tonight. I'd not taken it for a proper run for a few weeks simply because it lets me down and it takes a few weeks for confidence to return to convince me to take it out. It gets started up every week and does a few miles to blow the dust off it.

At first it did the normal surging when driving on a constant throttle i.e. 3k rpm in 3rd gear. It does it in 2nd gear when driving in traffic and reminds me of a learner driver kangarooing away from traffic lights.

It did something different tonight though. When lifting off the throttle the car didn't slow down. It felt like I had cruise control as on occasions it held the car at 3k rpm. Even when I got home and blipped the throttle at standstill it held 3k rpm for a few seconds then dropped back to the normal idle speed.

There was also sometimes a slight hesitation when I floored the throttle too. After spending so much on the best kit why am I having so many problems????????

Sounds like spiking to me.... is there an inbuilt noise filter in the ECU?

#493: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Jun 20, 2010 7:44 am
    ----
On my screen dumps above when at idle it would suddenly pick up revs momentarily. When it does this the 'Spark Total' value increases. Any ideas what this means?

#494: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sun Jun 20, 2010 7:53 am
    ----
I had an issue with noise affecting the fuelling. I had to increase the noise filter to nearly maximum to get rid of it... I traced it to the alternator in the end. Now I have the digidash I can see spikes and noise surges plainly on the tacho bar.... not enough now to affect the map. Worth a look in the manual to see if you can alter the filtering

#495: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Jun 20, 2010 9:43 am
    ----
I'll have a look. I can even feel the surging on the overrun. So it's jerky when driving and less than smooth on the overrun too.

#496: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Jun 23, 2010 3:09 pm
    ----
Did some data logging earlier. I reviewed some of the data and on occasions the coolant temperature suddenly dips. The car was run for ten minutes then switched off for 10 mins. The car was then driven for another 10 mins then sat for 10 mins. Then I drove the car and it did the cutting out problem where the engine dies and the rev counter dips to zero.

Analysing the data from the Omex it shows the coolant temperature dropping to very low levels. The lowest was 6 degrees, half a second later the temp was 90 degrees. After the engine was driven so far there's no way the temperature was that low, A similar thing happened a few times and can be seen on the blue lower line on the picture. All the dips are where the low temperatures are recorded. I can see how this could cause a cut out but when the engine is still turning I don't see why the rev counter dips.

 

Last edited by Edward on Fri Jun 25, 2010 11:50 am; edited 4 times in total

#497: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Wed Jun 23, 2010 4:33 pm
    ----
It must be adjusting the fuelling to compensate for the 'lower' temperate do you think?

In which case the problem would not seem to be the cutting out, but either a faulty sensor, or some sort of surge somewhere causing a spike and interfering with ECU readings?

#498: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Jun 23, 2010 11:38 pm
    ----
From looking at all the other sensor outputs though it just seems like it's the coolant sensor that's spitting out strange numbers. Unless there is some other logical reason for the sesnor to be showing low numbers it must point to the sensor being faulty. I never liked the look of it anyway.

#499: Re: Project sleeper Author: macj, Location: Essex PostPosted: Thu Jun 24, 2010 9:28 am
    ----
I am not keen on crimp connectors for sensors..... nice to see your upgrade will be solder conections, That is a sure fire way of good signals Wink

#500: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Jun 24, 2010 12:31 pm
    ----
So what coolant sensor do you use Mac?

It might be interesting to see the frequency of the temperature drop offs when the car is running normally - i.e. before it has got to the cut out stage.

I'm sure fitting a proper loom will cost a few quid but it's got to be worth it. I imagine I'll have to take the thermostat housing off to get it tapped for the Omex temp sensor so there's a bit of hassle involved too. So where's the best place for the Omex in the car? I quite like the idea of it sitting in the pocket at the back of the centre console behind the alarm button but the wiring would be quite long (not too big a problem) and although the car isn't parked anywhere but in the garage it's best not to leave it exposed.

I also fitted a silicone blue vacuum hose yesterday just to make sure the existing scruffy rubber hose wasn't a potential air leak problem. Anymore blue silicone and it might start looking a bit tacky.

#501: Re: Project sleeper Author: vanman_foci, Location: Barry, South Wales PostPosted: Thu Jun 24, 2010 12:39 pm
    ----
Edward wrote:
So what coolant sensor do you use Mac?

It might be interesting to see the frequency of the temperature drop offs when the car is running normally - i.e. before it has got to the cut out stage.

I'm sure fitting a proper loom will cost a few quid but it's got to be worth it. I imagine I'll have to take the thermostat housing off to get it tapped for the Omex temp sensor so there's a bit of hassle involved too. So where's the best place for the Omex in the car? I quite like the idea of it sitting in the pocket at the back of the centre console behind the alarm button but the wiring would be quite long (not too big a problem) and although the car isn't parked anywhere but in the garage it's best not to leave it exposed.

I also fitted a silicone blue vacuum hose yesterday just to make sure the existing scruffy rubber hose wasn't a potential air leak problem. Anymore blue silicone and it might start looking a bit tacky.

Would be good to have it on show so to speak Very Happy

I'm glad your now finding out whats wrong, prehaps soon it will be running like a dream for you Very Happy

#502: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Jun 24, 2010 12:47 pm
    ----
It's on permanent show in my garage because the bonnet is open all the time due to it's unreliability problems!

At least so far it's consistently and predictably unreliable under the same conditions.

#503: Re: Project sleeper Author: macj, Location: Essex PostPosted: Thu Jun 24, 2010 2:36 pm
    ----
will reply in full when I get home....away at present

#504: Re: Project sleeper Author: Christer, Location: Stockholm, Sweden PostPosted: Fri Jun 25, 2010 1:20 am
    ----
Maybe the wires from the coolant sensor picks up interference along the way to the Omex?

#505: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Jun 25, 2010 10:28 am
    ----
They could be...who knows...I'm just going to have the delve into the loom and what's there.

#506: Re: Project sleeper Author: macj, Location: Essex PostPosted: Fri Jun 25, 2010 11:58 am
    ----
Sorry for the delay in replying, I use the standard peugeot temp sensor, I feel that they think its good enough for a production cars so its good enough for me.
I also have a smaller one tapped into the bleed screw hole for my digital dash. In your case you may need to fit the omex sensor as previously discussed and calibrate it to the ECU. Have you found out the make of the Ecosse fitted sensor?
What cable connector has your ECU got to connect the laptop?

#507: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Jun 25, 2010 11:59 am
    ----
There's been quite a bit of emailling Omex this week. I must say their customer service is very impressive.

They asked for a copy of the data logging and the map calibration (thankfully it wasn't locked) and they agree the coolant temperature fluctuating isn't right.

Best thing is they even did some mapping adjustments to it to help it run better. They've lowered the default air inlet temp setting which was fixed at 25 degrees and lowered it to 20 degrees. This will sort itself when an inlet air temp sensor is fitted.

They also adjusted the ignition timing at idle and changed the scatter spark idle control slightly so hopefully that may help with the idle problem. They have also reduced the ignition timing at closed throttle at around 3000rpm to see if ignition timing is holding the engine speed up.

A few other companies could certainly learn a thing or two about the support Omex provide.

#508: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Jun 25, 2010 12:19 pm
    ----
macj wrote:
Sorry for the delay in replying, I use the standard peugeot temp sensor, I feel that they think its good enough for a production cars so its good enough for me.
I also have a smaller one tapped into the bleed screw hole for my digital dash. In your case you may need to fit the omex sensor as previously discussed and calibrate it to the ECU. Have you found out the make of the Ecosse fitted sensor?
What cable connector has your ECU got to connect the laptop?

Can you think of a reason the Omex can't be plugged into the standard sensor? Mine is just there to operate the dash guage but why can't it operate the Omex too?

So yours just works the opposite way round to mine...I don't know what make the sensor is.

I've just bought a serial to USB convertor that plugs straight into the laptop.

#509: Re: Project sleeper Author: macj, Location: Essex PostPosted: Fri Jun 25, 2010 12:27 pm
    ----
OK

I see no reason you cant use it for both. I would try using it for just the ECU, get it working and then see if it will run in parallel with your guage.

alternatively get an OEM sensor fitted in the casting and run them seperately, Got a feeling it may sort out your issues.

On a seperate note, I got MOT tested yesterday, Emissions were over double the limit at idle but the lambda was spot on across the range. A little tweak and passed with no advisories.... very happy

#510: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Jun 25, 2010 12:42 pm
    ----
I think I'll invest in one of the Omex temp sensor. At least it will look the part too.

When it comes to MOT I dread to think what mine will be pumping out. Were all your emissions a problem or just certain ones? Mine only just scraped through before the TB's were fitted. I don't think the 200 cell cat helped much.

#511: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Jun 27, 2010 4:34 am
    ----
 

#512: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Jun 27, 2010 5:50 am
    ----
Took it for a run today just to get some heat into it and to convince myself that it still works. A quick 15 minutes drive and then I plugged the car in to check all was well.

Did some logging today when it had warmed up. That coolant temperature gets as low as -16 degrees! That's not right after running it for so long.

The top line is engine speed, the middle lambda feedback and the bottom is coolant temperature.

 


Yesterday I did some brief logging from a cold start and the graph is below. It shows the coolant sensor can do what it's supposed to do. It just doesn't like the heat.. Coolant temp sensor output stays rock solid.

 


Plan now is to get a proper Omex temp sensor and get a new boss for the sensor welded into the thermostat housing. I want the original bleed screw back (this might mean getting a new thermostat housing) because it was there for a reason. The new sensor can then be directly wired into the Omex without using the original old Peugeot wiring that is used now.

#513: Re: Project sleeper Author: tomd0801754, Location: Moscow PostPosted: Sun Jun 27, 2010 5:55 am
    ----
Edward... I honestly admire you.

Your engine looks immense, and even though it has it issues, you still happily (maybe) carry on.

Everytime I check this thread I always hope I see a comment saying that it is working perfectly and you are impressed with it. Smile

#514: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Jun 27, 2010 6:03 am
    ----
Well luckily I have another car to use so I can deal with this one at a leisurely pace. It's a good learning experience that's for sure. If there weren't any problems I wouldn't know about the capabilities of the Omex software etc...
I suppose like any car we become experts in them by playing with them often as a result of problems.

With everything I have done to this car it's because I wanted the best kit available. The wiring on the Tb conversion just isn't the best. It's crap to be honest and there's no surprise that it has running problems. I will be happy when everything is up to standard. For the £4k I paid for the work to be done I am not unreasonable in expecting better!

#515: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Sun Jun 27, 2010 6:12 am
    ----
Ever seen one of Sandy's looms? Very neat!
Will you be hoping to do the loom yourself or are you going to get one made up again?

#516: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Jun 27, 2010 6:16 am
    ----
Have you got any pictures of his looms? I know roughly what I want it to look like. I just can't decide whether to heat shrink it completely or braid it. I'm also not sure how to get a good finish where a wire leaves the main loom. I've seen some rubber-like T pieces but not sure if everybody uses them.

I'm happy to do it myself. They take ages though, even attaching a AMP Superseal connector to my TPS sensor took a few minutes. Multiply that across a whole look and there a lot of time involved.


I got rid of these connectors which just aren't suitable for a car engine bay.

 


and swopped them for this which can just about be seen. I also added some braiding and heat shrink to the cables.

 

#517: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Sun Jun 27, 2010 6:28 am
    ----
I have yes I'll dig them up!

#518: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Sun Jun 27, 2010 9:15 am
    ----
Paul do you have Facebook? If so search for "Sandy Brown Racing Engine Technology" and there are plenty of photos on there!

#519: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Aug 07, 2010 12:16 pm
    ----
A bit more progress but not much as I've been away on holiday for a bit...

Ecosse sent me a new Semi Assembled loom with a new Omex coolant temperature sensor in order for me to create my own loom where the Omex ECU will run 100% standalone from the original Peugeot wiring.

 


With the wiring set up the way it is, if there is a problem with the quality of the splicing or problems with relays or the original ECU and immobiliser I'll have problems like I am experiencing. Omex have been very helpful and lent me a brand new ECU to test. With the new ECU in place the cut out problem still occurred so the problem lies elsewhere.

I've found it's possible to crack open the plugs on the original Peugeot loom to reuse them without having the splice the Omex wiring into the Peugeot wiring. This can be done with the crank sensor. More joints and splicing = more potential for unreliability.

My plan is to mount the Omex in the glovebox and have a couple of relays in there for the fuel pump etc. It should look quite neat when it's finished.

I also added my one and only sticker to the car.

 


A new addition to the family came today....another Peugeot. A 58 plate 207CC 1.6 GT. It's got full leather and is actually quite nice to drive. it's amazing how much scuttle shake there is with the roof down though, although it's not as noticeable as it was in a 206cc. The paint quality is terrible though. It's wafer thin on the roof and looks like they've just lacquered some primer in places!

 

#520: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Sat Aug 07, 2010 12:18 pm
    ----
Mrs PSO's new car?

#521: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Sat Aug 07, 2010 12:27 pm
    ----
Also have you seen Sandy's write up of the GTi he built on bodies?

#522: Re: Project sleeper Author: Antix, Location: Worcester PostPosted: Sat Aug 07, 2010 12:46 pm
    ----
I see the topless bug has rubbed off Wink Laughing

#523: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Aug 07, 2010 1:23 pm
    ----
Jamie wrote:
Also have you seen Sandy's write up of the GTi he built on bodies?

I did. Although it's a marginally bigger capacity than mine it did make me think mine was a bit weak on torque...which I've alwaus suspected it to be. At 157lb ft mine has little more than a GTi 180.

Antix wrote:
I see the topless bug has rubbed off Wink Laughing

Perfect timing with the end of summer in sight!

#524: Re: Project sleeper Author: Quarmbo, Location: Bristol & Leicester PostPosted: Sat Aug 07, 2010 2:16 pm
    ----
Love reading your updates Edward. But all this trouble, does it ever make you wish you could take it back up there for them to sort? Or is it something they can't/won't help you with?

#525: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Aug 08, 2010 1:31 am
    ----
They asked for me to take the car back to them. They wouldn't collect it and I wasn't prepared to pay a few hundred £'s to get the car recovered to them when it's obvious mistakes and shortcuts were made with the wiring. My RAC cover doesn't cover home start either and I don't see why the RAC should foot the bill anyway.
The car can't even be driven 10 miles with any confidence never mind 250 miles. I just want the car sorting properly, there was no excuse for the shortcuts made when they had the car for a month and so I asked for a new loom and sensor as a settlement and I'll get the wiring sorted locally.

#526: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Aug 08, 2010 2:07 am
    ----
did you have to pay for the loom your self paul?

#527: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Aug 08, 2010 4:27 am
    ----
No. All delivered to me free of charge. It's about £80 worth retail. Will cost me between £200 - £300 to get it all connected plus about £70 worth of other bits such as relays, switches, Junior Power Timer connectors (for the injectors and coolant temp sensor) and braided sleeving etc.

There is quite a long list of components needed to build up a loom.

#528: Re: Project sleeper Author: JoN-, Location: Redditch PostPosted: Sun Aug 08, 2010 9:39 am
    ----
Karma

#529: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Sun Aug 08, 2010 10:37 am
    ----
Karma?

#530: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Aug 08, 2010 11:01 am
    ----
glad i didnt take it to them now 2bf as they were on my list of garages when i had mine done, any way glad to hear your getin it sorted now mate.

#531: Re: Project sleeper Author: White_Noise, Location: Netherlands PostPosted: Mon Aug 09, 2010 2:55 pm
    ----
Nice car! Totally different then mine dough, but i love it!!

Where did you got the Peugeot Sport GP A wishbones? I can't buy them here in the Netherlands..

#532: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Aug 09, 2010 2:57 pm
    ----
Got them from Peugeot Sport in France...

#533: Re: Project sleeper Author: Schumi, Location: Istanbul / Turkey PostPosted: Mon Aug 09, 2010 3:37 pm
    ----
If you want a good job. You must do yourself.
I'm glad to help you about wiring loom or standalone ecu without stock ecu.

#534: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Aug 18, 2010 11:55 am
    ----
Things are about to start moving with this. Next week the car is getting rewired so the Omex can run truly standalone.

Just bought a lambda sensor boss plug too. £8 delivered for a stainless steel item! Bargain. Not. The downstream lambda sensor is still in place but isn't being used to control the engine in any way. So I might as well remove the lambda sensor and the wiring for it can also go too. I'm also going to remove the EGR valve and its wiring, only problem is the blanking plate and gasket with bolts cost £31 from the Peugeot dealer. It's a standard part from a GTi 180 too.

 

#535: Re: Project sleeper Author: macj, Location: Essex PostPosted: Wed Aug 18, 2010 12:12 pm
    ----
A man of your calibre should be able to make one. I used a bit of 3mm steel plate and used the old gasket as a pattern.

#536: Re: Project sleeper Author: Ape, Location: Clipping the Apex! PostPosted: Wed Aug 18, 2010 2:26 pm
    ----
I've got a lambda boss you could've had if you'd have said. I'm using my second sensor to prevent fault codes so the boss is sitting in a bits box now! Ah well

#537: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Aug 18, 2010 2:43 pm
    ----
I've already got a boss fitted. I just needed a plug to fill it.

As for the EGR plate I did think about making my own but sometimes it's just easier to put my hand in my pocket!

#538: Re: Project sleeper Author: Ape, Location: Clipping the Apex! PostPosted: Wed Aug 18, 2010 2:59 pm
    ----
Sorry bud, I meant the plug, it's been a long day

#539: Re: Project sleeper Author: macj, Location: Essex PostPosted: Wed Aug 18, 2010 3:18 pm
    ----
How much you want for it Ape

#540: Re: Project sleeper Author: Ape, Location: Clipping the Apex! PostPosted: Wed Aug 18, 2010 3:32 pm
    ----
Will let you know after this weekend bud. Getting the LCR remapped this weekend to marry all the modifications together so if we map the second sensor out I'll need it. Slim chance mind though so I'll let you know, I'm sure Blueflame would supply if asked thinking about it Smile

#541: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Aug 22, 2010 5:14 am
    ----
One exhaust lambda sensor plug fitted. Looks a bit better than a redundant lambda sensor sitting there. Just that one sensor removed from the loom makes the back of the engine bay look a bit tidier already.

 


I've got two Maniflow decat pipes to use too. One has a downstream lambda boss fitted, the other is a plain decat with a flexi hose attached. The latter is much smarter and much lighter too so I'm now able to use it if I want.

 


When the Omex is wired in as planned I'll be able to remove loads of surplus wiring from the original loom.
Ordered all the bits the other day. £65 of wiring accessories plus £200 to fit it all.

#542: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sun Aug 22, 2010 5:19 am
    ----
looking forward to seeing the results of the new wiring....hoping to hear a different reliability story then

#543: Re: Project sleeper Author: =ZiAn=, Location: Slovenia PostPosted: Sun Aug 22, 2010 7:29 am
    ----
@Edward, do you maybe know the size of the original injectors? If I remember correctly you're still using the oem ones right? Thanks

#544: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Aug 22, 2010 8:35 am
    ----
No, I am using GTi 180 injectors...

#545: Re: Project sleeper Author: =ZiAn=, Location: Slovenia PostPosted: Sun Aug 22, 2010 11:15 am
    ----
Okay thanks...Do you know the size of those?

#546: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Sep 02, 2010 2:49 pm
    ----
Bought this thermostat housing from Indigo GTi...

 


I intend on getting an alloy boss welded to this to fit an additional Omex coolant temperature sensor. It was fairly clean when I got it but a quick once over with some brick cleaner, turps and a stint in the dishwasher brought it up nicely. I might buy some Samco coolant hoses when I fit it....are they worth nearly £70 though?
I could have used my existing housing but I want a proper bleed screw to enable the system to be bled properly. With the existing coolant sensor stuck on the bleed screw hole it's not known how well the system is bled.

 


 


I also bought a new crank sensor from the Peugeot dealer for £17...The car is in at the moment at the auto electricians getting rewired so I thought I might as well change the crank sensor while it's apart. It's the only component that's not been changed although it's known where the problem lies.

 

#547: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Thu Sep 02, 2010 3:10 pm
    ----
Gimme a shout if you want the coolant hoses I can get them a fair bit cheaper for you!

#548: Re: Project sleeper Author: Lecktorious, Location: Scotland PostPosted: Sat Sep 04, 2010 10:37 am
    ----
Any updates then Paul?

#549: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Sep 04, 2010 11:38 am
    ----
It's not back yet but I went and had a quick look at the progress yesterday. The ECU is in the glovebox and a couple of relays will be sat in there too on a proper holder rather than the wires being connected directly to the terminals on the relay. That way the relay can be removed without having to take note of where the wires went.

When I get it back I'm planning on putting a sheet of plywood vertically across the glovebox maybe wrapped in carbon fibre wrap so the ECU and relays can all be mounted neatly. That will enable easy data logging too because the RS232 cable won't need to be trailled from the engine bay. Glovebox will be useless but never mind.

I told the auto electrician to take his time anyway! I quite like having the Jetta in the garage...more space on the driveway with it like that!
I expect it will be back by mid week - although I'm happy for him to keep it until next weekend!
Got the insurance renewal through the post too. Was £480 but after telling them it would only do 1k miles next year at most the premium was reduced to £360. Still expensive for a car that is hardly used. I'll do what I usually do and get another quote from another insurer as well.

#550: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sat Sep 04, 2010 12:09 pm
    ----
Sounds good Paul... glad to see it is going well. I like the idea of everything inside the car..... Thats where the laptop will be

#551: Re: Project sleeper Author: Dave_George, Location: Leicestershire, East Midlands PostPosted: Fri Sep 10, 2010 8:56 am
    ----
Just read this whole thread Paul, really nice job.

Shame about the experience being a frustrating one, you would expect nothing less than a perfect job for the kind of money involved, but life can be extremely disappointing at times, and the more you have specialist one off kind of jobs done, the more you realise your'e better investigating and learning yourself, as only then do things get done to your standards.

I would echo the sentiments of others though and would be very interested to see the engine set up by someone else, or even a power run and their opinion on the power/torque/fuelling. That wouldnt cost much either. Smile

#552: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Sep 10, 2010 10:25 am
    ----
Nice to hear from you Dave.

If I was to do it again I'd definately go to a motorsport specialist and I think others should follow that advice. The reason I went to Ecosse was because I was worried about the complexity of the wiring and wanted somebody with experience to do it. That's exactly where it has been done wrong. Corners have been cut resulting in reliability issues.

Longmans (and all other companies) did their cars with an independent loom for good reason. It makes no sense to combine two electronic systems. The wiring is actually quite simple and I wish I'd got it all done locally. That's what experience has taught me. In the end I got poor value for money. I paid top money for a top job but got 2nd rate electrics and delays that cost me a lot of money and the spending is still continuing. In short, as described by my auto electrician - they've been very lazy.

To judge whether the price was fair I estimated it would cost about £400 to wire the car up and all that's been spent is about £1 on 3 bullet connectors (not suitable for an engine bay directly behind the radiator), insulation tape and some heat shrink so there was plenty of budget available to do the job right.

Did I also mention I asked for a quote for the conversion? Yes a quote is a fixed price. They failed to stick to that.

I supplied some little parts such as water pump, cam seals, hydraulic lifters, airbox, inlet manifold and gaskets etc as I wanted no reason for parts supply delaying progress. After I complained to them about the increase in cost I was told that me supplying parts had denied them the opportunity to supply them and add their own margin to the cost! I'd always told them of my intention to supply such parts and they had never included them in the quote.

The car already being modified was also blamed for an overrun in costs. The only modification to effect them was the Longman head. I asked them if the inlet manifold would be matched to the head (just to check that a thorough job was being done - if you don't ask you might not get!) and they took the opportunity to charge £40+VAT for it!. This work should have been included in the basic quote in the first place.

If took them 9 days to decide whether the pistons should be pocketed (Greg told this over the phone and that they actually could have started the job a bit sooner!) and they told me that the Ultimate Road cams didn't normally require this work doing (even the Piper website says cams of this spec need pistons modifying). They blamed the cylinder head.

The head has a skim of hundredths of an inch but that doesn't mean valve cut outs 2+mm deep will be required in the pistons! The cams dictate the need for cut outs not the head! I also got charged an additional £200 for machining the pistons despite me telling them this work would be required. They obviously didn't read what I'd told them.

£200 for machining pistons? Who pays £200 for machining pistons? Even Longmans only quoted £100.

£100 was then knocked off this machining cost as a goodwill jesture because of the additional hire car costs I'd incurred. Why was the hire car cost knocked off the maching costs? Is that because the cost was artificially inflated already?

On a positive note the car is becoming mine all the time and as a result it getting better. The engine hasn't fallen apart although there is a bit of an oil leak from the sump seal.

#553: Re: Project sleeper Author: kevin, Location: Dalkeith PostPosted: Fri Sep 10, 2010 10:57 am
    ----
I have similar problems with them and sticking to budget. They specified no more than £2000 for work to be done on a car i once had. I later decided to add in a few extras which cam to another £500 fitted. After failing to give me a final cost r 2 weeks they phoned me on the day i was due to collect the car to give me a final figure of over £3200. I wasn't best pleased to say the least considering i had heaps of problems with what they done in regards to the coolant system.

#554: Re: Project sleeper Author: Dave_George, Location: Leicestershire, East Midlands PostPosted: Fri Sep 10, 2010 11:39 am
    ----
Think they should stick to bodykits?

#555: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Sep 10, 2010 12:41 pm
    ----
kevin wrote:
I have similar problems with them and sticking to budget.

As they are the specialists they should be very good at calculating the exact cost of mechanical work. If they really knew their stuff they'd overlook nothing.

#556: Re: Project sleeper Author: macj, Location: Essex PostPosted: Fri Sep 10, 2010 1:34 pm
    ----
Thats the difference between tuning and styling... never mix the two.... We dont fit body kits

#557: Re: Project sleeper Author: Ape, Location: Clipping the Apex! PostPosted: Fri Sep 10, 2010 1:45 pm
    ----
macj wrote:
Thats the difference between tuning and styling... never mix the two.... We dont fit body kits

Laughing

#558: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Oct 08, 2010 12:44 pm
    ----
Got the car back today...and it works! So naturally the first thing to do was to take it apart.

Fitted the EGR blanking plate from a GTi 180. Cost £33 for the bits from the dealer. Looks a bit neater. No point having the EGR valve there if it's not doing anything. Also means I can remove the wiring to it as well.

 


 


 


All this lot can now get removed from the original loom. There's hardly anything left of it anymore.

 

#559: Re: Project sleeper Author: Seabook PostPosted: Fri Oct 08, 2010 3:00 pm
    ----
macj wrote:
Thats the difference between tuning and styling... never mix the two.... We dont fit body kits
Cool

#560: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Fri Oct 08, 2010 4:34 pm
    ----
Glad to hear that you're happier about everything now! Very Happy I'm just happy that their bodyshop is top notch lol.

#561: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Oct 09, 2010 8:24 am
    ----
Finished it off today.

In the end I took out all this lot. It's a lot neater and there are only about 8 cables left in the old loom.

 


I wanted the knock sensor wiring into the Omex but it didn't get done but I'm not too bothered as the Omex isn't set up yet to use it. So I thought i might as well remove the sensor...saves a bit of weight!

 


 


This is how the injector wiring looks...it should always have been like this! Can't wait to get rid of that cheap throttle linkage too.

 

#562: Re: Project sleeper Author: st3v3n, Location: Liverpool Drives: 206 GTi PostPosted: Sat Oct 09, 2010 8:28 am
    ----
Looking good. I'm stripping wires out today too Smile

#563: Re: Project sleeper Author: Schumi, Location: Istanbul / Turkey PostPosted: Sat Oct 09, 2010 10:00 am
    ----
Good work. Any picture of complete new wiring from far.

#564: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Oct 09, 2010 10:15 am
    ----
Most of it is hidden. It runs from the glovebox over the inner wing in tubing then down behind the airbox to the air temp sensor and throttle position sensor. It then goes upwards to the injectors. It also goes over thee gearbox to the crank sensor which I was lucky to be able to get hold of replacement pins for the standard crank sensor plug so that was rewired and linked to the Omex and also the original ECU via shielded cable to run the rev counter.

Later I need to activate the air temp sensor via the laptop. Ecosse didn't fit one so they set the Omex at a default temp of 25 degrees. Omex did some adjustments to the map and set the default to 20 degrees.

When the car is started from cold if it touch the throttle in the first few seconds the engine wants to stall. The auto electrician thinks this is because the cold start fuelling is too lean. Omex also suggested I change the settings (very easy to do) to improve the cold start. I might give this a try as well.

#565: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sat Oct 09, 2010 11:32 am
    ----
You can richen the fuel in relation to the engine temp on the cold start/choke cycle... you should be able to pick out the section in the tuning menu on the laptop and sneak it yup a touch, the choke cycle will cut out at a given engine temp.... easy for a man of your knowledge mate

#566: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Oct 09, 2010 11:38 am
    ----
Yes Omex have given me the instructions how to do it. It's a simple case of changing a single number on the screen.

#567: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Oct 13, 2010 1:33 pm
    ----
Took the 206 for its MOT today. It went and over heated when doing the emissions tests! I could hear water somewhere then steam was coming from under bonnet. I think pretty much all the coolant came out the cap and landed in the pit!

The fan is working but something says it's only running at its slowest speed. The temperature guage is often seen beyond the vertical position when sitting in traffic. The car does run hotter than it used to but it's not something the fan shouldn't be able to deal with. I think the next step is to get the Omex to control the fan instead of the original ECU. I just don't trust the original ECU to do anything anymore!

I also ordered some more wiring kit just to do some tidying up. A few metres of various diameter split convoluted tubing and some T pieces and end caps for where the tubing meets Superseal connectors. It's certainly looking a lot tidier now.

 


 


 

#568: Re: Project sleeper Author: Jon, Location: 666ft Below PostPosted: Wed Oct 13, 2010 1:38 pm
    ----
Mmmmm tidy cables!!

Love the updates!

#569: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Oct 15, 2010 12:36 pm
    ----
Another little tweek today...

The airbox always sat a bit high relative to the carbon airbox on the bodies. It also made fitting the airfilter box lid a bit awkward sometimes too. It was sat on the mounting bracket perfecly too.

 


So this bracket needed a bit of adjustment. It was removed and drilled so it could be moved down 10mm.

 


The inlet air temp sensor was also fitted into the airbox too. The Omex didn't even need the sensor activating, it already knew it was there and was reading it as 9 degrees.

 


Result is it sits much straighter. I'm not convinced it's 100% straight but it's a lot better.

 

#570: Re: Project sleeper Author: mattievrs, Location: Leicester PostPosted: Fri Oct 15, 2010 1:03 pm
    ----
looks good, can i ask where you got the cable tubing and t pieces from?

#571: Re: Project sleeper Author: twed207, Location: borders, near carlisle. PostPosted: Fri Oct 15, 2010 4:01 pm
    ----
just been through the last several pages... good to see that it's getting there from the mess that eccosse made! Smile and good to see that Omex are being more than helpful too! Smile

dont think i'd let eccosse touch my car after reading all this and hearing other things too...


restecp mate... Cool Thumb Up

#572: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Oct 15, 2010 4:28 pm
    ----
mattievrs wrote:
looks good, can i ask where you got the cable tubing and t pieces from?

Pole Volt. They sell allsorts. Or there is Auto Electrical Supplies. Pole Volt are a bit quicker with deliveries though. Only downside with Pole Volt is with stuff like Superseal connectors, they sell every little component seperately so you have to know exactly what you need or if you forget something you'll be a pin or seal short etc. AES sell the plugs complete.


twed207 wrote:
just been through the last several pages... good to see that it's getting there from the mess that eccosse made! Smile and good to see that Omex are being more than helpful too! Smile

It's not quite done yet. The replacement thermostat housing is being drilled and tapped this weekend to fit the proper Omex coolant temp sensor. That way I will have a proper bleed screw again so I'll know for sure that there's no air trapped in the cooling system.

I'm in Monte Carlo for a few days next week so it will be a couple of weeks before I get it fitted, next job after that will be to wire up the Omex to control the cooling fan...
It's amazing how much work has been needed to bring the car to the standard it should always have been...

#573: Re: Project sleeper Author: tkracing, Location: glasgow scotland PostPosted: Fri Oct 22, 2010 4:52 pm
    ----
ive just read all 39 pages, every post.... im now drunk thru 3 hrs of drinking miller and reading. good night.
p.s. what a job edward, ill be in touch for some handy hints Smile

#574: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Fri Oct 29, 2010 10:39 am
    ----
hay Paul, just reading back through the tread, as i haven't been on in quite a while lol, and i must say nice job on the new harness mate, v.tidy.

rich

#575: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Nov 03, 2010 3:03 pm
    ----
Been spending more money today. Another £26 on a couple of thermostat housing gaskets and O ring for the coolant pipe and various new clips and bolts etc. The radiator isn't in perfect condition so could do with replacing too. It's just had a new battery too.

 


The coolant temp sensor is fitted in the housing although I'm not 100% certain it's perfect. The mechanic who did it said it would be fine but I'd really like a new alloy boss welding to the housing instead.

There is a little problem though. The sensor is very close to the bolt on the blanking plate on the side of the head. I've had to remove the washer from the bolt to enable it to screw in further. It's ok now but I'm going to fit two new thermostat housing gaskets to move it away from the cylinder head slightly. At the moment the JT plug that fits onto the temp sensor touches the bolt so hopefully fitting another gasket will give a little bit of extra clearance.

I do think some Samco coolant hoses would look good in here but I've spent enough on the car recently.

 


The nuts and bolts were to enable me to refit the original plate to the side of the thermostat housing as it's a very good support for the wiring loom.

 

#576: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sat Nov 06, 2010 12:13 pm
    ----
samco coolant houses are a must mate the look sweet under the bonnet and they aren't to expensive to, will you be taking the car to any tracks??

#577: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Nov 06, 2010 1:08 pm
    ----
I can't be bothered driving it actually. So it won't be going to a track, never mind onto a track.

It's back together now but I want the Omex coolant sensor fitting with a proper welded in boss. I just don't trust it when it's screwed into thin, soft aluminium. Then the radiator fan needs to be wired into the Omex.
I also need to thoroughly calibrate the coolant temp sensor and I was looking at the air temp sensor earlier and it said the air temp was 25 degrees inside the standard Peugeot airbox. Not sure whether I believe it or not.

The airbox also touches the radiator so the fan housing needs moving forwards.

#578: Re: Project sleeper Author: vanman_foci, Location: Barry, South Wales PostPosted: Sun Nov 07, 2010 1:59 am
    ----
I really still can't believe you are working on the car to get it right.

But fair play to you, your not cutting corners, and taking your time. Loving the attention to detail. Do you have OCD??? lol

Can't wait to see it finished properly. Probably sell it then.

#579: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Nov 07, 2010 3:51 am
    ----
I just want it to be the best it can possibly be which means as reliable and as well made as it can be.

#580: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Nov 07, 2010 3:54 am
    ----
no way im sad to hear that paul, will you be selling up when you have finishd? My thermostat is in the same place and i trust it as the standard stat is done the same isnt it?

#581: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Nov 07, 2010 6:04 am
    ----
I'm not selling it! Messing about with a VW Jetta at the weekend just isn't any fun. It's not the thermostat that's a problem. It want a boss welding into the thermostat housing that sits on the side of the head.

#582: Re: Project sleeper Author: T_bandery, Location: East london PostPosted: Fri Jan 07, 2011 3:02 pm
    ----
Been reading this project of yours, and one thing I dont get is when you found out the car wasn't working because of the ITBs why didn't you take it back to Ecosse?
If it was my car I would have been in there office kicking up a big fuss seeing as you paid top money for this job

#583: Re: Project sleeper Author: Ruffy_206, Location: Bristol PostPosted: Fri Jan 07, 2011 3:07 pm
    ----
distance, money, they messed it up once why go back. not sure but can see why he didnt. and as they saying goes want a job doing proberly do it your self

#584: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Jan 07, 2011 3:11 pm
    ----
You can't drive a car that doesn't work 200 miles! It wasn't an ideal long distance motorway car anyway and I refused to spend time taking to them and putting 400 miles on it.

No doubt I'd have had to leave the car with them while they sorted it and have had to go home i.e. 800 miles and a considerable amount of time.

I wasn't prepared to pay for a recovery company to take the car back and Ecosse didn't want to pay either.

#585: Re: Project sleeper Author: Addaz, Location: Suffolk PostPosted: Fri Jan 07, 2011 4:07 pm
    ----
Sir, you should take over ecosse in my opinion, or at least give them a good slap to sort out their work

People wish to be as proffesional as you mate, be proud of your car

And to add to the 'not wanting to drive', you get this feeling your holiday will do you well as working on cars 24/7 dull's your enthusiam for them and makes it into a chore rather than a hobby

Have a break, and wait till motivation comes around and you want to work on it/use it Smile

#586: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Jan 07, 2011 4:50 pm
    ----
I love messing with the car at the moment. I'm concentrating on the cooling system at the moment and next week I'll get my thermostat housing back from DP Engineering. The car isn't taxed so I'm in no rush. I'm going to buy it a new coolant reservoir and hose. Maybe some Samcos will be bought too...new stuff should mean total reliability - and confidence in the car.

If I can get a shortened alloy radiator of the quality below I'll be happy. Then I can have some longer trumpets on the bodies...hopefully to gain some torque.
There's one thing for sure, geting everything to a high standard isn't cheap.

 


I just think Ecosse need to raise their game a little. It was just the electrics that let the job down...

They did the absolute minimum to make the car go. No standalone loom, no air temp sensor and automotive grade connectors and old redundant plugs from the old throttle body loom left hanging in the engine bay.

They put the price up when I collected the car, my map sensor went missing from my original manifold, they took twice as long as expected, they charged £200 for pocketing pistons when everywhere else charges £100. As a goodwill jesture for taking so long and it costing me a fortune in hire car bills as a result, they knocked £100 off the piston pocketing price. That makes the original price of £200 sound a little fishy.

Nice wiring below.

 

#587: Re: Project sleeper Author: Addaz, Location: Suffolk PostPosted: Fri Jan 07, 2011 4:52 pm
    ----
Makes you sick dont it when you think you have spent so much time making your car prestine?

They dont need to pick it up a little, the need to complete review their game

#588: Re: Project sleeper Author: Jamie, Location: Ring y0 PostPosted: Fri Jan 07, 2011 4:54 pm
    ----
Disgusting to be honest, ever thought of taking it to a small claims court?

#589: Re: Project sleeper Author: Mattie-RS, Location: A Track near you ;) PostPosted: Fri Jan 07, 2011 4:57 pm
    ----
As a electrician that wiring makes me sick,, Don't know how the slept at night knowing what they have done!


Glad to see you will be getting bigger Trumpets that will be open,, Always thought that your current setup looks abit restricted imo.

#590: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Jan 08, 2011 3:59 am
    ----
Jamie wrote:
Disgusting to be honest, ever thought of taking it to a small claims court?

Not worth the hassle. I asked them to supply a semi assembled Omex loom and a coolant temperature sensor which they did. Making it work was down to me....which I did!

#591: Re: Project sleeper Author: wilson30, Location: Bo,ness PostPosted: Sat Jan 08, 2011 6:47 pm
    ----
Hi paul nice clean car you have mate sorry to here of all the problems you have had with eccosse hope you get the car running right soon and keep up the hard work mate

#592: Re: Project sleeper Author: Ape, Location: Clipping the Apex! PostPosted: Sun Jan 09, 2011 5:00 am
    ----
I've never rated Ecosse and this is testament to that. You've been much more amicable than I could have been about the situation. It's disgusting, surely bordering on not fit for purpose?

Good to see you're sorting yourself nonetheless, nothing quite like DIY engineering!

#593: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Jan 19, 2011 1:28 pm
    ----
Got my thermostat housing back today from DP Engineering. Now this is the best way of mounting an additional coolant sensor. It's much better than stuffing the sensor into the bleed screw hole. Cost €43 and about £13 to post it to them. So not cheap but well worth it.

Basically they've welded a plug of alloy into the housing, welded it in place then they drill and tap it.

 

#594: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Wed Jan 19, 2011 2:20 pm
    ----
looks like what pug1off did to mine mate, top job

#595: Re: Project sleeper Author: Ape, Location: Clipping the Apex! PostPosted: Wed Jan 19, 2011 2:28 pm
    ----
Could you straighten the plug? Would annoy me being at an angle like that.

#596: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Jan 19, 2011 2:33 pm
    ----
I just need to tighten it. Ideally it would be fitted with a sealing washer anyway. It will also be under the engine cover anyway.

#597: Re: Project sleeper Author: Ape, Location: Clipping the Apex! PostPosted: Wed Jan 19, 2011 2:40 pm
    ----
Ah good, as long as it lines up! Whether its under cover or not is irrelevant, still needs to be right underneath. Especially with the detail in this car already (minus the sh*t Ecosse bodge efforts)

#598: Re: Project sleeper Author: SAB206, Location: North West PostPosted: Wed Jan 19, 2011 2:51 pm
    ----
Positive progress there, looks like it's coming on a treat after Ecosse mistreated it somewhat.

Have you sorted the black scuff out on the offside front arch yet?

#599: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Jan 19, 2011 3:50 pm
    ----
Naah. the scratches on the arch are to stay!!!

#600: Re: Project sleeper Author: st3v3n, Location: Liverpool Drives: 206 GTi PostPosted: Wed Jan 19, 2011 6:25 pm
    ----
I just drilled and tapped mine without a boss. I'm using the standard pug position for the omex temp sender and the new one is an M10 fine thread sealed with an o-ring for the dash. cost nothing Razz

#601: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Jan 20, 2011 1:50 am
    ----
I tried that but the thin housing just didn't give me confidence that the sensor would stay in place.

#602: Re: Project sleeper Author: st3v3n, Location: Liverpool Drives: 206 GTi PostPosted: Thu Jan 20, 2011 11:18 am
    ----
I know what you mean, but the sensor i've got for my dash doesn't need lots of thread, i have pics somewhere.

#603: Re: Project sleeper Author: Chi, Location: North London PostPosted: Thu Apr 14, 2011 8:01 am
    ----
Meticulous as ever but will be perfection once completed!

Can't believe that Ecosse has messed you around so much.

#604: Re: Project sleeper Author: Addaz, Location: Suffolk PostPosted: Thu Apr 14, 2011 9:02 am
    ----
Any more news on the project?

Are you going to take her to any shows, or keep her locked up like usual? Laughing

#605: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Apr 14, 2011 11:21 am
    ----
Well these turned up yesterday. Only took eight weeks....Will order a new coolant reservoir and heater hose next week and put it all back together.

 


 


Might buy a proper Jenvey throttle linkage soon too because the throttle bodies reach their stop before the pedal does so it's possible to put a lot of pressure on the throttle splindles which isn't desirable and can twist them.

Next year or over the winter (maybe this summer - depending on lead time on custom radiators) I'll buy the shorter radiator, integrated fan and longer trumpets etc. I'll be getting the standard fan wired to the Omex this summer though to maintain reliability.

#606: Re: Project sleeper Author: macj, Location: Essex PostPosted: Thu Apr 14, 2011 12:03 pm
    ----
Good move Ed.... the ECU control on the fan is important... I have mine in line and its set wrong by a couple of degrees I think.... fan comes in as soon as I am stationary and doesnt really go off even when moving... need to plug the laptop in and sort it. The Jenvey linkage is very good BTW

#607: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Apr 14, 2011 12:51 pm
    ----
Is the linkage adjustable to allow for the cable pull of various throttle pedals? I'm trying to work out if the levers on my bodies will need changing. How is the Jenvey cable held on the pedal or linkage as surely only one end has the barrel end thing...

#608: Re: Project sleeper Author: macj, Location: Essex PostPosted: Thu Apr 14, 2011 1:13 pm
    ----
will get you a picture in the morning mate

#609: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Apr 14, 2011 2:32 pm
    ----
Thanks Mac.
This is my current set up. There are holes where the little adjustable rod on the linkage could maybe attach to.

 


 


 

#610: Re: Project sleeper Author: macj, Location: Essex PostPosted: Thu Apr 14, 2011 3:17 pm
    ----
That is a terrible bracket.... we can do better than that

#611: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Apr 15, 2011 1:40 am
    ----
It does look rough doesn't it. Longmans used something similar though.

#612: Re: Project sleeper Author: kingdom200, Location: Leamington Spa PostPosted: Fri Apr 15, 2011 3:40 am
    ----
i love this project..... good work edward

#613: Re: Project sleeper Author: macj, Location: Essex PostPosted: Fri Apr 15, 2011 1:41 pm
    ----
here you go mate
 

#614: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Apr 15, 2011 3:52 pm
    ----
Thank you. So from what I can see the levers on the bodies do look a bit different to mine.

#615: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sat Apr 16, 2011 12:29 am
    ----
hard to get a close up really but this is a bit closer
 

#616: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Apr 17, 2011 1:55 am
    ----
I'll ask Jenvey for exactly what I need.

Anyway, fitted the Samco hoses yesterday with the new thermostat housing that DP Engineering made with the built in temp sensor boss. A new thermostat was fitted too. Looks much smarter so now I just need to wire in the connector. I've already calibrated the new sensor and ECU together. New coolant reservoir and heater hose will arrive on Wednesday.

I also decided while access was easier to remove the noise insulation from the bulkhead. Looks a bit cleaner now and it was never going to cut out much noise from this car anyway!

 


 


 


 

#617: Re: Project sleeper Author: Lecktorious, Location: Scotland PostPosted: Sun Apr 17, 2011 6:35 am
    ----
Looks awesome Paul! Without a shadow of doubt, one of the cleanest and well specced 206's out there!

#618: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Apr 20, 2011 2:35 pm
    ----
Got the rest of the new parts today. Got a new heater hose that leads to the coolant reservoir. I also ordered a new reservoir but the one that arrived was a slight different design to the old one so the new hose wouldn't fit it. So I got the £48 back that I paid for the reservoir. I'll re-use the original.

So put it all back together and I thought it best to not use any coolant just in case there were any leaks and it needed stripping down again...good job I did...

I didn't even get to start the engine.

The thermostat housing that DP Engineering modified actually leaks. They said the welding can distort it but they'd skim the housing to make sure it's flat. Well if they skimmed it they didn't do it very well because it leaks and that's fitted with a new gasket too.

The weld is also porous!

So question is do I send it back to DP Engineering to get fixed or do I just get it fixed locally? I'm not going to be putting Radweld into the coolant system to fix it!

 


So it's all stripped down again.

 

#619: Re: Project sleeper Author: TRIS, Location: Cornwall PostPosted: Wed Apr 20, 2011 5:51 pm
    ----
I would personally get it fixed locally to save hassle/time with postage etc. But contact them with pictures and demand some sort of part refund.?
P*ss poor really.
From reading your whole thread, two of the biggest names in the peugeot modifiying scene have produced poor quality of goods/workmanship. DOH!!!

#620: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Thu Apr 21, 2011 3:49 am
    ----
That's probably because it just got too complex for them Very Happy

#621: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Apr 27, 2011 12:16 pm
    ----
Decided against sending stuff back to DP Engineering because I wanted the car together this weekend.

So I took it to a local engineering shop. So that's another £30!

 


To skim the thermostat housing they first had to machine the front face to make sure it would sit flat.

 


Why didn't DP Engineering do this when they said they would?

 


They also fixed the leaky weld!

 

#622: Re: Project sleeper Author: macj, Location: Essex PostPosted: Wed Apr 27, 2011 12:37 pm
    ----
Because they were not paying attention..... seems just lately that if you give people jobs they see as simple they tend not to pay proper attention to detail.
I have found this a lot recently... point in case, the S/C bracket.... seems simple but has not yet resulted in one I would put my name too because they cant get the maths right and the pullies dont line up properly.... so they go in the bin Shocked

#623: Re: Project sleeper Author: Lecktorious, Location: Scotland PostPosted: Wed Apr 27, 2011 12:41 pm
    ----
Question is Paul...will it be ready in time for a few sunny days?

#624: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Apr 27, 2011 12:52 pm
    ----
I think it just goes to show how many cowboys are in the industry. None of the work I've had done is rocket science but it's the simple things that have let it down. As Macj says it's the attention to detail that's lacking and as the saying goes - the devil is in the detail.

It will be back together this weekend. I might tax it at the beginning of May but then again I might spend the money on a proper throttle linkage instead. I'd like to get the cooling fan wired to the Omex before it goes anywhere.

So who understands relay wiring? Is the Omex fan output below a +ve or a -ve?

 

#625: Re: Project sleeper Author: macj, Location: Essex PostPosted: Wed Apr 27, 2011 1:03 pm
    ----
As I understand it. The ECU uses an earth return policy. You supply the live 12v to the relay and the ECU will earth it to turn it on. As with everything Paul. Double check with them first.
Last edited by macj on Wed Apr 27, 2011 11:42 pm; edited 1 time in total

#626: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Apr 27, 2011 1:05 pm
    ----
I'm going to email Omex tomorrow. The Omex ECU triggers the earth for everything else so I'll see what it does for the fan control!

#627: Re: Project sleeper Author: Seb, Location: Under your bed PostPosted: Wed Apr 27, 2011 1:15 pm
    ----
Edward wrote:

So who understands relay wiring? Is the Omex fan output below a +ve or a -ve?

 

From that diagram you supply a 12V live into the relay and it gets earthed.

EDIT: I'm not sure what else you mean however, the fan is evidently earthed, as the upside down triangular lines mean an earthing point, however you are talking about the Omex output? Where is it leading to?

As I understand it, most are lives, if they are not lives, they are earthed.

#628: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Apr 27, 2011 2:30 pm
    ----
The Omex output goes to the relay. When the Omex triggers the relay it switches the high current feed to the fan.

I'm thinking, for now, of keeping the standard relays and using the Omex to trigger them (or one of them) rather than fit a new relay in the gloebox.

#629: Re: Project sleeper Author: Bigbenj_08, Location: Cardiff PostPosted: Sun May 01, 2011 4:33 am
    ----
I've just read this whole thread front to back and while I don't understand the majority of the technical stuff being talked about, its a cracking read.

Glad you kept the car going after all the problems/disappointment after the original conversion. Sounds like you've spent a whole lot of cash!

Anyways, your 206 is a beast! Very Happy

#630: Re: Project sleeper Author: no_offences, Location: Leeds PostPosted: Sun May 01, 2011 4:35 am
    ----
very tidy engine bay

#631: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun May 01, 2011 7:28 am
    ----
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.

 

#632: Re: Project sleeper Author: CD-B3, Location: Salisbury / New Forest PostPosted: Sun May 01, 2011 5:56 pm
    ----
Still looks good but you have a rusty bolt on the bonnet latch Wink

#633: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon May 02, 2011 12:55 am
    ----
That picture was from years ago. It's a lot cleaner now.

#634: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat May 07, 2011 5:29 am
    ----
This is what makes it all work...Much better sat in here away from the elements.

 

#635: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat May 07, 2011 5:49 am
    ----
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???

 


 

#636: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat May 14, 2011 2:58 pm
    ----
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.

 

#637: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun May 15, 2011 6:20 am
    ----
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!

 


 

#638: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Sun May 15, 2011 10:46 am
    ----
Looking good! You could probably get away with chopping more out of the fan surround than the standard one shown too?

#639: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun May 15, 2011 1:31 pm
    ----
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.

#640: Re: Project sleeper Author: macj, Location: Essex PostPosted: Thu May 19, 2011 9:40 am
    ----
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

#641: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu May 19, 2011 12:42 pm
    ----
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.

 

#642: Re: Project sleeper Author: macj, Location: Essex PostPosted: Thu May 19, 2011 12:46 pm
    ----
mine has all gone.... its for another car that is getting an oil cooler but the plug was in the way

#643: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu May 19, 2011 12:49 pm
    ----
Is it fitted with an aftermarket ECU too?

#644: Re: Project sleeper Author: macj, Location: Essex PostPosted: Thu May 19, 2011 12:53 pm
    ----
no.... it has the standard set-up at present....

#645: Re: Project sleeper Author: Slowmotion, Location: Earth. PostPosted: Thu May 19, 2011 2:43 pm
    ----
If you get stuck on anything get in touch with Scott at SP-Developments i'm sure he can help you out with stuff. Smile

#646: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat May 21, 2011 7:35 am
    ----
A bit more messing today. I hadn't switched the engine on since the fan had been rewired.

Fan works fine and is set to come on at 93 degrees and go off below 91 degrees. I have definately never heard the fan on at high speed before so I think it had corroded terminals on the high speed relay for a long time.

Will have to drive the car one day and see what it runs at when driving it hard. I don't think it ever went over 85 degrees though. Don't want the fan switching on when the car is moving. Shouldn't be a problem though.

I noticed the air temperature was looking a bit high...it got as high as 50 degrees...

 


Air temp sensor is sat right above the lower coolant hose. Is it picking up heat from it? Might be ok on the move but I might have to think about relocating it. Long term it won't be a problem as it will be mounted in the air filter backplate when the longer trumpets are fitted.

 

#647: Re: Project sleeper Author: MrBSI, Location: What's it to you? ? ? PostPosted: Sat May 21, 2011 7:47 am
    ----
It could be picking up some heat soak from the coolant hose.

You got anything heat proof like a soldering mat you could use to shield the sensor area as a quick test?

#648: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat May 21, 2011 7:55 am
    ----
Yeah I could wrap it in something...

I think it's best to just move the sensor round the back of the air filter box or maybe even into the side of the lid. Maybe just moving it further down the airbox from where it is now will get it away from the hose. Will need to extend the wiring though.

Last edited by Edward on Sat May 21, 2011 7:56 am; edited 1 time in total

#649: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sat May 21, 2011 7:56 am
    ----
There is a possibility that you are getting a heat reading from the hose, I take it that the air temp sensor is in the standard airbox at present. I have fitted mine between the two centre trumpets to get a good average intake reading. With the carbon airbox you have on your T/B s
I would say they would be ok but fit some heat reflective film on the hose side of your standard airbox to prevent heat soak. An experiment with kitchen foil always works before you invest in the real deal. However I think that on the road you wont be affected by the heat as much.

#650: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat May 21, 2011 8:02 am
    ----
I'd love to put mine in the carbon airbox but what effect will having the oil vapour hose from the rocker cover have on the sensor???? I imagine in time it will get covered in a thin film of oil.

#651: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sat May 21, 2011 8:11 am
    ----
good point but, I have not fitted the engine breather in the airbox. I would say it would be ok as long as it is not in direct line of the oil entry point. Worth checking regularly though

#652: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat May 21, 2011 8:15 am
    ----
I suppose I might have to invest in a catch tank if I go for the short radiator, longer trumpets and sausage filter one day. Won't be a problem then if the air temp sensor goes in the back plate.

#653: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sat May 21, 2011 9:28 am
    ----
be fine in the backplate. Just keep an eye on its health until you get a catch tank

#654: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Jun 03, 2011 3:41 pm
    ----
Ordered some more electrical bits and bobs while on holiday. They were fitted today and that meant the air temp sensor could be moved to the opposite side of the airbox behind the headlamp.

Also spent £118 on six months road tax! So yes, it's back on the road for the first time since the end of December.

 

#655: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sat Jun 04, 2011 6:54 am
    ----
Nice one Ed... be good to get out and about in it after your efforts..... enjoy Very Happy

#656: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Jul 02, 2011 3:47 am
    ----
The car still continues to be haunted by the 'skills' of Ecosse.

The car has done very few miles in the last 12 months but I thought it was time I changed the oil. In all my time of owning cars I have always been able to get the oil filter off by hand. They just don't need to be tightened anything more than hand tight.

I was quite surprised when I couldn't get this off by hand. I thought I'd get my chain tool out. It's so tight it broke the chain tool. So I'm off to Halfords now to see if I can get a socket type tool.

 

#657: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Jul 22, 2011 9:16 am
    ----
More spending this week.

I spotted a slight leak from the joint between the bottom hose and coolant reservoir. The hose was replaced with a new one a few months ago but if I pull on the hose it can be pulled off the outlet from the tank! The little clip holding the hose onto the reservoir isn't good enough.

 


So I was aware that Peugeot had changed the design slightly where the hose simply slides onto the reservoir outlet and uses a conventional clip. So that means buying a new reservoir and another new hose.

 


But the new reservoir needs an adaptor for the small radiator to reservoir hose. This is about £30 which I need to buy tomorrow.

 


The new silicon hose I have bought is quite thick and so doesn't really want to bend easily near the reservoir so I've also had to buy a new 90 degree silicon elbow and an 8mm hose joiner too.

It's certainly expensive keeping this car perfect. The reservoir, hose and radiator brackets were £85, the silicone hose £10, 90 degree elbow hose with 4x hose clips and joiner £14 and the Peugeot adaptor kit is £30. So £140 to solve a leaky reservoir...bargain!

#658: Re: Project sleeper Author: Andy180, Location: Stoke on Trent PostPosted: Sat Jul 23, 2011 3:40 am
    ----
The joys of owning a peugeot

#659: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Jul 23, 2011 7:13 am
    ----
It certainly is.

Got the 3 clips from the dealer earlier. £28 for three and I only need one of them! They must cost 10p each to make too.

 


It just attaches to the new reservoir to allow the hose to fit. I'll be changing the standard hose for a silicon hose when the 90 degree elbow arrives. The hose is very thick walled and doesn't easily form sharp bends so the elbow is vital to avoid stressing the clip.

 


Why not take some other pictures while I'm there.

 


 


 


 

#660: Re: Project sleeper Author: Howey, Location: Kings Lynn PostPosted: Sat Jul 23, 2011 7:35 am
    ----
Looks absolutely stunning. Nom Nom Droolage!

#661: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Jul 27, 2011 2:43 pm
    ----
All finished now.

 


 


 

#662: Re: Project sleeper Author: Lecktorious, Location: Scotland PostPosted: Wed Jul 27, 2011 2:50 pm
    ----
What's left to do before it will make a fault-free outing?

#663: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Jul 27, 2011 3:04 pm
    ----
That's it now. Might take a look at the clutch over the winter but it's nothing that desperately needs doing.

Next job to do over the winter is to order a shorter radiator with 2x fans, longer trumpets and a big filter. Then it will need mapping again.

#664: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Thu Aug 11, 2011 5:41 pm
    ----
if you do get the new filter keep me inmind and ill have the box off you if you sell it paul

#665: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Sep 17, 2011 11:09 am
    ----
Who on this forum said the air conditioning on a 206 weighs 50kg??? They were talking our of their hat. I weighed mine and the pump, radiator and piping all weigh just 10kg.

I decided to remove all of mine because I decided to remove two nuts on a big grommet on the bulkhead. The intention was to see what was behind the grommet, but it let the gas out!!! Oh well, it's not worth regassing the system on a car which is used for just 400 miles a year. So I might as well bin all the air conditioning as this will also provide more space for a shorter wider radiator.

So I bought a new belt from the Peugeot dealer for £22.

 


I fitted it before the air con pump was removed just to make sure it fits.

 


Front bumper had to be removed and the radiator housing moved to allow the air con condensor to be removed. It all came apart very easily. The only pipes that needed to be cut were the long ones that run along the inner wing behind the engine to the bulkhead. I wanted to remove them without cutting but it's impossible.

 


Until I find what lower spec cars with no aircon have here I've left two stubs...Anybody know how to remove the evaporator from the car?

 


One big space where the pump used to be...

 


 

#666: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sat Sep 17, 2011 11:28 am
    ----
Heater box out mate to remove the evaporator Crying or Very sad

#667: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Sep 17, 2011 12:00 pm
    ----
Oh well, my stubby pipes will remain then. Unless a poverty spec car has a neater solution.

#668: Re: Project sleeper Author: MattyP, Location: Plymouth PostPosted: Sat Sep 24, 2011 6:44 am
    ----
liking it Ed! When you bought your new header tank mate could you see the coolant level clearly? Been quoted £180 to have a custom alloy header tank made with sight glass

#669: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Sep 24, 2011 9:49 am
    ----
Nope. As long as I can the coolant a couple of inches from the top of the tank I'm happy.

#670: Re: Project sleeper Author: MattyP, Location: Plymouth PostPosted: Sat Sep 24, 2011 10:18 am
    ----
not tempted by a custom alloy header tank then

#671: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Sep 24, 2011 12:06 pm
    ----
Not really any point when the standard item does the job.

#672: Re: Project sleeper Author: tomd0801754, Location: Moscow PostPosted: Sun Sep 25, 2011 1:19 am
    ----
Edward wrote:
Not really any point when the standard item does the job.

A standard engine does the job. Wink


Looks amazing mate. You might have a hassle free summer this year.

#673: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Sep 25, 2011 2:30 am
    ----
But the standard reservoir is perfectly adequate even with a modified engine. If an aftermarket part doesn't really perform any differently then can it be justified? The new coolant reservoir is perfectly fine.

I did think about a customer reservoir but that would still mean I'd have to buy the newer style heater hose which was the problem originally. New hose and new standard reservoir means there are no problems anymore.

#674: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sun Sep 25, 2011 3:31 am
    ----
Mine works fine as well .....I dont think looks are important enough to mess with it.

#675: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Oct 31, 2011 4:08 am
    ----
Did a bit more messing tonight. All the wiring is neat and tidy and covered in split convoluted tubing, all joins are made with T or Y pieces. There is no exposed insulation tape anywhere - except for one small area above the gearbox where there is some exposed blue tape. Can do better.

 


So it all got stripped down measured up for more T pieces and tubing so everything is hidden.

Also as the air conditioning has been removed that meant some extra wiring could be cut out too. If it's not needed it might as well not be there. There's something really satisfying about cutting out old wiring and making it all simpler.

 


Also the original ECU uses the PAS pressure sensor to increase engine revs when the pump is loaded. The Omex doesn't use this so the plug for the sensor can be binned too.

All resulted in this lot being removed.

 


New tubing and T pieces are on order so should be finished in the next couple of days.

I also have lovely verniers...

 

#676: Re: Project sleeper Author: MattyP, Location: Plymouth PostPosted: Mon Oct 31, 2011 6:05 am
    ----
Looks awesome Ed, looking at the engine bay you wouldn't think this car is 10yrs old. Once the engine is sorted and the clutch replaced, any other plans for it?

#677: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Oct 31, 2011 7:19 am
    ----
I've been driving it a bit more recently and the clutch is actually OK. Does feel a bit creaky when hot but it's nothing really worth changing.
Shopping list for next spring is the ITG filter, 90mm trumpets and the shorter radiator. Might have to think about a small oil cooler too.

Shorter gearing is a must too. 70mph in 2nd gear is silly really and if it maxed at 50mph in 2nd it would be substantially faster.

This winter I might take the dampers off and refurb them because they are looking a bit corroded. Then I'd like to strip the rear axle and change the bearings. There's nothing wrong with the existing ones but I just fancy stripping it all down and replacing anything that can wear out. Might get all the brackets zinc coated.

#678: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Nov 02, 2011 5:04 pm
    ----
All finished now...all the loom round the back of the engine to the speed sensor and oil temp sensor has been covered in new tubing, proper T pieces used too.

 


 

#679: Re: Project sleeper Author: LeeThr, Location: North West Wales PostPosted: Thu Dec 01, 2011 9:27 pm
    ----
Looks like it really has come on since the beggining. Just a shame Ecosse only did a half arsed job and you had to sort out there mess. But oh well I geuss it gives you a better understanding of your car.

Whats it like to drive now? Whats it like on fuel?

#680: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Dec 02, 2011 11:31 am
    ----
It drives fine. Quick enough when it gets some revs. Really need some longer trumpets to boost the torque though.
No idea what it does MPG wise but it's not mega thirsty. I'm sure at full throttle it's thirsty but you can't give it full throttle for long.
At the moment though the best roads for driving tend to be bumpy roads which slows the car down. The most fun is had when driving it hard at 60mph+ which can't be done on bumpy roads. So it's become more of a straight line, smooth road car.

I really want to look into how manufacturers make cars with good steering feel. Even when getting out of the Jetta into the 206 it highlights how poor the 206 steering is. There is hardly any feel at all which really dents confidence in the corners. The driving position doesn't help.

Anyway, tax ran out on 30th November so it's SORNed for six months. Time to move the battery, paint the corroded Bilstein dampers, replaces all the nuts and bolts underneath, buy a short radiator and longer trumpets etc.

#681: Re: Project sleeper Author: LeeThr, Location: North West Wales PostPosted: Fri Dec 02, 2011 11:42 am
    ----
Fair enough Smile How come you cant give it full throttle for long? Just run of straight road too quick?

I know what you mean about the steering, my 1.4 is terrible its not helped by the way it snatches in some corners something isnt right at the moment.

Ah right, winter hibernation then. Should look good when it's all done. Do you think there will ever be a time when you get the car to a point and think it's finished. All thats left to do is start it up and drive?

#682: Re: Project sleeper Author: MrBSI, Location: What's it to you? ? ? PostPosted: Fri Dec 02, 2011 11:45 am
    ----
Peugeot steering has been crap since they launched the 406.

206 isnt bad but its nothing like an older Peugeot for steering feel.

#683: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Dec 02, 2011 12:20 pm
    ----
LeeThr wrote:
Fair enough Smile How come you cant give it full throttle for long? Just run of straight road too quick?

2nd gear is good for 70mph. 3rd gear is almost 100mph. So there are 3 gears for getting best performance. So speeds are getting silly, too silly for twisty country lanes. 4th and 5th gear are for tootling along because to get best performance in these gears the speeds would be pretty high.

LeeThr wrote:

I know what you mean about the steering, my 1.4 is terrible its not helped by the way it snatches in some corners something isnt right at the moment.

Everything on mine with all new parts is fine but it still tramlines on some road surfaces.

LeeThr wrote:
Do you think there will ever be a time when you get the car to a point and think it's finished. All thats left to do is start it up and drive?

It's done a few miles this year, since Oct 2010 it's done 700 miles! In the last 5 weeks it has done 200 miles! No idea how it's done that many! It is actually quite nice to drive, it's just its natural territory should be country lanes but the rev range of the engine takes onto the quicker, better surfaced roads.

It will never be finished, it's not brand new and I'm trying to make a new car out of one that's nearly 11 years old.

Put it this way before spring the car needs/wants the following:

Shorter radiator
90mm trumpets
ITG filter
Throttle linkage
Respray dampers
New nuts and bolts for front suspension and brakes
Sump removal to fix oil leak that's been there since you know who had it.
Battery moved to boot

Longer term there's more work:
Think there's a small gearbox oil leak.
Moderately lightened flywheel
Shorter final drive gearing
Exhaust manifold wrapping
Small oil cooler

Even longer term I'd like to go for an engine with uprated internals and one that I know it perfect in terms of compression ratio and camshaft timing etc. I'd happily settle for a GTi 180 bottom end as they can handle 7500rpm as standard. Will a 138 head fit a 180 bottom end though?

#684: Re: Project sleeper Author: LeeThr, Location: North West Wales PostPosted: Fri Dec 02, 2011 12:40 pm
    ----
Ouch thats some pretty long winded gearing. Would be better suited to some shorter ratio's.

Yer most of mines 10 year old original parts with over 100k of millage on them.

Sounds an interesting mixture.

I would love a project car but just cant afford it right now.

#685: Re: Project sleeper Author: jeffchiz, Location: oxford PostPosted: Sat Dec 03, 2011 5:13 am
    ----
just been through all 46 pages, really feel for you with all the problems! ive almost completed my throttle body build on my saxo and im hoping i dont have this much trouble, my housemate works at pug1off so im lucky i get to take advantage of his skills for free Smile I;be also got red jenveys, never seen another set of red ones before lol

im running a predator ecu which thankfully is plug and play in the saxo so dont have to mess about with any wiring to make it fully standalone, also means all i have to do is cable tie the air temperature sensor to the bulk head in front of the trumpets nice and easy for the time being, will hopefully make a bracket up for it

whats it like working in the 206 bay? looks really tight compared to the space in the saxo bay, a lot of scuffed knuckles? lol

also what was the final bhp figure you achieved? sorry i think i missed it

#686: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sun Dec 04, 2011 4:43 am
    ----
Good call on the internal mods Ed, I opted to keep the 138 bottom end as Charlie reckons with a balance it will be safe at 8500rpm and as we only need 7500 there is a safety margin.
I would keep your entire engine together and just change the internals for 12.5:1 forged pistons and rods, this in effect gives you a 180 bottom end with forged rods, I would try the 4.2:1 CWP from the berlingo. Wink

I worked out my whole engine mods around the standard cams and arrived at the final build state I have now.

balanced bottom end with lightened flywheel (2kg off)
forged 12.5:1 Wossner pistons
PEC rods with ARP bolts
race spec shells
worked cylinder head with standard valves (runs out of air at 7500 due to cams)
Jenvey 45mm throttle bodies

The most important thing for me was the torque figure (190+ft/lb)

This engine really pulls at lower revs now

Keep up the good work....

#687: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Thu Dec 15, 2011 3:58 pm
    ----
I would of liked to go forged pistons at the time of mine but at the time I couldn't justifi the cost for the gain. But that's really the only thing I could of done extra on mine. And would be a bit pricey to have it all re done now.

Any ways Paul I can certainly say you have done a bitter job than what the company who did it in the 1st place. I should bring mine to you to fit the air box haha.

#688: Re: Project sleeper Author: Andrew, Location: Black Country Ay I PostPosted: Fri Dec 16, 2011 5:09 am
    ----
I read the first few pages where Paul summarised getting the car, buying the head, cams, standalone, bodies and exhaust system.. taking it to Ecosse and being disappointed, somewhere in the middle he identifies that Ecosse did a bad job on the ECU, then he taken some time to fix it. I haven't read all 46 pages but thats what I've got of the story ><

Before you said it was lacking mid range, did sorting the ECU help the torque?

Thanks

#689: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Dec 21, 2011 11:21 am
    ----
The mid range torque is probably down to the short inlet trumpets. 157lb ft is not great for the spec of the engine.

The Jenvey website suggests I need an inlet about 420mm long. It's currently about 360mm from trumpet to valve. With the 90mm trumpets it will be approximately 410mm which should be good enough. Ditching the airbox and having the filter in direct airflow should help too.

While is not being driven I thought I'd remove the airbox. I'll have to do something to support the injector wiring when it's finished.

 


I just hope the ITG back plate and filter will fit especially with the gap down the side of the PAS pump being so tight.

 

#690: Re: Project sleeper Author: simpsonrc, Location: coventry PostPosted: Wed Dec 21, 2011 6:44 pm
    ----
You could get the backing plate welded to the trumpets just behind the mouths then you should clear the pump with 90mm tumpets. Mine made 171 lb ft with the same inlet set up, im trying electric power so I can run a beter inlet manifold

#691: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Thu Dec 22, 2011 3:19 pm
    ----
I went to Jennvy Paul when I was on the look out for a filter as they are literally 2 miles away from my house we tried fitting the piperX back plate and it was hitting the pas pump so I do think to get a perfect fit with a mushroom filter would be to relocate / elec pas pump. Or individual sockes but they have a history of getting sucked in as I've heard of Numorous people lol.

#692: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Dec 29, 2011 10:44 am
    ----
I'll see how the ITG backplates fit because you can buy blanks that need drilling. I reckon I can offset one to the right which will give enough space - just!

#693: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Dec 29, 2011 10:58 am
    ----
I normally start a new topic each time the car has its birthday..well I'm not going to this year - simple because it isn't even sat on wheels.

 


As the Bilsteins were so rusty I decided to give the whole car a strip down. The passenger damper wasn't quite as bad as the drivers side but it's hardly brilliant.

 


The front springs were rusty where the coils were in contact with the damper and top spring seat. I'm undecided whether to sand the corrosion down and get them shot blasted and powder coated or I might just buy some new H&R springs to see what they are like. Motorsportworld want £90 for some Eibach Pro Kit spring and £116 for some H&R.
I'm sure the Eibachs are worth £30 to somebody.

 


While the car is up in the air I thought I'd get the silver Hammerite on the arches. Most of what you see is covered by the arch liners but it certainly looks a bit better than it did before. They were hardly dirty but ever little bit helps.

The wooden battens are there to stop the hubs rotating and falling off the axle stands while the dampers are removed. Next job is to remove the front subframe and get the exhaust and manifold off. I want to get the manifold as shiny as it was before it was fitted. Being stainless it should still be possible but it's too tight to polish it on the car. Then the subframe will be cleaned up (again hardly bad as it is) and put back in place with all new nuts and bolts.

 


 


 


 


 

#694: Re: Project sleeper Author: Schumi, Location: Istanbul / Turkey PostPosted: Fri Dec 30, 2011 2:35 pm
    ----
I hate you. How a 10 year old car can be clean as like this. Smile

#695: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Dec 30, 2011 4:49 pm
    ----
But it's now 11 years old!

#696: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sat Dec 31, 2011 11:27 am
    ----
If you fit a vauxhall astra P/S pump the backplate will fit mate

#697: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Dec 31, 2011 12:22 pm
    ----
If I was to go electric PAS I'd go for a PSA pump. They tend to be quite expensive though. I suppose the Vauxhall pumps might be in more plentiful supply.

Did some more dismantling today. Subframe had to come off because I want it respraying or maybe powder coating. That also give access to the exhaust manifold so it can be removed to get it polished.

 


 


This lot can be replaced.

 


This just wants cleaning up and respraying. Is it worth the expense of getting it powder coated though? Bearing in mind it sits under the car and is used to jack the car up at times.

 

#698: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sat Dec 31, 2011 12:46 pm
    ----
bear in mind you will need a remote reservoir for the Astra pump and a bit of pipework.... but its a job right up your street

#699: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Dec 31, 2011 1:10 pm
    ----
Well I'll see how this years jobs go and think about the electric PAS next year. Hopefully I won't need it.

#700: Re: Project sleeper Author: HDI90, Location: sunny stoke PostPosted: Sat Dec 31, 2011 1:29 pm
    ----
You say the springs were corroded where they sit on the cup , i know my eibachs have got rubber sleaves that go around 1 and 1/2 coils . Maybe that could be somthing you could do to stop the next ones rusting?

#701: Re: Project sleeper Author: Mattie-RS, Location: A Track near you ;) PostPosted: Sat Dec 31, 2011 3:01 pm
    ----
may aswell powder coat it, more durable finish and its not that expensive really

#702: Re: Project sleeper Author: Schumi, Location: Istanbul / Turkey PostPosted: Sun Jan 01, 2012 7:52 am
    ----
Currently I removed my belt powered PAS pump completely. 4 month ago I bought 307 steering pump and I go to local shot for custom pipes. All of them is completed. Just I cant be sure where can I locate pump. I changed oil housing with Clio one for vertical mount of behind of fog light. Smile

I'm considerin about Corsa C complete EPAS. This system dont need pipes and pumps. But I dont like idea about puting non Peugeot-Citroen parts to my car. Smile

#703: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Jan 01, 2012 10:51 am
    ----
HDI90 wrote:
my eibachs have got rubber sleaves that go around 1 and 1/2 coils . Maybe that could be somthing you could do to stop the next ones rusting?

I think the Eibachs came with the tubing after I got mine. If I buy some new springs I'll make sure they come with tubing.

Mattie-RS wrote:
may aswell powder coat it, more durable finish and its not that expensive really

After I cleaned it up it's a bit too good to justify spending the money geting it powder coated. I'd hate to spend a few quid on something that could easily to get marked lifting the car.

Schumi wrote:
Currently I removed my belt powered PAS pump completely. 4 month ago I bought 307 steering pump and I go to local shot for custom pipes. All of them is completed. Just I cant be sure where can I locate pump. I changed oil housing with Clio one for vertical mount of behind of fog light. Smile

The 206 1.6 HDi pump sits behind the front bumper similar to the Citroen C4 below.

 

#704: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Jan 05, 2012 1:56 pm
    ----
Manifold is off now, just to polish it!

Manifold now polished with Autosol. Still clean enough but not quite as shiny as it was when brand new.

 


Manifold when new.

 

#705: Re: Project sleeper Author: macj, Location: Essex PostPosted: Thu Jan 05, 2012 2:06 pm
    ----
I love your attention to detail Thumb Up

#706: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Jan 05, 2012 2:31 pm
    ----
Well it costs nothing to keep things clean!

#707: Re: Project sleeper Author: Ape, Location: Clipping the Apex! PostPosted: Thu Jan 05, 2012 2:44 pm
    ----
I wouldn't powder coat, it'll crack if you use it to jack the pug up.

Exceptionally clean though bud. You could enter that into some show and shine / concours and win I reckon, especially if you took the bumpers etc off. "Exploded Concours Entry"....

#708: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Jan 20, 2012 10:09 am
    ----
Shall I rename my topic to Project Pristine? That's the way it's going to be when I'm done.

The floor has all been painted and the rear axle will be off one day for a refurb (i.e. powder coating) and the boot floor might be covered in Epoxy Mastic.

More money spend this week. £67 on nuts and bolts! These are for the front hubs, wishbones, steering rack, column, heatshields and anti roll bar. A couple of brackets are yet to come from the dealer.

 


Heatshields have been cleaned up and painted.

 


 


Then I'm going to change the brake pipes that run under the floor. They are slightly bubbled under the coating, they are 11 years old after all. So while the front subframe is off I might as well get them changed. So I ordered some tools.

 


 


Exhaust manifold has been cleaned and the flange painted in HT paint like it was when new. The lambda sensor was changed and the connector replaced and covered in convoluted tubing and a end cover to make it look neat.

 

#709: Re: Project sleeper Author: simpsonrc, Location: coventry PostPosted: Fri Jan 20, 2012 1:07 pm
    ----
looking nice, have to watch that convoluted tubing doesn't melt. could you measure the inner diameter of you exhaust? also does the exhaust manifold flange match the ports in the head or is it slightly bigger? thanks

#710: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Jan 20, 2012 2:40 pm
    ----
It's a 60mm internal bore on the exhaust. The manifolds were designed to go with the Longman head and both are a couple of mm wider than standard. Standard exhaust ports are 42mm wide. The Longman exhaust ports are 47mm wide. The Maniflow manifold is 50mm at the entry to the port.

The tubing is rated to 120 degrees. It's pinned to the heatshield is well away from the exhaust.

#711: Re: Project sleeper Author: Seabook PostPosted: Fri Jan 20, 2012 3:35 pm
    ----
have you sort out your suspension yet?

#712: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Jan 20, 2012 4:44 pm
    ----
I'm going to go from some H&R springs and some Bilstein Sprint dampers. The H&R springs are about £30 more than Eibachs but I just want to see how they differ to the Eibachs.

I won't be ordering it until the rest of the car is back together. So I'll be waiting a month.

#713: Re: Project sleeper Author: simpsonrc, Location: coventry PostPosted: Fri Jan 20, 2012 7:12 pm
    ----
Thanks for the info. The lambda sensor has a heater that heats to about 400*c let alone when being driven hard, the original lambda sleeving is proper heat resistance stuff and I’ve seen that melt where the wires go into the sensor.

#714: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Jan 28, 2012 12:59 pm
    ----
Clean enough? Floor almost finished. Front end is getting rebuilt now starting with the manifold. Nect job will be the subframe now that the Peugeot dealer has got hold of some subframe bolts.

 

#715: Re: Project sleeper Author: D4NTP, Location: Not Leeds or its surrounding areas! PostPosted: Sat Jan 28, 2012 1:11 pm
    ----
There will be tears the first time it goes out in the rain!

#716: Re: Project sleeper Author: Lecktorious, Location: Scotland PostPosted: Sat Jan 28, 2012 2:53 pm
    ----
Looks great Paul, I'd dread taking it incase it rained though! With it being that clean though it should just wipe off.

#717: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Thu Feb 02, 2012 4:06 pm
    ----
Out of interest, how do you clean it?! I dont think you run a hose underneath it and sponge it down.

#718: Re: Project sleeper Author: Dillon, Location: Kent PostPosted: Thu Feb 02, 2012 5:45 pm
    ----
Steve206 wrote:
Out of interest, how do you clean it?! I dont think you run a hose underneath it and sponge it down.

He strips it cleans it and then replaces anything consumable with mostly original parts, other than the exhaust ecu's cams... well not as much as there once was Razz

If this doesn't end up a museum piece it needs to be entered for concourse at least!

#719: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Feb 03, 2012 2:49 pm
    ----
Yep, the floor has been painted because although it was clean they aren't fantastic looking even when new. All the other stuff is replaced with new bits.

#720: Re: Project sleeper Author: Nic_206, Location: cleaning the car PostPosted: Fri Feb 10, 2012 1:02 pm
    ----
hats off to you mate! the attention to detail on this car is second to none! would love to have the v6 in the condition of yours maybe one day, at the moment ive got enough to contend with too keep me busy for a while

#721: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Feb 19, 2012 1:05 pm
    ----
I've moved onto the back end now. Rear axle has been removed and will be stripped. One torsion bar screw is seized and one end of another torsion bar is stuck. They went in with plenty of copper grease so hopefully they won't be stuck for long. Brake pipes are stuck in the calipers too!

Boot floor has had a bit of a scrub but it needs a lot more time spending on it before the underseal gets applied. Fuel tank will be removed before underseal is applied.

 


 

#722: Re: Project sleeper Author: Matt PostPosted: Sun Feb 19, 2012 1:48 pm
    ----
This is easily the best car on this site.

I love it. And I respect the amount of work you are putting into it.

Keep it up!

#723: Re: Project sleeper Author: BigGreenDave, Location: The Rift PostPosted: Mon Feb 20, 2012 1:38 am
    ----
MATE that is so tidy love the work and effort you have put into this and how clean it is.

fantastic job!

#724: Re: Project sleeper Author: MattyP, Location: Plymouth PostPosted: Mon Feb 20, 2012 4:21 am
    ----
love this 206 mate, it's so clean, makes me wish I was able to make the underside of mine this clean but I use it everyday so not much point lol keep it up mate!

#725: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Feb 20, 2012 2:04 pm
    ----
Decided to clean the rear calipers a bit tonight...not perfect but not finished yet. A bit of Autosol and light sandpaper on the worst parts will make them good.

Before...

 


 


After...

 


 

#726: Re: Project sleeper Author: Seabook PostPosted: Mon Feb 20, 2012 2:32 pm
    ----
even my new rear caliper doesn't look as clean as yours lol

#727: Re: Project sleeper Author: Goldin, Location: Pula , Croatia PostPosted: Thu Feb 23, 2012 1:54 pm
    ----
Your's car is one of my favourite projects on this forum.
I am waiting for informations about differences betwen Eibach and H&R springs Wink

#728: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Thu Feb 23, 2012 2:39 pm
    ----
Paul, have a look into rust bullet before going down the epoxy mastic route. Looks great by the way! I knew this is how this project would go down the line!

#729: Re: Project sleeper Author: BioCustoms, Location: Leeds PostPosted: Thu Feb 23, 2012 3:37 pm
    ----
Bet them coils cost a bob or two Wink

#730: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Feb 23, 2012 3:39 pm
    ----
Decided to go for U-pol Gravitex for the underseal. Fairly cheap and can be applied with a normal schutz gun. What is rust bullet? A rust cleaner?

#731: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Feb 23, 2012 3:52 pm
    ----
Goldin wrote:
Your's car is one of my favourite projects on this forum.
I am waiting for informations about differences betwen Eibach and H&R springs Wink

Won't be ordering the springs and damper for a while because there's no point in splashing out £400 for new bits that aren't going to be used. If I ordered them now I'd be eating into any warranty on the parts even without using them so I'll keep the money in my pocket for now.

#732: Re: Project sleeper Author: Brian, Location: VVT Land, Fife PostPosted: Thu Feb 23, 2012 3:52 pm
    ----
Rust bullet is a rust preventer, but heard great things about it in the world of auld peugeots! www.rustbulletuk.com/ I've seen people use a combination of that and some form of stone chip.

Epoxy mastic got some good reviews too, but was quite a faff/messy to use from what I heard?

#733: Re: Project sleeper Author: BioCustoms, Location: Leeds PostPosted: Thu Feb 23, 2012 4:07 pm
    ----
alot of hard work here >>>> spot on mate Smile

#734: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Feb 24, 2012 12:52 pm
    ----
Got my back axle dismantled today. Wasn't too difficult, just one rounded torsion bar screw which was undone with a chisel and the torsion bars were assisted with Plus Gas applied to them for a few days.

 


Took the trailing arms off to check the bearing which looked very healthy.

 


Passenger side bearing surfaces on the beam were like brand new, lightly polished but that's all.

 


The drivers side felt slightly notchy when rotating the trailing arms...there is a very slight wear marks on the tube. You can only just feel the marks with your finger. The other bearing surface is smooth, just the inner surface has marks about an inch long. There is no play in the trailing arm though.

 


 


So I have a few choices. I've got to bear in mind the car does 1,000 miles a year at most.

1) Reuse existing bearings and get everything painted with solid beam mounts and fit it all back together. Not worth expense of powder coating an axle which isn't 100% perfect.
2) As above but fit new bearing (not convinced this will achieve anything).
3) But new axle from Peugeot (£485!), new bearing and seals etc. Brand new so no cost for painting etc as it's won't need anything.
4) Get axle repaired at one of the axle specialists.

So far I'm tempted to just get it cleaned up and put back together with the existing parts. With such low mileage each year it should take an eternity to become an MOT failure...but then maybe I'll investigate repairing the worn side.

#735: Re: Project sleeper Author: Lecktorious, Location: Scotland PostPosted: Fri Feb 24, 2012 1:42 pm
    ----
I though you would want to fully rebuild the beam with new parts and paint it up, to compliment the new front springs and dampers that are being fitted?

#736: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Feb 25, 2012 3:22 am
    ----
To fit a new pin in the worn side it would cost about £200 with parts, delivery and fitting. Add to that the cost of powder coating and it will be over £250. It will never be a new axle though, the rust will still come back through the mounts in a year or so.

So for an extra £250 I can have a brand new axle with two new pins rather than just one and it won't need powder coating. If the mounts are painted before it rusts the corrosion will stay away for much longer.

My current axle isn't at the end of its life, there's no play in the bearings so for now rather than fork out for a new axle, solid mounts and bearings which will total over £600 I'm just going to give it a lick of paint and regrease the existing bearing, fit new seals, screws and reassemble it all.

#737: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Feb 27, 2012 4:20 pm
    ----
Fuel tank came off tonight. 4 nuts, undo the filler from the rear quarter panel and disconnect the pump wiring and pipes. Now the big cleanup can begin on the underside, then it can be undersealed and painted.

 


Slightly dusty but easily cleaned.

 

#738: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Mar 04, 2012 10:34 am
    ----
Spent some money on tools this weekend...Machine Mart gave me a VAT free voucher so I had to go and use it...I think I did ok for £67...

So I got a grit blaster, a schutz gun, cheap trolley jack and a spray gun kit.

 


Rear axle and trailing arms looks quite nice.

 


 


Also got this for £8 from Halfords. Good price I thought. Saves breaking more expensive bike lights when I can't be bothered plugging my big light in.

 

#739: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Wed Mar 14, 2012 10:54 pm
    ----
Hay Paul just a quick question, I don't suppose you know the length of the 180 tb do you? As I have come a cross to different lengths.

#740: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Mar 15, 2012 3:01 am
    ----
All 206 torsion bars are the same length. I think it says on Servicebox the length. Something like 1031mm springs to mind but it’s worth checking.

#741: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Thu Mar 15, 2012 3:46 am
    ----
Ok nice one Paul as I've found some 180 bars in my garage and one is longer than the outher so not sure on that or it may be an ARB??

#742: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Mar 15, 2012 1:53 pm
    ----
Yes torsion bars are about that long and anti roll bar is about 1130mm I do believe.

#743: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Mar 16, 2012 11:20 am
    ----
Cleane enough? It looks ok but as it dried is started to sag a little. So I might see how it dries, overpaint a small area and see how it looks. If it's no good I'd do the bad areas again but thinner this time.

 


 

#744: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Mar 16, 2012 1:40 pm
    ----
Looks fine with a bit of paint...

 

#745: Re: Project sleeper Author: usher, Location: northallerton PostPosted: Fri Mar 16, 2012 2:12 pm
    ----
looking good
how long has it taken you from starting to take the axel off to now couple of late nights??

#746: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Mar 18, 2012 6:59 am
    ----
It took about 3 or 4 hours to clean it up and about an 2 hours to paint it all. Fuel tank had to come off too.

All done now. Time to order a stack of clips, seals, brackets, nuts and bolts from the dealer so it can be put back together.

 

#747: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Apr 01, 2012 2:02 am
    ----
Back axle reassembled now. News seals, plenty of grease on the bearings, new torsion bar bolts and washers. New bolts for the brake pipe and handbrake brackets. The U shaped metal clips at the end of the brake pipes have also been replaced.

Spent £100 on it all. Also bought a new fuel tank strap and 4 bolts for the tank.

Just waiting for new brake pipes, anti roll bar bolts and trailing arm clips from the Peugeot dealer. Hopefully they will arrive tomorrow. Then it will be fitted back onto the car.

Rear damper nuts and bolts, ABS sensor bolts and also the 4x rear axle bolts will be replaced eventually too.

 


 


 

#748: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Apr 02, 2012 2:51 pm
    ----
and today the axle went back on the car...connected all the new brake pipes too...fitted with new anti roll bar bolts, bolts for the rear calipers and the clips on the trailing arms for the brake pipe and ABS cable.

 


 


 


 

#749: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Mon Apr 02, 2012 3:02 pm
    ----
Immaculate!!

How much did you pay for your pug sport torsion bars??

#750: Re: Project sleeper Author: 00budham00, Location: Ips PostPosted: Mon Apr 02, 2012 7:50 pm
    ----
top job there mate!

#751: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Apr 03, 2012 5:04 am
    ----
spike_202 wrote:

How much did you pay for your pug sport torsion bars??

I got them for about £220 7 years ago. They are about £400 now from Peugeot Sport!

#752: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Apr 06, 2012 12:26 pm
    ----
Almost finshed, fuel tank back on with new strap, brakes all plumbed in, exhaust fitted with some new Jetex clamps, bumper fitted etc. Just needs discs fitting with backplates then the suspension height can be set.

 

#753: Re: Project sleeper Author: craigdmjv, Location: Wiltshire PostPosted: Fri Apr 06, 2012 6:40 pm
    ----
is this car always going to be this clean will be worth a mint in about 20 years

#754: Re: Project sleeper Author: 00budham00, Location: Ips PostPosted: Sat Apr 07, 2012 11:08 am
    ----
learnt alot from this thread interesting read Very Happy

#755: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Apr 08, 2012 12:12 pm
    ----
craigdmjv wrote:
is this car always going to be this clean will be worth a mint in about 20 years

I'm hoping it will still be around in 20 years time. Can't imagine it being worth much though. Even mint 205's don't demand big money.

00budham00 wrote:
learnt alot from this thread interesting read Very Happy

Hope you've learned something useful.

#756: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Apr 08, 2012 3:24 pm
    ----
Were did you get your engine bay tidy kit fron Paul? As the last one I got didn't come with any 'T' bits and elbows witch I could do with.

Thanks rich

#757: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Apr 09, 2012 12:52 am
    ----
I ordered all the convoluted tubing from PoleVolt. The T pieces are in the cable management section.

#758: Re: Project sleeper Author: Andy_, Location: Isle of Man PostPosted: Mon Apr 09, 2012 2:59 am
    ----
Read through this whole thread, fair play to you for all the work your putting in Smile

#759: Re: Project sleeper Author: gti_elston, Location: Nottz PostPosted: Sat Apr 14, 2012 6:02 pm
    ----
nice work mate Smile

#760: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Apr 18, 2012 2:31 pm
    ----
Ordered a pair of front Bilstein B8 Sprint dampers and H&R springs yeserday. Springs give a 30-35mm drop, the dampers are shorter than my previous ones so hopefully they will give a bit more suspension travel. When the Billies hit the bump stops inside they were very harsh so these should be better.

£380 from Motorsportworld...Hopefully they will arrive by this weekend. Then for the first time in 4 months the car can sit on it's own 4 tyres.

#761: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Apr 23, 2012 11:04 am
    ----
New bits arrived today...too nice to bolt it all together and I'll be coating everything in some wheelwax to helo prevent corrosion.

 


 


 


And a bit of a comparison between old and new.

 


 

#762: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Tue Apr 24, 2012 1:06 pm
    ----
can wait for the update paul, how the b8s do over the b6s

#763: Re: Project sleeper Author: Lecktorious, Location: Scotland PostPosted: Tue Apr 24, 2012 1:26 pm
    ----
Did you get the dust covers with the dampers? I never got any with mine Sad

#764: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Apr 24, 2012 2:35 pm
    ----
The blue covers? Yes they came with them.

Back together now...forgot the big washers at the top of the damper under the top mount...so it's all coming apart again.

 


 


 

#765: Re: Project sleeper Author: usher, Location: northallerton PostPosted: Tue Apr 24, 2012 2:42 pm
    ----
think your car would be cleaner then one that had just rolled out of the factory

looking good so far how long untill you get to drive it or have you more plans

#766: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Apr 25, 2012 1:27 am
    ----
Not sure...might not even tax it this year. Will see. Earliest it will see the road is in June, maybe July.

#767: Re: Project sleeper Author: Andrew, Location: Black Country Ay I PostPosted: Wed Apr 25, 2012 2:22 am
    ----
When you get it back on the ground could you take a picture of how the front sits please? Im looking at getting a suspension kit with a bigger budget next

A shame you won't be taking on the road till the summer to test it out, but in this weather I don't blame you

#768: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Apr 25, 2012 5:58 am
    ----
It should be back on its wheels this weekend. So will take a picture then.

#769: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Apr 29, 2012 4:12 am
    ----
All finsihed now. Might be my imagination but I think these H&R springs are very slightly firmer than the Eibachs. Sits at a very similar height to the Eibach Pro Kit springs.

Did quite well setting the rear suspension height. Got it right first time with just guessing the right height to set the arms at!

 


 

#770: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Apr 29, 2012 4:47 am
    ----
Looks spot on Paul.. But the exaust looks like it falling off?

#771: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Apr 29, 2012 7:13 am
    ----
Sits perfectly in the flesh.

#772: Re: Project sleeper Author: Richie_206, Location: southampton PostPosted: Sun Apr 29, 2012 12:12 pm
    ----
I really regret selling my nimrods. Simple yet classy!

#773: Re: Project sleeper Author: Andrew, Location: Black Country Ay I PostPosted: Fri May 04, 2012 1:40 pm
    ----
Looks spot on Paul, might get these springs when I get new top mounts, Apex springs are too harsh considering its a mild drop

Are you going to enjoy it now? Razz

#774: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon May 07, 2012 3:14 am
    ----
Took it out for a short run the other day, brakes are fine now too...without the airbox at 6k rpm it sounds much different to having the airbox fitted. There is a note change almost like VTEC engines give, obviously a different sound to VTEC engines but the same effect.
So I really want to drive it when it's 100% perfect...it's complete as it is but I think it could be better. So that means a Saxo/106 PAS pump, short radiator, longer trumpets, ITG sausage filter and proper Jenvey linkage...
So a few hundred quid to be spent yet.

#775: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Mon May 07, 2012 5:32 am
    ----
Lol I'll have feedback on that set up next month Paul as that's what's going in mine apart from Ive got the Jenvey deep back plate and the piperX Megga flow filter.

#776: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon May 07, 2012 7:02 am
    ----
So you going for a shorter radiator then?

#777: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Mon May 07, 2012 8:25 am
    ----
yes a custom alu one. macj's Toyota corolla one works well, but i would like the rad to be longer but even shorter as it will sit nicer behind my front grill.
as the standard rad cowling is being removed ill be interested on how your keeping your bonnet catch as i'm having flush fitting (lockable) bonnet pins as i'm removing the top end to maximise the air flow to the inlet.

#778: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon May 07, 2012 10:25 am
    ----
Keep the fan housing as it is. Keep the fan too.

The top radiator hose needs to be rotated 180 degrees so instead of bending upwards it bends downwards. This can be the top level of the new radiator. This will also be low enough to clear the bottom of any airfilter and trumpets you may have.

With no air conditioning fitted there is space to make the new radiator wider. There is a PAS cooler pipe down low but the radiator can be spaced a few mm higher that the old one to clear the pipe. Or move to a Saxo/PAS pump and the cooler pipe can go in the bin.

You can get the new radiator made with the same pegs at the bottom to fit the original mounts on the car.

That just leaves the top of the radiator to be supported. An aluminium bar can can made to fit across the fan housing and can use the standard top brackets to hold the radiator.

For more cooling the fan housing can be cut above the resistor hole to allow more airflow. Don't forget custom radiators are thicker than standard so the shorter height than standard shouldn't be an issue.

Doing it this way will mean no long non standard hoses are needed. There isn't much room behind the radiator for these with the oil filter and clutch release plumbing being in there.

#779: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Mon May 07, 2012 12:30 pm
    ----
i take it you want it as standard as possible?
as the air con rad is out the way my new alu rad is taking its place so it will sort of look like an intercooler.
also ive requested my in-let and out-let to be on the passengers side so all the piping will go to the massive empty space i have next to my oil catch tank.
also the header tank pipe will remain as it is, just a little longer as the feed is as it is on the standard rad.
and i see what your going to do but its still in the way for my liking so its all coming off lol
 

#780: Re: Project sleeper Author: macj, Location: Essex PostPosted: Mon May 07, 2012 12:48 pm
    ----
I have just replaced my toyota corolla radiator after a crash in last rally. This time it is still toyota but from an auto. I am doing away with the metal PS cooling pipe and using the pipe fittings in the bottom of the radiator for the gearbox cooling. I have a problem with the PS fluid boiling in stage.... hoping this will cure it.
I am going to try a different radiator next crash.... now you see why I dont buy an expensive custom one......yet Laughing

#781: Re: Project sleeper Author: simpsonrc, Location: coventry PostPosted: Mon May 07, 2012 2:46 pm
    ----
[img]
 
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#782: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon May 07, 2012 2:57 pm
    ----
spike_202 wrote:
i take it you want it as standard as possible?
as the air con rad is out the way my new alu rad is taking its place so it will sort of look like an intercooler.
also ive requested my in-let and out-let to be on the passengers side so all the piping will go to the massive empty space i have next to my oil catch tank.
also the header tank pipe will remain as it is, just a little longer as the feed is as it is on the standard rad.
and i see what your going to do but its still in the way for my liking so its all coming off lol

I just want mine to work with no potentially unreliable joins in hoses. The shorter route from engine to radiator the better too so the standard hoses do that best.

Trust me, take off the fan housing and the bonnet catch etc but the nose of the bonnet will still be in front of the inlets. With the airflow through the top of the existing cooling fan opening and cutting additional holes on the opposite side of the fan there will be no lack of cool air getting in.

Yours will be very similar to mine except your inlet and outlet will be at the end. Mine will be on top and bottom which reduces the cooling area of the radiator but with it's extra area of the right hand side and extra depth it will be fine.

Removing the fan housing also means you need a new fan which adds expense...if it's on the back of the radiator space is tight. I'd also use the original radiator mounts if possible because it keep it further back ever so slightly...think of the weight distribution!!!

macj wrote:

I am going to try a different radiator next crash.... now you see why I dont buy an expensive custom one......yet Laughing

I did think for you it makes sense to keep the radiator from a production car. Bit expensive if you are ruining £400 radiators regularly.

#783: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Mon May 07, 2012 3:10 pm
    ----
I may still use a 205 gti rad as this is the shortest I have come a cross that will fit straight in but the pipes are on the opposite sides I have no problem with the pipe work I just want something that will work and fit nicely behind the grill.
The company I'm in leazon with atm are on about custom wielding a golf rad as thats the one with the 2pipes on the passengers side. I'm open to all options Edward as this is the only thing I need to source as every thin else is on order.

#784: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon May 07, 2012 3:12 pm
    ----
Have you had a price from Radtec or Allisport?

#785: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Mon May 07, 2012 3:20 pm
    ----
I emailed radteck twice last month and had no reply I wanted a midlands based company so if any warrantee issues did arise I could sort it if need be I'll try Allisport

When I told Matt what I wanted to do he said accustom rad would be around £400 can we get them any cheaper?

#786: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue May 08, 2012 1:00 am
    ----
If you look at the Ebay Radtec stuff the prices vary a lot...what looks like a very simple radiator is lots of money where more complex ones can be cheaper...who knows. The Ractec 205 radiator is about £400 anyway.

#787: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Tue May 08, 2012 1:45 am
    ----
But the one that all the 205 owners use off another manufacture is nealy half that and comes with a fan. Radtec are local saying that looked at there location and it's in cannock that's only 15min drive away. I'm just waiting on emails back atm as I would like one this month as the cars goibg in on the 6 June lol

Found an ideal standard rad apart from the header tank feed is on the top left instead of the top right would it make any differnce having a longer tube to the header tank?

#788: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri May 18, 2012 10:52 am
    ----
A little bit more attention to detail...decided to take the PAS pump and alternator bracket off the car and spray it. It was quite shiny in places but I wanted it nicer...just a shame you can't see it...also got a new pulley as the bolt was rusty.

Looks a lot better in the flesh.

 


 

#789: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Mon Jun 25, 2012 4:44 pm
    ----
Hay Paul did you ever take off the heat shield under the exhaust tunnel? As I want to remove it so I can fit 2 harness eye bolts either side for the lap belts. Just need to take it off do some drilling then fit it all back.

#790: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Jun 26, 2012 5:41 am
    ----
Yes my heat shields have been off. Just undo the 10mm nuts holding it in place. I'd get some new nuts though.

#791: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Tue Jun 26, 2012 6:56 am
    ----
I don't supose you have any pics do you Paul?? As I've never looked under that part of the car so don't know what to look for, and does the exhaust actually need to be taken off to move it out the way?? Or can it be slid out?

#792: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Jun 26, 2012 10:23 am
    ----
 

#793: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Tue Jun 26, 2012 11:15 am
    ----
Superb, nice one Paul, just the 4 10mm nuts holding it on then.

#794: Re: Project sleeper Author: LeeThr, Location: North West Wales PostPosted: Mon Jul 02, 2012 5:51 pm
    ----
Edward wrote:
Took it out for a short run the other day, brakes are fine now too...without the airbox at 6k rpm it sounds much different to having the airbox fitted. There is a note change almost like VTEC engines give, obviously a different sound to VTEC engines but the same effect.
So I really want to drive it when it's 100% perfect...it's complete as it is but I think it could be better. So that means a Saxo/106 PAS pump, short radiator, longer trumpets, ITG sausage filter and proper Jenvey linkage...
So a few hundred quid to be spent yet.

How come you want to change to a 106/saxo PAS pump? Whats the difference?

#795: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Tue Jul 03, 2012 3:10 pm
    ----
Did you ever get yours back on the rollers Paul as I know you were unsure of the authenticity of your print out.
I'm having mine redone on Monday would be interesting to compare the difference as we have pritty much the same set up bar you have 42z and I have 45z

#796: Re: Project sleeper Author: Seabook PostPosted: Tue Jul 03, 2012 3:20 pm
    ----
LeeThr wrote:
Edward wrote:
Took it out for a short run the other day, brakes are fine now too...without the airbox at 6k rpm it sounds much different to having the airbox fitted. There is a note change almost like VTEC engines give, obviously a different sound to VTEC engines but the same effect.
So I really want to drive it when it's 100% perfect...it's complete as it is but I think it could be better. So that means a Saxo/106 PAS pump, short radiator, longer trumpets, ITG sausage filter and proper Jenvey linkage...
So a few hundred quid to be spent yet.

How come you want to change to a 106/saxo PAS pump? Whats the difference?

those are electric pump, compare to 206 pump which is driving by belt(engine).

that should in theory free up some power

#797: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Tue Jul 03, 2012 3:22 pm
    ----
And it feels better IMO it also allows you to mount a filter with a back plate Wink

#798: Re: Project sleeper Author: LeeThr, Location: North West Wales PostPosted: Tue Jul 03, 2012 3:31 pm
    ----
Seabook wrote:
LeeThr wrote:
Edward wrote:
Took it out for a short run the other day, brakes are fine now too...without the airbox at 6k rpm it sounds much different to having the airbox fitted. There is a note change almost like VTEC engines give, obviously a different sound to VTEC engines but the same effect.
So I really want to drive it when it's 100% perfect...it's complete as it is but I think it could be better. So that means a Saxo/106 PAS pump, short radiator, longer trumpets, ITG sausage filter and proper Jenvey linkage...
So a few hundred quid to be spent yet.

How come you want to change to a 106/saxo PAS pump? Whats the difference?

those are electric pump, compare to 206 pump which is driving by belt(engine).

that should in theory free up some power

Are they? I always thought with the fluid reservoir being in a similar position to the 206 they were belt driven.

#799: Re: Project sleeper Author: MrBSI, Location: What's it to you? ? ? PostPosted: Tue Jul 03, 2012 4:09 pm
    ----
The FAPTASTIC 206 also uses an electric power steering pump Wink

Is in the front left hand corner of the engine bay.

#800: Re: Project sleeper Author: MrBSI, Location: What's it to you? ? ? PostPosted: Tue Jul 03, 2012 4:10 pm
    ----
LeeThr wrote:

Are they? I always thought with the fluid reservoir being in a similar position to the 206 they were belt driven.

106 & Saxo are an electric power steering pump unit, there's 2 different types & they both go wrong a lot Laughing

There also very easily damaged in a front on accident.

#801: Re: Project sleeper Author: LeeThr, Location: North West Wales PostPosted: Tue Jul 03, 2012 4:30 pm
    ----
MrBSI wrote:
LeeThr wrote:

Are they? I always thought with the fluid reservoir being in a similar position to the 206 they were belt driven.

106 & Saxo are an electric power steering pump unit, there's 2 different types & they both go wrong a lot Laughing

There also very easily damaged in a front on accident.

How do they electric ones work? Is it basically the same as belt driven but just an electric motor turning the pump instead of the belt?

Also anything on a 106/saxo is easily damaged in a front on accident.

#802: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Tue Jul 03, 2012 4:55 pm
    ----
Yes Lee instead of a belt it's electric have a look at mine Wink

#803: Re: Project sleeper Author: Seabook PostPosted: Tue Jul 03, 2012 5:05 pm
    ----
LeeThr wrote:
MrBSI wrote:
LeeThr wrote:

Are they? I always thought with the fluid reservoir being in a similar position to the 206 they were belt driven.

106 & Saxo are an electric power steering pump unit, there's 2 different types & they both go wrong a lot Laughing

There also very easily damaged in a front on accident.

How do they electric ones work? Is it basically the same as belt driven but just an electric motor turning the pump instead of the belt?

Also anything on a 106/saxo is easily damaged in a front on accident.

what he said is the 106 pump is not reliable. and expensive to fix too.

compare to the belt driven one in 206 which is nearly trouble free

#804: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Tue Jul 03, 2012 5:14 pm
    ----
Are they? No one I know with a 106 has ever had any trouble with the elec pas pump that's why I opted for it over any other. Also the hole units are only around £60-£70.
If it ever did nakker up just change the unit.Job done. It's just the mounting that's a ballake, as it requires some custom fabrication I have my pump on an original mount/bracket with rubber mounts so it doesn't shake/vibrate thru to the chassis.

#805: Re: Project sleeper Author: LeeThr, Location: North West Wales PostPosted: Tue Jul 03, 2012 5:23 pm
    ----
Seabook wrote:
LeeThr wrote:
MrBSI wrote:
LeeThr wrote:

Are they? I always thought with the fluid reservoir being in a similar position to the 206 they were belt driven.

106 & Saxo are an electric power steering pump unit, there's 2 different types & they both go wrong a lot Laughing

There also very easily damaged in a front on accident.

How do they electric ones work? Is it basically the same as belt driven but just an electric motor turning the pump instead of the belt?

Also anything on a 106/saxo is easily damaged in a front on accident.

what he said is the 106 pump is not reliable. and expensive to fix too.

compare to the belt driven one in 206 which is nearly trouble free

I know he said they were unreliable but my post was referring to the sentence after that bit Wink

#806: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Jul 08, 2012 10:46 am
    ----
spike_202 wrote:
Did you ever get yours back on the rollers Paul as I know you were unsure of the authenticity of your print out.
I'm having mine redone on Monday would be interesting to compare the difference as we have pritty much the same set up bar you have 42z and I have 45z

Naah, not been on any rollers yet. If it look at the print outs from Ecosse they just dont make sense. A standard engine running just a K&N panel filter, Longman head and the Maniflow manifold and system makes 160bhp? I just dont believe it.

Even now it's quite fast at 7k rpm but 214bhp? It's quick but doesnt feel that quick.

The lines on the graph also dont cross at 5252rpm...
I think the main different in mine is the exhaust. Roll on the winter when I get the inlet and radiator sorted. I'm simply going to ask Radtec to make a copy of the standard radiator 4 inches wider and 6" shorter. Same mounting points and inlet and outlet etc.

#807: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Jul 08, 2012 10:48 am
    ----
spike_202 wrote:
It's just the mounting that's a ballake, as it requires some custom fabrication I have my pump on an original mount/bracket with rubber mounts so it doesn't shake/vibrate thru to the chassis.

I'm going to get a mount built so it attaches to the battery/engine mount...nice and strong and means the chassis rail doesnt need drilling etc. Standard airbox will be gone so there will be room for the pump.

#808: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Jul 08, 2012 3:15 pm
    ----
Matt said if I want over 210 I need to go froged internals but I'd like to keep it on hydraulic lifters also but I'll look into all that at a later stage as that's the next step that's bing done.

Yep thers loads of space once the air box is gone.

#809: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Jul 09, 2012 5:23 am
    ----
I think a GTi 180 bottom end would be a useful budget alternative to forged bits. Can handle over 7k rpm as standard and has oil jets cooling the pistons too. I'd just try to avoid the later cranks with no keyed crank pulley.

Might need some machining to sort the compression ratio but might be worth a look.

#810: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Tue Jul 31, 2012 4:54 pm
    ----
hay paul question abou your exhaust rubbers,
are they stiff/solid? as i had got hold of a red ex005 i think it is? and it seems very flex and its making the back box hit my bumper now, just wandering if yours are any better?

#811: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Aug 01, 2012 5:44 am
    ----
Mine are fine. Quite stiff. Cant make them flex much by hand.

#812: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Wed Aug 01, 2012 2:08 pm
    ----
Iter the ones I have are like a Dimond shape and they arnt joins in the middle so alows side ways movement, going to stick it in the middle section and orderd 2 box shape ones like you have as they look like they are joins in the middle and more stiff.

#813: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Aug 04, 2012 6:46 am
    ----
Took a video. The camera doesnt pick up the real sound of the bodies. They sound so much nicer than the video suggests. Love to hear what it sounds like on the outside.

youtu.be/uysMC4nnbv4

youtu.be/Cn5on0ExmO4

Last edited by Edward on Sat Aug 04, 2012 8:55 am; edited 1 time in total

#814: Re: Project sleeper Author: Schumi, Location: Istanbul / Turkey PostPosted: Sat Aug 04, 2012 8:37 am
    ----
Is this your car Edward ?

#815: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Aug 04, 2012 8:55 am
    ----
Yes.

#816: Re: Project sleeper Author: Barking, Location: sarcasm-in-shedloads PostPosted: Sat Aug 04, 2012 9:04 am
    ----
Fade to Grey <3 the song - that (non-original) video is pants though

206 GTi sounds good too Smile

#817: Re: Project sleeper Author: Schumi, Location: Istanbul / Turkey PostPosted: Sun Aug 05, 2012 9:43 am
    ----
Is this full throttle video ? It's look not to fast. Sorry. Sad

#818: Re: Project sleeper Author: Skittle, Location: North England PostPosted: Sun Aug 05, 2012 10:45 am
    ----
Been reading this over a few days. What a lovely and well kept car. Wish mine was like this.

#819: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Aug 05, 2012 10:55 am
    ----
It's full throttle from about 4.5k onwards. Thats the problem. The increased power output is now at a higher speed. So whereas before I might have had 140bhp at 6500rpm, I now have about 150bhp so I'm only 10bhp up on before at that point.
I dont have the same torque at 4k rpm either. I think it has less.

Any power increase is also at higher road speed which dampens the effect. i.e. the alleged 214bhp at 70mph in 2nd isn't going to work as well as if it was available at 55mph.

Overall it is faster but not by a massive margin.

So it needs the longer trumpets to increase the torque (apparently inlet length can have a dramatic impact on power delivery) and a shorter final drive to make the power available at lower speeds. This also brings the ratios closer together.

#820: Re: Project sleeper Author: Schumi, Location: Istanbul / Turkey PostPosted: Mon Aug 06, 2012 4:15 pm
    ----
Longer trumpets defiantly what you need but longer trumpets also move your power graph to higher revs. I'm still thinking your fuel and ignition map so far from perfect. Do you have any log on WOT. I know you dont have wideband AFR but narrowband afr still give an idea with ignition advance.

#821: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Aug 07, 2012 10:55 am
    ----
Longer trumpets are for lower revving engines, they dont push the power band higher. For the same reason the higher the revs the shorter the inlet needs to be.

#822: Re: Project sleeper Author: Schumi, Location: Istanbul / Turkey PostPosted: Tue Aug 07, 2012 12:20 pm
    ----
There a balance between ITB system total lenght with engine RPM. If your system length shorter than your engines max RPM's required length. Then longer trumpets give you more torque and your torque graph goes higher. But If you overlength your system with to long trumpets then you need more revs. There is an expert in our country on ford race engines and he write a very long article about ITB lengths. If I find again on magazine i will translate as I can and write here. And there a little quote from Jenvey.

Quote::
Induction length is one of the most important aspects of fuelling performance engines.
In our experience an under-length system is the greatest cause of disapointment, with loss of up to 1/3 of power potential. There are a number of good books on the subject and the serious developer is referred to these and, in particular, dyno trials. A guide figure, from the face of the trumpet to the centre of the valve head is 350mm for a 9,000 RPM engine. Other RPM are proportional i.e. for 18,000 RPM the figure is approximately 175mm.

#823: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Aug 07, 2012 1:31 pm
    ----
With 90mm trumpets (longest alloy ones available) my induction would be about 370mm. Looking at the Jenvey guidelines it needs to be about 430mm long.
I doubt anything longer would fit under the bonnet especially as the filter needs to be about 25mm from the entry to the inlet.

#824: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Tue Aug 07, 2012 1:34 pm
    ----
I'm sure I've seen 120mm alloy trumpets before.

#825: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Aug 07, 2012 2:00 pm
    ----
Yes on 45mm bodies but there must be a limit to how long they can be to fit under the bonnet. They do 100mm carbon trumpets but they cost twice as much.
I wonder if 45mm trumpets can fit 42mm bodies...a little bit of grinder action on the entry to the throttle body...only 1.5mm each side...cant be too hard...

#826: Re: Project sleeper Author: Seabook PostPosted: Tue Aug 07, 2012 2:45 pm
    ----
Edward wrote:
Any power increase is also at higher road speed which dampens the effect. i.e. the alleged 214bhp at 70mph in 2nd isn't going to work as well as if it was available at 55mph.

get a bigger crown wheel Razz

#827: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Aug 07, 2012 3:29 pm
    ----
Yep. 4.79 ratio from a 407 is about £110. But will it fit?

#828: Re: Project sleeper Author: Seabook PostPosted: Wed Aug 08, 2012 5:43 am
    ----
Edward wrote:
Yep. 4.79 ratio from a 407 is about £110. But will it fit?

as long as it is off from a BE4/5 gear box i can't see the reason why not?

i got mine (4.93) off a diesel van and it fit fine.

only thing is if you want to use the crown wheel off a BE3/5 gearbox you will have to use their gearset too as the spacing on the shaft is slightly different compare to BE4/5 box.

#829: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Wed Aug 08, 2012 6:02 pm
    ----
Edward wrote:
Yes on 45mm bodies but there must be a limit to how long they can be to fit under the bonnet. They do 100mm carbon trumpets but they cost twice as much.
I wonder if 45mm trumpets can fit 42mm bodies...a little bit of grinder action on the entry to the throttle body...only 1.5mm each side...cant be too hard...

Or maybe get the body's taperd but it may effect the inlet angles ect I'm sure if you contact with a local engineering place they could make some for you, yer with the 25mm minimum gap between the filter and the trumpet end its not to close, I could go bigger if I got rid of the grill but then bonnet stops you going much further than 100mm ish But I'm not sure thers much more positive gain as you will start to loose quite a bit of peak bhp for more torque.

#830: Re: Project sleeper Author: Andrew, Location: Black Country Ay I PostPosted: Mon Sep 10, 2012 4:39 pm
    ----
What is your review of the Bilstein B8 dampers? thank you

#831: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Sep 15, 2012 1:32 pm
    ----
Well it got MOT'd and i've taken the tax off the car for the winter. So now the work can begin...

A new shorter alternator belt has been fitted and that means the belt driven PAS pump can be removed. I always intended to replace that rusty looking pulley. I've noticed any engine related bolts on these engines seem to be quite expensive and often come in minimum order quantities.

 


Also removed the front bumper and the airbox feed into the inner wing because it will never be needed again.

 

#832: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sat Sep 15, 2012 5:24 pm
    ----
Sweet Paul mine bin running for quite a while now seems the best way To go 2bh. Good gains all round.

#833: Re: Project sleeper Author: Bigbenj_08, Location: Cardiff PostPosted: Sat Sep 15, 2012 5:51 pm
    ----
Brilliant read this, car is stunning!

Love the below pic, you'd never think it was from a 2001 206! Plus its helped me understand exactly where and what the torsion bars are Laughing

Edward wrote:

 


Last edited by Bigbenj_08 on Sun Sep 16, 2012 5:57 am; edited 2 times in total

#834: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Sep 16, 2012 4:02 am
    ----
spike_202 wrote:
Sweet Paul mine bin running for quite a while now seems the best way To go 2bh. Good gains all round.

I've been reading all about experience of fitting longer inlet trumpets. Quite interesting.

www.emeraldm3d.com/art...th-intake/

I've also come up with a plan for my radiator. I'm going to cut all the lower part of the radiator fan housing off, just leaving the top 4 inches where it bolts to the car and where the bonnet catch is.
The new radiator can then sit in the mounts that the bottom of the fan housing used to sit in on the cross member. The radiator can stretch right across to the horn and up to the remains of the fan housing. I'll get a fan fitted to the front of the new radiator.

#835: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Mon Sep 17, 2012 4:22 am
    ----
Cool, I got a fan fitted to the back of mine as it gives a cleaner look and there is plenty of room in the bay once you move it all forward.

#836: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Sep 17, 2012 12:31 pm
    ----
£139.20 for 4 x 42mm x 90mm air horns on order today....would have prefered the 42mm x 100mm carbon air horns but at twice the price it's hard to justify.
If I'm ever desperate for 10mm extra on the inlet, Jenvey sell spacers which of course aren't cheap either!

#837: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Sep 18, 2012 1:58 pm
    ----
Got my delivery today already! Ordered at lunchtime and it was delivered by mid afternoon the next day!

Might as well remove the fan housing and see how it all fits together. Next purchase is the ITG sausage filter and backplate.

 


 


 

#838: Re: Project sleeper Author: Lex206, Location: Holland PostPosted: Tue Sep 18, 2012 5:52 pm
    ----
that looks so good.
im seriously thinking about getting that set up next year

#839: Re: Project sleeper Author: Lex206, Location: Holland PostPosted: Wed Sep 19, 2012 7:16 am
    ----
you think you can get up to 175hp with a stock gti engine with TB's depending on the size and length?
what made you choose for 42mm and not 45mm?

#840: Re: Project sleeper Author: Seabook PostPosted: Wed Sep 19, 2012 7:26 am
    ----
Lex206 wrote:
you think you can get up to 175hp with a stock gti engine with TB's depending on the size and length?
what made you choose for 42mm and not 45mm?

you will hit at least 190-200 with good mapping.

#841: Re: Project sleeper Author: Lex206, Location: Holland PostPosted: Wed Sep 19, 2012 8:10 am
    ----
that sounds more like it Smile
i still have to look into all this,id like to get the tb set up but just use standard cams and everything else.
see what parts i need and maybe find some 2nd hand or ..still will cost a fortune but im sure it will be worth it in the end.

#842: Re: Project sleeper Author: usher, Location: northallerton PostPosted: Wed Sep 19, 2012 11:19 am
    ----
macj used standard cams and got good gains from the tbs

you can get bike car manifolds made up on ebay for 170 i think

#843: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Sep 19, 2012 12:27 pm
    ----
Lex206 wrote:
you think you can get up to 175hp with a stock gti engine with TB's depending on the size and length?
what made you choose for 42mm and not 45mm?

Shouldnt be far from 175bhp with bodies. A decent exhaust would help.

The manifold is 42mm and most people go too big on bodies so 42mm made sense. According to the Jenvey website 42mm is enough for 224bhp. Plenty enough for me.

Ultimately I would like to change to proper ITBs rather than these twin bodies. Then I'd be able to use the straighter inlet manifold as I'll be removing the PAS pump.

#844: Re: Project sleeper Author: Seabook PostPosted: Wed Sep 19, 2012 12:38 pm
    ----
usher wrote:
macj used standard cams and got good gains from the tbs

you can get bike car manifolds made up on ebay for 170 i think

bike body is way too short Confused

#845: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Sep 19, 2012 2:07 pm
    ----
Quite right. Really high revs can live with short inlet tract. Cars don't rev that high though hence the need for fitting longer bodies for my car.

#846: Re: Project sleeper Author: Seabook PostPosted: Thu Sep 20, 2012 7:44 am
    ----
Edward wrote:
Lex206 wrote:
you think you can get up to 175hp with a stock gti engine with TB's depending on the size and length?
what made you choose for 42mm and not 45mm?

Shouldnt be far from 175bhp with bodies. A decent exhaust would help.

The manifold is 42mm and most people go too big on bodies so 42mm made sense. According to the Jenvey website 42mm is enough for 224bhp. Plenty enough for me.

Ultimately I would like to change to proper ITBs rather than these twin bodies. Then I'd be able to use the straighter inlet manifold as I'll be removing the PAS pump.

what's the differences between proper ITB and twin bodies???

#847: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Sep 20, 2012 1:02 pm
    ----
Twin bodies are like DCOE carbs. They are a fix distance apart and each body has two inlets. They might not necessary match the port spacing of the cylinder head.

True ITBs are just that...independent of each other. These can be fitted to a manifold so the run into the ports on the head is arrow straight.

Paired bodies

 


True ITBs

 

#848: Re: Project sleeper Author: Seabook PostPosted: Thu Sep 20, 2012 1:15 pm
    ----
so is that in theory if both are port matched it should give the same performance?

#849: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Fri Sep 21, 2012 9:01 am
    ----
I'm Intrested to see how your fan mod turns out have started yet? Nice choice on the filter Are you going for a megga deep filter or a deep back plate/box like mine?

#850: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Sep 21, 2012 11:32 am
    ----
Looked at the filters with the carbon box but the box alone is about £90. Even with the deep 125mm (internal height) the filter and backplate are about £130.

Stripped it down a bit more today. I might end up moving the horn elsewhere to make more space for the radiator. Also thinking about running a hose across the bottom of the engine bay so the radiator inlet and outlet can be at opposite ends. The radiator will sit further forward than standard meaning there's more room for a hose at the back.

 


 


 

#851: Re: Project sleeper Author: macj, Location: Essex PostPosted: Fri Sep 21, 2012 11:45 am
    ----
A man of your skills will cut that lower Xmember off and lower it a shade.... the bumper will still cover it.... then you just need to modify the top mount.
You are at the stage where I was a year ago and ended up chopping it to bits and making my own with the toyota radiator.
Nice to see you still modding though

#852: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Sep 21, 2012 11:51 am
    ----
That cross member is staying where it is. That's proving the lower mount for the new radiator. You can see the rubber bushes that will hold the bottom of the radiator.
When I get the air filter that will show me what to cut off the original fan housing. I'll only be keeping the top 3" or 4" of it. That might give me something to hold the top of the radiator and also means I can use the standard bonnet latch.

I'm also hoping the standard PAS steering hose (the metal bit) will screw into a Saxo/106 PAS pump. They look quite similar. I can re-use the metal pipe and get a hose connected to it.

#853: Re: Project sleeper Author: macj, Location: Essex PostPosted: Fri Sep 21, 2012 11:55 am
    ----
the metal hose fits fine. I am interested to see how the "feel" is with the electric

#854: Re: Project sleeper Author: macj, Location: Essex PostPosted: Fri Sep 21, 2012 11:57 am
    ----
I have made up rubber hydraulic pipes on the rally car but it boils the oil too easily. I now have an oil cooler in the return line

#855: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Fri Sep 21, 2012 1:50 pm
    ----
Yer my carbon box was around that 2bh mate, the Jenvey filter I have is made by pipercross any ways as it's stamped on the inside lol.
 

I can see what you are doing now regarding the top part of the rad cowling I'm just using the upper grill to channel cold air direct into the inlet
Yer the metal bit fits fine as they used it on mine Paul see pic as for the conversion IMO I think that the feel is more positive and a better feel I also think it seems a bit lighter than the standard belt system.
 

#856: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Sep 21, 2012 3:14 pm
    ----
Just looked at my top hose that goes to the radiator as standard it bends upwards and I was just going to turn it 180 degrees to bend downwards. However if I just get a straight length of hose from thermostat it will fit perfectly with the height of my new radiator. Nice and simple.

#857: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Sep 23, 2012 9:03 am
    ----
That's what they did with mine. You don't want your rad to low or it will be lOwer than your bumper

#858: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Sep 24, 2012 3:30 pm
    ----
Bit more spending today. Decided I didn't like the play in the belt tensioner bearing. So I bought a new tensioner...of course it will be fitted with some new bolts too!

 

#859: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Sep 29, 2012 10:08 am
    ----
Decided to made a cardboard radiator today. It's not too good at holding water though. As soon as I know how deep Radtecs dual core radiators are I'm going to make a dummy out of hardboard or thin plywood.

Then I'll get all the measurements exactly as the final version will be and will probably trim the old rad housing a bit more. Once I have my wooden radiator it can then be fitted with all mounts in place to make sure it doesnt foul anything. I think I'll be able to re-use the original upper radiator mounts and hoses too.

I also need my new air filter before I trim any more off the remains of the slam panel. I just hope it's strong enough once it's trimmed.

Should be enough room at the front for one or two fans.

 


 


 

#860: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Oct 05, 2012 8:28 am
    ----
Order my ITG Sausage filter and backplate from MotorsportWorld yesterday...another £144. Will take about a week to make it. The 125mm internal depth filters are made to order.

A few little tweeks today...well I put some of it back together...all in the name of attention to detail.

New bolts for the tensioner.

 


New bolts for the sump...

 


Old bolts...

 


New bolts...

 


All fitted back together...

 

#861: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Fri Oct 05, 2012 2:58 pm
    ----
What flow rate filter did you order? Road or competition use?

#862: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Oct 05, 2012 4:36 pm
    ----
I ordered a Megaflow filter which is capable of flowing about 3 times as much air as my engine will consume.

What you think about this??? Use the original air conditioning pump mounts on the engine block and sump to fit the Saxo/106 steering pump to....will need a mount fabricating but it's solid and keeps the weight nice and low.
Hoses will be nice and short and also means no drillling of bodywork.

#863: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sat Oct 06, 2012 2:53 am
    ----
It's up to you were you fit it Paul, fitted mine in the same place the 106 has Thers fitted so it was a direct fit using the rubber mounted bracket that comes with it. Also it's accessible if you need to change/top up the pas fluid it's only like 3holes you have to drill iirc But be different and do it your way Wink

#864: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Oct 06, 2012 4:03 am
    ----
It might not even fit under the alternator and oil filter but I shall see. Not sure how it would like the vibration from the engine either. Some rubber in the mounts would be useful. I'll see if it fits when I buy one. I just don't like drilling bodywork!

I'd like to see how the electric pump fits on the 206 1.6 HDi.

#865: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Oct 10, 2012 3:57 pm
    ----
Filter has arrive today. Cut the back plate to fit. Just needs a Dremel to cut away the burrs from drilling it.

Next step is the Saxo PAS pump and then I'll know what space the radiator car fill.

 


 

#866: Re: Project sleeper Author: Addaz, Location: Suffolk PostPosted: Wed Oct 10, 2012 4:18 pm
    ----
Still great progress mate, one day you never know she might be complete Wink

Good to see the attention to detail is still there, but on the subject of power steering pumps, i only did my conversion because i felt the original looked quite ugly.....

#867: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Oct 11, 2012 12:50 am
    ----
Ugly? Well that could be said yes. The electric pump is also an opportunity to fit some nice braided hydraulic hoses too...

#868: Re: Project sleeper Author: JamieM PostPosted: Thu Oct 11, 2012 4:43 am
    ----
Looks awesome Smile

When you've put it all back together get some videos of it in action please lol

#869: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Oct 12, 2012 4:37 pm
    ----
Trimmed the remains of the radiator housing a bit today to fit round the air filter. Still needs another 5mm removing to give more room for the engine to move on its mounts.
I'm just keeping the slam panel to support the grille and provide a secure lock for the bonnet. I wouldnt think what's left is strong enough to secure the bonnet when driving.

 


 

#870: Re: Project sleeper Author: usher, Location: northallerton PostPosted: Fri Oct 12, 2012 4:44 pm
    ----
looking good, how long till you get your rad sorted?

you expecting much from the longer trumpets or just a little smoother power?

#871: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Oct 13, 2012 1:53 am
    ----
I'm going to get the new power steering pump fitted in the next month, that will show me what space I have for the radiator.

The longer inlet shouldnt do any harm. Apparently correct inlet length can have a significant affect on the power delivery.

#872: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Oct 23, 2012 2:25 pm
    ----
Steering pump arrived today. Needs a bracket to mount it and the cap is damaged so I need to soucre a new one. They don't seem to be available as a part on their own. If anybody knows where I can get one let me know.

Arrived a bit dirty...

 


 


A bit cleaner now. I also fitted the remains of the original 206 pressure hose from the old pump.

 


 

#873: Re: Project sleeper Author: usher, Location: northallerton PostPosted: Tue Oct 23, 2012 4:18 pm
    ----
looking much better now its clean,


is that rusty tools i see aka well used lol

#874: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Oct 23, 2012 4:22 pm
    ----
That's my 14 year old Halfords socket set. Just the imperial sockets have light corrosion on the inside of them!

#875: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Tue Oct 23, 2012 4:22 pm
    ----
Same pump as mine mate, when you do the loom, fuse it before and after the relay as they draw a hi current. You'll need the bracket that should of come with it off a 106 as it's got rubber mounts to stop it vibrating.

#876: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Oct 24, 2012 7:01 am
    ----
Yes the clips round the pump have the rubber on it. Is there any difference between Saxo and 106 pumps and brackets? I think the Peugeot bracket might be slightly cheaper.
I notice the current draw when I tested it yesterday. To make sure it worked one thick cable and a thinner one direct to the battery resulted in the thin cable getting quite warm!
It also needs a new cap and I'm hoping the caps are the same as the cars with a seperate reservoir as you can but new caps for those types.

You got any clear pictures of your bracket? I'm thinking it might need to be attached partly to the original airbox braket for extra support at the side.

#877: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Wed Oct 24, 2012 12:39 pm
    ----
I haven't mate I'll get some at the weekend for you it's sort of at a L shape so fits in the corner by the old air box at the bottom of the metal work were the abs pump is sitting on think they used 10mm cable for the loom

#878: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Oct 24, 2012 1:33 pm
    ----
Just looked at your picture from a couple of pages back. I can see how it's mounted. Your crossmember has definately been cut to fit that radiator.

#879: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Wed Oct 24, 2012 7:15 pm
    ----
I no, as I wanted it pushed forward and down so I had as much clearance as possible for the fan and the air flow to the inlet it doesn't go lower than the bumper so it's not a problem. You also need the room to mount the pump were I have mine

#880: Re: Project sleeper Author: usher, Location: northallerton PostPosted: Thu Oct 25, 2012 1:34 pm
    ----
Edward wrote:
That's my 14 year old Halfords socket set. Just the imperial sockets have light corrosion on the inside of them!

thats doing quite well then considdering, my bits have competley rusted now only a few years old, all tools get cleaned after each use Smile

#881: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Oct 25, 2012 2:16 pm
    ----
Also as you can see, some of the bigger imperial socket are like new. They do get damp occasionally when it starts to rain and I'm using them outside. They do get looked after though.

You need to use the tools a bit more, that will keep the rust off them!

#882: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Nov 05, 2012 2:15 pm
    ----
More goodies arrived today. Nyloc nuts and bolts to mount the steering pump bracket which should arrive this week. Also ordered stainless steel OMP bonnet pins. Decided on these because they just need simple holes drilling to fit them.
Ordered it from Demon Tweeks on Friday afternoon and it arrive by this morning. Not a bad price either at £21.75 delivered.

 

#883: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Mon Nov 05, 2012 3:52 pm
    ----
IMO mate your Gunna reck the look of your car if you fit them pins. they look gash they look ok on track car that's batterd and not in mint condition, I thought you were Gunna go a different direction to what I've done? As you found away to mount the bonnet catch?

#884: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Nov 06, 2012 12:56 am
    ----
The catches are small and will work perfectly. They are far easier to fit than Aerocatches too.
I'm binning the bonnet catch and the release lever and cable. Going to buy an aftermarket bonnet alarm switch to replace the original.
Keeping some of the original slam panel just to support the front grille.

#885: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Tue Nov 06, 2012 1:30 am
    ----
Lol fair enuf mate. I knew you would end up using pins as it's the only way of doing it so you get a good air flow with out blocking the intake I personsly wanted pins as they look cool aswell as do the job.

#886: Re: Project sleeper Author: Barking, Location: sarcasm-in-shedloads PostPosted: Tue Nov 06, 2012 1:37 am
    ----
spike_202 wrote:
Lol fair enuf mate. I knew you would end up using pins as it's the only way of doing it so you get a good air flow with out blocking the intake I personsly wanted pins as they look cool aswell as do the job.

lol @ bonnet pins to get good airflow.
His car never goes anywhere, except up and down his drive Wink

#887: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Nov 06, 2012 2:36 am
    ----
I’m still using the very top half of the slam panel. It’s just that with it trimmed so much to allow movement of the engine it’s got no strength left at all. The small amount that’s left won’t block any airflow now. It also provides something for the rubber bonnet feet to sit on.

#888: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Tue Nov 06, 2012 5:41 am
    ----
Oh I see what give done now Paul, yer that's a good way, on mine there are rubber mounts on the securing pin on the pins so it sits on them instead of the old rubbers.
I am interested in how your replacing the bonnet alarm/trigger switch were are you getting it from? as I do think the standard ones arnt the best 2bh. Whilst pressing mine up and down it feels gritty so it's a worth while change but can't find any were to get one from.

#889: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Nov 06, 2012 6:04 am
    ----
Standard bonnet switch is tiny. Pretty much all auto elec shops sell alarm switches. Polevolt sell them for peanuts.
I just need to check how the original switch works. I.e. is it pressed to break the circuit or make it?

www.polevolt.co.uk/aca...tches.html

#890: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Tue Nov 06, 2012 6:59 am
    ----
2nd that I can't find it? Thought I was looking at the right thing but I can't find any switch looking at them picks were 'should' it be located?
I think it would be push to make as when te bonnet is opened it breaks the circuit then sounds the alarm, yep just had another look for what I thought was the alarm switch and it's not and I can't even find what I thought was it now lol.
I could be just imagining it do pre-plexed alarms have one? I have dead lock ect.

#891: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Nov 06, 2012 1:14 pm
    ----
Non multiplexed cars have a bonnet switch yes. It's a tiny little thing that's part of the bonnet catch mechanism.

Bracket came today. £17.50 which isn't too bad. Might paint it silver when it's cleaned up. Will need to fabricate a piece of steel to go between the bracket and chassis rail as it appears the 206 chassis rail is higher than the Saxo.

 

#892: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Tue Nov 06, 2012 2:56 pm
    ----
That's the one mate, where abouts are you fixing it? I wanderd were it had gone as my bonnet catch has been taken out it's with that, do you know what the plug looks like/colour wiers as I have some plugs left over from the conversion.

My thinking is that as in this pic
You have the trigger wire as shown then the 2nd wire on a ring crimp that's attached to the mounting screw?
 

#893: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Nov 09, 2012 8:21 am
    ----
Got the steering pump mounted today. Also painted the bracket silver - not pictured. Maybe I'll change the way the upper mount works but for now it works fine.

Next job is to fit the bonnet pins and build a decent dummy radiator to see what fits.

 


Silver much cleaner looking...

 


Bolts look tidy enough...

 

Last edited by Edward on Fri Nov 09, 2012 10:31 am; edited 1 time in total

#894: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Nov 09, 2012 8:41 am
    ----
spike_202 wrote:
That's the one mate, where abouts are you fixing it? I wanderd were it had gone as my bonnet catch has been taken out it's with that, do you know what the plug looks like/colour wiers as I have some plugs left over from the conversion.

My thinking is that as in this pic
You have the trigger wire as shown then the 2nd wire on a ring crimp that's attached to the mounting screw?

Original switch can just about be seen below. Little thin black button on the latch.

 


This is the original plug. I think your idea might work to enable a new switch to be fitted.

 

#895: Re: Project sleeper Author: Seabook PostPosted: Fri Nov 09, 2012 11:49 am
    ----
may i ask why do you need the bonnet switch?

#896: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Fri Nov 09, 2012 12:24 pm
    ----
Bonnet alarm mate,
With pins you can open the bonnet from out side of the car even tho mine have locks on I'd still like the alarm bonnet switch to work as an extra protection as mine gets drove every day mine gets parked every were.
Yep that's the 1 paul I'm going to chop the plug off, extend the wires and put a new bonnet alarm switch up by the ecu.
Looking good mate have you decided on the rad yet? are you going custom made or ?

#897: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Nov 09, 2012 1:07 pm
    ----
Keep the plug, just buy a male Junior Power Timer plug and terminals to plug into it. That way it can be easily disconnected if anything needs stripping down. Split convoluted tubing can cover any wiring too. Or the existing wiring might be long enough to reach direct to the new switch.

As for the radiator, now the pump is fitted, the bumper, support, slam panel, horn and grille will be refitted with headlights and that will show me what space I have. A dummy radiator made from hardboard will be made. When I know how it fits and exactly where the mounts go I'll be contacting Radtec, Pace and Allisport for a price. Radtec tell me the radiator can be fitted with external piping welded to it to allow the standard Samco hoses to be used.

I'm not getting the steering pump hoses made until the radiator is fitted and plumbed in. The radiator and coolant hoses will dictate how long the steering hoses need to be and the route they take. They are very close to the pump though so should be quite short.

Bonnet pins will be getting fitted this weekend too. I also ordered a new cap for the steering pump reservoir.

#898: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Fri Nov 09, 2012 2:17 pm
    ----
I tried to set up an account with pole volt but it won't complete. I'm not fussed about chopping wires mate I'm good with a soldering iron as you said it may well reach. Just waiting for my switch to arrive so probably will be a job for next weekend or when I'm board lol.

#899: Re: Project sleeper Author: MrBSI, Location: What's it to you? ? ? PostPosted: Sat Nov 10, 2012 7:03 am
    ----
Edward wrote:
Standard bonnet switch is tiny. Pretty much all auto elec shops sell alarm switches. Polevolt sell them for peanuts.
I just need to check how the original switch works. I.e. is it pressed to break the circuit or make it?

www.polevolt.co.uk/aca...tches.html

You have pm Wink

#900: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Nov 10, 2012 10:51 am
    ----
Thanks Lee,

Bit more work today. Bonnet pins have been fitted. I think they looks quite smart.

 


 

#901: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Nov 10, 2012 2:03 pm
    ----
Right, I need one of these yellow plugs to fit alongside the original fan fuse. Hopefully Peugeot sell them...alternatively I could just stick a fuse in the slot and connect a terminal and wire to the fuse. Would rather have the proper connector block though that sits nicely on the side of the fuse box. This is to wire up the PAS pump.

 


 


 

#902: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sat Nov 10, 2012 5:48 pm
    ----
The pas pump will want a 50amp as I experimented with different sizes as the start up surge will pop anything below 50amp.

#903: Re: Project sleeper Author: JamieM PostPosted: Mon Nov 12, 2012 10:07 am
    ----
Looks great when did it last see action?

#904: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Nov 12, 2012 1:44 pm
    ----
Middle of September it was taken off the road.

#905: Re: Project sleeper Author: usher, Location: northallerton PostPosted: Mon Nov 12, 2012 3:05 pm
    ----
has it ever been dirty from new ??

must be a long process to keep it as clean as you like it

#906: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Nov 12, 2012 4:13 pm
    ----
Just dont get it dirty! It's never been dirty. It's certainly been used but it's always avoided dirty country lanes and anywhere with mud!

#907: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Nov 13, 2012 11:23 am
    ----
Got to have a decent level of attention to detail...£6.89 for a new PAS reservoir cap. Must better than the old damaged one.

 

#908: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Nov 17, 2012 10:29 am
    ----
Built a dummy radiator out of MDF today. It's still got a bigger surface area that the original. All of this will be exposed to the airflow too unlike the original. 74mm thick too as Radtec use a dual core. As the surface area is marginally bigger than standard I'm wondering if a twin core is actually necessary.
Next job is to work out where the inlet and outlets need to be and to built some dummy pipes through to the standard hoses.

 


 

#909: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sat Nov 17, 2012 11:49 am
    ----
It depends what your planning on using the car for? .....Full on race use then yes a twin core would be good but for road use it would take a while for the engine temp to get up and maintain at a optimum temp that's why I kept my standard rad.

#910: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Nov 17, 2012 12:16 pm
    ----
I have to remember that some of my new design is made up of end tank so strictly speaking it's not all radiator surface area.

You think thick silicone hose is adequate for the PAS pipes? I had some in stock so I popped it onto the pump and pas pipes...looks the part.

#911: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sun Nov 18, 2012 8:42 am
    ----
coming along very nicely Paul.

#912: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Nov 18, 2012 1:18 pm
    ----
Well you'll new a hi pressure pipe from the pump to the rack

#913: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Nov 18, 2012 1:23 pm
    ----
As a temorary measure I'll stick with the thick wall silicone hose that's on there. It's not going to get driven for some time yet. It's a very tight fit on the pipes so it's good enough for in the garage!

#914: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Dec 02, 2012 1:09 pm
    ----
Money, money, money. This car certainly need a lot of it even for the little bits. I need a yellow and green plug for the fuse box. These plugs are handed so both are needed. One for the fan wiring and the other for the steering pump wiring. Plugs and terminals thanks to modest minimum order quantities mean this lot was £25...wiring, connectors, terminals, sleeving and relays etc will be another £25 I reckon. So £50 just to wire in a fan and pump.

 


 

#915: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Dec 21, 2012 10:33 am
    ----
Another £42 spent on wiring bits!

Heavy duty relay for the PAS pump will be mounted alongside the fan relay and is mounted on the battery box.

 


This lot was purchased too. Amazing how much big terminal costs for connectors. Maxi fuses too with wiring for the pump.

 

#916: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Dec 21, 2012 10:56 am
    ----
This might delay getting the car back on the road next spring. In fact I have no intention of using it next year at all. Baby is due 15th June 2013, 12.5 years after our last one was born!

 

#917: Re: Project sleeper Author: Andrew, Location: Black Country Ay I PostPosted: Fri Dec 21, 2012 12:59 pm
    ----
Congrats Paul Smile

#918: Re: Project sleeper Author: Schumi, Location: Istanbul / Turkey PostPosted: Fri Dec 21, 2012 1:53 pm
    ----
Congrats. Smile

#919: Re: Project sleeper Author: MattyP, Location: Plymouth PostPosted: Fri Dec 21, 2012 2:09 pm
    ----
Congrats mate

#920: Re: Project sleeper Author: Dillon, Location: Kent PostPosted: Fri Dec 21, 2012 3:16 pm
    ----
Congratulations!

#921: Re: Project sleeper Author: 20Drift PostPosted: Fri Dec 21, 2012 3:22 pm
    ----
Congratulations!

#922: Re: Project sleeper Author: Barking, Location: sarcasm-in-shedloads PostPosted: Sat Dec 22, 2012 1:48 am
    ----
Congratulations Paul Thumb Up

Another addition to the stable Wink

#923: Re: Project sleeper Author: usher, Location: northallerton PostPosted: Sun Dec 23, 2012 2:15 pm
    ----
congrats

12.5 years thats baby sitting age Smile

#924: Re: Project sleeper Author: PezHdi, Location: Shrewsbury PostPosted: Mon Dec 24, 2012 10:19 am
    ----
Congrats Very Happy

#925: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Dec 24, 2012 10:53 am
    ----
Thanks everybody. So I've got six months to get the car finished. Got the PAS pump wired in today. It works too. I'm using the Omex shift light function to trigger the relay to the pump. Shift light is set to come on at anything above 0 rpm.

#926: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Jan 05, 2013 10:49 am
    ----
Steering pump all plumbed in today. Pirtek said compression fittings would be fine. The fitting take up a lot of space making the hose routing a little stiffer than I would have liked. It should do the job though.

Another £42 for the hose, £3 for the return hose, £5 for the fluid and 96p for the hose clips from Unipart. Much cheaper than Halfords.

 


Also decided the driveshafts would look better in yellow...

 

#927: Re: Project sleeper Author: Uz, Location: No Man's Land PostPosted: Sat Jan 05, 2013 11:51 am
    ----
Congrats on the new addition to the family bud... cars coming along nicely. How longs the list of thing to do over the next 6 months..?

#928: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Jan 05, 2013 12:02 pm
    ----
1 thing left to do now. The radiator and the wiring from the new relay to the fan. Job done then.

Ultimately I want a shorter final drive, it will need mapping for the new air horns and could do with some new tyres too.

#929: Re: Project sleeper Author: Lecktorious, Location: Scotland PostPosted: Mon Jan 07, 2013 6:36 am
    ----
Only just seen this - congratulations Paul! You must have a very understanding missus if your allowed to keep the car, never mind continue working on it Laughing

#930: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Jan 07, 2013 12:11 pm
    ----
It will cost nothing to keep it in the garage. I didn't get much time to drive it anyway so I'm happy to keep it in there for a few years.

#931: Re: Project sleeper Author: JamieM PostPosted: Tue Jan 08, 2013 7:15 pm
    ----
Congratulations,

And the car looks sweet nice progress.

#932: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Tue Jan 08, 2013 7:38 pm
    ----
Glad you got the PAS sorted mate its better than the belt pump by far. if your just fitting longer trumpets you don't really need it re-mapped I only had mine done as I was fitting bigger cycle injectors/fuelling sorted out as well as a few other bits done, but still I'm happy with 210 (@8,000rpm) but i had them put the limiter back down to 7.5k as its still on hydro lifters, at the end of the day I have no need to take it that hi. it was done at a very reputable place so I'm happy that the figures werent made to look better than they are like some places do. I hope yours turns out even better as it would complement all the hard work you've done over the years.

And congratulations on the news mate.

#933: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Jan 09, 2013 11:49 am
    ----
Reading the Dave Walker stories on the Emerald website it says only the big throttle opening load sites need mapping. It makes sense really because if more air is going into the engine the mapping needs changing to suit it.

#934: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Wed Jan 09, 2013 4:40 pm
    ----
It's not a massive change mate its only gaining some lower down torque, I drove it back from Northampron to bham drove it for 2weeks then when back down to get it mapped when I got paid and it didn't run any different apart from the fact it had more of a kick lower down and pulled better, I was just sort of giving you the heads up that you don't need to rush out and get it mapped ASAP as its no biggie Wink

#935: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Jan 10, 2013 2:12 am
    ----
No rush for me...a little less than perfect mapping wont do any harm in the garage!

#936: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Jan 11, 2013 2:25 pm
    ----
You are right about the steering with the electric pump. It's a bit lighter which is a good thing definately. Started the car up and drove it out of the garage for the first time in 3 months.

#937: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Fri Jan 11, 2013 5:11 pm
    ----
Lol I also love the priming sound of the pump, little things aye.

#938: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Apr 25, 2013 4:11 pm
    ----
Not bad for a 12 year old car...

 

#939: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Sun May 12, 2013 6:01 am
    ----
Out of interest Edward, have you ever had it professionally cleaned?

#940: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun May 12, 2013 9:08 am
    ----
Nope. Most professionals in my experience don't do the word justice. It will have swirls but nothing serious as it's never been near car washes or brushes etc.

#941: Re: Project sleeper Author: LeeThr, Location: North West Wales PostPosted: Fri May 17, 2013 12:59 pm
    ----
How's this coming along at the moment? Any changes lately? Or has all efforts been on the offspring that's soon to arrive?

#942: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat May 18, 2013 3:19 am
    ----
I've just added the bonnet catch but without the locking mechanism to catch the bonnet it the pins failed for some reason.

No point in spending the £450 for a radiator when it's not going to be driven until next year. It still gets started up and run for a short distance every few weeks though...

#943: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon May 27, 2013 4:40 am
    ----
I don't see the car very often so I forget how clean it really is...

 


Also decided to take the cam cover off to see what's going on in there. Not much room for cams of a higher lift.

 

#944: Re: Project sleeper Author: usher, Location: northallerton PostPosted: Mon May 27, 2013 11:21 am
    ----
im sure its the cleanest car that gets used on the road, any plans for this year of have other priorities taken over

#945: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon May 27, 2013 11:59 am
    ----
Used on the road? 200 miles last year! Junior No.2 is due in the next couple of weeks so my time wont be spent on the car. Maybe towards the end of the year I'll order the radiator but that's about it.

#946: Re: Project sleeper Author: LeeThr, Location: North West Wales PostPosted: Mon May 27, 2013 12:09 pm
    ----
Looks magnificent sat there, just a shame it doesn't get much further. How long have you owned it now?

#947: Re: Project sleeper Author: usher, Location: northallerton PostPosted: Mon May 27, 2013 12:27 pm
    ----
They do take up alot of time don't they. 200 miles is still used mmore than most cars of a similar standard of clean

#948: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon May 27, 2013 1:46 pm
    ----
Ten years in July I've had it!

#949: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Jun 22, 2013 4:48 am
    ----
Well Jake arrived on the 11th June. Weighing 7lb 1oz. So at 10 days old I thought he was old enough to have a picture in the 206.

 


Also bought a cheap catch tank for the car. Just needs a little filter on the other connector.

 

#950: Re: Project sleeper Author: macca1411, Location: Westhoughton, Lancashire PostPosted: Sat Jun 22, 2013 5:03 am
    ----
Congrats to you and the OH on the birth.

#951: Re: Project sleeper Author: MattyP, Location: Plymouth PostPosted: Sat Jun 22, 2013 5:17 am
    ----
congrats mate

#952: Re: Project sleeper Author: LeeThr, Location: North West Wales PostPosted: Sat Jun 22, 2013 6:39 am
    ----
Congratulations mate Smile glad to hear everythings okay and the 206 hasn't been forgotten about.

#953: Re: Project sleeper Author: PezHdi, Location: Shrewsbury PostPosted: Sat Jun 22, 2013 6:55 am
    ----
Congrats mate Smile brilliant pictures Smile

#954: Re: Project sleeper Author: Barking, Location: sarcasm-in-shedloads PostPosted: Sat Jun 22, 2013 7:40 am
    ----
He's the spitting image of you, Paul.
Has more hair too Laughing


j/k mate!

Congrats to you & L Very Happy

#955: Re: Project sleeper Author: DJ-, Location: UK PostPosted: Sat Jun 22, 2013 11:42 am
    ----
Congrats mate!

#956: Re: Project sleeper Author: usher, Location: northallerton PostPosted: Sat Jun 22, 2013 12:44 pm
    ----
congrats glad everything went ok

#957: Re: Project sleeper Author: Cabrioman, Location: Neath - South Wales PostPosted: Sun Jun 23, 2013 9:18 am
    ----
Stunning Motor!
and congrats on the new addition.

#958: Re: Project sleeper Author: tommyb32, Location: East Sussex PostPosted: Mon Jul 15, 2013 8:41 pm
    ----
i just dribbled! thats one stunning car!

#959: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Thu Aug 22, 2013 6:16 pm
    ----
One thing with those cheap catch tanks mate keep an eye on that level pipe guide thing as they go brittle crack or just disintegrate, I got one custom made for my spec from aluminium. 2bh I only empty mine every 2months or so as it don't collect to much its mostly water.

#960: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Aug 23, 2013 1:50 pm
    ----
I'm sure it will be fine for a while. It's done about 15 miles since last September!

#961: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Wed Aug 28, 2013 2:50 pm
    ----
Edward wrote:
Order my ITG Sausage filter and backplate from MotorsportWorld yesterday...another £144. Will take about a week to make it. The 125mm internal depth filters are made to order.

A few little tweeks today...well I put some of it back together...all in the name of attention to detail.

New bolts for the tensioner.

 


New bolts for the sump...

 


Old bolts...

 


New bolts...

 


All fitted back together...

 

How hard did you find it to refit the tensioner? Did you remove the top engine mount and do it from above, or below?

#962: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Aug 28, 2013 3:04 pm
    ----
I loosened it from below. Quite easy to change.

#963: Re: Project sleeper Author: usher, Location: northallerton PostPosted: Thu Aug 29, 2013 12:24 am
    ----
is that a pic of your aux belt without the pas aswell as ac, mine without the ac was a hell of a tight fit with tensioner and roller in place

#964: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Aug 29, 2013 1:54 pm
    ----
With a 16mm spanner on the tensioner it's no effort at all.

#965: Re: Project sleeper Author: usher, Location: northallerton PostPosted: Thu Aug 29, 2013 2:57 pm
    ----
Might be the wrong belt then as it took 2 of us half a hr of wiggling and pushing it on. The tensioner only moves 10mm max with it on

#966: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Sun Sep 01, 2013 3:00 pm
    ----
usher wrote:
Might be the wrong belt then as it took 2 of us half a hr of wiggling and pushing it on. The tensioner only moves 10mm max with it on

Took me 10 minutes to remove, 2 minutes to repair, 5 minutes to reinstall it, 30 mins to get the belt back on! So much tension I could get the belt around the crank pulley. Also resulted in a spanner flying towards my forhead!

#967: Re: Project sleeper Author: Harry, Location: Stafford PostPosted: Sun Sep 01, 2013 4:40 pm
    ----
If it's too tight just get a socket and a breaker bar it makes it 100 times easier.

#968: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Sun Sep 01, 2013 5:04 pm
    ----
I was using a breaker bar! Was just a tight fit, with not much room to maneuver!

#969: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Dec 23, 2013 3:10 pm
    ----
Spent some more money last week. Finally ordered my radiator from Radtec. I messed up the measurements even when I built a dummy radiator! So it's about 80mm narrower than planned but still fits nicely. It's twice as thick as the original so I'm confident it will be more than adequate.

I was also wanting to use the holes pre drilled in the front crossmember but my measurements error meant I had to drill new holes Oh well, it all fits perfectly.

Next job is to get the top radiator mounts fixed in place and to buy the hoses.

 


 

#970: Re: Project sleeper Author: LeeThr, Location: North West Wales PostPosted: Mon Dec 23, 2013 3:57 pm
    ----
Looking good Smile Is she going to see the road again in 2014?

#971: Re: Project sleeper Author: Addaz, Location: Suffolk PostPosted: Mon Dec 23, 2013 4:01 pm
    ----
Still looks awesome mate. Would love to have as much dedication as you do, but im too eager to get mine on the road again!

Side note, if you ever want a shorter final drive for your gearbox fitted, just let me know Wink

#972: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Dec 24, 2013 1:18 am
    ----
I don't have loads of time these days to mess with it and I'm perfectly happy with the Jetta for everyday use. Can't justify throwing loads of money at the 206 all at once when it gets driven so little. Might get it mechanically finished in 2014 and back on the road in 2015.

Shorter final drive is on the shopping list yes. Can you get hold of the bits?

Still a lot of money to get it on the road, set of tyres, final drive, remap, spacers for the throttle bodies - extra 10 or 20mm induction length could be nice.

For now I just need some little tube spacers to go round the bolts into the top of the radiator. No idea where I'd get something like that.

#973: Re: Project sleeper Author: Addaz, Location: Suffolk PostPosted: Tue Dec 24, 2013 3:12 am
    ----
Best place for tube is ebay mate. And yes I can, even get a bit of discount too.

The ratios arent exact but ones I can get ahold is:

3.98, 4.3, 4.52, 4.7 and a crazy 5.1!

#974: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Dec 24, 2013 4:00 am
    ----
I'm after the 17x81= 4.76 ratio

Should give me...much nicer than the current ratios.

2nd gear = 56 mph
3rd gear = 75 mph
4th gear = 95 mph
5th gear = 116mph

#975: Re: Project sleeper Author: usher, Location: northallerton PostPosted: Tue Dec 24, 2013 9:29 am
    ----
looking good as always, glad your still getting time on the car, i know its hard to find time with little ones, its taken me 6 month to strip and remove ac lol, how much was the custom rad if you dont mind

#976: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Dec 24, 2013 10:52 am
    ----
It was £500. I just hope its big enough. The fan is nowhere near as loud as the standard Peugeot fan so I just hope its adequate. Its hardly a car I plan to sit in traffic with anyway.

Much more of this radiator is exposed to airflow and its capacity is bigger so I'm confident. The standard radiator only has the fan area exposed.

#977: Re: Project sleeper Author: usher, Location: northallerton PostPosted: Sun Jan 05, 2014 4:50 am
    ----
thats more than i was expecting but it looks good quality, and a dam sight thicker than the std one, the height difference should be in favour of cooling as there isnt much air flow at the top due to the cover anyway,

are you getting a new manifold for the tbs? or just the longer inlet

#978: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Jan 05, 2014 8:42 am
    ----
It was expensive and I know other places will do them cheaper but Radtec have a good reputation for quality.

The original radiator has 1,017sq cm exposed to airflow.
The new radiator has 2,600sq cm exposed.

Old radiator capacity was 6,042 cm3
New radiator capacity is 9639 cm3

So it should be fine hopefully.

All plumbed in now. £50 of hoses. Then I just need to finish the wiring to the fan. The relay is in place so wont take too much effort.

 


 


The original standard GTi Samco hose was used at the bottom with a 20cm extension put in the middle. Clears all obstruction which is nice. Just need to support some of the wiring.

 

#979: Re: Project sleeper Author: usher, Location: northallerton PostPosted: Sun Jan 05, 2014 10:09 am
    ----
Looks good. With them figures I can't see it not being adequate especially as your not racing it (or driving it atm). Like how you have the hoses at least there out the way

#980: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Jan 26, 2014 7:59 am
    ----
Bit more tidying up done today.

Fitted the alarm sensor which cost a whole £1 as the original on the bonnet catch wont fit anymore.

 


Fitted some P clips to the radiator support bar to secure the wiring in place.

 


Looks almost finished now. A couple of things to finish off then it's all done.

 

#981: Re: Project sleeper Author: LeeThr, Location: North West Wales PostPosted: Sun Jan 26, 2014 9:59 am
    ----
Looking good, when you say its all done.... Does this mean it might see the open road again soon?

#982: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Jan 26, 2014 10:15 am
    ----
Not sure about this year. Still needs a set of tyres, insurance, tax, MOT, remapping and I'd like the lower final drive fitting too. Can't use it to the full potential without the remap. Can't be bothered doing that this year.
So just to get it on the road it will be nearly £1k. Add the remap and final drive and that will be another £800 ish. So there's a fair way to go yet. So I might just concentrate on the final drive and any other mechanical bits over the next 12 months.
At the moment I can't justify the money for the little use it will get.

#983: Re: Project sleeper Author: usher, Location: northallerton PostPosted: Sun Jan 26, 2014 12:00 pm
    ----
will this be a weekend car or trophie car when finished i wouldnt want to get it mucky lol

#984: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Jan 26, 2014 1:09 pm
    ----
It's not even a weekend car at the moment! I never get to stand back and look at it. I forget how clean it is.

#985: Re: Project sleeper Author: LeeThr, Location: North West Wales PostPosted: Sun Jan 26, 2014 3:06 pm
    ----
Wow still a fair bit to go then. What tyres will you run on this? Road legal semi slicks?

#986: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Jan 27, 2014 2:21 am
    ----
Goodyear Eagle f1 asymmetric 2 seem to get good reviews. Available in 16" which is fairly unusual for a new high performance tyre.

#987: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Jan 31, 2014 3:49 pm
    ----
Little bit more tinkering this week. I'd never given the front hubs and attention before and with the new dampers and clean calipers they always looked a bit scruffy.So I stripped the front suspension down and removed the hub carrier from the car. Cleaned it up and spray it silver.

To refit the hub I took the damper off the car and assembled them together. Getting the hub onto the damper is a lot easier when it's off the car.

I'd like the get the driveshafts properly powder coated sometime...maybe when they get replaced due to the ABS rings cracking because of corrosion!

 

#988: Re: Project sleeper Author: usher, Location: northallerton PostPosted: Fri Jan 31, 2014 5:20 pm
    ----
looks much neater all painted up, and how can you say your car will suffer corrosion its offencive lol

#989: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Feb 01, 2014 1:54 am
    ----
usher wrote:
looks much neater all painted up, and how can you say your car will suffer corrosion its offencive lol

Did you ever see the previous Bilstein dampers? After 25k miles and seven years they did this! Must have been made from the cheapest steel ever. The rest of the car remained immaculate but these dampers became quite dangerous!

 

#990: Re: Project sleeper Author: usher, Location: northallerton PostPosted: Sat Feb 01, 2014 3:42 am
    ----
yeah i remember that, and there german made lol, did you put them in the bin

#991: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Feb 01, 2014 5:34 am
    ----
Long gone now yes! The current Bilsteins have never seen rain!

#992: Re: Project sleeper Author: usher, Location: northallerton PostPosted: Sat Feb 01, 2014 5:44 am
    ----
best way. shame i dont have a garage the underside of my car is appaling, surface rust on new items and white spots all over the engine block

#993: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Fri Feb 07, 2014 3:51 am
    ----
I went for the hi flow pull fan on the inside of the rad, they seem to cool better than on the out side. Also would look better with the fan in the engine bay as you have a nice Alu rad and spoils the looks IMO

#994: Re: Project sleeper Author: MattyP, Location: Plymouth PostPosted: Fri Feb 07, 2014 4:44 am
    ----
This car is a beaut!! Wish my old moonstone was this mint. This would be awesome on a stand at FCS!!

#995: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Feb 07, 2014 8:34 am
    ----
spike_202 wrote:
I went for the hi flow pull fan on the inside of the rad, they seem to cool better than on the out side. Also would look better with the fan in the engine bay as you have a nice Alu rad and spoils the looks IMO

Its all down to packaging though. Didn't want anymore stuff behind the radiator with the hoses and other things that are already there. Perfect space up front so I thought I'd use it.

#996: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Fri Feb 07, 2014 5:26 pm
    ----
Ahh I see my rad sits quite forward so I've got plenty of room even after the fan was fitted, mines still going pretty well had all my work done for not far off 5 years and its still a Dailey driver and had the odd trip to a track, just needed a rear engine mount so putting a Bakerbbm next week.

#997: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Feb 08, 2014 2:10 am
    ----
These radiators are twice as thick as normal ones.

#998: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sat Feb 08, 2014 3:23 pm
    ----
Yer I know I was going to get one from rad tech but couldn't see the point in spending that much as the standard one is more than suffice with track use, also thought of if I had a knock or damage it in any way the pipe work is different so would need a replacement.

#999: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Feb 11, 2014 6:03 am
    ----
Other side is finished now.

 


As you can see there isn't loads of room behind the radiator for a fan. It might have fitted but it would have been difficult with the hoses running across the back.

 

#1000: Re: Project sleeper Author: 20Drift PostPosted: Tue Feb 11, 2014 6:30 am
    ----
Looks mint mate!

#1001: Re: Project sleeper Author: AndrewR2211, Location: Scotland PostPosted: Fri Feb 14, 2014 8:31 am
    ----
1000th reply Wink but iv actually read all of this, its a good read, and the outcome is pretty awesome, everything is so clean!!

#1002: Re: Project sleeper Author: JamieM PostPosted: Wed Mar 05, 2014 12:46 pm
    ----
Looks awesome exceptional attention to detail.

#1003: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat May 03, 2014 9:43 am
    ----
Well although the car won't be on the road this summer things haven't stopped.

Standard radiators have a cowling around them to make sure as much air goes through the radiator as possible. I've got two big gaps either side of mine so I wanted to fill them to stop air bypassing the radiator. So I've got two sheets of Perspex to fill in the gaps. Air can still go over the top of the radiator but that ok because that's where the inlet is.

 


I also spent some money on another toy. A Trek Superfly 9.7. Not convinced I'm going to get chance to use it much but it's nice to have anyway! It's all carbon fibre, 29" wheels etc etc. Feels massive compared to my old mountain bike.

 


 

#1004: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun May 25, 2014 2:47 pm
    ----
Hay paul, don't suppose you have a part number for the aux belt as is now on our cars? I.e w/o pas, w/o ac

Thanks rich

#1005: Re: Project sleeper Author: usher, Location: northallerton PostPosted: Sun May 25, 2014 3:48 pm
    ----
it was off a volvo on a previous page but i know there alot of pages to go through haha

#1006: Re: Project sleeper Author: samversteeg, Location: The Netherlands PostPosted: Sun May 25, 2014 4:51 pm
    ----
He mounted a 820 if I read it right.
I use a 6pk818. (as we call it over here) Meaning 818mm circumference and 6 'teeth'.
But it still slips occasionally.

#1007: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun May 25, 2014 4:58 pm
    ----
I have just had a 6pk825 by the local garage has been fine for about 1 month or so. but got off a working holiday last week (so stood still for 1week) started my car up and squealing like a b!@#h again. hmm but my 1st belt was ok for over 5 years of having this build but pug1off or me can't remember what we put on as it snapped off some were I can't measure it lol. I wasn't as wide I can remember that

#1008: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sat May 31, 2014 3:47 pm
    ----
Hmmm Does it slip or is it the bearing on the adjuster or the wheel on the adjuster just slipping on the belt. as I'm investigating this nose and it sounds like it's coming from the alternator but can't be, as that has no bearing just a pulley. So I'm thinking it's the wheel slipping on the belt.

#1009: Re: Project sleeper Author: t1mmy, Location: Reading PostPosted: Mon Jun 09, 2014 2:46 pm
    ----
This project is looking better than ever, nice bike too! It's good to see that you're still going with it.

#1010: Re: Project sleeper Author: JamieM PostPosted: Tue Jun 10, 2014 4:54 am
    ----
Looks nice as per Edward,

Shame it doesn't get to see the road though but obviously it's being overhauled. What is your plan with this build now? no doubt missed it somewhere in all those pages. Track?

#1011: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Jun 14, 2014 3:12 am
    ----
Next steps? Next purchase will be some 10mm throttle body spacers. They are about £120 delivered. I want the inlet as long as possible. I'd go for the 20mm spacers but I don't think there is enough space for them. After that I'm going to buy a different CWP to change the gearing and I might look at lightened flywheels.

I'm going to look into how to do the PAS steering hoses better too. At the moment the hose to the electric pump is a compression fitting which I'm not 100% certain is best in such a system. It might be fine but I think something more reliable can be made.

Then next spring it can go back on the road with a new set of tyres. It will need a remap ideally though and I want to calibrate the coolant temperature sensor on the Omex to that on the standard Peugeot ECU. I imagine the original ECU and sensor are well calibrated to the correct temperature so I want to make sure both ECUs match.

I guess by next year it could do with a new cambelt (it's only done about 2k miles since it was changed) and there is an oil leak from the belt side of the engine which has been there ever since Ecosse did the work.

So it's all time and money...Will be looking at new cars next year too as I've had the Jetta 4 years already. So I'll be looking at Passat CC GT TDi 170's....

#1012: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Jun 14, 2014 3:22 am
    ----
I actually took some pictures a couple of months ago.

 


 

#1013: Re: Project sleeper Author: JamieM PostPosted: Sat Jun 14, 2014 6:41 am
    ----
A project is never finished Smile

Fair play, the amount of things you have replaced or upgraded this must be basically a brand new 206 lol! I look forward to your updates, I wish I had the same level of knowledge as you on cars. I restrict myself and p***y it on trying to learn in case I ruin something. The belt would probably be ok but it's not worth the risk if it's not been in use in case it's gone funny over the time.

The overall spec of this car is quite something, I bet it is quite lethal!

Nice pics!

#1014: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Jun 14, 2014 7:20 am
    ----
You're right it's never finished. Ultimately I'd like a proper engine building where everything is spot on and not just a load of parts added to a basically standard engine.

#1015: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sat Jun 14, 2014 10:10 am
    ----
I can just confirm that a 6PK 818 fits very snug with no squealing.... as of yet

#1016: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Jul 05, 2014 2:43 pm
    ----
A little update. Things are moving on ever so slightly. I wanted some socket cap bolts to replace the studs on the throttle bodies as they look much better. Only problem is that they won't fit these DCOE style bodies so I'll have to keep the studs.

On the underside though Ecosse fitted a mixture of bolts and studs so I replaced them all.

 


I used them to mount the manifold onto the head too.

 

#1017: Re: Project sleeper Author: America, Location: Catania, Italy PostPosted: Fri Oct 03, 2014 5:54 am
    ----
Love this thread.... have you driven it recently? MAN!! I would love to put my foot down with those bodies!!

#1018: Re: Project sleeper Author: danlouiee, Location: Plymouth, Devon PostPosted: Fri Oct 03, 2014 6:08 am
    ----
This needs to be shown at FCS next year amazing build quality and hard work! Good job

#1019: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Oct 03, 2014 2:54 pm
    ----
It was started up last weekend and driven out of the garage that's all. It's been about 4 weeks since it was last started. I just don't have time anymore and I won't get much time to drive it either...throttle body spacers will be ordered very soon so things are still progressing.

#1020: Re: Project sleeper Author: PezHdi, Location: Shrewsbury PostPosted: Sat Oct 04, 2014 3:46 am
    ----
It's a shame it doesn't get driven but hopefully you will find some time at some point to have a day were you can have some fun and go hunting in it Smile
We need some more pics.

#1021: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Oct 08, 2014 4:18 pm
    ----
Well I ordered my throttle body spacers yesterday and they arrived today.
I realised today I actually have 45mm bodies but I thought they were 42mm. Even though I have 42mm air horns and spacers they still flow more than enough air for the engine.

£98 delivered and should hopefully bring the power band further down the Rev range. I now have an extra 60mm of intake length compared to when the engine was set up.

 


 

#1022: Re: Project sleeper Author: samversteeg, Location: The Netherlands PostPosted: Wed Oct 08, 2014 5:18 pm
    ----
The spacers are pretty smart.
How long is your intake now?

Im on 31cm right now without headlenght.
The powerband is from 5.000rpm till 7500rpm.
Although the torque is dropping fast after 6.000rpm.

#1023: Re: Project sleeper Author: andy83, Location: stoke on trent PostPosted: Thu Oct 09, 2014 11:18 am
    ----
gotta love a thottle bodied set up, and what a great place for them to be positioned should get decent air flow there

you have got a really good set up there going off your spec fella, what power are you making atm?

#1024: Re: Project sleeper Author: LeeThr, Location: North West Wales PostPosted: Thu Oct 09, 2014 12:29 pm
    ----
andy83 wrote:
gotta love a thottle bodied set up, and what a great place for them to be positioned should get decent air flow there

you have got a really good set up there going off your spec fella, what power are you making atm?

Don't ask Tedward about power figures...

#1025: Re: Project sleeper Author: Project2062014, Location: Cornwall PostPosted: Thu Oct 09, 2014 4:54 pm
    ----
What does it make ? 170 bhp ?

#1026: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Fri Oct 10, 2014 3:37 am
    ----
Less than that because he hasn't got 180 injectors, everyone knows you need them to break the sound barrier.

#1027: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Oct 10, 2014 5:17 am
    ----
Oh but I do have them fitted....

#1028: Re: Project sleeper Author: Addaz, Location: Suffolk PostPosted: Fri Oct 10, 2014 1:17 pm
    ----
Steve206 wrote:
Less than that because he hasn't got 180 injectors, everyone knows you need them to break the sound barrier.

What happens if you have ones bigger than 180 injectors? Does time go backwards?

#1029: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Fri Oct 10, 2014 2:34 pm
    ----
Sorry Edward!

You better ask project about the quantum physics regarding injector size!

#1030: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Oct 11, 2014 7:42 am
    ----
samversteeg wrote:

How long is your intake now?

Im on 31cm right now without headlenght.
The powerband is from 5.000rpm till 7500rpm.
Although the torque is dropping fast after 6.000rpm.

I'm on pretty similar. 90mm airhorns, 9.5mm spacers, TB's are 118mm long and according to the Jenvey website the manifold is 98.8mm long. So it looks like I have more or less 320mm. Allowing for maybe 50mm from head flange to inlet valve it's about bang on what Jenvey recommend for a 7300rpm engine.

#1031: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Nov 18, 2014 3:36 pm
    ----
More money spent yesterday. £168 for a proper Jenvey throttle linkage and a new throttle body lever.

Getting the old lever off the throttle body is a little bit difficult though. Its held on with a tiny grub screw and I suspect it's also glued in place. Predictably this make them much more likely to get rounded off. I imagine it will have to get drilled out unfortunately.

 


 


 

#1032: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sat Nov 22, 2014 11:46 am
    ----
Good mod there Paul.... it is a better set up for the throttle and the cable routes nicely.

#1033: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Nov 22, 2014 12:38 pm
    ----
It looks a lot neater. It's just a bit fiddly to fit. Nearly done though. Will probably keep the standard throttle cable.

#1034: Re: Project sleeper Author: andy83, Location: stoke on trent PostPosted: Sat Nov 22, 2014 12:42 pm
    ----
love this motor top work matey

#1035: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Nov 23, 2014 3:14 am
    ----
Almost finished now. Just need to sort the cable. The supplied cable fits the linkage but the other end doesn't fit with the standard Peugeot attachment on the throttle pedal. Can't be too hard to resolve it though.

Next job will be the fuel rail. I want to shift the injectors into the bodies and get a Jenvey fuel rail with Aeroquip fittings and braided hose. There's a connection in the standard Peugeot fuel hose that's behind the drivers side wheel. If I can get an adaptor to fit the standard fitting it will make life easier.

 

#1036: Re: Project sleeper Author: Addaz, Location: Suffolk PostPosted: Sun Nov 23, 2014 3:11 pm
    ----
I take you want the injectors away from the valves for better atomisation? Does this modification yield for anything more or just that?

#1037: Re: Project sleeper Author: macj, Location: Essex PostPosted: Mon Nov 24, 2014 1:13 pm
    ----
I used the standard Pug cable with a solderless nipple and found it to be fine if your not intending to pull it to bits a lot....... not what happened to me unfortunately so the splayed cable has to be replaced due to trimming back to get it back on Confused

#1038: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Nov 24, 2014 2:17 pm
    ----
Addaz wrote:
I take you want the injectors away from the valves for better atomisation? Does this modification yield for anything more or just that?

It cant do any harm although the emissions at idle speed could be affected by positioning the injectors further upstream.

macj wrote:
I used the standard Pug cable with a solderless nipple and found it to be fine if your not intending to pull it to bits a lot....... not what happened to me unfortunately so the splayed cable has to be replaced due to trimming back to get it back on Confused

I've used the Jenvey cable now with the new outer cable and I've attached a Jenvey cable trunnion to the top of the pedal.

#1039: Re: Project sleeper Author: Addaz, Location: Suffolk PostPosted: Mon Nov 24, 2014 4:08 pm
    ----
Edward wrote:
Addaz wrote:
I take you want the injectors away from the valves for better atomisation? Does this modification yield for anything more or just that?

It cant do any harm although the emissions at idle speed could be affected by positioning the injectors further upstream.

True, i noticed longman did this on his engines, i've just never seen a true great benefit. As some of the charge could be lost in pockets in the body, but then saying this it would dramatically reduce the chance of hot spots in the chamber

#1040: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Dec 30, 2014 8:28 am
    ----
Got some toys for Christmas...dollies and a car cover. Dollies under the rear wheels let me push the car sideways in the garage giving a bit more space in the garage.

 

#1041: Re: Project sleeper Author: Nic_206, Location: cleaning the car PostPosted: Sun Jan 04, 2015 11:19 am
    ----
They wouldn't be the Clarke dollies would they just bought them for my project seem pretty decent

#1042: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Jan 04, 2015 11:27 am
    ----
They certainly are. Made use of the VAT free voucher they sent.

#1043: Re: Project sleeper Author: usher, Location: northallerton PostPosted: Mon Jan 05, 2015 4:56 am
    ----
great idea with the dollies, guessing the cover is mainly for dust reduction lol

#1044: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Jan 17, 2015 2:35 pm
    ----
More spending! It has taken a bit of time to work out if it was even possible to fit the Jenvey rail and plumb it into any of the standard fuel system. So I started looking at what's available. After a bit of research it turns out the standard fuel rail, filter and most other connections are called 5/16" male/female quick connects.

Underneath the car just near the drivers seat lives the connector below. The measurements match those of the Aeromotive 5/16" male quick connect. So it made sense that their female quick connect would attach to it. I had to get the measurements from Aeromotives technical dept in the US.

 


This is Aeromotives Female quick connect. I believe this might be designed for a Ford.

 


So with a small amount of modification (I.e. removal of the bigger ring on the male part) the Aeromotive quick connect slid on and locked perfectly. I did want to run a braided hose all the way back to the filter but the length of the quick connect is too long to fit.

I think I need a JIC -06 fitting (AN-06) to attach to the quick connect. Or it could be an ORB-06. One has an O-ring, the other doesn't. The packaging suggests one thing but the Aeromotive website suggests the other.

 


As that end is sorted I bought a Jenvey fuel rail.

 


 


So next week I need a length of -06 Goodridge braided hose, a cap for one end of the fuel rail, a couple of hose end fittings and a male to male JIC adaptor.

#1045: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Jan 17, 2015 2:46 pm
    ----
The Jenvey rail comes with injector clips but they don't fit the GTi 180 injectors I have fitted. I have modified the standard Peugeot injector clips slightly.

The reason for the Jenvey clips not fitting is the design of the injector. The locking groove is in the wrong place, works ok on the standard rail but not the Jenvey one.

Peugeot injectors only have one locking groove.

 


Other injectors have two grooves which is what I need for the Jenvey clips to fit.

 

#1046: Re: Project sleeper Author: samversteeg, Location: The Netherlands PostPosted: Sat Jan 17, 2015 5:25 pm
    ----
The quick connects are a nice solution!
Why do you want to use a Jenvey fuel rail instead of the stock one?

I had to adjust the injector (Mini's 310-330cc) clips to my stock fuel rail haha

#1047: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Jan 18, 2015 2:20 am
    ----
The Jenvey rail and braided hoses look faster! I'm sure the original injector positioning will be better for low speed emissions but I just wanted to finish it off! It's just a bit of an expensive extravagance. Fuel mixing at higher engine speeds should be better though.
It's a bit like the Jenvey linkage. It doesn't do anything that the original didn't but it looks a lot better.

#1048: Re: Project sleeper Author: samversteeg, Location: The Netherlands PostPosted: Sun Jan 18, 2015 5:02 am
    ----
The injectors positioned in the throttle bodies is better for fuel mixing at high engine speeds indeed. I've seen comparison graphs with a remarkable diffrence.
And sure it looks a lot nicer Smile

Fitting the original fuel rail at throttle body position might have been easier.

 



It's nice to see you're making good progress. Are you considering a standalone ecu?

#1049: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Jan 18, 2015 6:27 am
    ----
It already has an Omex 600 ECU in the glove box.

#1050: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Sun Jan 18, 2015 9:27 am
    ----
What goes in the original injector holes now?

#1051: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Jan 18, 2015 10:17 am
    ----
The throttle bodies had plugs in them before I put the injectors in the holes. So I'll just put the plugs in the manifold now instead. I believe they aren't supposed to be a permanent solution but they've done ok for the last 5 years.

#1052: Re: Project sleeper Author: samversteeg, Location: The Netherlands PostPosted: Sun Jan 18, 2015 12:20 pm
    ----
Very nice, I missed that in your topic. And isn't visible on the engine bay photo's ofcourse.

#1053: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Jan 21, 2015 3:02 pm
    ----
Almost finished now. Got part of the hose plumbed into the fuel rail. Next job is to get the car up in the air and remove the front subframe to secure the hose in place through the engine bay and under the car.

 


 

#1054: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Jan 25, 2015 4:33 pm
    ----
Sorted underneath now as well. Just ordered some P clips to keep everything where it belongs. I want to replace all the standard plastic clips with metal p clips.


 

#1055: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Feb 02, 2015 3:36 pm
    ----
Got my stainless P clips fitted now. I removed the standard plastic clips and used the holes to fit some rivet nuts. The plastic clips might have been ok but I didn't know if they would soften when they got warm. There's only one I can't get to because it's on the bulkhead and there isn't enough space to get any tools in.

 

#1056: Re: Project sleeper Author: DJ-, Location: UK PostPosted: Mon Feb 02, 2015 4:10 pm
    ----
loving the updates - this is one thread that keeps me coming back to this forum Thumb Up

#1057: Re: Project sleeper Author: drmo, Location: Ljubljana, Slovenia PostPosted: Wed Feb 04, 2015 6:47 am
    ----
Just went through all the 71 pages...Oh my god, you do not have any luck, sir!

In my opinion and experience, such a steep torque graph comes when the engines is "overcamed" in therms of other components, or the cam timing is f****d up. You have stock pistons, right? Stock compression is 10.8:1, and with piston valve cutouts it is even less, I could even suspect without measuring, but would say around 10.5:1 or less, that is if the head chambers haven't been worked on. For these piper cams to work properly, I would say minimum 11:1, 12:1 preffered for a good low down torque. This is one of the problems I see in this build.

The other one is that longmans airbox with only 60mm feed of air and standard airbox before that. That thing is choking the poor thing! The proximity of bell mouths to airbox wall is also a little to close for a good feed.
Converting to a mesh filter from ITG was the best thing you did, but should f*** up the AFR quite a bit, so a remap is a must if you don't want something to melt.

And another observation. You said that the bodies are actually 45mm, but you fitted 42mm air horns. That is not good for air flow. Not at all. 45mm bodies might be ok for 2l engines (if you listen to jenvey), but if you want a really good midrange, you need bigger. If you look at this engine:
racecarsdirect.com/lis...4_bhp.html
It has 52mm jenvey bodies. Why would you need that big bodies if jenvey themselves say you don't need to? Intake length is also an important factor, but I wont go into that as it is quite a big topic. Just google 2nd and 3rd order harmonics and you would find a glimpse of it.

The EW head inlet ports are not 50mm long, but around 80-90mm. Can measure the exact length if anybody wants.

Just my thoughts about the whole build.

#1058: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Feb 04, 2015 11:34 am
    ----
You are talking as if the 42mm air horns will be strangling the engine of air. They will flow a lot more air than this engine will consume.

You talk about mid range needing bigger bodies but if the engine isn't restricted at max revs it's not going to be restricted at medium revs. Smaller bodies are better for throttle response anyway. This is a road car after all.

I've made the inlet as long as possible. The only change possible now is to go shorter and I have that option.

#1059: Re: Project sleeper Author: LeeThr, Location: North West Wales PostPosted: Wed Feb 04, 2015 11:38 am
    ----
The big question now... Is it going to go beyond the end of your driveway this year at all?

#1060: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Feb 04, 2015 11:46 am
    ----
Hmmm...possibly...needs insurance, tax, mot and a set of tyres....I'm just not sure I will get much chance to use it. I really want a decent hose making for the power steering too. I don't like the one with compression fitting so I'm going to see if I can get somebody to swage the existing metal pipe.

#1061: Re: Project sleeper Author: drmo, Location: Ljubljana, Slovenia PostPosted: Mon Feb 09, 2015 7:33 am
    ----
Edward wrote:
You are talking as if the 42mm air horns will be strangling the engine of air. They will flow a lot more air than this engine will consume.
Not entirely true. They are ok for around 200hp peak, but mid range torque can suffer. In your case it is not ok because the difference in diameter is changing from one size to another and then back again. There is a lot of turbulence because of that, and turbulence is never a good thing for flow.

Edward wrote:
You talk about mid range needing bigger bodies but if the engine isn't restricted at max revs it's not going to be restricted at medium revs. Smaller bodies are better for throttle response anyway. This is a road car after all.
Also not true. I can show you a dyno graph of breathing mods (bigger runners, same length) bumping the mid range quite a bit.
Yes, smaller bodies are easier to control, but you are far from that point with size.

Edward wrote:
I've made the inlet as long as possible. The only change possible now is to go shorter and I have that option.
I just want to help you out as by the looks of it the engine performance looks to be nothing but poor for the specs.

A lot of people think that exhaust or inlet size is not that important. Another example for you:
We changed a muffler on a customers car, because he wanted the exhaust to be quiet as a mouse. Before the entire exhaust was 70mm, from manifold to the end. Then we made it taper to 57mm like the stock muffler, everything else stayed 70mm. Here is the difference:
drive.google.com/file/...sp=sharing
That thing killed the mid range torque, but the top end the difference is minimal...

#1062: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Feb 09, 2015 12:02 pm
    ----
But you don't know how the engine performs as it's never been run with the current spec.

#1063: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Fri Feb 27, 2015 3:28 am
    ----
I had the injectors in my TB's from the start mate. was told by most engine tuners this is the best place to put them for maximum air mixture. I plugged the manifold holes with the standard plugs that came with the manifold from jennvey.

#1064: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Feb 27, 2015 7:59 am
    ----
They will certainly be better in that position for high rev power but at low revs it's not for no reason that injectors tend to be positioned pointing at the valves.

#1065: Re: Project sleeper Author: drmo, Location: Ljubljana, Slovenia PostPosted: Fri Feb 27, 2015 10:45 am
    ----
That stock position is more like sub 3000 rpm, over that, the higher position is better in most cases.

#1066: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sat Feb 28, 2015 11:45 am
    ----
Mine have been in the higher place for 6 years and have had no problems ticking over or revs under 3k so as long as it's mapped right imo you won't notice the change.

#1067: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Mar 27, 2015 3:39 am
    ----
A few more changes to the power steering hoses.

 

#1068: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Mar 27, 2015 8:53 am
    ----
I didn't like the old fitting and the hose was a bit messy with original Peugeot pipes joined together with an extension piece. So I bought an alloy PAS fitting from Torques UK and got a hose made up locally with a -6 JIC fitting on it.

 


The hose goes under the sump now and connects to the original metal pipe.

It's not 100% as I wanted it but it's neater than before. It also does away with the old redundant PAS pressure sensor.

 

#1069: Re: Project sleeper Author: t1mmy, Location: Reading PostPosted: Wed Apr 01, 2015 5:02 pm
    ----
Looking great as ever, keep up the good work.

#1070: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Apr 02, 2015 7:00 am
    ----
Thank you. Car is almost finished now. I think there is a slight leak from the PAS pump still. I might need to buy a seal kit but it's only minor. I think it would fail an MOT for that though. Other than that it needs a set of tyres and it's ready to go.

#1071: Re: Project sleeper Author: Andrew, Location: Black Country Ay I PostPosted: Thu Apr 02, 2015 12:33 pm
    ----
New PAS pump set up looks great. If you don't mind me asking, could you give me a rough figure on how much it has cost you to source the parts needed to convert? I will need to do this myself at some point

#1072: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Apr 02, 2015 1:39 pm
    ----
Roughly...pump is about £50, bracket cost £10, latest hose was £20, screw in fitting for the pump was £10, low pressure hose £5. The wiring cost a few quid as I wanted to use the standard Peugeot fuse box so with the high current connector for the pump it was about £35 for the electrics. PAS fluid is £5.

#1073: Re: Project sleeper Author: Horton898, Location: Earth PostPosted: Thu Apr 02, 2015 3:22 pm
    ----
Im pretty new to the forum so I've got a lot of catching up to do but from what I have seen you've got a keen eye for detail, that motor looks incredible!

#1074: Re: Project sleeper Author: tRiCk, Location: Mitcham PostPosted: Mon Apr 13, 2015 5:06 pm
    ----
Hey Edward, I'm trying to find out what car I can get a solid timing belt tensioner for my ew12, same as ew10 really. Do you have one fitted on your car?
Thanks in advance

#1075: Re: Project sleeper Author: drmo, Location: Ljubljana, Slovenia PostPosted: Mon Apr 13, 2015 5:20 pm
    ----
I think that 1.9d tensioner would do the trick. You just need a stud from dw8 engine, to bolt it to, and that is it. 0820.17 is the part number of the stud for the tensioner.

#1076: Re: Project sleeper Author: Schumi, Location: Istanbul / Turkey PostPosted: Wed Apr 29, 2015 3:31 pm
    ----
If you need solid tensioner I suggest 306GTI6 ones with early metal tensioners.

#1077: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat May 23, 2015 2:49 am
    ----
Spent some more money this month...I can't justify spending on the 206 when I don't get much time to drive it so I bought this. A Trek Domane 4.5 Disc...all carbon fibre, disc brakes, a few bits of Ultegra groupset...it's nice. It would have been far cheaper to get the 206 back on the road that's for sure.

 


 


 


 


Straight away I changed the monster cassette for one with closer ratios.

 


 


 

#1078: Re: Project sleeper Author: macj, Location: Essex PostPosted: Tue May 26, 2015 2:30 pm
    ----
As always Ed your attention to detail is impressive Thumbs Up

#1079: Re: Project sleeper Author: Carlos_WR1 PostPosted: Wed May 27, 2015 11:24 am
    ----
Nice to see someone else into cars and road bikes like myself (although technically thats a cyclocross) I have just upgraded my bike to a full carbon. Started on a Dedacciai SC61.10A and rode that for 3 years, just replaced it with a 13 Inuition Alpha, have swapped a few components over with it so im running Sram Apex and have FSA KForce Head Stem, SeatPost and Egonomic HandleBars. Ill have to get some pics up.

Have you used the Trek much? where abouts are you based, whats the cycling like around your way?

#1080: Re: Project sleeper Author: existenz PostPosted: Tue Jun 09, 2015 11:19 am
    ----
Hey Edward, have you driven you car and can give some feedback on your 21mm torsion bars?
I'm running Koni yellow dampers and HR 35mm springs. I use a 24mm rear ARB, but my rear is still rather soft. I would just like to know if its worth the upgrade, as I'm feeling I need that extra stiffness for autocross...

#1081: Re: Project sleeper Author: drmo, Location: Ljubljana, Slovenia PostPosted: Tue Jun 09, 2015 12:09 pm
    ----
Existenz, change the crapy koni dampers for some bilies. The difference is enormous.

#1082: Re: Project sleeper Author: existenz PostPosted: Tue Jun 09, 2015 7:07 pm
    ----
I'm really happy with them for what they are Wink

#1083: Re: Project sleeper Author: drmo, Location: Ljubljana, Slovenia PostPosted: Wed Jun 10, 2015 6:56 am
    ----
existenz wrote:
I'm really happy with them for what they are Wink
Very Happy

Don't know why you are complaining on the soft rear then, if you are so satisfied. Laughing With bilies it is a whole different car Wink

Ask forum member =ZiAn= about the 21mm torsion bars. He has 21mm torsion bars and he tracked the car, so could probably told you how the car handles and how big of a difference it is. He has bilies also.

Here is his topic:
www.206info.co.uk/Foru...t=418.html

#1084: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Jun 10, 2015 8:28 am
    ----
Dampers don't control pitching under braking and acceleration. 21mm bars are fine for road use especially with a bigger rear ARB.

#1085: Re: Project sleeper Author: drmo, Location: Ljubljana, Slovenia PostPosted: Wed Jun 10, 2015 9:12 am
    ----
You would be surprised. Smile

#1086: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Jun 10, 2015 11:24 am
    ----
They delay the movement or slow it down but that's all. They don't reduce body roll once settled into a corner either.

#1087: Re: Project sleeper Author: existenz PostPosted: Wed Jun 10, 2015 1:20 pm
    ----
The front is just fine. But under acceleration and tight corners with bumps and some uphill parts I always feel (and see on photos) that the rear really need some stiffer torsion bars, as a large part of the wheel diesappears under the arches. And I think 21mm might be the way to go with my setup, unless I am going for Grp N Bilsteins or something of that sort. It should greatly improve acceleration, especially in combination with the Quaife ATB.

#1088: Re: Project sleeper Author: drmo, Location: Ljubljana, Slovenia PostPosted: Thu Jun 11, 2015 3:12 am
    ----
I'm not denying that larger diameter torsion bars won't help, I always encourage people to go stiffer if they have changed front springs, but the dampers play a huge role here, and driving both koni and bilstein equiped cars, I can say that over bumps and turn-in, the bilies are in a whole different league.

Be careful when choosing the rear torsion bar/arb combination. Our experience is that when you go over 21mm torsion bars and 24+mm arb, the rear inside wheel always tends to loose contact and lock under braking. Torsion beam in this matter is really tricky.

I disadvise Quaife ATB in any form of motorsport. Maybe some people can sense the difference, but with fitting this ATB to many cars, and driving them, I can honestly say that it is not worth the money. There is so little difference, if any at all (it also depends a little on the suspension setup), that in my opinion it is money thrown away. Better to put money in sorting the suspension properly (camber/caster top mounts and suspension bushings etc.).
This ATB is not a real torsen diff, well it doesn't act like it. Try a Honda Civic with OEM Honda torsen diff and a civic with Quaife ATB. You won't believe that both are torsen. The oem one acts more like a plate diff when mid corner accelerating, and that is how it should be, while the Quaife is more like open diff. I was really disappointed when I first tested it and since then, every car we put it in didn't feel anything like it's supposed to be. Don't get me wrong, the quality of manufacturing is really good compared to others, it always fits like an oem part, but for less money you can get a plated diff from Gripper, which also has a lifetime warranty and does its job. It doesn't fit without a hassle though, in any gearbox that we fitted (BE,MA,JC5,...) Laughing

#1089: Re: Project sleeper Author: existenz PostPosted: Thu Jun 11, 2015 4:48 am
    ----
As I said it works good. It's still a street car. In case I go for a new suspension setup, I'd go for a race suspension anyway. I'd love to go for 22mm bars, but that would be too much for the front springs I guess. So I think 21mm is a good compromise.
But right now, I am simply looking for a way to make my rear stiffer Smile

#1090: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Tue Jun 23, 2015 4:42 pm
    ----
Edward wrote:
The blue covers? Yes they came with them.

Back together now...forgot the big washers at the top of the damper under the top mount...so it's all coming apart again.

 


 


 

Bit stage as this. When I removed all my strut setup to replace the springs my washer was under my BIG nut on the top side of the top mount? So is your nut just onto the top mount with no washer?

#1091: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Jun 24, 2015 1:47 am
    ----
I think there are two washers. One below and above the top mount beneath the nut.

#1092: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Wed Jun 24, 2015 9:03 am
    ----
I think so mate

Just been down to the pug garage on me dinner and orderd 2new top and 2new bottom washers and 6new top mount bolts. But they've got to do some ringing around as they don't stock them and come in packs of 20.

70
71
73

 

#1093: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Wed Jun 24, 2015 9:07 am
    ----
Another thing I was going to ask was with the b8 dampers being a short shaft did you have to get a shorter profile spring? Or would my new pro lines fit straight onto the b8? Although my b6's went any way near as bad as yours I'd still like to change them in a year or so.

#1094: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Jun 24, 2015 11:36 am
    ----
The shorter damper internals just mean the car can be lowered without the dampers bottoming out as easily. Bumps stops on these dampers are internal unlike most dampers which use a big rubber external Bumpstop.

#1095: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Wed Jun 24, 2015 11:49 am
    ----
Got ya. so it's nothing to do with the physical size of the shock. Just alows you to go lower if you need to.

#1096: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Fri Jun 26, 2015 10:16 am
    ----
I don't suppose you have any of the top mount bolts spare that I could buy? As the main dealer wants me to buy a bag of 30 at £1.02 per bolt.

#1097: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Jun 27, 2015 2:31 am
    ----
I'm quite sure I might have some bolts. I will check my stock.

#1098: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sat Jun 27, 2015 3:04 am
    ----
Edward wrote:
I'm quite sure I might have some bolts. I will check my stock.

Thank you paul I'd be very grateful.

#1099: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Jun 28, 2015 10:13 am
    ----
I have exactly six brand new top mount bolts in my parts tray.

#1100: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Jun 28, 2015 11:27 am
    ----
Are there any that could be for sale?

#1101: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Jun 28, 2015 11:48 am
    ----
All six are up for grabs. With the use that my 206 gets I'm hardly likely to wear out my existing bolts!

#1102: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Jun 28, 2015 11:53 am
    ----
Ok mate how much?

#1103: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Oct 21, 2015 4:24 pm
    ----
So what's this? Car out in the open? Might be back on the road soon. It's about time!


 

#1104: Re: Project sleeper Author: Sim, Location: West Country PostPosted: Wed Oct 21, 2015 6:36 pm
    ----
Bang on! We wanna hear the roaring Very Happy

Funnily I keep one of them pugs also half-way on the lawn Smile i1060.photobucket.com/...g~original

#1105: Re: Project sleeper Author: LeeThr, Location: North West Wales PostPosted: Wed Oct 21, 2015 8:47 pm
    ----
Are you feeling okay Edward?

Or is the real story that the car's turned into Herbie & got that fed up of garage life it's tried to make a run for it Laughing

#1106: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Oct 22, 2015 2:09 am
    ----
Well despite it coming into winter now, the car is insured and just needs a couple of tyres, MOT and tax. For the sake of just over £300 I could use the car...might get dirty though... so I might as well use the thing.

#1107: Re: Project sleeper Author: Addaz, Location: Suffolk PostPosted: Thu Oct 22, 2015 12:27 pm
    ----
You feeling okay?!

#1108: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Oct 22, 2015 2:50 pm
    ----
The weather this morning kind of made me wonder if I should delay it coming out by six months...

#1109: Re: Project sleeper Author: Sim, Location: West Country PostPosted: Thu Oct 22, 2015 3:25 pm
    ----
I haven't read the whole thread, so no idea why you're having a go Very Happy

Edit: ..ok you got me (interested), at page 14 now Smile

#1110: Re: Project sleeper Author: LeeThr, Location: North West Wales PostPosted: Sun Oct 25, 2015 6:02 pm
    ----
Get it out & give it some use man. Don't know how you've left it so long, mine's not seen the light of day for about 2 months and im itching to get back behind the wheel of it.

#1111: Re: Project sleeper Author: Addaz, Location: Suffolk PostPosted: Mon Oct 26, 2015 5:38 pm
    ----
Im just saying one thing, at least you lot can bloody use your cars! Ive still got a few months work before i can hear my screamer pipe again! Laughing

#1112: Re: Project sleeper Author: Sim, Location: West Country PostPosted: Mon Nov 02, 2015 5:29 pm
    ----
Ok, just finished the whole 75 pages as bedtime reading, wow! Neutral Best 206 glamour illustrated magazine article ever Very Happy Nom Nom Droolage!

Sadly the roaring youtube vids have been privatised by Edward :< www.youtube.com/watch?v=Cn5on0ExmO4 www.youtube.com/watch?v=uysMC4nnbv4

I quoted you speaking highly about Omex support to a mate, who slates them for being the opposite. I think his story about Omex being arrogant and insisting the fault was the wiring (to an auto electrician!) was just a one-off, unless they've replaced their call line staff over past 5 years..!

As I read, Edward's TODO list kind-of stuck in my head, and I see that remap is still due, car can't be back on the road just yet!!! Very Happy (being sarcastic, but shouldn't give myself out, so that Edward doesn't keep on teasing us for what we've been waiting for soo long Very Happy )

#1113: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Nov 03, 2015 11:53 am
    ----
Car can be driven perfectly well with the current map I'd just prefer to give it a tidy up to account for the new intake length etc.

Won't have time to get it sorted for a few weeks yet...

#1114: Re: Project sleeper Author: Sim, Location: West Country PostPosted: Tue Nov 03, 2015 3:41 pm
    ----
Could you make those videos public again please? At least I could hear her Very Happy
www.youtube.com/watch?v=Cn5on0ExmO4 www.youtube.com/watch?v=uysMC4nnbv4

And any comment on Omex support scandal? Very Happy

#1115: Re: Project sleeper Author: Lateral_Soup PostPosted: Thu Nov 12, 2015 6:53 am
    ----
Ive read the majority of this post and the build is awesome. I'm just curious, what made you spend so much time and money on a 138 engine and not just start with an engine swap?surelyyou would have gained much more from doing the mods on a 180? you managed to gain 60+ bhp but only really 20+ over the 180. Is it down to one having a better engine over the other or just purely a labour of love for your car??

#1116: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Nov 12, 2015 4:51 pm
    ----
But in tuning a 138 engine you go further than that of the 180 engine. All the the things that make the 180 more powerful than the 138 are binned.

The 180 engine is after all a tuned 138 engine.

#1117: Re: Project sleeper Author: drmo, Location: Ljubljana, Slovenia PostPosted: Fri Nov 13, 2015 4:15 am
    ----
Not entirely true. It is more difficult to make 138 with good power and wide torque spread. You can do that with an almost stock 180 easy. We've made a little over 200hp with almost stock engine, with usable torque band from 2000rpm to 7500rpm. Just catcams 804 cams and exhaust, on DTA S60. This year we have taken it a little further with VVT delete cams and solid lifters, custom exhaust manifold and ported stock intake manifold - 235hp. Powerband from 4500-8500.
With throttle bodies I think we can get in the region of 250hp, with even better torque spread.

The main difference is in the head, which is a different casting than that of 138. The valves are 2mm bigger and ports are huge compared to 138 ports. The tappets are also bigger, which means you can have more aggressive cam profiles. All in all it is more racing oriented engine than the 138 engine.

#1118: Re: Project sleeper Author: Lateral_Soup PostPosted: Fri Nov 13, 2015 6:31 am
    ----
So in theory you could fit a 180 head onto a 138 and gain 40 odd bhp with all standard engine parts? Don't think I'm tryingto take anything away from the build, as I've said the work and effort gone in is awesome. 4/5k just seams a lot, and I personally don't have that kind of money to spend, I do however have an off the road 180 so if it's just a case of a head swap and maybe a re-map and a few other mods I could probably gain 20bhp andbe close to the same amount of power output as yours has for around £1000. Or am I being nieve?

#1119: Re: Project sleeper Author: drmo, Location: Ljubljana, Slovenia PostPosted: Fri Nov 13, 2015 9:12 am
    ----
Lateral_Soup wrote:
So in theory you could fit a 180 head onto a 138 and gain 40 odd bhp with all standard engine parts? Don't think I'm tryingto take anything away from the build, as I've said the work and effort gone in is awesome. 4/5k just seams a lot, and I personally don't have that kind of money to spend, I do however have an off the road 180 so if it's just a case of a head swap and maybe a re-map and a few other mods I could probably gain 20bhp andbe close to the same amount of power output as yours has for around £1000. Or am I being nieve?
Not Exactly like that. The 180 engine has VVT, which 138 doesn't. That is a problem as 138 ECU can't control it.

I wouldn't advise this kind of mods, except if a standalone ECU is fitted.

#1120: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Nov 13, 2015 11:24 am
    ----
But mine has a Longman head which will be better than the 180 head. For the road there is no point in fitting longer duration cams than I have fitted. The only advantage that the 180 would offer me is the higher compression and stronger bottom end.
The 180 does have bigger valves but with that comes VVT which makes life more difficult with choosing cams and to take full advantage you need a more expensive ECU which has variable cam timing control rather than the 'on/off ' control that the Omex 600 has.

#1121: Re: Project sleeper Author: Lateral_Soup PostPosted: Fri Nov 13, 2015 11:56 am
    ----
drmo wrote:
Lateral_Soup wrote:
So in theory you could fit a 180 head onto a 138 and gain 40 odd bhp with all standard engine parts? Don't think I'm tryingto take anything away from the build, as I've said the work and effort gone in is awesome. 4/5k just seams a lot, and I personally don't have that kind of money to spend, I do however have an off the road 180 so if it's just a case of a head swap and maybe a re-map and a few other mods I could probably gain 20bhp andbe close to the same amount of power output as yours has for around £1000. Or am I being nieve?
Not Exactly like that. The 180 engine has VVT, which 138 doesn't. That is a problem as 138 ECU can't control it.

I wouldn't advise this kind of mods, except if a standalone ECU is fitted.

Ah okay. Well I've only got the 180 for the interior and wheels really I was just wondering if it would be as simple as that. I'm happy with the power I've got with the engine standard if anything I'll probably just get a remap and possibly replace the paper air filter for a performance washable type and focus more on how it looks and handles Smile

#1122: Re: Project sleeper Author: Lateral_Soup PostPosted: Fri Nov 13, 2015 12:01 pm
    ----
Edward wrote:
But mine has a Longman head which will be better than the 180 head. For the road there is no point in fitting longer duration cams than I have fitted. The only advantage that the 180 would offer me is the higher compression and stronger bottom end.
The 180 does have bigger valves but with that comes VVT which makes life more difficult with choosing cams and to take full advantage you need a more expensive ECU which has variable cam timing control rather than the 'on/off ' control that the Omex 600 has.

ok well yea that makes sense, I'm pretty good with cars but I'm quite new to the newer peugot engines. Cheers for the advice guys, looks like I've got a fair bit of reading to get through lol Cool

#1123: Re: Project sleeper Author: Lateral_Soup PostPosted: Fri Nov 13, 2015 12:03 pm
    ----
Edward wrote:
But mine has a Longman head which will be better than the 180 head. For the road there is no point in fitting longer duration cams than I have fitted. The only advantage that the 180 would offer me is the higher compression and stronger bottom end.
The 180 does have bigger valves but with that comes VVT which makes life more difficult with choosing cams and to take full advantage you need a more expensive ECU which has variable cam timing control rather than the 'on/off ' control that the Omex 600 has.

ok well yea that makes sense, I'm pretty good with cars but I'm quite new to the newer peugot engines. Cheers for the advice guys, looks like I've got a fair bit of reading to get through lol Cool

#1124: Re: Project sleeper Author: drmo, Location: Ljubljana, Slovenia PostPosted: Fri Nov 13, 2015 12:51 pm
    ----
What makes you think that the longman head is better than the 180 head? Just asking about some evidence, or is it just because it is "Longman's"?

About vvt cams. No need in fitting vvt cams if you don't want to. You can fit those piper cams that you have in yours and still make better figures. We have fitted the bigest piper cams, and it still has decent powerband, which will get even better with itb's.

#1125: Re: Project sleeper Author: Motorracingbruce1980, Location: West Sussex PostPosted: Sat Nov 14, 2015 2:55 am
    ----
Out of 3 180's I've been involved with the best output I ever had on a dyno from them when standard was 171bhp! The worst one only hit 165bhp! After messing about with cams, inlets and exhausts on a 138 I'm easily reaching 165bhp and a much more usable torque curve.

Its all down to opinion and taste but I would of thought Longman would of done the research as they built many competition engines for Peugeot and were very sucessful.

#1126: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Nov 14, 2015 4:36 am
    ----
And the main reason for tuning the 138 engine is because that's what was already in the car!

#1127: Re: Project sleeper Author: drmo, Location: Ljubljana, Slovenia PostPosted: Sat Nov 14, 2015 9:33 am
    ----
Yes, of course. I didn't say that the engine is rubish, just that the 180 is a much better option to start with, and not all tuners know how to tune vvt (most think it is just an on/off thing, like with 2.2 16v).

Edward, did you solve the peaky nature of the engine?

#1128: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Nov 14, 2015 2:44 pm
    ----
It should be as good as it can get - apart from a compression increase, a N/A engine will always appear relatively gutless compared to my daily driver with 236lb ft of torque at low revs!

#1129: Re: Project sleeper Author: drmo, Location: Ljubljana, Slovenia PostPosted: Sat Nov 14, 2015 3:25 pm
    ----
With this spec cams:http://www.pipercams.co.uk/pipercams/www/product.php?pid=GTI2BP285
I would suspect a broader torque curve and much less peaky nature of the engine. May I suggest someone to look at cam timing? I've seen this before, when cam timing was off.
You still have that good looking Longman's plenum over itbs?

#1130: Re: Project sleeper Author: Lateral_Soup PostPosted: Sat Nov 14, 2015 4:37 pm
    ----
Edward wrote:
But mine has a Longman head which will be better than the 180 head. For the road there is no point in fitting longer duration cams than I have fitted. The only advantage that the 180 would offer me is the higher compression and stronger bottom end.
The 180 does have bigger valves but with that comes VVT which makes life more difficult with choosing cams and to take full advantage you need a more expensive ECU which has variable cam timing control rather than the 'on/off ' control that the Omex 600 has.

ok well yea that makes sense, I'm pretty good with cars but I'm quite new to the newer peugot engines. Cheers for the advice guys, looks like I've got a fair bit of reading to get through lol Cool

#1131: Re: Project sleeper Author: Lateral_Soup PostPosted: Sat Nov 14, 2015 4:38 pm
    ----
Edward wrote:
But mine has a Longman head which will be better than the 180 head. For the road there is no point in fitting longer duration cams than I have fitted. The only advantage that the 180 would offer me is the higher compression and stronger bottom end.
The 180 does have bigger valves but with that comes VVT which makes life more difficult with choosing cams and to take full advantage you need a more expensive ECU which has variable cam timing control rather than the 'on/off ' control that the Omex 600 has.

ok well yea that makes sense, I'm pretty good with cars but I'm quite new to the newer peugot engines. Cheers for the advice guys, looks like I've got a fair bit of reading to get through lol Cool

#1132: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Mar 11, 2016 11:50 am
    ----
Ooh a bit more spending....this can only mean one thing!

 


 


 


 

#1133: Re: Project sleeper Author: LeeThr, Location: North West Wales PostPosted: Fri Mar 11, 2016 12:28 pm
    ----
New rubber? That mean it might get a bit further than the end of you drive sometime soon? Surprised

#1134: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Mar 11, 2016 12:43 pm
    ----
Yep. Didn't want to fit new tyres if the car wasn't going to be used as they just age....so now that the weather is looking better I'm going to get it used.

#1135: Re: Project sleeper Author: LeeThr, Location: North West Wales PostPosted: Fri Mar 11, 2016 1:39 pm
    ----
Surprised I think I need to go sit down....

When was the last time it was on the road?

#1136: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Mar 11, 2016 2:35 pm
    ----
I think it was September 2012!

#1137: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Mar 12, 2016 6:15 am
    ----
£14 spent the other day. I noticed ages ago that one wheel was slightly difficult to turn by hard. The caliper was sticking slightly but the sliders were free to move when the caliper was removed. As soon as the slider bolts were tight it stuck again.
So I ordered some new sliders from Brakes International for £14. Problem fixed!

 


The old sliders did have some polished marks on them so that could suggest they weren't 100% straight. Who knows.

 

#1138: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sun Mar 13, 2016 10:09 am
    ----
and the new ones are prettier Wink

#1139: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Mar 13, 2016 11:53 am
    ----
Yes they are nice and shiny ! Might try and get it MOT'd this week.

#1140: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sun Mar 13, 2016 12:12 pm
    ----
I think we can expect a nice shiny clean pass there as well

#1141: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Mar 13, 2016 1:42 pm
    ----
Lets hope...emissions are always a concern.

#1142: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Mar 17, 2016 4:43 pm
    ----
Passed the MOT and it's now taxed too. Took it out tonight. Put it this way, those changes I made to the inlet length were well worth it. It feels like a little rocket now!

#1143: Re: Project sleeper Author: Nic_206, Location: cleaning the car PostPosted: Fri Mar 18, 2016 2:16 pm
    ----
Glad too see its now in use I can imagine there was a comment or too about just how clean it is underneath

#1144: Re: Project sleeper Author: PezHdi, Location: Shrewsbury PostPosted: Fri Mar 18, 2016 2:23 pm
    ----
Get some videos up Edward.
Congrats on passing the MOT Smile

#1145: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Mar 18, 2016 2:30 pm
    ----
They did have a close look at what had been done.

Is the gear change in the GTI always notchy and slightly stiff at times? It's been so long since its been driven I've forgotten what it was like. Maybe some new linkages could be needed.

I reckon it goes better now at 4.5k rpm than it did at 6k rpm before.been wondering what a GTI 180 engine with a ported head and my cams would be like. Higher compression and bigger valves with a stronger bottom end could be interesting.

#1146: Re: Project sleeper Author: LeeThr, Location: North West Wales PostPosted: Fri Mar 18, 2016 6:07 pm
    ----
The gear change is never the best, but generally once the box & oil come up to temperature there is no issues. When was the oil changed last? There quite fussy when it comes to oil & age/spec.

Will you take it anywhere to have the map tweaked at all?

#1147: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Mar 19, 2016 4:28 am
    ----
Oil was last done in 2012 which was less than a thousand miles ago.

I would like to get the mapping looked at. It's not perfect especially from cold and occasionally I can hear it spitting through the throttle bodies.

#1148: Re: Project sleeper Author: RandomGT, Location: Croatia PostPosted: Tue Apr 26, 2016 2:04 am
    ----
PezHdi wrote:
Get some videos up Edward.
+1
let us all enjoy the sound of it Smile

#1149: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Apr 26, 2016 11:54 am
    ----
Will see what I can do.

#1150: Re: Project sleeper Author: Sim, Location: West Country PostPosted: Tue Apr 26, 2016 5:14 pm
    ----
Nom Nom Droolage!

#1151: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Sep 10, 2016 5:48 pm
    ----
Today I finally worked out where to put my big Jenvey sticker...must be the best modification ever!

 


 

#1152: Re: Project sleeper Author: Nic_206, Location: cleaning the car PostPosted: Thu Sep 15, 2016 5:33 pm
    ----
Looks amazing as ever mate! We are still waiting on these videos though Wink

#1153: Re: Project sleeper Author: Sim, Location: West Country PostPosted: Thu Sep 15, 2016 10:22 pm
    ----
What He Said

#1154: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Oct 05, 2016 4:19 pm
    ----
Ooh what's this....? Box out of a 2007 Picasso with the 4.76 ratio final drive. Cost me £75 + postage. Peugeot dealers want £500 for the crown wheel and pinion now!

 


 


 

#1155: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Oct 22, 2016 6:28 am
    ----
Big strip down is starting this weekend. Gearbox is coming out and then the engine will be removed to change the Cambelt and locate the source of the oil leak that's been there since Ecosse had it apart.
The shorter final drive will be going in the gearbox and I'm going to fit a lightened flywheel too.


 

#1156: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sat Oct 22, 2016 12:05 pm
    ----
some great modifications there Ed..... as always, carefully planned and I have no doubt they will be well excecuted

#1157: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Oct 22, 2016 3:53 pm
    ----
Hopefully it will make the engine power a bit more accessible and more fun.

One more driveshafts to remove, exhaust can come off and the gear linkages removed and then it's time to remove the gearbox first. There's a few hours work just to get this far.

I've already decided that next year I want to make a really neat wiring loom. All the bits cost a fortune but I want it tidier. I'd love one on those looms where everything is hidden from view... Might not be possible though.

 

#1158: Re: Project sleeper Author: MattyP, Location: Plymouth PostPosted: Sat Oct 22, 2016 4:34 pm
    ----
Forgot how clean this thing is!! Makes me miss my old moonstone gti!!

You referring to what they call a "tucked engine bay"? That would look well smart mate Thumb Up

#1159: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Oct 22, 2016 6:46 pm
    ----
I'm not sure it's possible though with all of the standard original wiring still in place. Most cars with hidden wiring have the battery elsewhere too. I don't want to move the battery from the engne bay. Also with the car running two systems i.e. the original wiring for the clocks and the Omex it might always be slightly messy.

#1160: Re: Project sleeper Author: MattyP, Location: Plymouth PostPosted: Sun Oct 23, 2016 2:28 pm
    ----
Yeah definitely alot more wiring than most cars have to consider and if your wanting to keep the interior oem then you can't move the battery as you said.

Could still try and tidy the wiring up and may route them elsewhere but keeping all the components where they are

#1161: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Oct 25, 2016 5:43 pm
    ----
Engine is out now. I definitely need a bigger garage!

 


 


 

#1162: Re: Project sleeper Author: pAvax, Location: Essex PostPosted: Wed Oct 26, 2016 9:13 am
    ----
Such a clean car and engine Very Happy

#1163: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Oct 27, 2016 6:41 pm
    ----
If anybody is interested a standard 138 GTI flywheel weighs 6.6kg. It's massively lighter than the dual mass flywheel on my Jetta!

#1164: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Oct 29, 2016 5:11 pm
    ----
Finally got the engine on the stand today. Flywheel was removed the other day to enable the crank to be turned when it was on the stand. It has a slight oil leak but I'm not sure where it's coming from. I think there's one from the cam housing as there's a little puddle between the cams and on the thermostat housing. There's also one on the Cambelt end of the engine. Does anybody know what that core plug is covering on the head? Is it oil or water jacket?

 


 


 


 

#1165: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Sat Oct 29, 2016 5:59 pm
    ----
I'd replace the crank oil seal as its out anyway.

#1166: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Oct 29, 2016 6:39 pm
    ----
I did think about that but I'm also thinking that 15 year old seal that's not leaking might be more likely to be a problem if it's disturbed and a new one fitted...if you get what I mean?

#1167: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Sat Oct 29, 2016 8:16 pm
    ----
I understand what your saying, but when I changed my flywheel and clutch and put gearbox back on, my seal started leaking! All of again for a 2 minute job! Your call!

#1168: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Sun Oct 30, 2016 8:27 am
    ----
Is your leak coming from between the cam and the block? That's where mine was, just needed resealing.

#1169: Re: Project sleeper Author: MrBSI, Location: What's it to you? ? ? PostPosted: Sun Oct 30, 2016 8:47 am
    ----
Pretty sure there is a known oil leak issue on these which will be an easy fix with the engine in its current state, ill find the details.

Also if it was mine, I would replace the crank seal with a new genuine part while I had the opportunity.
A 15 year old rubber seal will be getting very tired & near the end of its working life.

The seal is £24 from a Peugeot / Citroen main dealer parts department.

Last edited by MrBSI on Sun Oct 30, 2016 9:08 am; edited 1 time in total

#1170: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sun Oct 30, 2016 9:03 am
    ----
I can whip one out and see Ed, I have several blocks here Wink

#1171: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Oct 30, 2016 10:36 am
    ----
I think the leak might be from the front camshaft seal. I will think about the crank seal.... the core plug is on the head but there's a little oil on the head directly below the cam seal.

 


 


 

#1172: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Oct 30, 2016 8:14 pm
    ----
Source of one leak found.

 

#1173: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Nov 13, 2016 5:55 pm
    ----
Bit more slow progress. Inlet cam housing has been off and resealed and a new cam seal was fitted. New water pump has been fitted too. A new Continental cambelt kit has now been fitted with new pulleys and tensioners. The sprung tensioner is a bit of a fiddle even when holding it in position with the allen key the pointer kept moving away from the correct position.
I'm not 100% how the tensioner works and the instructions state that it shouldn't be turned by a whole turn. I'm not sure if I have turned it completely or not so I think I'll spend the £38 from the Peugeot dealer and buy another one just in case! It looks ok just now, belt seems tensioned enough but best try again!

 


 


 


 

#1174: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Sun Nov 13, 2016 7:30 pm
    ----
I remember doing my belt and found the tensioner a fiddle to work out. What did you use to reseal cams?

#1175: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Nov 13, 2016 9:09 pm
    ----
It must be really hard with the engine in the car. It's probably easier with 2 people.
I used loctite 5980.

#1176: Re: Project sleeper Author: LeeThr, Location: North West Wales PostPosted: Mon Nov 14, 2016 1:39 am
    ----
I used the conti kit on mine last year, don't remember the tensioner being any issue nor has it caused any issue since fitting either.

#1177: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Fri Nov 18, 2016 8:23 pm
    ----
wow your still finding things to do? I'm just getting mine back to usable condition. I haven't used it for 8months

#1178: Re: Project sleeper Author: macj, Location: Essex PostPosted: Sat Nov 19, 2016 9:44 am
    ----
I am still experimenting with the solid tensioner from an XU engine, apparently it stops the belt whip at high RPM. I just haven't got the right belt length sorted yet

#1179: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Nov 19, 2016 10:54 am
    ----
I did think about how a solid tensioner would work and how it fits. I've got a tensioner from Peugeot now. Bit expensive and even the bolt was £6! I put the original tensioner back on the other night and we got the position correct first time.

Ordered a flywheel from Pug1off which are made by TTV in the UK. When that's on and the cam bolts are threadlocked in place the engine will be ready to go back in.

#1180: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sat Nov 19, 2016 2:25 pm
    ----
what flywheel did you get mate? I had one fitted when they built my engine.

#1181: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Nov 19, 2016 2:53 pm
    ----
The road one. 4.4kg I thing it weighs. I will be checking when it arrives.

#1182: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Dec 02, 2016 4:03 pm
    ----
Finally got the flywheel fitted. This needed some attention from the machine shop. So much for being ready to fit.

 

#1183: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Dec 02, 2016 4:19 pm
    ----
 

#1184: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Fri Dec 02, 2016 7:58 pm
    ----
What was up with it? Whats the weight difference?

#1185: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Dec 02, 2016 8:54 pm
    ----
It weighs 2.2kg less than the original. The hole for the crank dowel was drilled 0.5mm too far away from the hole. So it wouldn't fit. The dowel makes sure the flywheel sits perfectly in position to make sure the timing is perfect. There's more free play on this one so I just hope it's in exactly the right place rotationally.

#1186: Re: Project sleeper Author: pAvax, Location: Essex PostPosted: Mon Dec 05, 2016 9:16 am
    ----
Edward wrote:
 
Piece of art, that is.

#1187: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Dec 23, 2016 6:13 pm
    ----
206 is back on the road now. The final drive change makes it feel like the engine has a useful mid range now. It's much more usable and the engine can show its power without doing silly speeds. The tall gearing before only allowed the high rev power to show. It's on the edge of traction in 2nd gear now.
I'm not convinced the new flywheel was worth the expense but it won't slow things down.

Next step is a remap. It's a bit spluttery at low revs and so it definitely needs a tidy up.

#1188: Re: Project sleeper Author: Sim, Location: West Country PostPosted: Fri Dec 23, 2016 6:23 pm
    ----
Well done just in time for Xmas! What's your next challenge Edward? Shocked

#1189: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Dec 23, 2016 6:39 pm
    ----
Well after the remap I might eventually look at building a high compression bottom end with forged rods and pistons. That will allow for a higher rev limit...that will need another remap! Might look at oil coolers soon. So that will come first.

#1190: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Jan 21, 2017 6:19 pm
    ----
Hard to believe the car is 16 years old now and I've owned it for nearly 14 years. Time flies!

 

#1191: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Jan 21, 2017 6:25 pm
    ----
 

#1192: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Jan 21, 2017 6:25 pm
    ----
 

#1193: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Jan 21, 2017 6:26 pm
    ----
 


 


 

#1194: Re: Project sleeper Author: Andrew, Location: Black Country Ay I PostPosted: Sat Jan 21, 2017 6:36 pm
    ----
I love the standard OEM look

#1195: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Jan 21, 2017 6:45 pm
    ----
Reckon wheels like on Jeremy's Maserati would suit a 206? I've always liked them. They look like O.Z Rallyes to me.

 


 

#1196: Re: Project sleeper Author: MattyP, Location: Plymouth PostPosted: Sat Jan 21, 2017 7:27 pm
    ----
this thing is so clean, reminds me of my old moonstone, the one you kept saying about a private plate lol

these might look alright on yours

www.wheelbasealloys.co...oC-0Dw_wcB

#1197: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Jan 21, 2017 7:38 pm
    ----
Yeah they look ok. Years ago they also did Sparco Chromadora wheels and they looked good.

#1198: Re: Project sleeper Author: MattyP, Location: Plymouth PostPosted: Sat Jan 21, 2017 7:44 pm
    ----
considered these for my 180 but ended up buying td pro race 1.2's in anthracite which I never got round to fitting Laughing

#1199: Re: Project sleeper Author: Andrew, Location: Black Country Ay I PostPosted: Sat Jan 21, 2017 8:39 pm
    ----
I think you should get some MO5's like I want to Cool

goo.gl/images/wQuL2e

#1200: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Jan 22, 2017 10:00 am
    ----
These are similar but I think they only do 16" max.

 

#1201: Re: Project sleeper Author: PezHdi, Location: Shrewsbury PostPosted: Sun Jan 22, 2017 3:00 pm
    ----
Iv thought about this ask and Crapply PS some on and it looks alright in all fairness.
You could also look at some ronal areo or turbo wheel's.
I think turbos only go up to 15's tho.
Areo's go from 16 to 18 I think.

#1202: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Jan 29, 2017 9:23 am
    ----
I'm thinking about upping the power on mine can't decide what direction to go 2bf. I know the 180 head allows for bigger valves ect could this be an option? the only thing I really can do to mine is go forged solid lifters and more aggressive cam.
but that's practically rebuilding the engine would this spec be better used in a gti6 or 180 lump.

#1203: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Jan 29, 2017 12:24 pm
    ----
Might as well just stick some big valves in the 138 head of its going to be ported as well.

#1204: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Jan 29, 2017 6:06 pm
    ----
true I had ready have a polished and ported head. not sure how much bigger you could go in these heads. as I wanted to reuse my itb setup it was mentioned that the 180 inlet is quite a bit bigger than the 140 inlet. and my manifold could restrict the inlet and not make use of the bigger valves in the 180 head.

#1205: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Feb 26, 2017 3:50 pm
    ----
Took the car for an MOT the other day and of course it passed. It did quite a lot of stop start driving and as time went by the clutch was feeling a bit sticky. It could be felt through the pedal and I suspect it's heat from the exhaust manifold getting to the clutch slave cylinder. So I bought some heat shield stuff. Fitting it would have been so much easier when the engine was out. Never mind. Not tested it yet but hopefully it will work.

 

#1206: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Feb 26, 2017 5:41 pm
    ----
Just had a thought. Next time the subframe is off or the engine is out I might get some threaded studs welded onto the exhaust manifold. Then I can get a sheet of heat shield bolted onto the manifold. I can shape it to fit perfectly round the manifold.

#1207: Re: Project sleeper Author: LeeThr, Location: North West Wales PostPosted: Mon Feb 27, 2017 4:05 am
    ----
That'll be the clutch master cylinder Wink slave's on the front of the gearbox.

Is your manifold not heat wrapped?

#1208: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Feb 27, 2017 5:42 am
    ----
I knew that really! No heat wrap. Was advised that heat wrap can sometimes harm the manifold.

#1209: Re: Project sleeper Author: LeeThr, Location: North West Wales PostPosted: Mon Feb 27, 2017 3:39 pm
    ----
Ah right, it does seem to be a rather 50/50 split over the pro's and con's of heat wrap.

Another thing you could look at though is what brake fluid are you using? Might be worth looking at a more sport/racing orientated fluid with a higher boiling point so the heat build up of stop start takes longer to have any detrimental effect on the fluid inside the line.

#1210: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Feb 27, 2017 4:42 pm
    ----
I don't think the heating affecting the brake/clutch fluid. It's just the heat is getting to the master cylinder. Hopefully this will solve it anyway.

#1211: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Mar 05, 2017 6:22 pm
    ----
Well I think the heat shield works. Drove for a few miles yesterday and the pedal remained smooth.

Spent some more money. Wanted to replace the rear damper nuts and bolts. I didn't change them when I refurbished everything 5 years ago. However due to stupid minimum order quantities it would have cost me £50. So I settled for just replacing the nuts. Even these cost £25. I have resprayed the bolt heads in silver. The time has come to avoid peugeot dealers for fixing like this and buy stuff from Ebay instead. They are just nuts at the end of the day.

 

Last edited by Edward on Tue Mar 07, 2017 6:15 am; edited 2 times in total

#1212: Re: Project sleeper Author: PezHdi, Location: Shrewsbury PostPosted: Tue Mar 07, 2017 6:04 am
    ----
As always good work.
Glad the heat foil/sheet is working
How did you make your cross member for the radiator, im guessing it's so kind of box section?

#1213: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Mar 07, 2017 7:30 am
    ----
I just got some aluminium box tubing from B&Q and fitted some angle brackets to the end to fix it to the car. I used the original plastic radiator mounts to hold the radiator in place.

#1214: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Mar 17, 2017 4:32 pm
    ----
Hopefully this video link to Photobucket will work.

It's filmed from a Blackvue dashcam so hardly the best audio quality.

 

#1215: Re: Project sleeper Author: MattyP, Location: Plymouth PostPosted: Sat Mar 18, 2017 6:48 pm
    ----
Edward wrote:
Hopefully this video link to Photobucket will work.

It's filmed from a Blackvue dashcam so hardly the best audio quality.

 

sounds awesome mate Thumb Up

#1216: Re: Project sleeper Author: Sim, Location: West Country PostPosted: Sat Apr 08, 2017 10:13 am
    ----
Music to me ears! After all these years, even a sh*te audio quality tells a hundred words Smile

..ok and now please get a better mic Very Happy

Any plans for the impending warm weather times?

#1217: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Jun 20, 2017 11:26 am
    ----
I will get a better video up soon...a video of the gearbox going bang! No idea why it did it but it's knackered now!

#1218: Re: Project sleeper Author: Sim, Location: West Country PostPosted: Thu Jun 22, 2017 9:38 am
    ----
Sounds like another brilliantly clean sub-project is coming up Smile

#1219: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Jun 22, 2017 3:57 pm
    ----
 

#1220: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Fri Jun 23, 2017 5:27 pm
    ----
Edward wrote:
I will get a better video up soon...a video of the gearbox going bang! No idea why it did it but it's knackered now!

Didn't you change the gear ratios a while back? Bummer for you either way.

#1221: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Jun 23, 2017 9:11 pm
    ----
It had a new final drive and pinion put in it. I've not taken it apart yet to see what's broken.

#1222: Re: Project sleeper Author: spike_202, Location: West mids PostPosted: Sun Jun 25, 2017 7:40 pm
    ----
ouch, the good thing is that gearboxs are cheap to fix / get hold of engines of our spec and tune are not so hope nothing has gone that side. keep us posted on your findings

#1223: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Jun 25, 2017 8:18 pm
    ----
At first I thought it had thrown a rod through the block but when there was no smell of oil or smoke I was slightly puzzled. I don't think this will be that cheap to fix. I just hope the new CWP is ok because they are difficult to find as you know!

It was previously a perfectly good low mileage gearbox. The ones from salvage yards are so good. Will check out the ratios on gti 180 boxes to see what they are like with this 4.76 FD in it.

#1224: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Sep 16, 2017 6:16 pm
    ----
Oh dear. So what could cause this?


 

#1225: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Sun Sep 17, 2017 12:31 pm
    ----
Have you been crunching your gears!!

#1226: Re: Project sleeper Author: macj, Location: Essex PostPosted: Wed Sep 20, 2017 2:47 pm
    ----
Too much power mate

#1227: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Sep 20, 2017 5:25 pm
    ----
Must be that invisible turbo that is attached! I doubt I've gone over the 188lb ft torque limit of the BE4 gearbox.

#1228: Re: Project sleeper Author: macj, Location: Essex PostPosted: Thu Sep 21, 2017 1:42 pm
    ----
Lol..... looks like one of those things unfortunately.... things that are sent to try us mate

#1229: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Oct 24, 2017 6:02 pm
    ----
And this is what happened. Looks like 1st gear got very hot and welded itself to the output shaft. This had the effect of engaging two gears at the same time.

One reason for this could be because some sealant got into the oil journal on the shaft. Another reason is these boxes come with different thicknesses of roller bearing. The older 2mm thinner bearing is used with a needle roller bearing but my mechanic fitted the new shaft with the later thicker bearing and also fitted the needle roller bearing. This meant things would be tighter which probably explained why he struggled to get the shaft nut on properly without loctiting it!

Two gearboxes are now on order- a gti 180 box for its gears and another Picasso for the final drive. I've also got new bearings on order and bits of gear teeth might have got into the existing bearings.

 

#1230: Re: Project sleeper Author: PezHdi, Location: Shrewsbury PostPosted: Tue Oct 24, 2017 7:54 pm
    ----
As always Edward interesting stuff.
These things are sent to try us tho.
Onwards and upwards Smile

Pez

#1231: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Nov 22, 2017 6:23 am
    ----
So I now have one 307cc 180 gearbox (code 20DM43) and another Picasso 1.8 gearbox (20DM71), as well as the original 20DM17 from the 206 GTI and 20DM71 from the first Picasso.

The 307 CC 180 gearbox comes with a 17x73 = 4.29 final drive which might be a good compromise in terms of ratio. I will be fitting the shorter 4.76 from the Picasso though.

My plan is to fit the 307cc 180 ratios (inc tall first gear) with the short 4.76 FD and the 5th gear from the Picasso as 65mph meant 4k rpm. The taller 5th gear should mean 4k rpm equals 78mph. Perfect for motorways....not that it will be used on motorways.

Lots of spares NOW!
 


 


 

#1232: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Nov 22, 2017 6:30 am
    ----
And ive also found a few small differences between these gearboxes which vary from bearing thicknesses and diameters to changes in the gearbox casings . I will take pictures later.

#1233: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Nov 25, 2017 9:50 am
    ----
As the car will be going back together soon I've started buying some little bits.

£6.19 for a new clutch release bearing from GSF.

 

#1234: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Dec 01, 2017 4:28 pm
    ----
More from GSF car parts.

£16.64 for an FTE clutch slave cylinder. Same brand as the OE part.

 

#1235: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Dec 10, 2017 8:25 am
    ----
Both the GTI 138 AND 307CC 180 gearbox housing went for soda blasting and they both cleaned up pretty well. The 138 housing which I will be using had been cleaned up to remove any soda has started to change colour already. It might be the white spirit that I used to clean it out with.

 


 


I've also ordered new driveshaft seals and reverse switch with the JPT connection rather than the standard peugeot plug. I'm trying to get rid of standard peugeot plugs as id rather use the more widely available JPT plugs.

#1236: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Dec 15, 2017 4:11 pm
    ----
Noticed another difference earlier. I just happened to put the original 138 GTI diff next to 2 of the other diffs I have. Looks like the crownwheel attached to the opposite face on the diff flange...

 

#1237: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Mar 24, 2018 6:22 am
    ----
Gearbox has been rebuilt with fresh gears, seals and bearings.this time I used the Picasso 5th gear which is taller than the 206 GTi gear.

 


 


 

#1238: Re: Project sleeper Author: Sim, Location: West Country PostPosted: Tue May 01, 2018 11:31 am
    ----
How does it feel to drive now after all this shiny soda-blasty rebuild? Nom Nom Droolage!

Me and potentially VorTechS have some photos lined up, that are from the Edwardian era (read: spanking new parts!)

#1239: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue May 01, 2018 4:10 pm
    ----
Dunno yet. It's only been up and down the driveway so far. Needed a new wire exhaust gasket for the flexi joint but it should be completely ready to drive now. Also.got some new bolts for the exhaust too.

 

#1240: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Oct 02, 2018 8:09 pm
    ----
I've decided it's time for an oil cooler!

I've fitted a Mocal thermosat sandwich plate and I've sent the Radtec radiator back to get some oil cooler mounts fabricated to mount the cooler on the front of it.

Hopefully it will come back with some -10 JIC fittings and I will then get some hoses made.

 


 

Last edited by Edward on Tue Oct 02, 2018 8:16 pm; edited 1 time in total

#1241: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Nov 04, 2018 2:35 pm
    ----
All finished now. It's amazing how much this costs. Over £300!

Oil is going into the cooler so hopefully it will keep the oil temperatures down.

 


 


 


 


 

#1242: Re: Project sleeper Author: VorTechS, Location: Gloucestershire, UK PostPosted: Mon Nov 05, 2018 10:32 am
    ----
It's amazing just how 'uncluttered' all that looks!

Looks like there's so much room to be able to get to bits easily, or is it just a trick of the camera?

#1243: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Nov 05, 2018 1:38 pm
    ----
There is plenty of access. The jenvey inlet is a lot less bulky than the standard plastic inlet so that frees up a lot of space under the manifold.

#1244: Re: Project sleeper Author: Rubyoptics, Location: Warsaw - Poland PostPosted: Tue Nov 20, 2018 2:02 pm
    ----
A work of art.

#1245: Re: Project sleeper Author: RandomRoss PostPosted: Fri Nov 23, 2018 4:11 am
    ----
Wow! It's looking amazing! can't wait to see it finished!

#1246: Re: Project sleeper Author: RandomRoss PostPosted: Fri Nov 23, 2018 4:11 am
    ----
Wow! It's looking amazing! can't wait to see it finished!

#1247: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Nov 23, 2018 4:36 pm
    ----
It is finished!

#1248: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Fri Nov 29, 2019 6:57 pm
    ----
Any updates Edward? Not that you could do much more to it!

#1249: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Nov 07, 2020 9:22 pm
    ----
 


 

#1250: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Sun Nov 08, 2020 4:56 pm
    ----
As clean as ever!

#1251: Re: Project sleeper Author: Sim, Location: West Country PostPosted: Sun Nov 08, 2020 7:46 pm
    ----
Indeed! Reckon we can expect another update in a year's time Smile

#1252: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Nov 08, 2020 9:42 pm
    ----
It's been 8 years since it was last done so it needed a refresh. I'm going to get the wheels refurbed again - last done 12 years ago and get the mapping sorted at last!

Should be getting the rear brake disc shields back from powder coating this week.

#1253: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Tue Nov 10, 2020 6:16 pm
    ----
Does it get driven much now? How many miles have you put on it in the last 12 months?

#1254: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Nov 12, 2020 7:51 pm
    ----
It probably did maybe 200 miles in the last year... it's only done 800 miles since 2012!

#1255: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Nov 13, 2020 1:24 pm
    ----
Got these powder coated too.

 

#1256: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Nov 13, 2020 3:42 pm
    ----
These will be getting sprayed with Hammerite as they couldn't be powder coated.

 

#1257: Re: Project sleeper Author: VorTechS, Location: Gloucestershire, UK PostPosted: Mon Nov 23, 2020 10:50 am
    ----
It's not surprising how bad the backing shields get, given the amount of crap they have to put up with.

I've never stripped the back wheels down far enough, and it didn't look like the shields were replaceable, for some reason! Always wondered what the next move would be!

Now I know... Wink

#1258: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Nov 29, 2020 5:37 pm
    ----
These went off for a refurb the other day. Not bad at all from a distance but starting to look scabby on the back of them.

I've gone for a standard silver this time so hopefully they'll look brand new again.

 

#1259: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Dec 05, 2020 9:16 pm
    ----
Looking pretty good now with the wheels refurbed too.

 


 


 

#1260: Re: Project sleeper Author: Mike PostPosted: Fri Jan 01, 2021 1:53 pm
    ----
Great to see this is still alive!

Looking at a 180 as a track toy currently

#1261: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Feb 27, 2021 7:03 pm
    ----
I moved the injectors back to the original position pointing at the valves. Runs massively better than when they were upstream in the bodies.

Needed a custom Jenvey fuel rail for this...does exactly the same job as the Peugeot rail!

 

#1262: Re: Project sleeper Author: Andrew, Location: Black Country Ay I PostPosted: Mon Mar 01, 2021 9:43 pm
    ----
The original 206 so clean that you could see your reflection in the underbody

#1263: Re: Project sleeper Author: Sim, Location: West Country PostPosted: Mon Mar 22, 2021 4:29 pm
    ----
Top-drawer Edward no doubt!

VorTechS wrote:
It's not surprising how bad the backing shields get, given the amount of crap they have to put up with.

I've never stripped the back wheels down far enough, and it didn't look like the shields were replaceable, for some reason! Always wondered what the next move would be!

Now I know... Wink

As the saying goes, "new is the long-forgotten old" Wink Scroll up/down from www.206info.co.uk/Foru...tml#656817 Cool Laughing

#1264: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Jun 28, 2021 6:09 am
    ----
The attention to detail of Ecosse continue to haunt this car even ten years later.
I paid them best part of £50 to port match the inlet to the cylinder head. They weren't actually going to do this until I checked whether they'd be doing it as part of the installation - you'd expect this to be done when spending £4k on the job!

They did nothing about checking whether the bodies that they supplied matched the inlet though! All 4 inlets have the same sort of problem!

 

#1265: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Mon Jun 28, 2021 7:25 pm
    ----
Did they actually port the head?

#1266: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Tue Jun 29, 2021 10:23 am
    ----
No it's a Richard Longman head.

#1267: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Oct 06, 2021 7:18 pm
    ----
I should update this.

Finally got the car remapped recently. It spent 5 hours on the rolling road no doubt getting rather hot. It did sound rather nice even from behind triple glazed glass..

What was supposed to be a few hours of minor adjustments ended up being a complete fresh start as the original mapping had a few corners cut!

It made 204 BHP.

#1268: Re: Project sleeper Author: andy83, Location: stoke on trent PostPosted: Fri Oct 08, 2021 6:55 pm
    ----
love this fella, great dedication to the cause Smile

how does it feel out on the road?

power seems to be bang on the money as well, im hoping to see similar if not a tad more running newman ph4 cams down the line.

#1269: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Oct 17, 2021 8:00 pm
    ----
Car feels fine to drive. It's never going to be as flexible as a turbo engine but for a quick blast it's a fun little car.

It will be SORNed soon and the cam belt will be changed and I want a v band joint fitting to the exhaust to replace the leaky sleeved joint.

Does anybody know if Peugeot sell replacement clutch hoses still?

#1270: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Wed Feb 23, 2022 10:40 am
    ----
This year is cambelt change time! I noticed a little bit of extra movement in the engine mounts when stripping everything down. A bit odd and this turned out to be a cracked mount - this possibly happened when the gearbox went bang a few years ago.

 


Mount removed from the car.
 


 


All welded up and reattached to the car and fresh paint applied.
 


While the engine was out I also got the coolant pipe powder coated.

 


New exhaust manifold studs and nuts. Manifold was polished a bit too and more heat proof paint applied to the flange.

 


The alternator bracket and PAS pump bracket have also been powder coated too.

 


 


Next job is to change the water pump and cambelt then the engine can go back in the car.

#1271: Re: Project sleeper Author: andy83, Location: stoke on trent PostPosted: Thu Feb 24, 2022 4:59 pm
    ----
top work fella, love the updates

#1272: Re: Project sleeper Author: JamieM PostPosted: Wed Jun 08, 2022 11:24 am
    ----
Love the attention to detail Edward,

Super cool 206! It must be a right hoot to drive!

#1273: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Jul 21, 2022 9:55 am
    ----
All back together now. I even went against my own advice and fitted a 22mm front ARB from a GTi 180. I had it powder coated in a light grey too so looks better than new. It does give a bit more feel at the front end. That 1mm does add a fair chunk of stiffness.


 


 


 

#1274: Re: Project sleeper Author: Quarmbo, Location: Bristol & Leicester PostPosted: Tue Jul 26, 2022 10:12 am
    ----
[quote="Edward"]All back together now. I even went against my own advice and fitted a 22mm front ARB from a GTi 180. I had it powder coated in a light grey too so looks better than new. It does give a bit more feel at the front end. That 1mm does add a fair chunk of stiffness.

Logged on after 10 years and to still find this thread going is as reassuring as day and night. Good man Edward.

#1275: Re: Project sleeper Author: MattyP, Location: Plymouth PostPosted: Tue Aug 02, 2022 6:37 pm
    ----
Good to see progress is still being done on this Gti.

Should be worthy of a spot in the Haynes Motor Museum if it is ever finished.

#1276: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Sun Nov 20, 2022 5:28 pm
    ----
Any updates?

#1277: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Nov 25, 2022 9:22 pm
    ----
Updates???

I've bought a spare engine and I've ordered a coil pack plug from the dealer as I want to order a custom race spec loom from Omex. Once i have that connector i want to finally find out how to make the Omex tacho output work the Peugeot rev counter.
When I know the answer to that I will order the lovely loom from Omex.

#1278: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Nov 25, 2022 9:28 pm
    ----
 

#1279: Re: Project sleeper Author: Steve206, Location: UK PostPosted: Fri Nov 25, 2022 9:32 pm
    ----
Well I meant updates as in have you done anything! What’s the plans with the engine?

#1280: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Nov 26, 2022 12:33 pm
    ----
I can't really move on until I get that coil pack connector. They are on back order and have been for a few weeks.
When the new loom is done it will look much smarter and everything will be hidden away more.

#1281: Re: Project sleeper Author: Addaz, Location: Suffolk PostPosted: Tue Dec 20, 2022 10:19 pm
    ----
Did you manage to get your rev counter working? I stupidly run an omex 710 for no other reason than wanting a headache when ever I use MAP4000.

I've managed to get mine working but I haven't the foggiest what I did, I have a suspicion it was relatively simple, just a bit of wiring digging for the cluster (yours is preplex too from memory?)

Also what connector do you need? The coilpack one for the 138? May be able to source one if you need.

#1282: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri Dec 23, 2022 6:33 pm
    ----
My rev counter has always worked, I just don't like the way both the Omex and original ECU are connected and share the crank sensor.

I'm trying to get hold of a new coil pack plug. I've got a spare plug on a loom but it's not obvious how to take it apart to reuse it with new terminals. The dealer has the terminals but the rest hasn't turned up yet.

#1283: Re: Project sleeper Author: Addaz, Location: Suffolk PostPosted: Sun Dec 25, 2022 10:48 pm
    ----
The terminals are just junior power timers, nout special and easy to remove with the right tool. You shouldn't need to share a crank signal. On preplex there is no real need for the original ecu as the omex/original sensors will do everything you need.
You need to run both if the can network has not been sorted on the standalone for any mux car.

#1284: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Thu Apr 13, 2023 11:35 am
    ----
If anybody ever wants to de-pin one of these coil pack plugs you need a 2 pin tool. Each terminal is held in with 2 barbs which need pushing back at the same time.

So i now have a plug from the used engine and some new terminals from the local Citroen dealer. So I can now get on with ordering the custom race loom from Omex.
I'll also order a new lambda sensor and throttle position sensor to go with the new loom.

#1285: Re: Project sleeper Author: Addaz, Location: Suffolk PostPosted: Mon May 15, 2023 7:34 pm
    ----
If I was you mate and you had the funds, I'd ditch the omex and get nicer ecu that's up to date and a bit more user friendly!
I've got an omex 710 and detest every second of working with its annoyingly clunky interface, the turbo conversion kit for the 180's I do run SCS delta 700 and it's so much nicer to work with.

#1286: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sat Dec 30, 2023 12:23 pm
    ----
Next little job. I've noticed some parts are no longer available for the 206 from the Peugeot dealer anymore. This includes the hydraulic clutch hose. Mine wasn't in bad condition but I'm sure one day it would need replacing which would be difficult if spares weren't available. #
I noticed Beignat Competition in France did adaptors to fit the standard master cylinder and slave cylinder. So while these adaptors are still available I decided to convert my rubber and metal hose to a -4 JIC fitting using Goodridge 600 hose and fittings from Merlin Motorsport.

Total cost is about £160.

 


 


 


 

#1287: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Mon Apr 15, 2024 5:53 pm
    ----
Treated the car to a new loom. Always wanted to tidy the wiring and this one does the job. It's a bespoke race loom from Omex and was over £700.

I decided to fit a new lambda sensor too as the original is over 20 years old. The mild steel lambda boss in the stainless manifold didn't want to cooperate though so the subframe had to come off to get the manifold off. So I've ordered a lambda boss thread chaser which will hopefully clean up the threads to allow the new sensor to be fitted.

 

#1288: Re: Project sleeper Author: Sim, Location: West Country PostPosted: Fri Apr 19, 2024 11:20 am
    ----
As always, clean as a whistle!

Thanks for pointing out how to refresh brake fluid hydraulics. Didn't like when bleeding brakes I pressurised the reservoir (2bar as PP2000 said) on our CC, and before too long it started to leak from here:
 


Nothing leaks under normal operation, but such tests sure point out the weak links!

#1289: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Fri May 17, 2024 7:51 pm
    ----
Next job. As I wanted a totally standalone loom this meant the original tacho couldn't be connected to the original crank sensor. The only way to get this to work was to fit an aftermarket tacho.
Ideally the old tacho could be removed and a new one fitted but as the clocks are all built around a printed circuit board there's no way I'm hacking it apart.

So this is the next best thing. Stack ST200 sat in a pod. It blocks the view of the temperature gauge but I can live with that.

That's another £400 spent!


 

#1290: Re: Project sleeper Author: Edward, Location: In the garage PostPosted: Sun Sep 15, 2024 6:06 pm
    ----
More money spent, the rear dampers were 20 years old, so for no other reason than them not looking particularly smart anymore I decided to replace them.

 



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