#1: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Fri Apr 09, 2010 5:44 pm ---- Ok so i have been saying for a while that I would start a project thread so here goes!
Bought the car from a guy WAY up north of Scotland and had the interior etc stripped out it and partly seam welded plus a few bits to install to make it a rally car.
original car before any work!
Inside all stripped out and welding started on all the seams
Engine bay with all the seams welded and painted to try and stop rust
All the sealer removed from the underside of the car and welding along the chassis rails etc
Ok so that was the state of the car when I bought it so the rest of the work was me. Thanks very much to the guy i bought it from for removing the sealer ive just done it on a 205 rally car im preparing and its one horrible job!!
Customs weld in cage to be fitted
New engine bay with the cage fitted
Inside the door. How i get in and out of there when the seats are in i dont know!!
Inside of the car with the cage fitted, seat rails welded in, all seams welded up
Bilstien jack points welded into the sills!
Roll cage finished
Then i faced the engine problem. What one to use.
I first started with the standard GTI engine.
Thought that i might get bored with that one so i bought a GTI 6 engine
Decided that putting a heavy engine in the front of a rally car may not be the best for handling and with a standard 180 engine the same performance id try a 180 engine!
Think i could join them together???
Ok look another engine this time an MI16 from a 405 mhhhh which to choose!!!
Choices!!! So that is where i stand so far with the project
Future work includes:
The quaife gear close ratio gear kit and tran x diff to be intalled into either the standard or gti180 box
Peugeot sport group a suspension to be fitted
I have plumbed in fire eater all ready, electrical cut off switch ready. I bought the reg plat BIG 2066 last year as well which i think is a cool touch for the car.
Im after Jamie's throttle bodies so i will see if i can raise the funds to purchase them and make this a real 180 BEAST!!
Im still working on the 206s older sister the 205 just now so progress may be slow but i hope to have the car done for September to compete in the International Rally of Scotland.
205 rally car
Comments welcome and any advice!!
#2: Re: 206 GTI 180 Rally car project Author: andre206, Posted: Fri Apr 09, 2010 5:48 pm ---- Good luck mate, looks really interesting and i look forward to the end result!
#3: Re: 206 GTI 180 Rally car project Author: Brian, Location: VVT Land, FifePosted: Fri Apr 09, 2010 6:53 pm ---- Have fun wiring that all up pal. LOL. Cool project
#4: Re: 206 GTI 180 Rally car project Author: jimmyfloydreturns, Location: SittingbournePosted: Sat Apr 10, 2010 12:10 am ---- Good work! I'll follow this thread with interest....
#5: Re: 206 GTI 180 Rally car project Author: pug150, Location: birminghamPosted: Sat Apr 10, 2010 1:43 am ---- gota be the 180 engine to put in id say as them mi16s are old and worn out compared to newer engines!!! great project though be good to see the finish
#6: Re: 206 GTI 180 Rally car project Author: Edward, Location: In the garagePosted: Sat Apr 10, 2010 2:13 am ---- There are pros and cons of using the 180 engine. Setting up the 138 engine on throttle bodies is easier and there are more engines out there if spares are needed.
The 180 has a modified bottom end which could mean it's stronger and the cams will help get more power out of it. The downside is the VVT which is harder to set up but also gives a torque advantage if you can set it up with standalone management.
#7: Re: 206 GTI 180 Rally car project Author: spike_202, Location: West midsPosted: Sat Apr 10, 2010 2:44 am ---- id say the gti6 mate buletproof block, like ed said you need to get spair parts and id imagin 180 parts are rather expensive lol. Looks a good project mate would like to see this against macj's rally project
#8: Re: 206 GTI 180 Rally car project Author: macj, Location: EssexPosted: Sat Apr 10, 2010 7:32 am ----
spike_202 wrote:
id say the gti6 mate buletproof block, like ed said you need to get spair parts and id imagin 180 parts are rather expensive lol. Looks a good project mate would like to see this against macj's rally project
So would I.... Good to see someone else in the sport building a 206 stage car
#9: Re: 206 GTI 180 Rally car project Author: wagsy206, Location: Coatbridge, LanarkshirePosted: Sat Apr 10, 2010 7:54 am ---- nice project man. just a shame though, the car looked stunning before all the work was started. but i suppose rally performance comes at a price. lol
keep it updated as often as you can. will be good to see the finished article and how it performs
nice project man. just a shame though, the car looked stunning before all the work was started. but i suppose rally performance comes at a price. lol
keep it updated as often as you can. will be good to see the finished article and how it performs
It was a CAT D right off so i have saved it from a life in the scrapie
Tried to fit the dash but it was a total pain in the a$$ trying to cut bits out to get it to fit around the roll cage!! Next step is to paint i think or maybe take the sump off the 180 engine to check its all ok. Should be as it has only done 30000 miles but best to check i suppose
#11: Re: 206 GTI 180 Rally car project Author: Austin, Location: TelfordPosted: Wed Apr 14, 2010 10:34 am ---- sounds like you got a great project going, look forward to watching this. B)
#12: Re: 206 GTI 180 Rally car project Author: DJ-, Location: UKPosted: Wed Apr 14, 2010 2:02 pm ---- Interesting project, will def follow this progress!
Been working hard over the last few weeks on the 205 but i have finally managed to get some time to work on the 206!!
I have removed all sealer from the bottom now as well as the inside, welded up all the drainage plug holes which takes ages!
The engine bay was primed ready for paint on tuesday and i have just finished off the rest of the body in primer tonight. Will update with those photos tomorrow its like a purple haze out there just now with the fumes.
Anyways here are the pics of the engine bay, inside all primed and the rest of the body all prepared for the primer to go on.
#14: Re: 206 GTI 180 Rally car project Author: twed207, Location: borders, near carlisle.Posted: Thu Jul 15, 2010 5:52 pm ---- wow, great project there mate! will keep a close eye on this one!
are you using standard internals or going the whole hog?
#15: Re: 206 GTI 180 Rally car project Author: Quarmbo, Location: Bristol & LeicesterPosted: Fri Jul 16, 2010 2:34 am ---- Cool project. You decided on what engine to use?
#16: Re: 206 GTI 180 Rally car project Author: Schumi, Location: Istanbul / TurkeyPosted: Fri Jul 16, 2010 6:11 am ---- Good choice of engine. Always EW>XU ;). Dont worry about VVT and DWB. If you have any standalone its not problem. Because you can use 1999 year 206 gti vernier pulley for disable VVT and very simple butterfly modification for older mechanical style.
Yes i will be using the 180 engine with cat cams and throttle bodies. I have two 180 engines here just incase anything goes wrong.
I have one of the engines in bits to check its all ok inside and it seems to be fine so i think i will go with this.
I am going to use an aftermarket ECU to power the engine side of things but i will have to keep the existing wiring to power all the dash equipment.
#18: Re: 206 GTI 180 Rally car project Author: Jamie, Location: Ring y0Posted: Fri Jul 16, 2010 7:09 am ---- Steve how far have you got with the bodies etc? Have you had the Jenvey manifold machined yet?
You still got my email?
#19: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Fri Jul 16, 2010 11:04 am ---- Hi Jamie. Not got the throttle bodies yet but I was looking at another car that had throttle bodies fitted on a 180 so i have a rough idea of the problems that need to be dealt with. Have you got yours fitted yet?
Yeh i still have you email addy.
#20: Re: 206 GTI 180 Rally car project Author: Jamie, Location: Ring y0Posted: Fri Jul 16, 2010 11:08 am ---- Mine's going in to be done in the next few weeks, do you have all the bodies and manifold/linkages etc?
What ECU are you going to be using?
#21: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Fri Jul 16, 2010 4:01 pm ---- That sounds good you will need to let me know how it goes and anything that needs modified then lol No i dont have any of the kit yet. Im still doing the bodywork so i put the engine on hold. I will be starting on it fairly soon though.
I am going to use emerald for the ECU i have dealt with them in the past. Do you know if you can use the aftermarket ecu for the speedometer/re counter or do you have to keep the standard ecu to deal with that?
#22: Re: 206 GTI 180 Rally car project Author: Schumi, Location: Istanbul / TurkeyPosted: Fri Jul 16, 2010 4:07 pm ---- 206gti180 cluster is communicated with BSI. Not ECU. So if you remove your stock ecu your a lot of gauge didnt work. (maybe fuel and temp work). Because gti180 have to much electronic (i hate that). Solution is simple. Paralel installation. Keep your stock ecu and move ignition and injection operations to your emerald. Both ecu will work with happiness. All gauge and cluster will work. This is used method on 206gti180 turbo car in Turkey.
#23: Re: 206 GTI 180 Rally car project Author: macj, Location: EssexPosted: Fri Jul 16, 2010 4:23 pm ---- The emerald has been rumoured to work with VVT. Dave Walker at Emerald is very easy to talk to so it pays to discuss your requirements with him. Good choice
#24: Re: 206 GTI 180 Rally car project Author: Jamie, Location: Ring y0Posted: Fri Jul 16, 2010 4:48 pm ---- I equally recommend DTA
#25: Re: 206 GTI 180 Rally car project Author: Schumi, Location: Istanbul / TurkeyPosted: Sat Jul 17, 2010 5:23 am ----
Jamie wrote:
I equally recommend DTA
How can you recommend DTA. You just bought. Not connect to car and not actualy using. Emerald is oke. Maybe DTA is also oke but dont recommend before use.
#26: Re: 206 GTI 180 Rally car project Author: Edward, Location: In the garagePosted: Sat Jul 17, 2010 8:11 am ---- At the end of the day no ECU can give anymore power than another.
In my experience the datalogging ability of the Omex 600 and the 710 with its onboard logging facility are very worthwhile. Do other ECUs offer this facility?
Omex technical support is extremely good as well.
#27: Re: 206 GTI 180 Rally car project Author: macj, Location: EssexPosted: Sat Jul 17, 2010 8:20 am ---- Not many offer onboard logging but with the software available now it is possible to get most ECU`s to datalog live. I have the capability on the Mtech to datalog and self learn, but I inhibit the self learning as I dint want it getting all enviromental on me and leaning off my fuelling map.
As far as the pro`s and con`s of any ECU is concerned I feel personally it is down to the useage and the technician who is programming. If you want an ECU that just deals with ignition, you buy a cheaper version. Most nowadays will handle full ignition/injection capabilities and only vary really by the power of their individual processors, memory storage and sensor language. Same as a PC really in laymans terms.
Hope this helps
#28: Re: 206 GTI 180 Rally car project Author: Schumi, Location: Istanbul / TurkeyPosted: Sat Jul 17, 2010 8:39 am ----
Edward wrote:
At the end of the day no ECU can give anymore power than another.
In my experience the datalogging ability of the Omex 600 and the 710 with its onboard logging facility are very worthwhile. Do other ECUs offer this facility?
Omex technical support is extremely good as well.
Yes ECU brands didnt give extra power. They give good or bad support on phone or email. Solutions for problems. Most difference is tuning software. Onboard logging to SD card is good but not important for me. MS3 is also provide logging to onboard SD memory card slot. Anyway.
Some ECU have different boost level for each gear. (low boost on 1-2 gear and middle boost on 3 and finaly full boost on 4-5 maybe 6)
Better corrections. Better extra parameters. Better idling. Better knock control etc.etc. All of this possible when you have money.
#29: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Sat Jul 17, 2010 8:48 pm ---- I decided to use emerald as my local tuner knows them best plus I have had good help when using them before.
Finished the paining tonight so here are the pics. Just need one final layer and then a good polish before i can start putting all the new bits in
#30: Re: 206 GTI 180 Rally car project Author: macj, Location: EssexPosted: Sun Jul 18, 2010 8:30 am ---- Looking good.... how long do think the build will take?
#31: Re: 206 GTI 180 Rally car project Author: spud_owen, Location: ashby de la zouchPosted: Mon Jul 19, 2010 7:12 am ---- looking very good, proper job! sorry to be abit cheeky but do you think you could send me a few more pics of the 205, im building one on a very tight budget and just interested in how others have gone about things, dash board sump guard mountings etc, any help would be good!
#32: Re: 206 GTI 180 Rally car project Author: Schumi, Location: Istanbul / TurkeyPosted: Tue Jul 20, 2010 4:53 am ---- I will be jealous. Very beautiful.
Looking good.... how long do think the build will take?
Im not really sure how long it is going to take to finish it off. I dont think it will take too long to do all the standard parts but fitting the ecu and electrics may be a wee bit more complicated. I am hoping to have it done before the year is out though.
Quote::
looking very good, proper job! sorry to be abit cheeky but do you think you could send me a few more pics of the 205, im building one on a very tight budget and just interested in how others have gone about things, dash board sump guard mountings etc, any help would be good!
Sure thing i will post some photos up later on. Is there any particular area you want photos of?
#34: Re: 206 GTI 180 Rally car project Author: spud_owen, Location: ashby de la zouchPosted: Tue Jul 20, 2010 9:49 am ---- cheers mate, mainly the 'c**k pit' area need to see where others are putting switches etc, also be interested in some of the sump guard and how its mounted, as ive been given a good thick alloy one but im not sure weather itl be wide enough, so for the tank guards would be a help to as i got some cheap and there the next job to fit! But anything would be a help, many thanks, pm and email them if you like instead of hosting here, whatever is easier for you.
#35: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Tue Jul 20, 2010 6:15 pm ---- Update on the 206 from work done today:
#36: Re: 206 GTI 180 Rally car project Author: Jamie, Location: Ring y0Posted: Tue Jul 20, 2010 6:16 pm ---- What's the lever for? Hydraulic handbrake?
#37: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Tue Jul 20, 2010 6:31 pm ---- Pictures of the 205 for spud_owen. I have the seats out just now because it took a bit of a battering on the last rally so it need a bit of welding and some painting on the floor
General view
Engine bay
Wheels
Sump guard mount and side plates
Dash
Rear of the car
Where the seats would be
Under the back
Tank guards
More of the car with a nice covering of over spray from the 206
#38: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Tue Jul 20, 2010 6:33 pm ---- Yeh Jamie it is the hydraulic handbrake. I need to keep the standard one to comply with the road traffic act sadly. Unless i can get it tp look like the hydraulic one pulls the cables
#39: Re: 206 GTI 180 Rally car project Author: Jamie, Location: Ring y0Posted: Tue Jul 20, 2010 6:49 pm ---- Yeah you need a machanical handbrake for MoT or RTA like you said!
How's the progress regarding the engine coming along?
#40: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Tue Jul 20, 2010 7:02 pm ---- Just got the sump to put back on and then i can put it in place. I will need to order uprated mounts before that.
I will call emerald tomorrow as well and remind them they owe me a discount off my ecu so will get that ordered up as well soonish i hope.
Do you know when yours is going in to be done yet?
#41: Re: 206 GTI 180 Rally car project Author: Jamie, Location: Ring y0Posted: Tue Jul 20, 2010 7:09 pm ---- Where are you getting your mounts from?
What are you doing regarding cooling too? What rad do you intend on using?
Mine should have been going up this week but haven't had a response from Sandy for a while...
#42: Re: 206 GTI 180 Rally car project Author: Jamie, Location: Ring y0Posted: Tue Jul 20, 2010 7:11 pm ---- Also have you managed to source any kind of baffle for the sump?
#43: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Tue Jul 20, 2010 7:31 pm ---- I will use a mix of the Baker and Vibra techcnix ones i think. That seems to be the cheapest option anyway.
Ooh i havent thought about the radiator yet what are you fitting?
The only baffled sump that i have found was on the Peugeot Sport France website but i dont think it was very cheap tbh. I was considering fitting one but i havent had a problem really with oil surge before on events. May be a good idea if you are doing a lot of fast track stuff though?
#44: Re: 206 GTI 180 Rally car project Author: spud_owen, Location: ashby de la zouchPosted: Wed Jul 21, 2010 7:00 am ---- cheeers for them them mate, got a couple of questions if thats ok? does your sump guard cover the entire underside of the engine bay, ie does it extend to cover the gearbox as well? the one i have been given will cover the sump and I can make some side plates up for it how much further do i need to go? also is that a metal strap you have around the rear beam to stop the tank guards from 'flapping'? last one is a query aboutt he hydralic hand brake, my car has one fitted but it is in the postion of the standerd handbrake and it also has a locking falicity which enables it to act as a normal handbrake, to your understanding to I need another mechanical lickage as well?? again many thanks much appericated.
#45: Re: 206 GTI 180 Rally car project Author: Jamie, Location: Ring y0Posted: Wed Jul 21, 2010 7:05 am ----
imjeeves wrote:
I will use a mix of the Baker and Vibra techcnix ones i think. That seems to be the cheapest option anyway.
Ooh i havent thought about the radiator yet what are you fitting?
The only baffled sump that i have found was on the Peugeot Sport France website but i dont think it was very cheap tbh. I was considering fitting one but i havent had a problem really with oil surge before on events. May be a good idea if you are doing a lot of fast track stuff though?
Apparently a good one for bodies is a Toyota Corolla one as it is shorter than the standard unit. I think a baffled sump is a good idea, ie prevention > cure!
I have a mix of the Baker/Vibratechnics items and you only need the gearbox mount from VT, however the Baker engine mount (called RHS mount iirc) will require some of the thread being taken off as it is too long as standard!
Jamie
cheeers for them them mate, got a couple of questions if thats ok? does your sump guard cover the entire underside of the engine bay, ie does it extend to cover the gearbox as well? the one i have been given will cover the sump and I can make some side plates up for it how much further do i need to go? also is that a metal strap you have around the rear beam to stop the tank guards from 'flapping'? last one is a query aboutt he hydralic hand brake, my car has one fitted but it is in the postion of the standerd handbrake and it also has a locking falicity which enables it to act as a normal handbrake, to your understanding to I need another mechanical lickage as well?? again many thanks much appericated.
Yes my sump guard goes the whole way across the engine and gearbox. It then has side plates that come up into the wheel arches. TBH it depends what sort of rallying you want to do. If you are going to do some gravel rallies then i would say you should invest in a genuine PTS sump guard as it really does take a hammering from rocks and i have heard of cheap copies shattering. i also have another plate off the back of the sumpguard that coveres the bottom of the downpipe as this can be flattened if hit hard enough
The metal strap just holds the tank guard on at the back so that it doesnt hang too low as they fall down with rocks hitting them.
Yes for the handbrake you will need to have some cable operating as well or it will fail scruitineering and its MOT. Unless you can fake that the hydraulic system pulls the cables as well.
Apparently a good one for bodies is a Toyota Corolla one as it is shorter than the standard unit. I think a baffled sump is a good idea, ie prevention > cure!
I have a mix of the Baker/Vibratechnics items and you only need the gearbox mount from VT, however the Baker engine mount (called RHS mount iirc) will require some of the thread being taken off as it is too long as standard!
Jamie
That is what i wil do then just buy the vt gearbox mount. Will have to look into the corolla rad then
#48: Re: 206 GTI 180 Rally car project Author: spud_owen, Location: ashby de la zouchPosted: Wed Jul 21, 2010 12:31 pm ----
imjeeves wrote:
Quote::
cheeers for them them mate, got a couple of questions if thats ok? does your sump guard cover the entire underside of the engine bay, ie does it extend to cover the gearbox as well? the one i have been given will cover the sump and I can make some side plates up for it how much further do i need to go? also is that a metal strap you have around the rear beam to stop the tank guards from 'flapping'? last one is a query aboutt he hydralic hand brake, my car has one fitted but it is in the postion of the standerd handbrake and it also has a locking falicity which enables it to act as a normal handbrake, to your understanding to I need another mechanical lickage as well?? again many thanks much appericated.
Yes my sump guard goes the whole way across the engine and gearbox. It then has side plates that come up into the wheel arches. TBH it depends what sort of rallying you want to do. If you are going to do some gravel rallies then i would say you should invest in a genuine PTS sump guard as it really does take a hammering from rocks and i have heard of cheap copies shattering. i also have another plate off the back of the sumpguard that coveres the bottom of the downpipe as this can be flattened if hit hard enough
The metal strap just holds the tank guard on at the back so that it doesnt hang too low as they fall down with rocks hitting them.
Yes for the handbrake you will need to have some cable operating as well or it will fail scruitineering and its MOT. Unless you can fake that the hydraulic system pulls the cables as well.
ah rubbish looks like i got some nore money to spend then! cars going to be tarmac spec to start off with on standard shooks as i cant afford biltens at the minute one day itll get in the forests though!!
#49: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Fri Oct 15, 2010 1:02 pm ---- Wee update since its been a while.
Got my new seats and finished the wiring loom just needs fitted now.
Rear beam with peugeot sport solid mounts fitted.
Front suspension fitted with Peugeot sport suspension, grp a bottom arms, brembo 2 pot calipers.
Engines to go in this weekend hopefully and then its trying to get the throttle bodies set up.
#50: Re: 206 GTI 180 Rally car project Author: DJ-, Location: UKPosted: Fri Oct 15, 2010 1:06 pm ---- possible for you to throttle body the gti 180 engine? i thought Jamie said there's issues with that due to the electronics?
#51: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Fri Oct 15, 2010 1:12 pm ---- Yeh can be done ok. I have seen it done to a few cars. Can be a bit awkward with the VVT. The wiring is not a problem just not ideal for a road car as in Jamies case
#52: Re: 206 GTI 180 Rally car project Author: macj, Location: EssexPosted: Fri Oct 15, 2010 1:22 pm ---- Lock up the VVT... it next to useless with bodies and you can map in the lost torque.... run stand alone management and let it run the engine completely.... much better
I would be interested to know where you got your tank guard.... I am looking at making one after Ramsport let me down big time
#53: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Fri Oct 15, 2010 1:40 pm ---- Havent got my tank guard yet. How come ramsport let you down? I was looking at them for buying one
#54: Re: 206 GTI 180 Rally car project Author: macj, Location: EssexPosted: Sat Oct 16, 2010 1:34 am ---- Paid them for the guard.... waited 2 weeks, phoned them to be told problem with mould.... waited 2 weeks more and still the same outcome. Asked for a refund and still waiting for that now
#55: Re: 206 GTI 180 Rally car project Author: st3v3n, Location: Liverpool Drives: 206 GTiPosted: Sun Oct 17, 2010 5:26 pm ---- Looking good matey. I was talking to a mate who rallies and he reckons if you have a twin master cylinder setup like you do then you don't need the old handbrake. The rules say you must have 2 separate braking systems incase one fails. the dual master cylinders count as two systems so currently you have 3! You can then fit a line lock in after the hyd handbrake so you can still have a parking brake. I'm not saying that what ive said is gospel, but just check it out and see.= for yourself.
#56: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Mon Oct 18, 2010 4:46 pm ---- Yeh cheers mate will have a look at the blue book and see what it says. That would be ace if I could take all the standard stuff away
#57: Re: 206 GTI 180 Rally car project Author: spud_owen, Location: ashby de la zouchPosted: Tue Oct 19, 2010 6:00 am ----
macj wrote:
Paid them for the guard.... waited 2 weeks, phoned them to be told problem with mould.... waited 2 weeks more and still the same outcome. Asked for a refund and still waiting for that now
ive heard allot of bad stories about ram sport, i know some certain top british guys wont use them because the service is poor!
#58: Re: 206 GTI 180 Rally car project Author: macj, Location: EssexPosted: Thu Oct 28, 2010 11:49 am ---- Check this out for good floor protection. cgi.ebay.co.uk/Peugeot...3cb1d6de12
#59: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Wed Nov 10, 2010 1:09 pm ---- I already got those floor guards rady to go on. I also got the side guards as well"
That video is amazing. Would be goof to see it with a diff to see what it was like then
#60: Re: 206 GTI 180 Rally car project Author: st3v3n, Location: Liverpool Drives: 206 GTiPosted: Sun Nov 14, 2010 1:22 am ---- Which engine mounts are needed from baker? You can buy them individually and they list the part numbers. Also, what is the part number for the vibratachnics mount? Cheers
#61: Re: 206 GTI 180 Rally car project Author: Edward, Location: In the garagePosted: Sun Nov 14, 2010 3:30 am ---- Just get on the Vibratechnics website. It's PUG301B - the only one listed.
#62: Re: 206 GTI 180 Rally car project Author: st3v3n, Location: Liverpool Drives: 206 GTiPosted: Sun Nov 14, 2010 4:56 am ---- No need to be a smart a**e! There are 5 listed vibra-technics.co.uk/p...asp?mid=37
#63: Re: 206 GTI 180 Rally car project Author: Edward, Location: In the garagePosted: Sun Nov 14, 2010 5:46 am ---- The answer is there. Do you want the mounts for road use or competition? The car only has 3 mounts and if you know what use the car i being put to then it's even easier to decide.
#64: Re: 206 GTI 180 Rally car project Author: macj, Location: EssexPosted: Sun Nov 14, 2010 6:41 am ---- Go for the rally/race spec..... they are fairly solid
#65: Re: 206 GTI 180 Rally car project Author: Teebag, Location: exhall, bedworth, coventryPosted: Mon Nov 15, 2010 7:45 am ---- nice project this... just read it all
#66: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Wed Nov 17, 2010 1:59 pm ---- What I have done is to get the vibra technics gearbox mount and all the rest from baker bushes. Get the competition ones. I have used his stuff on the 205 and never had a problem.
#67: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Wed Nov 17, 2010 2:13 pm ---- Ok so a quick update for everyone.
I have now ordered all the kit to do my TB conversion. Aim is to get the engine and box in place this weekend and to see if the pedal box fits on the left hand side of the car!
Going to keep the vvt system as well as the throttle bodies
After being shocked by how much I have spent on parts I have decided to change my Peugeot sport suspension to use Proflex which is well.... just the best. Might as well totally blow the budget
Hopefully will update this weekend but if not i will the week after as i am on holiday for a week to fix the car.
Deadline for the car to be finished is end of January 2011 so will need to get moving
#68: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Mon Nov 22, 2010 3:10 pm ---- Engine is in!!! and new proflex suspension fitted. Looks the biz and it is top quality stuff.
#69: Re: 206 GTI 180 Rally car project Author: T_bandery, Location: East londonPosted: Mon Nov 22, 2010 3:14 pm ---- Nice
Engine bay looks really empty though
#70: Re: 206 GTI 180 Rally car project Author: Seabook, Posted: Mon Nov 22, 2010 3:23 pm ---- proflex suspension?
wow, you really have a deep pocket lol
#71: Re: 206 GTI 180 Rally car project Author: Edward, Location: In the garagePosted: Mon Nov 22, 2010 3:23 pm ---- Are you going to remove the EGR/Air injection valve from the side of the head? The 138 GTi comes with a blanking plate that screws on the head that might be useful.
#72: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Mon Nov 22, 2010 3:51 pm ---- Yes i will blank that off. I have a 138 engine sitting there so I will get that sorted this weekend. I take it that its not a problem to do that?
I decided that i had to have the proflex it would just not be the same without them
Engine bay is a bit bare yes. I am waiting for the emerald ecu and the throttle bodies to arrive
#73: Re: 206 GTI 180 Rally car project Author: Schumi, Location: Istanbul / TurkeyPosted: Mon Nov 22, 2010 5:02 pm ---- Remote Reservior Proflex looking amazing. You helper spring is fully compressed. Will you remove helper spring.
#74: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Tue Nov 23, 2010 11:38 am ---- No i will leave the helper spring in. The suspension will need set up correctly when its all ready to go. The car has to be rolling by friday so i can take it to get all the braided hoses done for the brakes so my dad is working away at it this week whilst im working in London.
Then its a week off from work to get some hardcore work done on this thing. Biggest job will be the wiring as the whole car will need redone.
Carbon bonnet should arive this week and then i can get all the bonnet fastners fitted etc.
I will need to get the paint done on the bumpers, boot and doors soon as the winter is coming in fast with the cold weather and paint doesnt like that too much:)
#75: Re: 206 GTI 180 Rally car project Author: T_bandery, Location: East londonPosted: Tue Nov 23, 2010 11:44 am ----
Seabook wrote:
proflex suspension?
wow, you really have a deep pocket lol
Pockets aint empty cuz
#76: Re: 206 GTI 180 Rally car project Author: st3v3n, Location: Liverpool Drives: 206 GTiPosted: Tue Nov 23, 2010 11:50 am ---- Looking good My Baker GrpN mounts came today so just in the process of fitting them. The wiring is the fun part, if you need any pin positions for re-wiring it let me know as mine is fully running now with my homemade loom.
#77: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Tue Nov 23, 2010 12:19 pm ---- The wiring is the worst part!!! It alright for you! Does the BSI act like a relay in some cases? I notice when i trace the wires that the inicators etc all go in there?
#78: Re: 206 GTI 180 Rally car project Author: st3v3n, Location: Liverpool Drives: 206 GTiPosted: Wed Nov 24, 2010 2:12 am ---- Yeah BSI is a pain in the tits tbh. It does things like hazards, indicators, wipers. I think in a rally car you are best ditching the original loom as there is so much crap in there you don't need. Once it's out it isn't to hard making a new loom, if you work through it in stages and do a circuit at a time it's less daunting.
#79: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Wed Nov 24, 2010 5:11 am ---- Yes that is what the plan is.
I was going to trace the original wires from lights etc and where they go into the BSI etc then trace where they go from there. Then I will modify so that they don't go through the BSI.
Is this a good idea or did you just start from scratch? How did you find what the wires from the stalk controls for the light/ indicators did?
Could you possibly send me what you ordered from the electrical suppliers as I presume that I will be ordering something similar?
Cheers
#80: Re: 206 GTI 180 Rally car project Author: macj, Location: EssexPosted: Wed Nov 24, 2010 10:58 am ---- The stalk switches are reasonably easy to sort out.... find the live feed to the switch and it all falls into place... a poweer probe from Snap On is very useful for the loom work because you can liven up a circuit and the probe has a built in trip for mistakes
I started from scratch.... it was easier than I thought and you can lose all the earth points that the french use and run in a common chassis earth. You are right to seperate the cabin loom and find the rear light wiring... you will junk a big heap of useless wiring that way.
#81: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Wed Nov 24, 2010 12:08 pm ---- Thanks for the advice. I think my mate has one of those power probes. I will try and steal it next week to do the wiring then
#82: Re: 206 GTI 180 Rally car project Author: Schumi, Location: Istanbul / TurkeyPosted: Thu Nov 25, 2010 2:21 pm ----
imjeeves wrote:
Yes that is what the plan is.
I was going to trace the original wires from lights etc and where they go into the BSI etc then trace where they go from there. Then I will modify so that they don't go through the BSI.
Is this a good idea or did you just start from scratch? How did you find what the wires from the stalk controls for the light/ indicators did?
Could you possibly send me what you ordered from the electrical suppliers as I presume that I will be ordering something similar?
Cheers
Its better wiring from scratch. And I think you have to go preplexed stalks.
#83: Re: 206 GTI 180 Rally car project Author: st3v3n, Location: Liverpool Drives: 206 GTiPosted: Thu Nov 25, 2010 2:51 pm ---- Does anyone know how to get the wipers to stop at the bottom when the BSI is removed ?
#84: Re: 206 GTI 180 Rally car project Author: macj, Location: EssexPosted: Thu Nov 25, 2010 3:06 pm ---- I have the same problem... I just put in a dash switch and the co-driver has to get the timing right.... but if you find a way let me know mate
#85: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Sat Jan 01, 2011 6:52 pm ---- Quick update. I intended to post these a while back as the car has moved on again since these pics.
Seat mount positions finally sorted and drilled. Kevlar tank guard fitted. Proflex suspension fitted all round. Lexan windows installed. Brake lines in. Engine timing belt changed.
Got the gearbox back with the quaife gearkit fitted, new 4.9 cwp and tranx diff. Now installed on the engine with helix paddle clutch
Still working on the wiring loom which is a pain in the a$$ i hate electrics.
Waiting for the Throttle bodies to arrive now and then i can start on the engine loom with the emerald ecu system which arrived just before xmas. Thank you santa
#86: Re: 206 GTI 180 Rally car project Author: briant, Location: IrelandPosted: Sat Jan 01, 2011 7:28 pm ---- looking good great work your doing there
mind me asking a price for the Gearbox setup your running
#87: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Sat Jan 01, 2011 7:37 pm ---- I got the gear bits with the car but i think the gearkit is 1600 then its about 650 for the tran x diff, The lad that built it all up for me said its a cracking kit so we will see when it goes how good it really is
#88: Re: 206 GTI 180 Rally car project Author: macj, Location: EssexPosted: Sun Jan 02, 2011 5:33 am ---- Can you do me a massive favour.... post a picture of your poly tailgate window..... I am going to have to fit one.... not happy with mine after the spoiler issue.... cheers mate
#89: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Sun Jan 02, 2011 9:38 am ---- I havent done the tailgate mate as you need to thermofom the shape of the glass in order to fit it. I just used the standard glass tailgate with the film
#90: Re: 206 GTI 180 Rally car project Author: SAB206, Location: North WestPosted: Sun Jan 02, 2011 9:59 am ---- Interesting thread, good read! Keep up the good work
#91: Re: 206 GTI 180 Rally car project Author: st3v3n, Location: Liverpool Drives: 206 GTiPosted: Sun Jan 02, 2011 12:30 pm ---- That film is a t**t to fit. I tried mine last week but give up and pulled it off. just waiting on a reply from plastics4performance for a price for the rear screen. I was even thinking of trying to heat up some polycarb between 2 glass screens and making my own, but at £80 a sheet it could all go wrong.
#92: Re: 206 GTI 180 Rally car project Author: macj, Location: EssexPosted: Sun Jan 02, 2011 1:11 pm ---- I got my signwriter who is a sponsor to fit my film.... he said the same thing..... its got no flex and it looks bad.... going down the poly route now. Just waiting on prices
#93: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Fri Jan 07, 2011 4:15 pm ---- Look at what the postman brought me this week
180 Front brakes as my 406 Brembos wont fit under the 15 inch on gravel without problems
Jenvey throttle bodies and manifold etc and a carbon fiber strut brace to top it all off.
#94: Re: 206 GTI 180 Rally car project Author: Addaz, Location: SuffolkPosted: Fri Jan 07, 2011 4:21 pm ---- Have fun with the mapping.....
#95: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Fri Jan 07, 2011 4:24 pm ---- My base map is already sorted. I know another guy that rallies a 180 and he has kindly given me his map to start with. Will need to take it to the rolling road to get it the way I want though.
Emerald ECU's are where its at!!
#96: Re: 206 GTI 180 Rally car project Author: Edward, Location: In the garagePosted: Fri Jan 07, 2011 4:30 pm ---- That's the first time I've seen the cam sensor in the 180, it's normally hidden. You running a servo? I take it the levers on the bodies need removing? Is your TPS going on the TB closest to the gearbox?
#97: Re: 206 GTI 180 Rally car project Author: Addaz, Location: SuffolkPosted: Fri Jan 07, 2011 4:33 pm ----
imjeeves wrote:
My base map is already sorted. I know another guy that rallies a 180 and he has kindly given me his map to start with. Will need to take it to the rolling road to get it the way I want though.
Emerald ECU's are where its at!!
I will reserve my judgement as a certain longman took rather long to have a 180 on TB's set up right
#98: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Tue Jan 25, 2011 1:32 pm ---- Got some more painting done in the warmer weather! Also got the radiator fitting with the TB which were sitting far too close. Wiring is still going on. Made myself a handbrake mount which im actually pretty happy with. Starting to look more like an actual car now!
#99: Re: 206 GTI 180 Rally car project Author: macj, Location: EssexPosted: Tue Jan 25, 2011 2:16 pm ---- looking good mate..... its the best part of the build from now on
#100: Re: 206 GTI 180 Rally car project Author: briant, Location: IrelandPosted: Tue Jan 25, 2011 6:06 pm ---- What rad did you use? can i be real cheeky and ask you to take few close up pics of rad and throttle bodies area please
Also what length trumpets are you running on tb's
ps. your build is coming along very nicely
#101: Re: 206 GTI 180 Rally car project Author: Schumi, Location: Istanbul / TurkeyPosted: Wed Jan 26, 2011 10:08 am ---- Looking amazing. Do you have closer pictures of side skirt
#102: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Wed Jan 26, 2011 10:20 am ---- Im home on Friday for four days so I will get some more pictures then. Hoping to get all the wiring done and the fuel lines in. New wheels should be here on Friday so im looking forward to that.
Side skirts are made of kaylan. It has the same material all along the underside of the car as well. Seems good stuff but not cheap
#103: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Thu Feb 03, 2011 7:10 am ---- More updates.
8 new Revolution wheels arrived. New model GR6 wheels which are very nice.
Got another 6 to come possibly in a month or two so thanks to Revolution for those
Got my fuel pressure regulator fitted and new radiator hose as it is now lower. More wiring done. Digital dash fitted in place but I forgot to take pictures. Im back tomorrow night so no doubt I will get some more pictures.
#104: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Thu Feb 03, 2011 7:15 am ----
Engine bay
#105: Re: 206 GTI 180 Rally car project Author: st3v3n, Location: Liverpool Drives: 206 GTiPosted: Mon Feb 07, 2011 6:35 am ---- Looking good mate. Keep up the good work!
#106: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Sun Feb 27, 2011 5:21 pm ----
#107: Re: 206 GTI 180 Rally car project Author: macj, Location: EssexPosted: Mon Feb 28, 2011 11:02 am ---- Thats a cracking job mate..... nice to see it coming together now.
#108: Re: 206 GTI 180 Rally car project Author: Edward, Location: In the garagePosted: Mon Feb 28, 2011 12:15 pm ---- I've seen nicer looking wheels!
#109: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Mon Feb 28, 2011 12:21 pm ---- True about the wheels but the grow on you. Plus they are the best in the Market and they sponsor me and they were free
#110: Re: 206 GTI 180 Rally car project Author: Edward, Location: In the garagePosted: Mon Feb 28, 2011 12:28 pm ---- So what radiator are you using? Standard hoses too?
#111: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Mon Feb 28, 2011 1:36 pm ---- Yes I lowered the radiator and just used the standard one. Samco hoses for the radiator
#112: Re: 206 GTI 180 Rally car project Author: Edward, Location: In the garagePosted: Mon Feb 28, 2011 2:00 pm ---- So is the radiator angled now? Or vertical still? We need pictures.
#113: Re: 206 GTI 180 Rally car project Author: Schumi, Location: Istanbul / TurkeyPosted: Tue Mar 01, 2011 5:40 am ---- Is the ecu tune completed ?
#114: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Tue Mar 01, 2011 6:26 am ---- No not yet. I finished off all the wiring last night so tonight i should be calibrating the sensors and then i will try to start it for the first time!
#115: Re: 206 GTI 180 Rally car project Author: Schumi, Location: Istanbul / TurkeyPosted: Tue Mar 01, 2011 10:10 am ---- Good luck. I hope you enjoy when you tuning.
#116: Re: 206 GTI 180 Rally car project Author: imjeeves, Location: Glasgow / WellingPosted: Tue Mar 01, 2011 6:57 pm ---- Tried to start the car tonight but with no luck. The engine turned over all ok but the ecu didnt seem to pick up the crank sensor and so the engine wasnt seen as turning over by the ecu. Therefore no spark etc.
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Very beautiful. 
