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Forums › Tuning, Modification & Legal › Project Cars › Andrew's Project |
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 Posted: Thu May 19, 2016 3:29 pm |
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Joined: Mar 03, 2010
Posts: 2636
Trade Rating: +11
Location: Black Country Ay I
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A bit of progress today in the way of test fitting the manifold and offering up the turbo. I have ran into a few issues as you can see below.
I taken out most of the studs on the head to just about squeeze it past the power steering pipes (which I have always considered to be an eyesore). At first glance you may think it looks fine, but the external wastegate flange fouls the pipes. I need to consider my options in either getting the pipes replaced with custom made ones, or finding out if there is another 206 or PSA model that has the power steering pump on the same place but with the pipes routed down the left hand side of the engine.
The next slight concern is how close the external wastegate flange is to the radiator hose. I am going to get the manifold ceramic coated at some point and hope that the radiant temperature doesn't affect that hose.
And wait - there's more! If I offer the turbo up with the hot side on the right, it fouls the block and line up with the flange.
If I offer it up with the hot side to the left, the downpipe piece sits nicely and it mates up to the manifold flange. However, it leaves me very little room for fitting any pipework from the impeller to an intake filter, as you can see on the very far top right of this picture the radiator hose bend is in the way.
Lastly, although minor, the dipstick mounting blocks the manifold seating onto the face of the head, which can be sorted by grinding some of the mounting to suit. Everything looks a little dirty right now but I intend to get everything painted properly once the initial teething issues are sorted.
With what I have learned today, I am in half a mind to sell the turbo in favour of a smaller GT17 that is more likely to fit in the space without impacting other components. The guys who made my manifold recommended a GT17 for my car. As this is an excerise and learning curve for a bit of fun rather than a quest for balls-out power, I'd be happy running a turbo capable of 7-10psi.
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Posted: Sun Jul 03, 2016 8:21 pm |
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Joined: Jun 20, 2012
Posts: 1171
Trade Rating: +1
Location: West Country
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Any news Andrew boy? 
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Posted: Sat Jul 16, 2016 1:18 pm |
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Joined: Mar 03, 2010
Posts: 2636
Trade Rating: +11
Location: Black Country Ay I
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Hey Sim, not so much recently. There is a Citroen C2 model that I can rob the power steering pipes from to re route them out the way of the turbo and be more aesthetically pleasing.
The next job, is for me and "Big Andy" to strip down the engine bay and prepare it for painting. I have settled on this colour for the bay and the whole car - Range Rover Santorini Black, as seen below on a customer's car I detailed some years ago
Currently most of my theory and research is being put into a suitable engine management that can retain the fly by wire throttle body (removing it will render the dashboard and ABS useless). Perhaps leaving the factory ECU in control of the throttle body, and then sharing some sensors as input for an Omex 600 piggyback will just about suffice. The injectors that I have are the 380cc ones from Matty's old turbo thread 6 years ago. I assume a rising rate fuel pressure regular will also help.
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Posted: Sat Jul 16, 2016 3:12 pm |
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Joined: Feb 08, 2010
Posts: 7045
Trade Rating: +5
Location: In the garage
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Why not just let the standard ecu think it's still controlling the throttle body? Leave all the wiring but mount the TB or part of it elsewhere in the engine bay? Can the wiring to the pedal remain while also allowing it to operate a cable?
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| 2001 GTi 138, Bilstein Sprint dampers, H&R springs, 21mm Peugeot Sport torsion bars, 22mm rear ARB, Peugeot Sport Group A wishbones, 283mm discs, Goodridge stainless hoses, Maniflow 304 grade 4-2-1 2.5" manifold and system, 200 cell cat, Richard Longman head, 45mm Jenvey throttle bodies, 9.5mm TB spacers, 90mm air horns, Jenvey throttle linkage, Jenvey fuel rail, Aeromotive and Goodridge fuel fittings and braided hose, ITG sausage filter, Radtec custom radiator, Piper Ultimate Road cams, Piper vernier pulleys, Omex 600 ECU. Saxo electric PAS pump, Vibra Technics engine mounts. Samco coolant hoses, TTV steel flywheel, 4.76 final drive ratio, 307 CC 180 ratios. 2019 BMW 530i. 2017 Mercedes C300 convertible. | |
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Posted: Sat Jul 16, 2016 9:10 pm |
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Joined: Mar 03, 2010
Posts: 2636
Trade Rating: +11
Location: Black Country Ay I
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From what I have found, the throttle pedal and it's pedal box control unit must be removed in order to convert to a cable body. I am wholly keen to incorporate the DBW body into this build in the interest of safety and getting things to retain functionality as much as possible. Also there are Models just the same as mine in Brazil that have achieved 220hp from a 1.4 motor by using a piggyback AND retain DBW. EFI parts has told me that a plug and play Canbus ECU is available for the Clio 182 turbo conversion retaining DBW, but being such a rare model my 2007 has little support compared to such a popular car. He suggested to research using the Omex 600 in the way I said in my post above. Mike Evans Motorsport replaced my 1.4 engine when another place rendered it useless by not tightening a radiator hose jubilee clip up properly; Mike and co got the 1.6 replacement, auxilary differences and Kent hot cam timed and working great, on standard management and since then I trust them to find out what's what being as they deal directly with Omex - they're going to give them a ring on Monday
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Posted: Fri Jul 22, 2016 9:12 pm |
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Joined: Jun 20, 2012
Posts: 1171
Trade Rating: +1
Location: West Country
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Looks like the wheels are turning at your end Andrew, great!
That colour has some fleck to it  More than metallic or pearlescent, similar to a finish of that of a TVR or a custom paint one mate did on a Jag (glitter is seen only when one moves )
Another fun fact with those flakes: red sporty Mazdas from late 2000s have golden fleck in the paint, that is visible only in sunshine:)
And I'll keep an eye on your turbo progress, your rare model is giving you a proper challenge job Say hello to the Big Andy!
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Posted: Mon Aug 08, 2016 1:39 pm |
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Joined: Mar 03, 2010
Posts: 2636
Trade Rating: +11
Location: Black Country Ay I
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A massive change in plan has come about, as a result of being offered something too good to turn away. So this is the end of the 8 valve turbo dream.
So yesterday I started clearing things out of the engine bay for a couple of hours, ready for the block and gearbox to be removed.
Hello sweetheart.
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Posted: Mon Aug 08, 2016 5:05 pm |
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Joined: Jun 20, 2012
Posts: 1171
Trade Rating: +1
Location: West Country
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Dayum!! Which lump is tha
As we say back home: good start = half job done! 
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Posted: Sun Aug 14, 2016 10:40 pm |
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Joined: Feb 07, 2010
Posts: 278
Trade Rating: +3
Location: cleaning the car
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Looks good mate as stated on Facebook will be a good little conversion what box are you going to run with it?
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Posted: Mon Aug 15, 2016 3:22 pm |
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Joined: Jun 20, 2012
Posts: 1171
Trade Rating: +1
Location: West Country
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| Nic_206 wrote: |
| Looks good mate as stated on Facebook will be a good little conversion what box are you going to run with it? |
Now even more intriguing 
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Posted: Fri Aug 19, 2016 1:44 pm |
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Joined: Mar 03, 2010
Posts: 2636
Trade Rating: +11
Location: Black Country Ay I
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It just made sense really! It's a BE1.
Fuelling needs looking at down the line, I am looking at a Walbro 255, but a little confused as to what happens with an FPR. My car as standard does not have a fuel return either.
I now understand what Edward meant about the throttle body. It's going to have to remain connected to the standard ECU and be hidden away somewhere, just so that ECU still thinks it's controlling something, then the Omex takes care of the rest.
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Posted: Fri Dec 16, 2016 6:30 pm |
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Joined: Mar 03, 2010
Posts: 2636
Trade Rating: +11
Location: Black Country Ay I
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It's been much longer than I thought with updates. The last two days I have degreased the engine bay, keyed the surfaces and painted in Satin Black. Originally I wanted a professional spray job but would rather save the money for the little things that will be required to get the engine running - my patience for the lack of progress has worn thin as of late.
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Posted: Fri Dec 16, 2016 6:37 pm |
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Joined: Feb 08, 2010
Posts: 7045
Trade Rating: +5
Location: In the garage
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You'll need an EW/DW subframe.
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| 2001 GTi 138, Bilstein Sprint dampers, H&R springs, 21mm Peugeot Sport torsion bars, 22mm rear ARB, Peugeot Sport Group A wishbones, 283mm discs, Goodridge stainless hoses, Maniflow 304 grade 4-2-1 2.5" manifold and system, 200 cell cat, Richard Longman head, 45mm Jenvey throttle bodies, 9.5mm TB spacers, 90mm air horns, Jenvey throttle linkage, Jenvey fuel rail, Aeromotive and Goodridge fuel fittings and braided hose, ITG sausage filter, Radtec custom radiator, Piper Ultimate Road cams, Piper vernier pulleys, Omex 600 ECU. Saxo electric PAS pump, Vibra Technics engine mounts. Samco coolant hoses, TTV steel flywheel, 4.76 final drive ratio, 307 CC 180 ratios. 2019 BMW 530i. 2017 Mercedes C300 convertible. | |
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Posted: Fri Dec 16, 2016 6:50 pm |
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Joined: Mar 03, 2010
Posts: 2636
Trade Rating: +11
Location: Black Country Ay I
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...
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Last edited by Andrew on Fri Dec 16, 2016 6:58 pm; edited 1 time in total
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Posted: Fri Dec 16, 2016 6:51 pm |
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Joined: Mar 03, 2010
Posts: 2636
Trade Rating: +11
Location: Black Country Ay I
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| Edward wrote: |
| You'll need an EW/DW subframe. |
I have a GTI180 one on the side
My next dilemma is power steering, hydraulic will be easier considering that there is already a sensor in the pipework, that section can be cut out and welded into whatever gets fabricated. Or if I go electric, a resistor could be put in the sensor to trick the OEM ECU.
After that, I need to get my friend who is an expert with Omex to have a day with me, cut out all the wiring that is not needed, drop the engine in, and go from there.
The engine will need a flywheel that is suitable for the crank position sensor, I need suitable driveshafts
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