[engine_work] 205 Gti6

[jimbean 0]

getting bored of doing work on other peoples motors so i dug my rolling shell from the corner of the unit and wont be happy till she is a living breathing monster

 

got this 1.6 shell last sumer it was missing a few bits but not many....

 

the full engine loom had been removed so i was thinking about a turbo conversion.... but done one already so i was really exited when i found this

 

my bosses son killed his new gti6 3 days after been given it whith 27000 miles on clock

 

so i did the decent thing and pulled it apart and got some good bits

 

engine/ box/ loom/ecu/ rack/cluster

 

next step

 

engine bay... seam welded

 

 

 

 

subframe/ seam welded with a 309 gti anti roll bar

 

 

 

 

 

i used the gti6 rack with some 205 drum sticks to sort steering

 

i am using the gti6 engine mounts on both sides[

 

o/s was easy just a slight mod needed to screw it in

 

 

n/s was mor dificult... i have made a hybrid mount using part of the 306 and part of the 205 housing

 

 

 

 

 

and yes... quite chuffed with how it came out

 

the brake and servo has been stepped with washers to hopefully miss the rocker

 

suspension... koni

 

the alt belt was a quandry... i went with a modified version of the static idler

 

 

 

now for engine in.... went quite smooth

 

 

 

 

hopfully will get lots done tomorrow

[welshpug 1,622]

why the odd battery tray arrangement? they bolt straight in to the original 205 mounting as its jut a BE gearbox.

Edited May 2, 2009 by welshpug

[jimbean 0]

why the odd battery tray arrangement? they bolt straight in.

 

 

unless i am really stupid i could not get it in in the correct position

 

i may have just wanted to use the mig though

 

need practice..

[max0 5]

looking good jim

[jimbean 0]

fk me you not been on here for a while

 

you got the bug again?

 

hope to have them both done asap fella... i am bored of diesel power

[max0 5]

you got the bug again?

 

Deffo - Might give you a bell tomorrow if your down the unit?

[jimbean 0]

will be there in afternoon...

 

if i can slip away...

[jimbean 0]

why the odd battery tray arrangement? they bolt straight in to the original 205 mounting as its jut a BE gearbox.

 

 

sorry read the question again this morning without a bottle of wine in my system...

 

i find the weak point of the cast engine conversions in a 205 is the gear box mount iether killing the mount/twisting the tray/ or worse

 

on the gti 6 the mount is twice the diameter of the 205 but fits in different position so i drilled the spot welds and made it fit with the 205 battery tray as the top the mount has been braced and welded to be stronger

 

i am using as much of the gti 6 as i can and if the mount is bigger.... must be there for a reason

Edited May 3, 2009 by jimbean

[calvinhorse 870]

sorry read the question again this morning without a bottle of wine in my system...

 

i find the weak point of the cast engine conversions in a 205 is the gear box mount iether killing the mount/twisting the tray/ or worse

 

on the gti 6 the mount is twice the diameter of the 205 but fits in different position so i drilled the spot welds and made it fit. the mount has been braced and welded to be stronger

 

i am using as much of the gti 6 as i can and if the mount is bigger.... must be there for a reason

 

bloody hell your up early! must be keen?

[jimbean 0]

i put one of the 6 speed boxes in my last turbo project but hated the config with the turbo engine.

 

but the thing the really did not like was the missing gate if you do not put the reverse cable in

 

i will be fitting the be4/6 in this project and have come up with a novel way to combat the missing gate

 

 

 

 

i am using a diesel stop sol to pull the plunger up when reverse is needed

 

my other fun bit is the taco problem

 

i know it can be sorted with a loom to coils with a diode setup but i gat a cluster with the engine milage

 

so i did this

 

 

 

 

i hope this will sort the dash out

[jimbean 0]

bloody hell your up early! must be keen?

 

got a 7 week old son fella if i sort him out this morning and let the missus have a lie in i will get lots of brownie points...

 

and i will be allowed to go to me unit this aft

 

roll on this aft.... as his next sceaming fit is about to start

[welshpug 1,622]

love the stop solenoid

[pugpete1108 62 1 Cars]

got a 7 week old son fella if i sort him out this morning and let the missus have a lie in i will get lots of brownie points...

 

and i will be allowed to go to me unit this aft

 

roll on this aft.... as his next sceaming fit is about to start

 

it dont get any better, mines 2 and he was up a half six this morning .

luckily it was the old ladys turn to get up

 

good job really as we were out on the raz last night

[jimbean 0]

been fairly busy today

 

got the cooling pipes done

 

 

 

 

and made a sleve to modify and enlarge top hose on rad

 

 

 

 

the master cylinder shaved to clear the rocker

 

 

 

and the fuel pipes matched up

 

 

i think the white fuel is in and green return?

 

not quite happy with the bottom engine mount and driveshaft angle as i have extended the fork i will have a better look at it tomorrow if i get time

[djinuk 2]

hats off to you, this is going at an alarming pace. Persoanlly im going to cut and reweld the manifold to get my gti6 in.

[jimbean 0]

hats off to you, this is going at an alarming pace. Persoanlly im going to cut and reweld the manifold to get my gti6 in.

 

that was my next thought but i want it running now...

 

if it kills the drive shaft i will go down that route at a later date

 

i might not get back on it tommorrow but exhaust is the next job so i will see how much more i can get playing with the fork length

[djinuk 2]

to be honest man, from what others have said the manifold angle modifying dosent seem to be a major job. Might be worth just going for it.

[maxi 36 1 Cars]

All credit to you with the progress here.

 

Just a few things I wondered:

 

How come you havent just used a lift up reverse cable for the gearbox? Or am I missing something? Phase 2 cars are easily converted with an earlier gearstick and the cable, hole is still there in the bulkhead.

 

Glad you have seam welded the bay, as the top engine mount does pull off the inner wing. However, not quite sue what the crack is with that battery tray/gearbox mount?

 

Secondly, I tried all the solutions with manifold clearence, extending fork, lowering engine, etc etc and the best way is to cut the exhaust manifold. I broke a couple of shafts with the modified mounts, since going back to std mounts and a modified manifold I have never had problems.

 

Good luck with it all mate!

 

Maxi

[jimbean 0]

All credit to you with the progress here.

 

Just a few things I wondered:

 

How come you havent just used a lift up reverse cable for the gearbox? Or am I missing something? Phase 2 cars are easily converted with an earlier gearstick and the cable, hole is still there in the bulkhead.

 

Glad you have seam welded the bay, as the top engine mount does pull off the inner wing. However, not quite sue what the crack is with that battery tray/gearbox mount?

 

Secondly, I tried all the solutions with manifold clearence, extending fork, lowering engine, etc etc and the best way is to cut the exhaust manifold. I broke a couple of shafts with the modified mounts, since going back to std mounts and a modified manifold I have never had problems.

 

Good luck with it all mate!

 

Maxi

 

 

in answer to your questions

 

 

as for the cable and gear lever

i like tinkering with electrics... the solinoid will also be part of my imobiliser.. i hide the switch in the cabin and run a relay powered bt the reverse light switch

 

it won`t start untill reverse is engaged... did this on my last 306 and it worked quite well

 

i have decided to cut and weld the manafold as suggested i would have sorted it today but had too much on and just ran out of time....

 

and for the mount.... the 205 mount/tray is quite light and had a few problems in the past with the smaller mount... the 306 is quite substantial... it`s like twice the dia of the 205 and the bottom half is quite heavy and strong it was straight forward to do and is as it was in the gti6 iff not stronger

 

 

 

doing the same as every one else because they say it is the way to do it is not my style i like to keep it as it was or make it better it might my stubborn nature but it keeps me happy

[jimbean 0]

finally i got back on the 205 today

 

got some bits done

 

got the manafold off and re angled it

 

 

 

got the engine back in and the standard fork back on

 

 

been looking at the angle of the drive shaft and it still has a very slight kink.. the fork could do with been shorter than standard the get the shaft perfectly straight.... i am not too worried as it is 100% better than it was and the manafold sits nice in its new position

 

 

while i was on i sorted out the front pipe

 

 

 

 

got the big jobs done so it should be plane sailing now

 

fuel filter in and secured with unions also sorted

 

 

and the altering of the fork messed with the master cyl... so modified it again

 

 

hope to get back down tomorrow night to get it rolling

[djinuk 2]

glad to see you reangled your manifold mate, you getting it done damn quick Ive still not decided how to go about doing my fuel hosing, just want to make sure whatever i do it safe.

[jimbean 0]

glad to see you reangled your manifold mate, you getting it done damn quick Ive still not decided how to go about doing my fuel hosing, just want to make sure whatever i do it safe.

 

 

the fuel hoses were quite good i bent the two metal pipes it the base of the bulkhead so they pointed to the o/s strut top...

then the fuel pipes tucked in quite tight to the bulkhead by the clutch cable

 

 

worked quite well and cept out of way of manafold

[taylorspug 7]

Are you running a carbon cannister? IT doesnt look like it so you can take the solenoid and wiring off (the brown bit) in the fuel filter picture.

[jimbean 0]

Are you running a carbon cannister? IT doesnt look like it so you can take the solenoid and wiring off (the brown bit) in the fuel filter picture.

 

 

not running the canister no....

 

started on the wiring tonight.... did not get far though... to many phone calls

 

the sol might be going but might just keep it in that position and cut 1 of the wires further back it the loom as keeps the pipe work looking standard....if it is closed in off position it won`t need to be blocked off

[jimbean 0]

got a bit done this weekend...

 

but not as much as i would have liked after a road trip to liverpool yesterday to pick up a engine...

 

got the front struts and arms in and got her on her feet only to move it forward 10 foot

 

 

and i past my local scrappy and got most of the bits i was missing

 

 

gear linlkage

 

and fan cowl

 

 

then got down to it

 

sorted the gear linkage with a bit of fettling.. got the lever nicley in mid position

 

i have not tried my reverse solinoid but i am sure it will be fine

 

 

there is just a slight tweak needed to the L pivot to totaly clear the exhaust

 

and the front pipe got a oxy sensor boss

 

 

it is close to the gear set up but seems to miss at the mo

 

the rest of the exhaust got sorted quite quickly after chopping the front pipe down it nicley slieved over the magnex mid pipe

 

 

had her cranking on starter to get oil moving and it sounded healthy

 

next job is the wiring

 

can`t wait!!!!