[rally_prep] My 205 Constantly Evolving 205 Xs Road Rally Car Project

[Cammyc26 1]

Hi TDr

 

I'll start off with saying your car looks wicked and this feed has been helpful in my xs road/stage rally project plans.

 

I'm looking for a single or double carb intake manifold as you had on the tu motor but I'm stuck finding one, any advice on where to get them

 

Thanks

[tdr_1976 41 1 Cars]

Very,very nice Dyl.

 

O.T.

Thanks O.T

[tdr_1976 41 1 Cars]

Hi TDr

I'll start off with saying your car looks wicked and this feed has been helpful in my xs road/stage rally project plans.

I'm looking for a single or double carb intake manifold as you had on the tu motor but I'm stuck finding one, any advice on where to get them

Thanks

Hello!

 

I'm glad that my project page has been helpful to you

 

The twin 40 setup was bought as a whole from this forum, it'd be hard to find another setup like it.

 

The single 40 manifold was made by Bogg Bros, if you google them you'll find them easily enough, they would be able to make you a manifold:)

[Cammyc26 1]

Thanks for the help I'll try them ????????????????

[tdr_1976 41 1 Cars]

I'll be sorting the fuel lines out this week, can anyone tell me which one the feed is?

 

Edited January 2, 2017 by tdr_1976

[tdr_1976 41 1 Cars]

Been fairly quiet the past couple of weeks, but, the conversion made another significant step forward last Saturday by getting the Exhaust manifold sorted

 

I finished plumbing the fuel system bits in the engine bay last night, got the fuel filter fitted, and fuel pipes all connected, machined an extra port onto the oil catch tank to fit a breather filter, fitted the oil filter on and filled the engine with oil.

 

A few photos;

 

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Bought a few bits to finish off a few loose ends;

 

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As it stands at the moment;

 

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Got the following jobs to do;

 

1. Finish wiring loom
2. Fit GTi Tank
3. Fit new clutch and new flywheel bolts (wasn't keen on the ones that came with the engine - so got new ones from Peugeot)
4. Rewire fuel pump wiring to control panel
5. Heat wrap manifold
6. Spanner check
7. Plug in ECU & Fuel relay
8. Fil tank with Petrol and see what happens......

 

 

[Anthony 1,000]

Looks very tidily done - no surprise of course given how nicely you'd done the previous 8v.

 

Indeed, dare I say it, if it weren't for the "trick" bits (ie induction setup, braided fuel hose etc) then I suspect a layman would believe that was like that from the factory such is how nicely that all fits in the bay.

 

It's been a while since I've done anything with a TU 205, but from memory isn't there a bracing point on the downpipe as standard that attaches to the engine/gearbox area? Do you not need to replicate something similar for that 4-branch manifold, as that subjectively looks like a fair length of pipe to have unsupported and I would imagine risks cracking over time given how far away the flexi/doughnut is relative to the manifold?

[tdr_1976 41 1 Cars]

Looks very tidily done - no surprise of course given how nicely you'd done the previous 8v.

 

Indeed, dare I say it, if it weren't for the "trick" bits (ie induction setup, braided fuel hose etc) then I suspect a layman would believe that was like that from the factory such is how nicely that all fits in the bay.

 

It's been a while since I've done anything with a TU 205, but from memory isn't there a bracing point on the downpipe as standard that attaches to the engine/gearbox area? Do you not need to replicate something similar for that 4-branch manifold, as that subjectively looks like a fair length of pipe to have unsupported and I would imagine risks cracking over time given how far away the flexi/doughnut is relative to the manifold?

 

Hi Anthony,

 

Thanks for the compliment - I've tried where I can to make it look as stock as possible

 

Regarding the support bracket, I used the bracket that came with the std downpipe I purchased, although it had to be modified to fit due to it fitting at the point where the two pipes merge

[Anthony 1,000]

Fair enough - I couldn't see it in the pictures, but sounds like you've already considered and sorted it... should have guessed really given how much thought you've put into the rest of it

[tdr_1976 41 1 Cars]

Cheers mate

 

If I spent as much time "doing" as "thinking" it'd been finished ages ago........haha! I believe if you think things through properly then you should have a good job and no problems in the future

Edited January 17, 2017 by tdr_1976

[tdr_1976 41 1 Cars]

Not done a great deal of work on the car recently, been busy with work and other stuff, but enough has been done to show a little progress;

 

Bigger brakes Upgrade - 266mm 106 GTi Calipers and Disks;

 

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106 XSi wheels blasted, primed and painted in Technic Grey;

 

Blasted

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Primed;

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Painted and lacquered;

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Today I've ordered a professionally made custom wiring loom to plug into the engine to work with a DTA S40Pro Stand Alone Engine management system. Expensive morning ........

Hopefully won't be too long before its on the road again and get the engine run in prior to a session on the rollers.

Edited March 13, 2017 by tdr_1976

[RossD 43]

You mean 206 GTi calipers? 106 GTi stuff was 247mm.

[tdr_1976 41 1 Cars]

You mean 206 GTi calipers? 106 GTi stuff was 247mm.

 

oops.... yes mate, 206 GTi units - Sausage finger strikes again

[tdr_1976 41 1 Cars]

Yesterday's progress - new tyres and wheels fitted

 

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Edited March 15, 2017 by tdr_1976

[TAG 25 1 Cars]

Very nice standard of work Dyl. I'm curious for your verdict on putting the heavier/more powerful valver in.

[tdr_1976 41 1 Cars]

Thanks mate - fairly happy with it so far.

 

I'm looking forward to getting the new electrics fitted and getting it on the road, so I can see what difference it makes to the handling.

 

I'll let you know how it goes, but will need to run in the new engine first!

[blandy 29]

Really like that looks very tidy/factory

[tdr_1976 41 1 Cars]

Thanks mate

[tdr_1976 41 1 Cars]

A small update on the project;

 

My DTA S40pro ECU, wiring loom, and comms lead have all arrived this morning from mefmotorsport

The work of connecting it all together and finishing the project continues this evening - I can see the light at the end of the tunnel now

 

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Progress photo's to follow.

[Graz 1]

Always watch out for your updates. Look forward to your next.

[tdr_1976 41 1 Cars]

Well...... Friday afternoon/evening didn't work out the way I had planned it.

 

The plan was to make a hole in the bulkhead for the new wiring loom connect the ecu to the switched live, permanent live and a good ground connection, upload a base map, check oil and water, and get it started, it all went well until the starting stage, everything was good but it just wouldn't start. So I abandoned it and went in the house for a few beers.

 

Saturday morning - after reading the DTA manual and learning about the diagnostic tests I could carry out off I went back into the garage with laptop in hand.

 

Crankshaft oscilloscope test was good, no issues other than the engine was cranking a little slow, but that was to be expected after a full rebuild.

 

The coil test was all good - 1&4 and 2&3 were firing in the correct order with good healthy blue sparks.

 

The injector test also proved to be successful, both dry and wet tests - plenty of fuel going in, so there shouldn't be any reason that the engine wouldn't start...... but still, it wouldn't start.

 

In a moment of desperation, I decided to check the coil pack again to check that the plugs were contacting the coil terminals - all good no problem...... or at least until mounting it onto the plugs on the head that was..... the contact springs on the coilpack weren't contacting the plugs. So I removed the rubber insulation boots and all the springs were compressed, so I stretched them all one by one refitted the rubber boots, fitted the plugs back in, put the coil back on and finally the engine started - What a feeling of total elation and accomplishment! Chuffed would be an understatement.

 

A few photos of the wiring work and process with a video of the first start;

 

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Older type xs sensors fitted for instrumentation.

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Chasis - engine wiring connectors

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All good to go - still got to fit air sensor on the inlet system, hence its red on the display!

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Video of the first start!

 

https://www.youtube.com/watch?v=_8albX_-I00&feature=youtu.be

[dawning 11]

Well done mate! Look forward to seeing more on this. The video on youtube is set to private so can't watch it.

[tdr_1976 41 1 Cars]

Thanks mate - was good to meet you the other week

 

I've changed the video settings now, not quite sure what happened there.........

[dawning 11]

You too! We made it up snowdon in the end

Still can't see the video mate!

[tdr_1976 41 1 Cars]

Haven't done much to the car recently other than drive it around having a lot of fun!

 

Gave it a service on Saturday and made this quick video of the finished conversion - Best viewed in 1080p.

 

As it's now running DTA management I'm tempted to invest in a set of ITB's next year

 

Edited September 12, 2017 by tdr_1976