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Strictly_Derv

[misc_work] 91' 205 Dturbo Rallye Rep

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Strictly_Derv

Allot of mates can't accept it's a quick car because it's diesel but when they see it go then soon accept it lol

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Tom Fenton

Those harnesses are a seriously bad idea. If you have an accident they could break or badly injure your back. Please fit a proper seatbelt for the driver.

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Strictly_Derv

Those harnesses are a seriously bad idea. If you have an accident they could break or badly injure your back. Please fit a proper seatbelt for the driver.

 

why's that?

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BenC

Any more pics of the engine going in?

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Strictly_Derv

Yeah sure, thought I'd put them up.

 

002.jpg

009-1.jpg

011-2.jpg

012-2.jpg

001-1.jpg

007.jpg

008.jpg

004-1.jpg

 

Does look better under there now as that was just after it was slotted in.

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welshpug

rear needs dropping a tad, should be more stable under braking if you sort that.

 

Tom's right with the seat belts, they're far too close together and not centrally mounted, IMO you should never use any sort of harness with a standard seat or without a roll cage.

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Strictly_Derv

Fair point, shame though as I enjoy using the harness, feel really secure in the seat and give confidence when taking corners.

 

I want the back lowered but the torx bolt has seized on the TB

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welshpug

Chisel usually gets that out quickly, or just drill the head off.

 

 

Not had any problems taking that torx bolt out for ages though, decent torx bit and clean the head up before trying does the job.

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BenC

Yeah sure, thought I'd put them up.

 

 

mmm derv porn! Cheers for putting them up, really enjoying your project, looks great!

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Strictly_Derv

Cheers welshpug i'll that ago. But if I were to drill it would the left over bit come out easy enough?

 

 

BenC, no worries, i'm glad some people are taking some interest in it as its not often done even though it makes a really good all-round 'hot hatch' with the 1.9 DT. People often say having a heavy derv lump ruins the handling but these engines are actually lighter than the 2.0GTI-6 engine which alot people use for track cars.

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Anthony

Cheers welshpug i'll that ago. But if I were to drill it would the left over bit come out easy enough?

Yes - I've had to drill a fair few out now, and the stub that is left in the torsion bar just unscrews with very little effort.

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BenC

 

BenC, no worries, i'm glad some people are taking some interest in it as its not often done even though it makes a really good all-round 'hot hatch' with the 1.9 DT. People often say having a heavy derv lump ruins the handling but these engines are actually lighter than the 2.0GTI-6 engine which alot people use for track cars.

 

Yeah, it's nice to see some derv power! It's a very intersting thread, there's not much to read about these compared to gti6's and mi16's! I've got a 1.8td myself. Thinking about giving it a stage 1 tune now ;)

 

Out of interest why do you use 405 inlet and outlet manifolds? Is it for the FMIC, I thought you could just use an inlet adaptor on the 306 manifold? Also which forge model is the IC, do they do an xud9 specific one?

Edited by BenC

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Strictly_Derv

I used a 405 inlet because I already had it lying around with the adapter fitted plus I cleaned the internals of any crap. I got them because I was expecting the engine to have an EGR but it hadn't. The manifolds where identical .

The intercooler isn't XUD specific, but the designs perfect for a small car like this. I bought the whole set-up stupidly cheap of someone's 306 DT

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Jamal

only if fitted the wrong way round, 1.9 beam sits further forwards by about 5mm, fitted wrong it pushes it back probably 10mm but I haven't measured it.

 

Hi welshpug,

 

How can I recognise the normal and the 1.9 mounts? Servicebox says that there was 3 type mounts. 5142 27 for all the 205s except XU9JA and 5142 20 for XU9JA left and 5142 21 for XU9JA right.

 

If I mess it up what are the symptomes? One side of the beam is further forward than the other?

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welshpug

no, just the whole beam too far back,

 

they are marked d and g.

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Jamal

no, just the whole beam too far back,

 

they are marked d and g.

 

Sorry but I cant understand fully :blush:

 

If I change up one of the mounts, will it bring back the side of the beam where I messed up the console?

 

Where to find the markings? On the side where the bolts are, or at the bottom of the mount?

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Alan77

I'm taking a stab at 'droit' and 'gauche', considering the french nature of our cars...

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welshpug

indeed, they'll be on the underside of the mounting.

 

if you use a mismatched pair the car will crab.

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Strictly_Derv

Right i'm bord so I thought i'd right a spec list on the car....

 

 

 

  • 405 mi16 seats
  • GTI wheel
  • lightened (pointless bits stripped) interiour
  • Barry 'boy sub
  • GTI gear gator
  • GTI spoiler
  • straight-through zorst
  • 20mm PUG to Ford hubcentric spacers
  • Compomotive CX alloys
  • Rallye arches
  • yellow fogs
  • red strips
  • 1.9 beam
  • rear disk conversion
  • 247mm brakes
  • adjustable coilovers
  • door and roof wind deflectors
  • 1.9 DT engine
  • Bosch pump
  • Forge FMIC
  • Boost gauge
  • K n N air filter

 

boosting 26psi, 100% clean apart from a whisper of smoke when throttle is applied

 

I'm sure there's plenty more but I cant remember them all. Hopefully there will be a few more bits added by tonight, I will add some pics aswel.

Edited by Strictly_Derv

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Russ_T

Thanks for the spec :) Can't wait to do the conversion myself now. Looked at the HDI option but it looked like fifty times as much work which I don't have time for atm. Just have to wait to get another car whilst this one is off the road before I make a start.

 

 

I'd like to pic your brain, sorry if some of these questions are answered in the thread and I've missed them, just say.

 

 

straight-through zorst - is this the same as a normal GTi/DTurbo or did you have to mod it to fit?

 

yellow fogs - I wanted to do yellow dipped lights but I think they'll crap, what are you thoughts?

 

rear disk conversion - pretty easy to do right? Just need to get stub axles, calipers, run new lines. Does yours have ABS and those weird biasing valves on the rear? PITA they are.

 

247mm brakes - 306 DTurbo conversion right?

 

adjustable coilovers - are they very stiff? the roads around here are crap and my 306 Spax RSX kit leaked after about 6 months.

 

1.9 DT engine - any XU9D lump or does it have to be a particular year?

 

Bosch pump - thats an upgrade on standard and better to tune?

 

Forge FMIC - any FMIC that'll fit is fine I guess? Or is it a 205 model from Forge?

 

Haven't you changed driveshafts and gear box etc?

 

I guess the standard gearbox linkages are ok?

 

 

 

"boosting 26psi, 100% clean apart from a whisper of smoke when throttle is applied" - Congratulations mate! What sort of MPG would that return though? :D

 

 

More pics please! :wub:

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Strictly_Derv

NO problem, I have lots of people asking on the conversion now lol

 

straight-through zorst - is this the same as a normal GTi/DTurbo or did you have to mod it to fit? It's a home-made Arc welder jobbie, just cut the box's out and replaced with pipe.

 

yellow fogs - I wanted to do yellow dipped lights but I think they'll crap, what are you thoughts? I dont think they'r legal TBH

 

rear disk conversion - pretty easy to do right? Just need to get stub axles, calipers, run new lines. Does yours have ABS and those weird biasing valves on the rear? PITA they are.

 

I bought a complete beam, went straight on.

 

247mm brakes - 306 DTurbo conversion right? Yep. You can buy them dirt cheap on the PUG306.NET site. They are the same as VTR/S 106 GTI and many other pug/cits

 

adjustable coilovers - are they very stiff? the roads around here are crap and my 306 Spax RSX kit leaked after about 6 months.

 

Yes they are very stiff, not recomended for bumpy lane :lol:

 

1.9 DT engine - any XU9D lump or does it have to be a particular year? Yeah XUD9 TE. The earlier the better as it will most likely be Bosch'd, t2's and non-EGR

 

Bosch pump - thats an upgrade on standard and better to tune? They come fitted standard to some dervs. Much easier to tune plus there's plenty of mods such as gov mod, 11mm head ect.

 

Forge FMIC - any FMIC that'll fit is fine I guess? Or is it a 205 model from Forge? Anyone's fine, this was off my old 306, but i'm sure a Forge will flow better than say a standard transit intercooler.

 

Haven't you changed driveshafts and gear box etc? standard box and shafts, NEED a longer box though!

 

I guess the standard gearbox linkages are ok? yep because I used the standard box

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Strictly_Derv

TBH with you the conversion is so easy, it was my first engine swap apart from removing one at college in a fully kitted workshop with 5 people.

Just don't rush things

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Strictly_Derv

I got my 106 24MM ARB fitted today after much frustration removing plates from the 306 at the scrappie. Paid £3 for them ;) Need to get it more central tomorrow. Deffinatly a noticeable difference on turn-in and the back is kept much more level. Was only a quick test drive though, nearly hit 2 deer aswel

I have some pics of the fitting process in case anyone's interested

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Strictly_Derv

Fair size difference!

 

 

6766915645_02db54cfa9_m.jpg

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Strictly_Derv

6767228163_bf1a096932_m.jpg

 

 

this is the original ARB in the 306 plate to show the width difference

 

 

6767299939_a92835d550_m.jpg

Edited by Strictly_Derv

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