[Misc_Work] My Roland Garros Tu3S Highbrid

[R.G_205 0]

]hi guys and welcome to my build,

 

im a fair way into my project but have a long way to go. i have been a bit slow to get the ball rolling as the project strips me of most of my time and money! but now i have got nearly all the expensive stuff out the way im making good progress the aim is to have a 1.4 that really goes for it! i dont expect it to be the fastest thing ever but just faster than most 1.4's

 

i was going to go for mi16 but the old man put his grumpy ass foot down and disallowed it out rite ahaha

 

right so lets get down to it!!!

 

things iv done already body work wise....

 

- from the front doors forward has been fully stripped every nut and bolt!

- shot blasted engine bay (didn't even have to get the welder out!!!)

- Schultz out the engine bay

- sprayed up engine bay a dark blue

- after a lot of searching i managed to get hold of a pair of original pug front wings (leaving them till last)

- braided brake lines

- shot blasted hubs,brakes and carriers, sprayed black

- 1.9 gti front brakes

- grp n engine mounts

- coil overs

- rallye arches

- shot blasted subframe,ARB and bottom arms and sprayed black and silver

 

engine wise......

 

- purchased a 1.4 xsi engine

- pulled the xsi internals out got the crank reground and all new bottom end shells and piston rings

- shot blasted the tu3s (alloy block) engine and sprayed orange

- honed out the tu3s cylinder liners and replaced the seals

- put the xsi internals in the tu3s block

- cleaned out oil pump

- shot blasted the sump and sprayed blue

- DIY polished head

- saving for a piper ultimate road cam

- skim the head (but not sure how much to take off)

- have made inlet mani for bike carbs (but will be fitting them after iv fully run it in)

- fitted the xsi gear box and sprayed black as (the original box needs rebuilding box)

 

i think that's all but i still have a long way to go!!!

 

comments and tips will be appreciated!!

 

 

 

 

more pictures to come !!

Edited September 27, 2011 by R.G_205

[burr_2000 1]

yah well done pal. should be a little rocket and credit ya for keeping the 1400 8v. would love to see more builds like this.

[R.G_205 0]

http://i1119.photobucket.com/albums/k629/gulley1992/IMG-20110927-00041.jpg

 

 

got the engine and box in yesterday evening as well i for got to mention really looks nice i think.

 

but as i used the xsi gear box i didnt know that the gearbox mount was different so on instillation i had to swap it over there is about an inch of difference in length and would not ever fit

 

http://i1119.photobucket.com/albums/k629/gulley1992/IMG-20110927-00056.jpg

 

and iv also uploaded a load of pics of things if done and still have to be finished

 

and tonight i started to bed the valves into my head but only managed to get two done as i had to be els where :/

 

i used a upgraded clutch off ebay so whether or not it is upgraded is a mastery lol but the forks on the pressure plate where alot thicker i forgot to take a picture befor i installed it so this is all i have

 

http://i1119.photobucket.com/albums/k629/gulley1992/IMG-20110927-00059.jpg

 

this is my prototype attempt of making a mani for my bike carbs its not perfect but its given me some idea of where to start. the carbs are 36mm mukini ones but are they big enough?

 

http://i1119.photobucket.com/albums/k629/gulley1992/IMG-20110927-00055.jpg

 

domed pistons from the cast iron xsi block (witch was surprisinly ALOT heaver than the alloy one)

 

http://i1119.photobucket.com/albums/k629/gulley1992/IMG-20110927-00051.jpg

 

there are some marks ontop of the pistons but i don't actually have a clue how they got there or what there from :S

 

http://i1119.photobucket.com/albums/k629/gulley1992/IMG-20110927-00049.jpg

 

grp n gear box mount...... but i had to drill out the center of it so it would fit over the gear box mount but there was still a good amount of metal around the hole so it was no problem

 

http://i1119.photobucket.com/albums/k629/gulley1992/IMG-20110927-00047.jpg

 

grp n engine mounts

 

http://i1119.photobucket.com/albums/k629/gulley1992/IMG-20110927-00046.jpg

 

lower grp n engine mount

 

http://i1119.photobucket.com/albums/k629/gulley1992/IMG-20110927-00045.jpg

 

found some rust on the drivers side lower part of the wind screen had to do it on my mates gti too but was a simple repair just need to got scrappy and cut out the bit i need and replace it

 

http://i1119.photobucket.com/albums/k629/gulley1992/IMG-20110927-00038.jpg

 

fitted the rear arches how i want them now all i need to have done is have them spayed gloss black and get some nicer looking screws

 

http://i1119.photobucket.com/albums/k629/gulley1992/IMG-20110927-00040.jpg

 

fitted some 1.9 gti front seats and omp harnesses my gf got holed of the seat of some mug and got them refurbished for me.. they are immaculate!!!

 

http://i1119.photobucket.com/albums/k629/gulley1992/IMG-20110927-00036.jpg

 

tided up the loom with some blue covering

 

http://i1119.photobucket.com/albums/k629/gulley1992/IMG-20110927-00035.jpg

 

cleaned out under the arches and gave it another protective coating

 

http://i1119.photobucket.com/albums/k629/gulley1992/IMG-20110927-00034.jpg

 

1.9 gti fornt brakes all shiny and braided lines

 

http://i1119.photobucket.com/albums/k629/gulley1992/IMG-20110927-00033.jpg

 

all new copper brake lines and resprayed brake servo but want to get a new master cylinder as i cant get paint to stick the that one :S

 

http://i1119.photobucket.com/albums/k629/gulley1992/IMG-20110927-00032.jpg

 

engine bay

 

http://i1119.photobucket.com/albums/k629/gulley1992/IMG-20110926-00031.jpg

 

i got really lucky on ebay and picked this up for £30 i thought was good

 

http://i1119.photobucket.com/albums/k629/gulley1992/IMG-20110924-00024.jpg

[allye 530 3 Cars]

Looks really good so far (some interesting colours ) You should have bonded the arches though!

 

 

 

Silkaflex is your friend! Really good stuff.

[R.G_205 0]

thanks i wanted something that stands out and fordson major orange was all i had at the time!! ahaha

 

but i must admit i feel like abit of a cock for screwing them on :S but it looks okay abit rough and ready and your rallye looks so nice!!! i wanted one originally but when then the garros popped up and it was too clean and to cheap to turn down.

 

but the rear ones need some adjusting and they didn't fit as easy as i expected but look okay and i want to bring the wheels out to come flush with the arches spacers or 309 rear beam ideally

 

roddy

Edited September 28, 2011 by R.G_205

[burr_2000 1]

Allye would the Gti front bumper not of suited the arches better or is the gapping ok, hard to tell from photos.

[allye 530 3 Cars]

Allye would the Gti front bumper not of suited the arches better or is the gapping ok, hard to tell from photos.

 

No I don't think so, they fitted well up to the standard bumpers and I would designed for them.

[R.G_205 0]

finished off bedding in my valves tonight now all i need is new valve stem seals and have the head skimmed but i don't know how much :S i read on here that some one els was running the same internals and had there head skimmed off 1mm or some thing and that gave him a compression ratio of about 11.1 but will i be able to have that much compression with the high lift cam i would like to have? im at a stump and its slowing up my project so any help would be great!!!! thanks

 

this is the cam i would like to run

 

http://www.pipercams.co.uk/pipercams/www/product.php?pid=P13BP285

 

roddy

Edited September 29, 2011 by R.G_205

[burr_2000 1]

roddy what head you using the 205 xs or the 106 xsi?

 

if using xsi pistons and head All the clearances should be the same leaving you the same compression ratio too.

if using the xs head the combustion chamber is smaller which will lead to a pretty high Compression ratio. (i had all info but will look)

 

considerations when i looked into building the similar engine was:

 

Swapping pistons and liners becomes more of an issue. Be aware that the pistons and liners are machined and classified for 3 different tolerances (A, B and C from memory for pistons and I, II and III for liners) you can only use 'A' pistons in 'I' liners etc. This is what makes this swap tricky if you want the tolerances to be correct, as you can't re-use the XSI liners in the TU3 bottom end as the XSI doesn't have any! It might take a bit of looking to find a compatible set of liners and pistons. TU3 liners in good condition are easier to find than XSI pistons as there is a wealth of engines to look at in scrappies etc. Then you need to trial fit them in the block to see if the tolerances for the liner protrusion are OK. If not you can try changing the order to get them to fit. Once sorted get them de-glazed, fit new rings and give it a go!

[R.G_205 0]

im using the xs head because of the smaller combussion chamber as you said

but im not going to lie i didnt know about the I,II or III liners or the A,B or C piston sizes :S but i measured it all up with a micromiter and the measurements all mached up i put the old xs pistons in the XS liners and they sat and moved about just the same as the xsi pistons so fingures crossed that it will be okay :S ahaha if not just have to pull it out and put my spare xs engine into it

And about he high lift cam.....do you think it will hit the crowns?

Thanks for your help!!

Roddy

[burr_2000 1]

i am not sure, for peice of mind i used a dummy head and sharpened a normal valve and using a drill just took small cut outs of each piston and with a dremmel tidied them up a bit. use putty with dry build and check clearance.

[R.G_205 0]

ahhhh great idea! now im not to worried thanks mate order that cam at the end of the week then happy days!!

thanks

roddy

[R.G_205 0]

sprayed up my alternator and crank pulley in the week some pics

 

http://i1119.photobucket.com/albums/k629/gulley1992/utf-8BSU1HLTIwMTEwOTMwLTAwMDcyLmpwZw.jpg

 

http://i1119.photobucket.com/albums/k629/gulley1992/utf-8BSU1HLTIwMTEwOTMwLTAwMDczLmpwZw.jpg

 

http://i1119.photobucket.com/albums/k629/gulley1992/IMG-20110930-00074.jpg

 

got my head back from the skimmers yesterday he said he had taken off 3/4 of a mm which was alot and he also said he was impressed with my polishing on the ports

 

http://i1119.photobucket.com/albums/k629/gulley1992/IMG-20111006-00082.jpg

 

http://i1119.photobucket.com/albums/k629/gulley1992/IMG-20111006-00083.jpg

 

 

i took this picture from an old mankey head i had lying around in the yard but i wanted to show the indents in the head on a standard one compared to my skimmed one

 

one indent on the edge of the combustion chamber and a round one on the left hand side of the pic

http://i1119.photobucket.com/albums/k629/gulley1992/IMG-20111006-00085.jpg

 

http://i1119.photobucket.com/albums/k629/gulley1992/IMG-20111006-00086.jpg

 

and iv also bought my cam!!!! the last expensive part. it hit the overdraft hard

 

http://i1119.photobucket.com/albums/k629/gulley1992/IMG-20111007-00088.jpg

 

should be in some time next week so should be able to get the head one and torqued down by the end of the week

 

nothing els to report really but my brother in his gti6 205 and my mate in his mi16 had a race the other night..... was really surprised how close it is!! they where both neck and neck the hole way

 

 

[R.G_205 0]

havn't posted for ages but its all running now and going lovely but i have some issues i have to keep my distrebuter turned as far clock wise as it will go :S i adjusted the cam pully but no better so i sucked on the vacume advance and there is no restriction so i think thats up the creek (please correct me if im wrong tho!!)... as far as i can hear theres no nocking banging grinding tapping of any kind so thats a good thing im abit curious about my rpm meter though i can get it down to about 1200rpm but any lower it stalls but i thing its because of the dizzy and cam and highier compression but i dont mined about the slighly higher tick over but i took it for a run up the road and well.... it all went wrong :S i thought i would toe it abit but... it decided to light up the tyers emediatly putting me back in my seat therefor pulling off the steering wheel and hitting the hedge nearly rolling it!!! but no damage done WHAT A WEPON!! ahaha so bolted that back on asap then had a second atempt but i gave it abit of toe and it reved off the clock???? i must admit it did sound violent as fook but when it went past the flat spot it picked up on the revs instantly so really happy with it.. but can the reves be out and can they be that far out because when i say off the clock i mean past 8000 where 9000 should be know i shouldnt be doing it as iv only just rebuilt it.. but it/i got carried away :S

 

will try to up load some pics and a video tomorrow

 

roddy

[harryskid 193]

Sounds like a hell of a "Wepon" !

[R.G_205 0]

i was refuring to my self when i say 'weapon'

[allye 530 3 Cars]

Those rev guages on TU engines are horribly inaccurate so won't be 9,000rpm.

[trogboy 17]

yeah, mine used to under read by ~25% at the top end. I only found out when I asked the rolling road operator why he was only taking it to 4.5k.

[309jazzpanda 39]

So did you have any issues with the bike carbs or is it not set up yet?

[CallumCurwood 1]

What's the round about price this engine build has cost you?