rallyeash 155 Posted January 22, 2015 Will be having decent wheels chaps! Share this post Link to post Share on other sites
camgti 56 Posted February 4, 2015 This project is like Heroin. Updates please!!! Cam Share this post Link to post Share on other sites
rallyeash 155 Posted February 4, 2015 Not had much chance to get it in the workshop as the business has gone really busy. Did a few hours Saturday morning, fited waterpump, alternator and wired up the alt and starter from the existing 309 loom. Offered up the down pipe and my option looks to be to cut and re angle the manifold like on an mi16 and also cut the drop out of the 309 downpipe. Either that or look at 4-2-1 options which will most likely still need a mod. I haven't looked to see if the standard manifold is restrictive. I've now purchased a new DTA S60 from Jorg along with Colin Satchell lotus 45mm TB's on a XU inlet. Plan is to cut the XU flange off the Satchell inlet. Cut the standard K20 inlet flange off and give it to someone to make fit. Also bought the SPA 0-9K tacho he had for sale. Share this post Link to post Share on other sites
rallyeash 155 Posted February 4, 2015 (edited) Also drilled the bulkhead, fitted the gear shift cables which are now under the carpet as the angle won't allow under the exhaust tunnel. Full set of working 6+reverse gears. Just need to make the brackets to fit the gearstick as I've got all the positioning done Edited February 4, 2015 by rallyeash Share this post Link to post Share on other sites
Reebmit 51 4 Cars Posted February 4, 2015 Sounding good Ash, saw you had bought the DTA, good move I reckon Share this post Link to post Share on other sites
rallyeash 155 Posted February 4, 2015 Yeah the 205 is in DTA but an older E48 Share this post Link to post Share on other sites
kyepan 291 Posted February 5, 2015 Either that or look at 4-2-1 options which will most likely still need a mod. I haven't looked to see if the standard manifold is restrictive. Maniflow do some nice custom manifolds, give dave at maniflow a call, granted its a bit of a trek for you but would be a very good option, speak to sandy about them as he knows them pretty well. Share this post Link to post Share on other sites
welshpug 1,627 Posted February 5, 2015 a trek of about 24 miles Share this post Link to post Share on other sites
rallyeash 155 Posted February 5, 2015 Yeah to be fair Salisbury is too far... Haha nah it's about 40 mins! But I don't want to spend £1000 on a system and manifold on a near enough standard engine. If I was chasing 270hp or something then I would be booking it in. Share this post Link to post Share on other sites
kyepan 291 Posted February 5, 2015 They build mine for about 500 ish mild steel, phone them for a quote. Share this post Link to post Share on other sites
rallyeash 155 Posted February 5, 2015 Made a new plate to cover the original hole Then after a few hours I had this. Completely a bolt in job Share this post Link to post Share on other sites
Kezzer30 40 1 Cars Posted February 6, 2015 I decided to read thus from the start , and I think your doing a great job , I'm happy I took my 205 engine out last night hahaha and your making engine mounts and fitting a engine non pug , just banging this and that on like it's nothing haha Seems you have attracted the odd crack smoker aswel but we always come across them lol. Keep up the good work , and what a little find the 309 was in the first place , looks clean as ever Share this post Link to post Share on other sites
j_turnell 134 3 Cars Posted February 6, 2015 Very cool project and credit to you for taking it all on, it's looking really good. How much does that gear stick assembly weigh? I'd have been tempted to mock it all up in aly and get it tig welded up. Maybe could re-use the original cover plate and just blank over the hole. 1 Share this post Link to post Share on other sites
camgti 56 Posted February 6, 2015 Nice one Ash, keep up the good work. Do you know what suspension your going to run? I had the berlingo 21.3mm bars in a 309. Made a nice difference fir a road car. Cheap bars and still well made! Cam Share this post Link to post Share on other sites
rallyeash 155 Posted February 7, 2015 Very cool project and credit to you for taking it all on, it's looking really good. How much does that gear stick assembly weigh? I'd have been tempted to mock it all up in aly and get it tig welded up. Maybe could re-use the original cover plate and just blank over the hole. Next to nothing. It's 2mm sheet and 8mm bar. Share this post Link to post Share on other sites
rallyeash 155 Posted February 7, 2015 Nice one Ash, keep up the good work. Do you know what suspension your going to run? I had the berlingo 21.3mm bars in a 309. Made a nice difference fir a road car. Cheap bars and still well made! Cam Gaz coilovers on the front, Gaz rear dampers, possibly 21mm bars and just GTI running gear. Should be fine for fast road Share this post Link to post Share on other sites
rallyeash 155 Posted February 12, 2015 Had to drive past Merlin's today so purchased a Simons centre and back box in 2.5" along with two 2.5' pipe. Going for a straight centre exit! Picked up a GTI tank and pump as will be injection Got the dimensions of the civic radiator today and will fit nicely In the 309 bay and isn't much bigger than a 309 one plus has the benefits of the right size and position outlets. Ordered one and will be turning up tomorrow so big weekend planned on the 309! Share this post Link to post Share on other sites
johniban 59 1 Cars Posted February 12, 2015 Is that a clamp together exhaust? Share this post Link to post Share on other sites
rallyeash 155 Posted February 12, 2015 They are clamp together silencers yes and the lengths of exhaust pipe are clamp on. However may weld it and make a 2 piece system. Will need to be welding hangers anyhow. Share this post Link to post Share on other sites
rallyeash 155 Posted February 14, 2015 Full day on the car today Civic radiator drops in like so. Exhaust fabricating... Now this is the first time I've tried to make an exhaust, I don't have access to any proper equipment except welder, grinder etc. Because I'm running the standard tank the exhaust has to run through the gap for it, else it'll sit low. So an angle was required, I cut 3/4 of the way through with a grinder and cut out a wedge shape, closed the gap and welded it back together like so. Exhaust boxes didn't have mounts on them so made some out of 6mm bar and welded them on, also had to weld hooks onto the boot floor to hang the exhaust. Had to angle the pipe work up after the beam so the box sits up nice and high. The front section will have 12 inches or so cut off, silencer added and the cut off section will mate upto the manifold. Will wait till I get it before doing that section. How it'll fit Need to get my hands on a 4-2-1 civic manifold to finish the system. Share this post Link to post Share on other sites
calvinhorse 870 Posted February 14, 2015 Spot on ash 1 Share this post Link to post Share on other sites
Loose Hand Luke 6 Posted February 25, 2015 Amazing work mate. Really loving this project. Keep it up Share this post Link to post Share on other sites
johniban 59 1 Cars Posted February 25, 2015 Looks good to me that exhaust Share this post Link to post Share on other sites
rallyeash 155 Posted February 25, 2015 Cheers chaps. Hopefully more progress the weekend. Share this post Link to post Share on other sites
