[engine_work] 2.0 Turbo Cti Project Begins

[M@tt 77]

yeah i think you might be right Miles i was hoping not to chop it out but it will probably be easier in the end.

 

Out of interest what did you do about the locating holes for the grill as they are attached to the fan cowling but i presume you dropped this down as well or got rigd of the cowling and used some after market rad.

 

I take it you got the cowling to fit over your intercooler? as it looks like it sticks out quite a bit like mine

[tom_m 0]

  Miles said:

A good way mount the rad, Just cut the bottom cross member away and make a drop down frame

 

+1

 

[markd6303 2]

  M@tt said:

yeah i think you might be right Miles i was hoping not to chop it out but it will probably be easier in the end.

 

Out of interest what did you do about the locating holes for the grill as they are attached to the fan cowling but i presume you dropped this down as well or got rigd of the cowling and used some after market rad.

 

I take it you got the cowling to fit over your intercooler? as it looks like it sticks out quite a bit like mine

hi mate,had a quick read through your build very impressed. i was going to do the same conversion in my 205 4x4 track car but ended up doing the mi16/gti6 conversion instead.

[Henry Yorke 269 3 Cars]

  M@tt said:

yeah i think you might be right Miles i was hoping not to chop it out but it will probably be easier in the end.

 

Out of interest what did you do about the locating holes for the grill as they are attached to the fan cowling but i presume you dropped this down as well or got rigd of the cowling and used some after market rad.

 

I take it you got the cowling to fit over your intercooler? as it looks like it sticks out quite a bit like mine

 

Not sure if you can see on this pre-respray pic but I made two brakets out of those drilled metal strips and they bolt to the side of the headlight surround on an existing fitting.

 

This also shows the rad dropping method too of a couple of similar brackets from the botom of the cross member. I would be careful about dropping the rad too much, given Sheffields speedbumps. Surely one of the PSA range must have a shallower radiator?

[M@tt 77]

i managed to do a bit more over then weekend

 

i took miles et al advice and chopped the bottom cross member off the front of the car so that i can lower it and mount the radiator properly using the standard rad cowling, but it will mean fitting some new grill locating points but that'll be fairly straight forward

 

 

I've also tried to finish up the coolant plumbing and almoost got there

 

i fitted the T piece as pictured above for the heater matrix/exapnsion tank

 

 

and i started making the pipe from the distribution block on th back of the blockup to the T piece

 

 

thsts it for now as i'm tto driunk

[Gibbo GTI 0]

Sorry to go off topic. What's peoples thoughts on using copper pipe on the cooling system? I asked a few months ago about replacing a crappy hose on mine with copper pipe and I was told that there'd be problems with disimilar metals etc... For some reason I can't find the topic though.

 

This was a reply I got on PSOOC:

 

I wouldn't use copper tubing in the cooling system of a car, the copper will react with the alloy and iron of the block, effectively creating a battery!

Edited November 24, 2008 by Gibbo GTI

[M@tt 77]

i've done a quick google and i don't think it will be a problem. Anti freeze also contains inhibitors which protect against rusting caused by the disimilar metals, but you can also buy an additive to add to the coolant mix which also protects against the electrolysis effect

[cybernck 403 1 Cars]

i've got copper pipes and i haven't noticed anything wrong with it really .

[Tom Fenton 1,562]

  Gibbo GTI said:

Sorry to go off topic. What's peoples thoughts on using copper pipe on the cooling system? I asked a few months ago about replacing a crappy hose on mine with copper pipe and I was told that there'd be problems with disimilar metals etc... For some reason I can't find the topic though.

 

This was a reply I got on PSOOC:

 

I wouldn't use copper tubing in the cooling system of a car, the copper will react with the alloy and iron of the block, effectively creating a battery!

 

Beware of internet mechanics, there are more than a few out there spouting nonsense.

[M@tt 77]

also you will already have a mix of dissimilar metals in the engine as you may have an alloy head, iron block, copper/alloy core radiator.

[DM88PUG 0]

brilliant read was considering this myself but think il leave it to the profesinals

[Alastairh 47]

  Tom Fenton said:

Beware of internet mechanics, there are more than a few out there spouting nonsense.

 

Agreed. I've used Copper T piece's from Focus before on GTI6 conversions, and they work fine and still going today...

[M@tt 77]

DM88PUG there's nothing massively complicated about this project and i'd say you should defeinitely give it a go yourself. You'll end up paying someone hundreds if not thoudsands to do it for you as even though its not complicated it can be time consuming and time = money.

 

You'll learn a hell of a lot about the car in the process which can be nothing but good. The only bits that might need some outside help on is possible fabricating the intercooler pipes/welding the bottom mount bracket/ welding the exhaust which i'm sure you could find a local person who could do those for you for not alot of cash. The rest is nut and bolt stuff and patience

[M@tt 77]

finally got round to doing a bit more over the weekend and tonight

 

i cleaned up the hubs for the CTI and replaced the wheel bearings which took a couple of hours

 

i then turned my attention to finishing the coolant plumbing round the turbo.

 

I finally settled on this configuration

 

http://img.photobucket.com/albums/v230/meb...TI/SNC00217.jpg

 

http://img.photobucket.com/albums/v230/meb...TI/SNC00221.jpg

 

which was a bit of a bugger to fit due to the tight space but once finally in place fits nicely and keeps everything away from the hot turbo and outlet pipe.

 

Then using some angle steel from B&Q i made some support brackets to hold the crossmember from the front panel that i'd previously cut off so that i can fit the standard radiator fan setup under the intercooler

 

http://img.photobucket.com/albums/v230/meb...TI/SNC00223.jpg

 

http://img.photobucket.com/albums/v230/meb...TI/SNC00224.jpg

 

and thats about it for now

Edited December 30, 2008 by cybernck
very large images!

[Peetypug 5]

its coming along nicely mate

[Henry Yorke 269 3 Cars]

You might want to paint that steel as that area is prone for road salt etc

[M@tt 77]

it's going to be painted once its all in place, infact i think i'm going to weld it rather than bolt it as first planned

[maxi 36 1 Cars]

Matt, are you a plumber by any chance? The steel brackett system you have devised is similar to what I settled on with my latest build. I had a few wall plate straps knocking about so used them.

 

Keep up the good work.

 

Maxi

[Death_Machine 0]

im following this closely as im hoping to build one myself very soon top job fella!!!

[M@tt 77]

cheers gents

 

almost got her started today but the battery was flat so had to put her on charge overnight which was a bit disspointing.

 

sorted all the coolant pipes bar one, i need to extend the thin pipe that goes from the expansion tank to the top of the rad back as now that i have lowered the rad the standard pipe doesn't quite reach. i've got some matching hose but i just need a couple of copper 10mm joiners for it.

 

i also found the subframe L bracket as standar was fouling the turbo wastgate arm so i had to bend the longer arm slightly so that it clered it. i had tried first grinding off the ball socket and putting it on the underneath but found that the gear rods would then impact on each other so had to grind it off again and attach it back to stndard and then bend the arm instead. Those L brackets are tougher than they look and needed a fair old smack with a lump hammer to bent it

 

 

The rest of the day was spent doing various other tidying up tasks

 

I extended the looms positive feed wire to the black shunt box on the slam panel as the standard XM turbo loom one was too short.

 

Extending the wires for the ICV so that it would reach its new location which is next to the dump valve on the short aluminium pipe section before the intercooler

 

I also pulled apart the suspension again to find out why i had such a large amount of play in the top mount. It turned out that there was aun unecessary washer between the 2 cups so once that was removed i found that one shock was nice and tight again with no play however the other one still had some play and on closer inspection looked like it was because the edges of the small cup were bent up slightly so a couple of mins with a hammer banging the lip down and the play was gone!!

 

so fingers crossed sometime this week i might be able to start her up

 

Maxi: Not a plumber mate although i now have a small mountain of plumbing suppliers after numerous trips to screwfix

[M@tt 77]

SUCCESS!!!

 

 

last night after finding ou that my double relay was up the duff i nipped over to Henrys tonight who kindly let me temporarily rob the Double Relay from his CTI to test mine and guess what it fired up first go it was pretty noisey without the exhaust but there were no worrying rattles/bangs or clunking which was good

 

i haven't got any coolant in it yet so hence the very brief turn over but everything appears to be good, now its a case of finishing the last remaining bits.

 

modify exhaust downpipe and weld lamda boss on

sand the front panel, prime, stonechip and paint it

fit the new door locks/ignition barrel

do rev counter mod

refit bumpers etc

sort interior

[DrSarty 100 1 Cars]

 

Whoop!!!

[dazEmad 0]

Well done matt.

[sonofsam 5]

Sounds familiar

 

Nice one!

[maxi 36 1 Cars]

I now have no speakers left on my P.C.....

 

Well done for getting it running though! I have had murders with them in the past, so many different types of loom.

 

Maxi