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pip470

[Engine_Work] N/a Fwd Drag Pug Project

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pip470

The plan.............

 

To build a road car that will take part in the euro trip in may 2009.

I have bought a car from a member on here already, (James travill cheers mate). It’s a k plate 1.9, very tidy and a very reasonable price. I also bought a gti-6 engine with the intention of fitting it but in the back ground I was already rebuilding my drag car engine (xu7jp4) and as we are going to be doing quite a few miles , I feel more confident putting this engine in the car for a number of reasons,

 

1. Its had all the new parts I would of liked to of changed on the gti-6 as a matter of coarse such as the head gasket, cam belt ect ect

 

2. I’ve already fitted an run this engine in another 205 so don’t have to worry about mc clearances or down pipe issues

 

3. A 1.8 will use less fuel than a 2.0 especially as it’s on bike carbs (fuel consumption is a big consideration for this long trip)

 

4. There will be a few gti 6's and it will nice to have a whole variety of engines on the trip

 

5. The gti-6 engine is destined for the drag car :)

 

So their briefly is the plan.

 

 

To come the engine build and car build

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pip470

The engine build...........

 

The engine is a 1.8 16v, producing around 112hp as standard, the head looks a lot like a gti-6 but the ports are cast very small and there are no vacuum pumps on these heads. I have opened these ports up, had multi angle seats machined, 30 thou skim taking the cylinder head cc to 34 from 36 which I make the new compression ratio to be 11 to 1. I’ve also fitted gti 6 cams, (had to block the end of the exhaust cam as it has an oil feed for the vacuum pump which is not fitted on this head) and a gti 6 exhaust manifold. I’ve used a modified bog bross manifold and r1 carbs for the fuel and the ignition is an mbe ignition only ecu. Ignition advance is rpm based only. It is also fitted with a direct port nitrous kit.

 

I am hoping with the head porting and the cams and increase of compression to be around the 140bhp mark N/A and 160 on gas. This coupled with the lighter block should see me right on the tails of the standard gti 6 boys.

 

Heres some progress pics,

 

Standard head ports

http://i207.photobucket.com/albums/bb271/p...ld/DSCF1711.jpg

 

After some novice porting

http://i207.photobucket.com/albums/bb271/p...ld/DSCF1715.jpg

 

http://i207.photobucket.com/albums/bb271/p...ld/DSCF1716.jpg

 

Seats being cut

http://i207.photobucket.com/albums/bb271/p...ld/DSC00487.jpg

 

http://i207.photobucket.com/albums/bb271/p...ld/DSC00493.jpg

 

Finished head after skim and rebuild

http://i207.photobucket.com/albums/bb271/p...ld/DSC00494.jpg

 

http://i207.photobucket.com/albums/bb271/p...ld/DSC00495.jpg

 

Engine being built up slowly

http://i207.photobucket.com/albums/bb271/p...ld/DSC00497.jpg

http://i207.photobucket.com/albums/bb271/p...ld/DSC00500.jpg

http://i207.photobucket.com/albums/bb271/p...ld/DSC00496.jpg

 

Thats all for now, moving in to our new house with garage this weekend so will get some pics of the car in its new home.

 

Phill

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DrSarty

Phill> Just great mate! YOU are the Euro Trip; I've never known someone so excited. I won't let you down........or keep up for that matter. :)

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pip470

Thanks Rich, Im sure keeping up won't be a problem for the 2.2 rip snorter, You will be like a kitten playing with a half dead mouse lol. More to come soon.

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pip470

Just a little update, engine is now on its mounts, the exhaust is fitted, and the driveshafts are in. I had a bit of a delay as i bought an mi clutch and I think I remember someone saying it would fit the xu7 flywheel. I found out it wouldn't but luckily had a gti 6 engine i recently purchased so I fitted it with the gti 6 flywheel instead. Im now just going to conect things up slowly as money is very tight at the moment. Another reason money is tight is I just had to bu one of the 306 forums carbonfiber plug covers as I think they are uber cool. Will post pics soon.

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welshpug

if you have an 8 valve clutch that will fit the XU7 flywheel (200 mm clutch face, as opposed to the Mi and XU10's 215mm)

 

I'd fit the 8v one myself, as it should be a bit lighter :)

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16v205

Get a pic up of the carbon fibre plug cover :)

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DrSarty
Get a pic up of the carbon fibre plug cover ;)

 

I've touched it <rubs thighs again>. :)

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pip470

Had a great day with the pug today and I even remembered to take some pics so heres an update.

 

Ive been trying to sort out all the little jobs like filling the gearbox oil, fitting new clutch cable, mounting the fuel pump in the engine bay on the old ignition coil mounts. Not sure if the pump will work in this position but I have seen a couple in a similar oreintation but near the fuel filter, only time will tell. Ive also mounted the nitrous bottle in the boot and removed all the seats to run the fuel line under the carpet. Gave it a good hoover too whilst its all out. There is still a long way to go before its ready for a rolling road session and mot but I have a week of in feb just after payday so I'm planning on getting it prety much completed ready for an mot tax insurance in march. That should give plenty of road time before the road trip to sort out the niggles.

 

I'm finding this car much harder to build than the drag car as things have to be a lot tidyer and fitting everything in with all the standard gear takes a lot longer. I will carry on regardless though and hope fully build a nice road car. So heres some pics of the garage and car and things. Cheers Phill

 

This was not the final pic of the modified standard fuel pump. I used the housing to make a pick up pipe but in this pic the pick up pipe is too long, The bottom of the tank seems to actually only be the legnth of the fuel pump body.

 

http://i207.photobucket.com/albums/bb271/p...ld/DSCF1809.jpg

 

 

The fuel line under the passenger.

 

http://i207.photobucket.com/albums/bb271/p...ld/DSCF1818.jpg

 

 

The fuel pump mounted in the engine bay.

 

http://i207.photobucket.com/albums/bb271/p...ld/DSCF1811.jpg

 

The nitrous bottle mounted.

 

http://i207.photobucket.com/albums/bb271/p...ld/DSCF1848.jpg

 

The tasty carbon fibre spark plug cover.

 

http://i207.photobucket.com/albums/bb271/p...ld/DSCF1841.jpg

http://i207.photobucket.com/albums/bb271/p...ld/DSCF1827.jpg

http://i207.photobucket.com/albums/bb271/p...ld/DSCF1828.jpg

 

The ignition managment mounted in the drivers foot well

 

http://i207.photobucket.com/albums/bb271/p...ld/DSCF1830.jpg

http://i207.photobucket.com/albums/bb271/p...ld/DSCF1831.jpg

 

My new garage

 

http://i207.photobucket.com/albums/bb271/p...ld/DSCF1837.jpg

http://i207.photobucket.com/albums/bb271/p...ld/DSCF1842.jpg

 

Thats all for now really, I need to start buying a few things no but until payday comes its just carrying on with the fidley jobs. Thanks for looking.

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Pug_Power_Dave

Mmmmm sexy carbon! top stuff phil! Your garage looks a lovely place to work! bet your out there working on the car everyday now! Hope to catch up again at the pod soon! roll on race day!

 

Dave :D

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Para

Cool place to work , and nice car to drive :wacko:

 

I will stay way behind all of you guys , I don't have much time , knowledge and budget to prepare my car like that for the trip. :D

 

Hope that engine will stay alive for all the trip. :D

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pip470

It would be rude not to go to the pod this year dave, would really like to see this lancia you got too.

Thanks para, Looking forward to meeting you on the Euro trip.

 

So on with the update,

 

Brakes.

 

I have gone for a pair of 278mm two piece disks and a pair of pro race 3 4 pot calipers from comp brake on the front,

 

The rear has just been replaced with new stuff and the claiper yokes painted to match the front. New disk's, pads, calipers and braided hoses.

 

I have fitted a new ali peugeot 406 non abs 23.8 mastercylinder and also by mistake a 235mm servo as i broke mine trying to adjust the rod in the center. I had to bash a little on the scuttle area and also virtually dismantle all the work I had done fitting the engine so that the engine could be lifted forward to allow the servo to squeze past the head. It was very tight but after I scratched my cam covers to hell it went in. All the brakes have now been bled and all thats left to do is run a servo pipe to the take off ive had rewelded on the manifold. I was going to go for an electric servo pump but it worked out way more than I could afford. I know these brakes are well overspecced for the car but I have two points really. One is when the car is somewhere demanding like the stelvio pass, I dont want brake fade to be a reason not to enjoy driving it. Especially if I have the chance to do something about it. The other is I have an unhealthy obbsesion for buying shineys for my car, I dont drink every weekend or smoke so i have to waste my money on something but unlike the other two mentioned these might actually save my life.

 

 

The car is waiting for some niggly things now thats holding the build up, mainly the cambelt cover, whilst the engine is hoisted to clear the servo it seems the best time to try and fit a cover, I tried my gti-6 one and its different (no suprise) so If you have one please get in touch. I can then get all the engine conected up and the wheels on as its depressing when its on axel stands. Im pushing hard for an MOT at the end of feb and also the rolling road tune up, If theres no problems then I may make it my full time untill after the Euro trip as my van is slowly dying. Enough wabble, heres some pics I hope.

 

DSCF1995.jpg

 

DSCF1999.jpg

 

DSCF1997.jpg

 

DSCF1996.jpg

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DrSarty

Good work Phill. Keep it up. Badges for the motor should arrive tomorrow.

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pip470

DISASTER with the 1.8 will update tonight when I get to work!!!

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Tom Fenton

Doesn't sound good <_<

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tom_m
DISASTER with the 1.8 will update tonight when I get to work!!!

 

oh sheet don't say that! i've been on tenter hooks waiting for some headline figures on this build!

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DrSarty

! :mellow:

 

Phill's just asked me for some "2.0" top badges (I guess he's keeping the NOS), so what's going on then?

 

:(

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pip470

Well, after litterally months of rebuilding the cylinder head for this engine, my desision to leave the bottom end as it was has bitten me in the bum. Two words, Liner seals. Ive had the engine running in the car for a couple of weeks now and it sounded a lot more throughty than it had done before which was promising, but I was waiting for some nice bbm hoses before I did the water system. Saturday was a great day for progress, I was flying through the list of jobs left to do. I fitted all the water hoses, filled with water and ran the engine up. after about 3 or 4 mins i noticed very emulsified oil streaming out of the oil breathers on the rocker cover. (they werent conected to anything). My head scrambled instantly and I turned the light off in the garage and went to watch a film with the girl friend.( well she thought I was watching, really I was contemplating the disaster) Next day I draineda liter of the oil from the sump and sure enough its completely emulsified after only three minutes of running. Whilst running a rather strange noise that only lasted 3 or 4 seconds which did not sound good, happened, it was like a high pitched ticking and then a sort of knocking like a big end knock, I can only imagine this was the watered down oil not working correctly in the bearings.

 

The plan is with this engine is to rebuild the bottom end as I have already put a lot of effort in and I do want to see the results Tom so I know how you feel. However, i will be doing a leak down test and a water pressure test with the sump off to confirm if it is the liner seals. I do not have the time to do this before the euro trip unfortunatly so it will have to wait.

 

So, what I'm I going to use, I had a gti-6 engine at the back of my garage , so it seems the quickest route. The engine has had a recent belt change and looks likes its had regular oil changes from the condition inside the rocker covers. The only thing I cant verify is how good the head gasket is so no nitrous will be used untill after the Euro trip.

 

I stayed up till 2 am last night swapping most of the parts over such as the flywheel, clutch gearbox, inlet manifold and actually got the engine in the car and on two mounts. Ive used the rs2000 mount with a 10mm spacer and another 10mm space on the gearbox end. Ive just got to extend the lower mount now as master cylinder clearnce just isnt good enough but I don't think my neighbours would of appreciated the grinding and welding at that time of the night. So thats where I am.

 

Luckily I cant see any major differances other than the bottom mount that will slow me down, so all the work I did on the 1.8 should work for the 2.0. Apart from my coil bracket which used to mount on the end of the cylnder head but now this engine has the vacuum pump there. That shouldnt cause a big problem, niether should the alternator, as my baby alternator bracket that I made up doesn't fit the steel block. I'm hoping to have it finished for sunday though so watch this space.

 

Heres a pic of the new scabby engine in place.

post-8104-1235415816_thumb.jpg

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DrSarty

Bummer.

 

Engine doesn't look scabby to me.

 

These things were sent to try us. Keep battling on Phill.

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Pug_Power_Dave

Really sorry to hear that about the engine mate! Lucky I guess that you have a 'spare'.

 

Good luck getting it all sorted in time!

Loving the brakes though! they look the business!

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pip470

MOTED

 

TAXED

 

INSURED

 

ROLLING ROADED

 

Euro trip here I come. Its been my first day driving the car after seven months when I decided to do this trip. The car lives up to every expectation. I love it. I cant wait for the trip.

 

The rolling road produced 146ft lb @ 5473rpm and 168bhp @ 6707

 

 

 

Its breathing quite a lot on idle so the engine is not completely healthy but I think it will do the trip. I will be putting some miles on it between now and the trip just to make sure I trust it. If theres any dobt I will strip it and do a quick rebuild but that will hamper on my funds for the trip.

 

To say im happy is an understatement. I've got face ache from smilling.

 

Have fun Peugeot friends.

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Goliath

Nice one, good job well done! I still need to get my car sorted!

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DrSarty

Well done Phill; good result. Get some miles under her belt, traffic jams and test the brakes. Gonna need 'em at Stelvio.

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pip470

Lake district meet went well, the car sat at at around 85 for around an hour and although now partially deaf, it showed no problems crunching the miles and around the twistys it had no problems with constant second and third gear pulls. The brakes have immense stopping power although I may need to bring some spare pads as the dust produced can only mean a very high wear rate. The tyres, gearbox and kaaz diff all did a great job and it was a very rewarding drive. I only wish I could use the nitrous but I can wait. Total number of miles so far is around 450, Number of tank refills 3, eeek.

 

 

I am having an alarm fitted on friday, concept 650 so thats cleared me of any funds this month so im going to have to come up with a plan on how to get some individual spares such as another vauxhaull coil pack and facet fuel pump.

 

 

Roll on 4 weeks!!!

Edited by pip470

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platty

Good stuff, although 450miles to three tanks.......ouch!

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