Phase 1 D80OTW

[Thundercat]

Hi all, thought i'd join the restoration board with my silver phase 1 D80OTW. Some members may recall my car as it been owned by RTOC members through it's life. Not really a restoration but an ongoing refurb of bits and parts when time allows.
After a good exterior valet last month i decided to pull my finger out and remove the old lump out due to rattles/oil leaks.
But one thing leads to another, so engine came out last thursday and subframe dropped out for a good engine bay clean up on.

[Thundercat]

Well saturday saw me fit a refurbed subframe, with the old bottom arms swapped across. Amazing what you can find under the muck, as the old arms were pollybushed so a bonus.
Then on sunday i dropped in a recently built up engine with a few shiny bits for show.
The new engine should give the old girl a fresh set of legs with tubular manifold from group buy and also a ported inlet manifold. Also found use for my soft clutch conversion kit bought of ebay, was destin for my raider but i'll copy it at a later date.

[Mr Raider]

Niceone Jon, looking in very good nick, silver phase 1's gotta be rather rare! :cool:

[Scoff]

sparkies old car ?

[Thundercat]

Yes scoff sparkles old car. Got her running last Monday but seems there's always something else to be done. Impressed with raceland manifold as car runs so quiet at idle. Hopefully upload some more pics after weekend.

[Sparkie]

the anti roll bar was poly bushed too...

[Thundercat]

Looks like I missed them lol, so much oil on the old subframe that I did not notice.
New engine no oil leaks those gearbox now leaking and new core plug in inlet manifold weeping.

[Penfold aka The Dealer]

Looking good, got my engine home this week, gonna clean it to, fit the same mainfold, repaint engine and gearbox, de grease the engine bay etc... who knows maybe on the road intime for pod :)

[Thundercat]

Well long over due but spent 5 hours in garage last night till 11pm and got some progress with the engine. Stripped out new inlet core plug and fitted another with liberal helping of rtv sealant. Also whilst delving in the engine removed down pipe and weleded in lamda bung ready for afr gauge to be fitted. Also fitted phase 1 heat shield bracket under turbo, what a rave and can honestly say i know why people threw these back in the day.
Anyway car run back up this morning and all water leaks sorted, well for know and system bled again.
So boost hoses refitted and engine run up a few times to check fluid levels and all seems ok.

All that's left to do is change king lead, replum in my boost gauge and install afr gauge for fuelling adjustments to commence.

[Jimmy5]

Looks amazing Jon

Engine porn lol!

[elmof1]

Nice to see another Ph1; excellent progress, putting my efforts to shame :)

[Thundercat]

Well after running the old girl around for a few days and sorting any issues ithought it was time to fit afr gauge. So yesterday fitted aem gauge supplied by scoff and got it up and running. After a run about round town it was obvious she was running very rich indeed. 10's on boost and 12 at idle.
Carb was set up over 4 years ago very crudly for my raider running at 23psi. So stripped it down and fitted original jet sizes. A few new gaskets and run back up again. Idle now at 13.7 any higher and idle to irratic.
I've drilled out second stage jet to 1.2 and on boost is now approx 12.3. Car pulling really well on boost of 0.8bar.
Those now i have nuisance crap in carb blocking up idle jets so tomorrow will see carb stripped down again.

[Thundercat]

Well been busy sorting back list of jobs needing attention.
New RTOC club supplied clock facia kit fitted and looking mighty bright orange know, wasn't to bad to fit those loosing temperature gauge operation ment clocks had to be dismantled twice.
Full matching set of 195/55/13 Pirelli P600 tyres fitted including the spare. Front pair brand new with nobleys still, Ebay find well chuffed.
OE wheels powdered coated slate grey to match bodykit and fitted with new bolts.
Those i know realise my bodykit is all different shades of grey. It's going to be a slow process of cleaning the kit back to original plastic finish with tfr and a bit of effort.
New N/S outer CV gaiter fitted as found split when swapping wheels, the joys. Those these stretch on CV gaiters are a great invention.
Drivers seat replaced with my own mix and match cloths passenger seat. Which looks quite respectable.
OE boost hoses and dump valve removed.
Large boost gauge fitted with AFR gauge, still haven't got fuelling quite right and my feeling is to go back to a good T2 as too much lag on T25.
Dug out me OE R5 boot tidy and fitted.

Anyway some thrsh pics after a wash.

[Thundercat]

A few more pics

[Jimmy5]

Looks absolutely spot on Jon

Total credit to yourself for the hard work you've put in on this car!

[Lomo]

Gorgeous! :niceone:

[Brizza]

That boot tidy is really sweet! :)

[TNT ANDY]

Sexual
:agree:

[Thundercat]

Thanks for the comments, actually quite proud of the old girl. Been out for a good blast this evening and seems boost could do with a little more tweeking as plenty rich enough. Put my armtech rev limiter through its passes. Set full rpm at 6200 and tried full throttle gear change a couple of times but switch needs adjusting tomorrow.
Also found I've got to get used to 13inch tyres again, understeer fun.

[Thundercat]

Tomorrow is a big day, a trip across to kenobi for dynodaze Renault event and hopefully get some bhp figures. Not to happy with fueling as a bit rich for my liking.

[Trevhib]

Fab car, well done.

Can't say the colour of the wheels makes the most of them or the car tho. Go OE :)

[Thundercat]

Yer wheels not really blending in with the car but are the same shade of grey as grill when not covered in silicone spray. The aim was to match upto the bodykit, but most parts of kit have been painted black as sparky pointed out lol. Got a half cage to put in might just get it coloured to match.
Had a run upto dynodaze last sunday and was a good run there. Achieved 127ps and 180Nm of torque but was over fueling quite a bit on boost. Some alterations to carb this week and a new spring for the collins 31 actuator.
Pictures by kenobi.

[Thundercat]

Also bumped into sparkie at dynodaze.

[Thundercat]

Update, yesterday removed collins 31 actuator in favour of a garrett 31 actuator. Fitted GTT spider valve to cup mod. Only realised yesterday that i've only been running 12psi at inlet manifold which would explain why my carb set up is overfueling. So a quick run out this morning and i'm seeing 14psi at inlet know but hopefully later tonight with a little more tweeking there be 16psi. Hopefully then i can finish off the fueling.
Undecided it to change thermostat for low temp item or wait for the cold weather to come.
One item definetely needing an upgrade is the intercooler, found after a run out today that the heat soak on the standard size pace unit is quite warm.

[Kenobi]

Also bumped into sparkie at dynodaze.


OMG im in those photos looking incredibly fat :wasntme:

[andybond]

OMG im in those photos looking incredibly fat :wasntme:

Photos dont lie Danny

:cooter:

[Sparkie]

OMG im in those photos looking incredibly fat :wasntme:

coming to a dyno day near you.....

http://www.bryanreesman.com/blog/wp-content/uploads/2009/07/stay_puft.jpg

[Thundercat]

Well another year of ownership and another MOT straight through with no advisories. Just an annoy sticking starter motor. Also after a brisk run i'm think 15 inch alloys are needed for again, there's not a lot of traction with 13's running Pirelli P600 tyres at 15 psi.

[Jonny5]

Well done mate. Looking forward to a few runs out this year together.

[Thundercat]

Yer be good to get the 5 out and about lincolnshire or some meets. Need to pull me finger out and decide on wheels for the old girl. Had some compomotive MO refurbished for the raider, but can't make me mind up on what to fit on the phase 1. Thinking of running out to kenobi dynodaze tonight and getting an update on bhp since new set up.
To add really chuffed with running an afr gauge, makes mot a doddle with emissions.

[Thundercat]

Well had a change of plan with the car, Gaz coil overs on order thanks to scotty, so soon be slammed a little and to give the car its old look back i'm having the old alloys polished.

[shaggy]

I like what you've done to the phase 1 wheels mate.

[Jimmy5]

Jon, thats **** hot mate, loving the rims! Can understand now why you said your hands were dead!

[Penfold aka The Dealer]

wheels do look good, thought about doing similar on mine, instead just going to get them powder coated. :)

[Thundercat]

Hi penfold, keeping me other set of phase 1 wheels for winter with them being powder coated. Hi James, well i'm cheating with these wheels, got our mate steve doing them in his dinner hours at work for a good price. I still haven't finished rubbing down the Kei alloys, another two ro three days of work needed on them.

Another couple of jobs need attention on the 5, oil cooler needs fitting as the old oil feed pipes to radiator have started to leak. Bonnet and roof hopefully to be repainted ready for nationals, picked up paint yesterday so just waiting on me mate steve to sort.

[Thundercat]

GOD dave your phase 1 looks stunning, my mate has offered to do other wheels for peeps for a good price, so get yourself a spare set of straight rims.

[Trevhib]

Yes, those wheels work! :D

Pics with them fitted asap pls :agree:

[Thundercat]

Once coilovers are fitted, wheels all polished and tyres retrieved from storage in pit. Only question is do I fit uniroyals or pirelli p600 lookalikes Jupitor Darkhorse. Not tried them before but acquired a set of 185/60/13.

[Penfold aka The Dealer]

My ph1 has gaz coilovers, & brand new uniroyals... Handles really well. Not to harsh either which is nice :)

[Thundercat]

Just an update, had a very late night tuesday early wednesday morning, eventually got down to replacing inlet manifold core plug for the second time. Had to completely strip back of engine down, those i love the raceland manifold it pissed me off that night in trying to get to the bolts and so now rebuilt with a gas flowed standard cast manifold all heat rapped.
Second issue was radiator oil cooler feed pipes had worn themselves away at knuckle joint, so know have a mocal oil cooler set up fitted and with a bit bracket work it sits nicely behind bumper under number plate location.
Third issue oil pressure sender was reading full pressure all the time, so replaced phase 1 set up with a later phase 2 sender and still have high oil pressure. So on this instance me thinks oil pressure relief valve may have jammed up in the pump. Runs fine those but there is alot of oil going to the turbo so may have to fit a restrictor to oil feed pipe. It has been commented on that there is some smoke on boost so may be possible cause of oil passing seals on turbo.

[Thundercat]

Well fixed all the leaks and now popped its head gasket. Parked up a for a week now, need a break from it.

[Jonny5]

Well fixed all the leaks and now popped its head gasket. Parked up a for a week now, need a break from it.

Any updates mate?

[Thundercat]

Well not done to much in past couple of weeks. Fortunately engine is fine, seems me turbo bearings have failed. After six years or more off high boost had to fail one day.
Anyway fitted a standard T2 and run up to temp a few times till all oil burnt of in exhaust. Ordered two more phase 1 alloys from mike gt turbo spares. Hopefully then will have a set of rims polished up by May.
New bonnet cloth fasteners arrived yesterday so hopefully Wednesday cloth will be fitted. More updates by the weekend.

[Thundercat]

Well got me phase 1 back up and running today. Changed turbo for a T25/T2, removed spider valve, fitted new chrome actuator bracket, fitted new chrome actuator link, flushed oil out, new oil filter and fresh oil. In need of some driving now so i can reset boost level back to 1.2bar atm. Took some fresh pics with replacement bonnet fitted with bonnet cloth and new fixings.

[Trevhib]

Really looking the part in that engine bay now mate, well done :)

[Thundercat]

Another update needed, since fitting my replacement turbo all seems well. Those with removing spider valve i've been unable to get boost level back up to 1.2 bar using the t31 actuator.So a quick look on ebay found myself an actuator rated for 1.2 bar, Kinugawa from Taiwan comes with 5 different spring rates from 0.5 to 1.2 bar, those designed to fit saab turbo after a couple of hours in garage it now on the T25/T2 turbo. Been out for a couple drives and boost already peeking at 1 bar with no tension on rod so looks promising, just need a dry day now to set up.
Also found myself building up the new coilovers today, thanks to group buy got some GAZ GHA coilovers, now fitted with new doughnut rubber, new bearings and refurbished brackets etc. Just need an evening to fit them and get ride height set on torsion bar.

[Thundercat]

Well a happy chap this weekend, eventually got car running at 1.2 bar atm with solid boost. All so finished fitting Gaz GHA coilover kit, rear torsion bars were a nightmare but eventually came out and all greased up now. Ride height set up with about 2 inch drop and slightly lower at front. Car is completely different on the road now pulls in a straight line. Just got to tweek shockers and tyre pressures.

[Coops]

lovely car, however i'd of been tempted with a much more conservative drop on the coilies, looked excellent at standard height, looks a bit strange slammed and standard imo

cracking project though :agree::smokin:

[Trevhib]

It's good enough weather for those polished ph1 rims I think :D

[Jonny5]

It's good enough weather for those polished ph1 rims I think :D

:agree: Couldn't agree more! :agree:

[Thundercat]

Just waiting on my man, he has two more to polish this weekend and then all down to me to dig tyres out and get them fitted.

[Trevhib]

:)

[Thundercat]

Just for Trevhib, my polished alloys are at last fitted, some issues with a pair of my alloys being beyond polishing and thankfully GT Turbo spares sent a good pair that polished up well.

[Andyturbo!]

Just for Trevhib, my polished alloys are at last fitted, some issues with a pair of my alloys being beyond polishing and thankfully GT Turbo spares sent a good pair that polished up well.


Looks great John :agree: looks like a mint phase one that

[Thundercat]

She's getting a bit long in the tooth, but with the fresh engine and suspension she holds her own with newer motors. Raider is next port of call for next years ND and then perhaps restore phase 1 in the future.

[Jonny5]

Good work Jon :yeah: :yeah:

[Trevhib]

:smokin: Top :)

Thanks Jon. :agree:

[Thundercat]

Well ND2012 was an awesome event, chickened out with tracking my car but got her on rollers instead. Happy with results of 149.9 bhp with plenty of boost still on tap, suggested to raise my rev limiter by 500 rpm to 6750 and also saw my fuelling at 10.9 on afr gauge so room for a little more boost on current carb set up.
Car ran sweet all day and very pleased for all the nice comments on the day.
Decided next things on the list of jobs is to replace inter-cooler for the ktec behind the grill affair and fit my alloy radiator with spial fan.

[Alan]

Well ND2012 was an awesome event, chickened out with tracking my car but got her on rollers instead. Happy with results of 149.9 bhp with plenty of boost still on tap, suggested to raise my rev limiter by 500 rpm to 6750 and also saw my fuelling at 10.9 on afr gauge so room for a little more boost on current carb set up.
Car ran sweet all day and very pleased for all the nice comments on the day.
Decided next things on the list of jobs is to replace inter-cooler for the ktec behind the grill affair and fit my alloy radiator with spial fan.

I lOve this car

[Thundercat]

Well another sunny day with a trip to 'Kenobi' Dynodaze PFC event, good run there and back cruising at 80+ mph. New run on the dyno with an outcome of 155bhp and 222Nm of torque. Car run sweet all day even those my starter still sticking occasionally, runs a little lean of boost with part throttle so need to adjust carb and very happy with consumption ( 140 mile round trip with two runs on dyno and only used 1/4 tank of fuel).

[Kenobi]

Well another sunny day with a trip to 'Kenobi' Dynodaze PFC event, good run there and back cruising at 80+ mph. New run on the dyno with an outcome of 155bhp and 222Nm of torque. Car run sweet all day even those my starter still sticking occasionally, runs a little lean of boost with part throttle so need to adjust carb and very happy with consumption ( 140 mile round trip with two runs on dyno and only used 1/4 tank of fuel).

Hey man we have a Retro event coming up. Would love to see this again. Save me from a load of cars ive never heard of. lols

:laugh:

[Thundercat]

Long overdue update, since my daily decided to break on me back in october the ph1 has since been used daily
Numerous issues have reared there heads in the first month mainly water leaks, mainly my fault really has i made a decision to refit the oe ph1 hose setup and some hoses had seen better days. Best mod that has been a joy when fixing is the good use of stainless jubilees, not found a single one yet that has got stuck or threaded.
Another issue that rear its head, a new ph1 header tank from CGB couldn't hack the water temp flowing back from turbo, as i run the ph1.5 cooling setup, the header tank lasted all of 3 weeks. The replicas don't have the internal supports and water deflector. They also split along the seams! Luckly for me a very good oe renault header tank appeared on fb group and all been well since.

Since the early issues i've clocked up some miles, car always looks filthy at present which is annoying but engine is running good.
Another job was to replace the oe air horn compressor, seems every year it decides to fail and this year it was knackered. So in it's place i now have a Nautulas twin tone all in one comporessor, fits nicely where original horn was and in original mounting hole. Very loud 136dB certainly gets your attention.
So to now, went for an MOT about two weeks ago, failed on only outer drivers CV gaiter. A simple task of changing drive shaft for new one i had, so so wrong fitted a new shaft in pouring rain in the dark and was a bitch to fit. Next days drive to work was disaster, couldn't drive over 50mph, car was whinning its head off. Found on removal of drive shaft it was longer than original by quite bit. Had to refit old shaft after changing CV gaiter, went back to my supplier and found shaft was more like a clio valver and now got bearing rumble coming from car.
They now supplied me with another drive shaft, which i measured up to be identical to my old unit. So friday changed wheel bearing for new, fitted 2nd new shaft and guess what new shaft faulty. A 45mph drive to work and back with vibration comeing from shaft. So on inspection today found inner cv sloppy as hell so old shaft back on again and still have a noisey car.
Going to change n/s bearing monday and have it out with supplier for my second useless shaft.

[bood]

Sorry to hear about the pain in the arse problems you're getting.

[B18ftMOJO5]

Sorry to here your having problems. Hope you sort it soon. Such is the life of a 5 owner. :o

[Thundercat]

Fortunately my parts guy is all for the customer so expecting a few actions his end to suppliers

[Trevhib]

Keep at it mate.

Could you not have just replaced the gaiters on the old shaft?

[Thundercat]

Little more work done Monday, got a refund on drive shafts and there paying for a new wheel bearing. Changed near side front wheel bearing Tuesday to find another leaking cv gaiter, so another job to sort. Also found n/s front tyre badly worn, so yesterday had a pair of Toyo r888 GG fitted and tracking adjusted.
Next is to adjust camber with some camber bolts, fit bbtuning lobster with oe actuator pipework and final fit scorpion exhaust.

[Trevhib]

Pics pls! :smokin:

[Thundercat]

New Toyo r888s on front, vast improvement on handling and traction.

[Thundercat]

Had an evening in the garage stripping near side drive shaft down so i could fit new cv gaiters and little bit of paint to.

[Thundercat]

Another afternoon/evening trying to fit a mk1 scorpion exhaust, wasn't going well at first so got the grinder and welder out and fabricated a better system.
Fitted a mongoose downpipe, these are direct copies of oe up-swept design and fitted mongoose centre section. Then fitted scorpion s-bend modified to give better clearance over axle and allows for tail pipe to fit bang on central to bumper hole.

[Thundercat]

Also was informed camber on near side was a degree out whilst having wheel alignment done so took matters into my own hands and adjusted camber old skool way.

[Trevhib]

Great work. The exhaust looks absolutely perfect! :agree:

[Bealo]

New poster! (less than 10 posts)

Loving your car... miss my phase 1 badly