R5 - 172 Turbo Project **Updated**

[Ashy]

Ok, so as the old website lost my project thread I thought I'd start it off again as I need a thread to update as things progress!

Luckily I had a thread running on the Cliosport site which I can copy across...

Here goes.

------------------------

My latest project was given to me in the form of a fairly tatty rolling shell... It was fully stripped out no dash seats etc... engine had been removed, and it was in a bit of a mess...

From the word go I knew I wanted to make a track day car, something light but with a pokey reliable engine...

I set about it, cleaning out the inside, fitted bucket seats a roll cage and harnesses. Next came the engine, I decided to go for a 172 engine for reliability and power... so set about sourcing one and dropping it in.

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/DSCF2007.JPG

The first engine had a dropped valve so that had to come back out and was replaced with engine nuber 2!! I fabricated the manifold to suit, and ran it on a DTA ECU

http://www.rtoc.org/boards/picture.php?albumid=342&pictureid=3264

The bonnet needed a bit of a lump in to clear the taller engine

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/Image069.jpg
http://www.rtoc.org/boards/picture.php?albumid=344&pictureid=3268

It hit the road in NA form around the end of 2006 and was fairly nippy, i had it rolling roaded on Motorscopes new rollers at a RTOC day out and it made 173bhp which was nice... However I missed the turbo rush and as with all things it started to feel slow and boring. So next stage turbo... http://www.cliosport.net/forum/images/smilies/smiley1.gif

So I set about re-building engine number 3

Machined the pistons down to drop the compression -

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/Image004.jpg
http://www.rtoc.org/boards/picture.php?albumid=344&pictureid=3266

Machined the flywheel to take my multiplate clutch -

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/Image015.jpg
http://www.rtoc.org/boards/picture.php?albumid=344&pictureid=3267

Stripped the block & Painted it yellow -

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/DSCF2486a.JPG
http://www.rtoc.org/boards/picture.php?albumid=344&pictureid=3269

Blasted and powder coated the inlet manifold and plenum - http://www.cliosport.net/forum/images/smilies/smiley15.gif

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/DSCF2499a.JPG
http://www.rtoc.org/boards/picture.php?albumid=344&pictureid=3270

Knocked up a manifold and downpipe to suit a T3

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/1a.JPG

[Ashy]

One of the problems with the NA engine was movement, it rocked about too much on the gtt mounts, so I had to brace it with a bit of a pikey stabiliser bar onto the strut top.... So once the engine was removed for the turbo conversion I decided to weld in a clio top mount...

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/DSCF2784.JPG


Welded In

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/DSCF2843.JPG

Primed

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/DSCF2845.JPG

And Painted

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/DSCF2848.JPG

[Ashy]

so, new engine needed a better fuel rail and FPR that could cope with a bit of positive pressure, so instead of re-inventing the wheel I stole Scoff's idea of using the volvo T5 fuel rail... with a bit of machining i made a bracket to mount it to the inlet manifold.

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/DSCF2983a.JPG

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/DSCF3174.JPG

Fitted that to my new engine

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/DSCF2958a.JPG

I also machined a new turbo oil feed banjo as the gtt one I was planning to use wouldn't fit properly...

Heres a vid of when it ran for the first time!!


http:// www.youtube.com/watch?v=QBumHOeqKow (http://www.youtube.com/watch?v=QBumHOeqKow)

[Spooky]

Good job Ash!

How long did all that take you if you don't mind me asking ?

[Ashy]

Next Job was to fit a phase 1 172 Dash,

I broke my R5gtt gearbox (it was an unknown in the first place and 2nd gear was never that good) So I decided to go for a 172 box. Only problem was the speedo on the Gtt clocks wouldnt run, so I decided the only way to go was to use the 172 clocks.

Started off

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/dash1.JPG

Finished Up

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/DSCF3469a.JPG

Its better now i've got a glove box and 172 steering wheel (cheers Adey). But you get the idea... All the gauges and switches work as they should :)

more pics of that modification in here (http://www.rtoc.org/boards/album.php?albumid=348) incase anyone wants to try it.

[Ashy]

My multiplate clutch was goosed so it came back out and I went for a 200mm AP paddle (couldn't get a 215mm one in time for RTOC Pod day)

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/DSCF3521a.JPG

Seems to do the job as the R5 172T made 238bhp & 230lb/ft @10psi on the rollers @ Motorscope


http://www.youtube.com/watch?v=rdLvu_LGE9k (http://www.youtube.com/watch?v=rdLvu_LGE9k)

[Ashy]

This is pretty much how it looks now, although I've changed the FMIC pipe run since to tidy things up a lot!

[Bodell]

i like that new dash actually, makes the car look a little bit more modern.

lol @ your cat hiding behind the dash in one of them photos, they always seem to get in the way when i try and do work to the car :laugh:

[Ashy]

Good job Ash!

How long did all that take you if you don't mind me asking ?

Erm, I think I started it around May 2006 and had the NA engine up and running towards the end of 2006. I started to build the F4R Turbo up early 2007 and swapped them over after my wedding at the end of 2007. The turbo versions been running about a year now I would say... So took about 6 months to get the NA version up and running from scratch and then a year later I swapped it for the turbo version.

[Ashy]

lol @ your cat hiding behind the dash in one of them photos, they always seem to get in the way when i try and do work to the car :laugh:

Shes a nightmare mate, always want to be involved with everything i'm doing!!

[Rob@Backyardracing]

Great car Ashy :agree: i like the dash too, looks well.. Out of interest does anyone know what sort of tapper the 172 pistons have? :confused:

[James5]

Niall I am so loving this, top job matey.
:)
Ps - many thanks for all the advice and parts

[Adey aka Ewok]

looking good man, nice to see , will have to get a blast in her someday ;)

[Os8472]

Ashey that is blood good work mate, keep it up

[Trevhib]

...so I just machined a new... :gagged:

...then I fabricated a manifold... :scared:


:worship:

Looks great Ashy. :agree:

[dgdogz]

just read the whole thing there
looks bloody amazing
well done
a lot of time and efoort and money i bet

beautiful end pic you have aswell
:)

[mad manz]

do u fancy doing the same to mine m8 ? lol

[Arrows]

Love that Clio dash, wish someone would post up a how to do on this would really love to do this to mine, really updates it.

[Ashy]

Quick update, the 5 hasn't moved since it the last rolling road day in November...

In that time I've decided to do a few upgrades in the form of a new ECU, bigger injectors and a bigger blower!!

http://www.rtoc.org/boards/picture.php?albumid=407&pictureid=10212

Looking forward to an interesting 2010 :)

[Logg]

Cool is that a GT30?

[Andrew Cooke]

Cool is that a GT30?

I'm, gonna make a guess that since there isn't a shaft or nut shown it's an upgrade for the existing T3, so, complete guess, 50trim T4?

[Ashy]

I'm, gonna make a guess that since there isn't a shaft or nut shown it's an upgrade for the existing T3, so, complete guess, 50trim T4?

Yeah its a T04B that i relieved Mr Scoff of!! the unit I'm using is a 2WD cossie unit with the T04B bolted onto the front... Happy days.

[SP33DY]

Hmm wonder whos gonna be buying lunch this year then? unless Matts got something up his sleeve

[Trevhib]

Latest pics bud?

[Scoff]

T04B "v" trim from memory, but you'd have to measure it up again to be sure. I recall the map suggesting it would be pretty handy at 300hp.

[benj88]

New poster! (less than 10 posts)

Class project mate! I said to a mate a 172 dash would look fresh in a 5 and it does! Is this on the road mate? Are you ashy who knows nikki? Keep up the good work :)

[Ashy]

New poster! (less than 10 posts)

Class project mate! I said to a mate a 172 dash would look fresh in a 5 and it does! Is this on the road mate? Are you ashy who knows nikki? Keep up the good work :)

Hi m8, yeah been on the road a few years now... Although its currently in bits!

Aye I know Nikki from Sunderland? Used to go out with a good mate of mine Chris Scott. Has she still got the Raider?

[benj88]

New poster! (less than 10 posts)

Yeh I remember him he does cage fighting n that doesn't he? Were bouts at Durham you from? My girlfriend lives in Belmont.

I spoke to her a few month ago she stil has the raider it's in a unit or garage, she bought loads of stuf but never got round to fixing it after she bumpd it. Did you use to have a raider? A gud few year ago I went to york with my mate, chris was there with his red gti lump rallie and followd nikki and someone else I'm*sure there was someone calld ashy 'the doctor' was there ?

[Ashy]

New poster! (less than 10 posts)

Yeh I remember him he does cage fighting n that doesn't he? Were bouts at Durham you from? My girlfriend lives in Belmont.

I spoke to her a few month ago she stil has the raider it's in a unit or garage, she bought loads of stuf but never got round to fixing it after she bumpd it. Did you use to have a raider? A gud few year ago I went to york with my mate, chris was there with his red gti lump rallie and followd nikki and someone else I'm*sure there was someone calld ashy 'the doctor' was there ?

Im in Chester-le-street mate, aye that would of been me mate. That was my old 5, it was the ex DD Autosports car and Glen T was known as the Doctor... Think it had some stickers on promoting the business and Glen the Doctor... That was a long time ago, that car went up in flames at the side of the motorway in 2005!

Have you got a 5 now then?

[firstchoicegary]

what rpm does it go to ??? 7000-8000 , when does turbo boost up? im thinking hard at 4000

[Ashy]

what rpm does it go to ??? 7000-8000 , when does turbo boost up? im thinking hard at 4000

I haven't run it yet with the new turbo, but Mr Scoff compared it to a T28 on a 5. The old smaller T3 wasn't laggy at all on full boost by 3300rpm.

Had the dash flocked...

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/SAM_8593.JPG

[firstchoicegary]

standard 172 is bout 7200 limit am i right? so if you cuming on boost at 3.5k say and it holds thats gona be bloody quick, my old five had a top t2 hybrid cum in at 2.5k but no stem after 5k realy , 172 def got that top end power shuld be fast as f??k what u plan using it for?

[benj88]

Im in Chester-le-street mate, aye that would of been me mate. That was my old 5, it was the ex DD Autosports car and Glen T was known as the Doctor... Think it had some stickers on promoting the business and Glen the Doctor... That was a long time ago, that car went up in flames at the side of the motorway in 2005!

Have you got a 5 now then?

Never! Nightmare mate! Was a smart raider like, had a nice cage in. Yeh iv got a tungy iv started a thread for it check it out! Lol.

[xenon]

news of this superb project of GT RS ???

would you have a video of your GT ? ;)

[Ashy]

news of this superb project of GT RS ???

would you have a video of your GT ? ;)

I broke it at Santa POD in May, so its been off the road since then...

Did the crank, looks like she spun a shell...

http://www.rtoc.org/boards/picture.php?albumid=1157&pictureid=12909

I'm currently stipping he down as she needs some welding and a re-spray. Engines also in bits, I've got steel rods and forged pistons going in plus a clutch upgrade.

Hope to be back on the road spring next year.

only vids I have are on you tube, search for Ashy_gtt

:)

[Ashy]

And so it begins.....

After the engine letting go at pod I decided it was time to take her off the road. I moved house in June so the cars really not been touched until a few weeks ago... The plan was to strip and re-build the engine, steel rods, low comp pistons etc etc and sort the body work at the same time.

So here we are, been on the go for a few weeks now but I dont get as much time in the garage as I'd like so progress is slow... But here we go...

Windscreen Surround was totaly shot

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/DSC_0724a.jpg


The drivers side was just nasty....

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/DSC_0727a.jpg

So out it came....

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/DSC_0779a.jpg

Cleaned and painted ready for the new surround

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/DSC_0782a.jpg


New surround tacked in place

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/DSC_0792a.jpg

[Ashy]

Next bit was the sills and rear bumper brackets...

Once I'd removed the outer sills it was clear the inners needed a once over... the more I probed the worse it was... So I cut all the rot out leaving this...

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/DSC_0768a.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/DSC_0769a.jpg

I made a template and drew it up in CAD, then got some inner sill repair patches laser cut at work to save time cutting and welding...

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/DSC_0771a.jpg

I painted the sills and the rear of the repair strip to stop it rusting once welded....

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/DSC_0784a.jpg


Then Spotted it into position...

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/DSC_0788a.jpg

Next was onto the bumper brackets... Again they were pretty rusty so I decided just to start from scratch...

I made a paper template, drew it up in CAD and had some laser cut...

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/DSC_0775a.jpg

And welded into position

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/DSC_0785a.jpg


And thats where I'm up to... Just thought I'd sahre that with ya'll :)

[wrightygtt]

:)Brings back memories, nice work mate:agree:

[TNT ANDY]

Been there, done that - didn't have cad and laser stuff, so not as clinical as that, fappin' good stuff.

[Trevhib]

Great work as ever :)

[Brigsy]

Proper job mate :agree:

[jesus in the seat of a 5]

well done ashy, nice to see you doin a bit on her despite being a dad...:), good work mate, coming along nicely...despite the orange peel effect on the paint...;){in house banter}...:laugh:..:wasntme:

[Ashy]

coming along nicely...despite the orange peel effect on the paint...;){in house banter}...:laugh:..:wasntme:

:laugh::laugh:

:cooter:

[philg]

Good work ashy, you are a right good handy man :cool:


Is dave giving it a paint, If so what colour?

phil

[DaveMayGTT]

Very nice body repairs, good work

[Sparkie]

maybe you could knock some more cad stuff up and sell em on the site?
rear bumper mountings always go?

[James5]

maybe you could knock some more cad stuff up and sell em on the site?
rear bumper mountings always go?


:agree: Yes please,
Also the inner sill plate would be good :)

[Ashy]

I've started a THREAD (http://www.rtoc.org/boards/showthread.php?p=180986#post180986) in group buys if any one wants any repair panels.

Cheers Ashy.

[Adey aka Ewok]

let me know when that engines in bit ;):agree:

[Adey aka Ewok]

the extra bits of pipe you needed for you turbo mani, what size did you use?

[jimmy_b]

what was the clio dash like to fit? my bro has the old 16v style dash in his but steering wheel sits really low as had to have the colum rewelded to fit the dash

[Ashy]

Been busy over the last few weeks... Don't get as much time as I used to in the garage but the shells nearly ready for Dave SBS to work his magic....

Just got a few small bits to do and its booked in for Feb :cool:

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/DSC_0187%20%281%29a.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/DSC_0188a.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/DSC_0189a.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/DSC_0193%20%287%29a.jpg

[James5]

Niall, looking good matey:agree: bonnet looks familiar :laugh:

[Matt Cole]

panel gaps look suspect!:D

[Ashy]

Niall, looking good matey:agree: bonnet looks familiar :laugh:

Ha yeah, bit of a sl@g that bonnet!!

Mat - F.R.O. :cooter: Gaps are spot on... Grinder sorted that. :smokin:

[philg]

This is going to be nice, one of the north easts best modified r5s, i say one of the best ;)

[jesus in the seat of a 5]

looking good bud, make sure dave doesnt give you any orange peel effect...;), hmm , nice garage too , ya lucky bugger...:D

[Matt Cole]

This is going to be nice, one of the north easts best modified r5s, i say one of the best ;)

Was going to say mate, it wouldn't even make the top 10 at the local scrapyard ! :cry:

[Robbo]

:laugh:
Was going to say mate, it wouldn't even make the top 10 at the local scrapyard ! :cry:

:laugh::laugh::laugh: its like a rats nest inside there

[Ashy]

well she's away to the paint shop...

Should have her back in 3 weeks... Can't wait to get stuck into the re-build :)

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/car.jpg


http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/car1.jpg

[Jonny5]

Looks good mate ;)

[Matt Cole]

thats the best it's ever looked!:D

[Ashy]

thats the best it's ever looked!:D


HAHA You wish yours was in as good condition mate.... You caught all your tin worms yet? :cooter:

[Josie172cup]

thats the best it's ever looked!:D



HAHA You wish yours was in as good condition mate.... You caught all your tin worms yet? :cooter:


now thats enough you two. you both know your 5s are scrappers compared to mine

:rolleyes:

[Ashy]

Now then, got a call today to say the shells in primer, could I pop dwn to make sure I was happy wih it.... Heres a few pics.

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/DSC_0019.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/DSC_0021.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/DSC_0022.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/DSC_0024.jpg

Looks really good, they've done a cracking job so far tidying up all my dodgy filling!

Had to ask them to remove the door striker pins and VIN plate to paint underneath but appart from that its coming along really nicely... should have the top coat done this week then they'll send it back whilst they paint the cage, wheels and body kit :)

[Ashy]

Double Post.....

[Ashy]

:wasntme: :wasntme: :wasntme: :wasntme: :wasntme: :wasntme: :wasntme: :wasntme:
:wasntme: :wasntme: :wasntme: :wasntme: :wasntme: :wasntme: :wasntme: :wasntme:
:wasntme: :wasntme: :wasntme: :wasntme: :wasntme: :wasntme: :wasntme: :wasntme:

Just had the paint shop on, the shell (less doors) and wheels are painted and will be dropped back off on Sat morning........ Can't wait....

Apparently it looks absolutely mint, and its a gorgeous colour.... Can't wait to see it!!

:wasntme: :wasntme: :wasntme: :wasntme: :wasntme: :wasntme: :wasntme: :wasntme:
:wasntme: :wasntme: :wasntme: :wasntme: :wasntme: :wasntme: :wasntme: :wasntme:
:wasntme: :wasntme: :wasntme: :wasntme: :wasntme: :wasntme: :wasntme: :wasntme:

[DaveMayGTT]

Nice to see its a full inside out job, look forward to them pics!

[Ashy]

Well got the shell, wheels and rear cage back at the weekend... heres a couple of pics...

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/DSC_0038.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/DSC_0039.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/DSC_0040.jpg

Can't wait to get stuck into the re-build now :wasntme:

[Markey Mark (BD)]

Nice choice of colour there mate ;)

It looking good.

[Brigsy]

Looks reem mate, how much did the paintjob set you back??

[Ashy]

Looks reem mate, how much did the paintjob set you back??

Duno yet, haven't had the bill :scared:

I was quoted between £800 - £1000 but that was before I asked them to paint the wheels....

[Tony Walker]

Duno yet, haven't had the bill :scared:

I was quoted between £800 - £1000 but that was before I asked them to paint the wheels....


looks good value :D:D:D

[elcie]

Looks mint, such a deep red :agree:

What wheels have you had painted white ?

[djinuk]

very cheap that is for a full paint job matey, and the finish looks nice :)

[philg]

You went for red in the end then, looks great mate, i will have to have a pop down :)

[Ashy]

Any time Phill... Well long as I'm in :smokin:

[mattk]

This is fantastic can't wait to see it finished :)

[tom t]

looks amazing m8 must be well chuffed! good stuff

[Robclio98]

Looks so nice and fresh :D keep up the work :D

[Ashy]

New windscreen fitted today... Looks lovely :)

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/DSC_0138a.jpg


http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/DSC_0140a.jpg

[T.K]

Looks awesome. Will be such a good car when done. :agree:

[Josie172cup]

any updates ashy :D

[Ashy]

Aye but I havent taken any decent pics mate...

All the interior is back in now, seats, cage & dash.... Just got belts to fit then its onto the engine re-build.

[Ashy]

Was just in the garage so took a pic...

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Interior/paint.jpg

[jesus in the seat of a 5]

looks good ash, is there a bit of orange peel to it though.....:laugh::wasntme:;)

[Ashy]

looks good ash, is there a bit of orange peel to it though.....:laugh::wasntme:;)

Joking asside there is mate, needs a bit more flatting and polishing before the cash changes hands ;)

[Josie172cup]

that colour is going to look **** hot in the sun :D

nice work m8

[Matt Cole]

well she's away to the paint shop...

Should have her back in 3 weeks... Can't wait to get stuck into the re-build :)

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/car.jpg


http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Body%20Work/car1.jpg
Thats the ginger feker responsible........................get him!:D

[Ashy]

Been making a bit of progress this week, failry slowly but I've been collecting all the bits required to build my new engine.

I havent looked at the bank balance this week but its taken a hammering, heres some of the bits I've been buying...

Steel Rods - ARP Bolts, Mains, Head stud kit and big rod bolts.

http://www.rtoc.org/boards/picture.php?albumid=883&pictureid=2879


Wossner Pistons

http://www.rtoc.org/boards/picture.php?albumid=883&pictureid=2872

Tial Wastegate

http://www.rtoc.org/boards/picture.php?albumid=883&pictureid=2877

Loads of new bits from Reno:

Head gasket kit..

http://www.rtoc.org/boards/picture.php?albumid=883&pictureid=2874

Timing Belt

http://www.rtoc.org/boards/picture.php?albumid=883&pictureid=2881

Bearing Set

http://www.rtoc.org/boards/picture.php?albumid=883&pictureid=2882

And a few bits I've made:

Flywheel Spacer

http://www.rtoc.org/boards/picture.php?albumid=883&pictureid=2876

VW Gearbox Adaptor Plate.

http://www.rtoc.org/boards/picture.php?albumid=883&pictureid=2880

Engine and box mated together.

http://www.rtoc.org/boards/picture.php?albumid=883&pictureid=2878

Engine and box mounted to subframe

http://www.rtoc.org/boards/picture.php?albumid=883&pictureid=2875

So over the next few days it should all be put together and dropped in.

[Matt Cole]

Awesome marrow. Hope it all goes together well!:agree:

[James5]

Ashy Looking good, very impressive:agree:

[Lewis]

Have you mated the renault and VW driveshafts or had custom shafts made?

[Ashy]

Engine and box in position to measure up for the engine mounts...

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/Engine_Bay.jpg

[philg]

Engine and box in position to measure up for the engine mounts...

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/Engine_Bay.jpg

I must be lost, are you not just refiiting the old engine and box back in the car Ashy?

Its all coming together nice mind :)

[Ashy]

No mate, decided to fit a stronger box (VAG 02J from a Cupra 1.8T) whilst I was on. Hence the need to make up mounts.

[philg]

No mate, decided to fit a stronger box (VAG 02J from a Cupra 1.8T) whilst I was on. Hence the need to make up mounts.

Got ya ;)

[Ashy]

Have you mated the renault and VW driveshafts or had custom shafts made?

Sorry missed your post, I'm using Scoff's old set.

[Ashy]

So, thought I'd update the thread with a few pics...

This weekend I wanted to get the engine mounts sorted, so i took a quick visit to the scrapyard firstly for ideas on how other cars do it and secondly to leave with a few new mounts to play with.

Had a good rake around and came away with a couple of different mounts that I thought I could modify to fit.

Heres some pics.

Bracket to mount the side gearbox mount onto the chassis leg.

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/Side%20mount%20bracket%202.jpg

Side mount in place and front gearbox mount tacked up.

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/Tacked%20Up%202.jpg

All welded up and you can see the rear gearbox mount in this shot also.

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/Finished2.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/Finished.jpg

Now they just need tidying up and powder coating and we are done. Just the engine to build then! :scared:

[jamie_clioGTT]

that is fantastic and makes me very jealous! keep it up and all the luck in the world for the engine!

[HAndy]

spot on :smokin:
will be going down this route myself next year,02j/m= bigger clutch /flywheel and stronger box is a win win situation :agree:

just the cable shift system that concerns me (engine in the back)

are you using the audi gear stick /selector or something out of the newer renaults:)

[Brigsy]

Nicely done mate:)

[Ashy]

spot on :smokin:
will be going down this route myself next year,02j/m= bigger clutch /flywheel and stronger box is a win win situation :agree:

just the cable shift system that concerns me (engine in the back)

are you using the audi gear stick /selector or something out of the newer renaults:)

Its an old Golf one I believe but the previous owner modified it to it inside a corrardo's tunnel (made it narrower) so it fitted perfectly in the 5!

[Ashy]

Couple of update pics...

Cleaned the block and started the re-build.

Main bearings in position:

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/DSC_0301.jpg

Lubed up ready for the crank...

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/DSC_0302.jpg


Threads chased to remove any cr@p.

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/DSC_0303.jpg

Crank in and ARP bolts fitted.

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/DSC_0308.jpg

Pistons & Rods built up

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/DSC_0312.jpg

Pistons in block

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/DSC_0315.jpg

Just letting my sunday dinner settle then the heads going on.

[philg]

:)

[5teve L]

Looks good, I think I may end up going down the VW/Audi box route if mine blows boxes, prob cheaper in the long run... You able to make up adapter plates at all ?

[allanr5gtt]

Looks good, I think I may end up going down the VW/Audi box route if mine blows boxes, prob cheaper in the long run... You able to make up adapter plates at all ?

and the fly wheel spacer?

[Ashy]

Looks good, I think I may end up going down the VW/Audi box route if mine blows boxes, prob cheaper in the long run... You able to make up adapter plates at all ?

Yeah sure... No probs...

Flywheel spacer is a bit harder, I just don't have time to mke them... Can give you a drawing though?

Bit of an update.......

I'm now back to square one, after discovering that the pistons were actually oversize 92.93mm versions I took some advice and decided it would be worth taking the head back off and gapping the rings (something I've never bothered to do in the past) and luckily I did becasue it turns out the instructions from Wossner were incorrect. The instructions said to bore the block to the size on the box which was 82.93mm + 0.01mm. However this size is actually the piston size... So bottom line is the engine has had to come back appart and needs re-honing out.

So I've found a machine shop to do it for me and its all getting dropped off there tomorrow...

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/Square_one.jpg

Big thanks to Scoff for all the help so far, I bet he'll be as glad as me when its built and I stop pestering him :laugh:

[Ashy]

Quick update, engines back together but I don't want to run VVT on the new engine so I needed a way to modify the standard inlet pulley so It doesn't develop the dreaded rattle.

So I've designed a solid version to replace the std item

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/Machined%20Bits/inlet%20cam.JPG



Then got it made up at work...

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/DSC_0331.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/DSC_0332.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/DSC_0330.jpg

Just modified the design slightly with the lightening holes to ensure the solid version was the same weight as the std pulley.

Hopefully over the weekend I should be able to get the engine finished, back together and mated up to the VW box for fitting! :cool:

Cant wait to get it in the bay!

[SP33DY]

Top work mate, how you gonna compensate for the 16 degrees that the VVT gives though?

[Ashy]

I'm not at this stage mate, on my last setup I didn't run the VVT anyway and it was running standard timing. So in this setup it will just run off VVT all the time.

The plan is to make a vernier pulley and once the engines run in and ready for a few tweaks swap them over!

[SP33DY]

I'm not at this stage mate, on my last setup I didn't run the VVT anyway and it was running standard timing. So in this setup it will just run off VVT all the time.

The plan is to make a vernier pulley and once the engines run in and ready for a few tweaks swap them over!


I actually have a set of catcam vernier pulleys, if you need something to copy :)

[Ashy]

I have a basic design mate...

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/Machined%20Bits/Vernier%202.JPG

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/Machined%20Bits/Vernier%201.JPG

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/Machined%20Bits/vernier%203.JPG

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/Machined%20Bits/vernier%204.JPG

But if you've got a set to copy and they are just gathering dust then I wouldn't say no :)

Are both pulleys adjustable?

[SP33DY]

The only problem is there for non VVT cams so if you could use your current design with the added benefit of adjustability it would do away with the need to upgrade to VVT delete cams.

Obviously when using the OE timing tools it will time the cams 16 degrees advanced, so to get it back to a VVT enabled situation your gonna need a minimum of 16 degrees of adjustment.

Heres the ones i have

http://www.k-tecracing.com/show_product.asp?id=2374&appid=2

[Ashy]

The only problem is there for non VVT cams so if you could use your current design with the added benefit of adjustability it would do away with the need to upgrade to VVT delete cams.

Heres the ones i have

http://www.k-tecracing.com/show_product.asp?id=2374&appid=2

My Inlet cam has been VVT deleted mate so wouldn't be a problem. I would just need to change the camshaft oil seal for an Exhaust type.




Obviously when using the OE timing tools it will time the cams 16 degrees advanced, so to get it back to a VVT enabled situation your gonna need a minimum of 16 degrees of adjustment.


Eh, I hought setting the timing with the std tools would set the timing at 0 deg. My understanding was that once the VVT was activated it gave you 16 degrees advance.

[SP33DY]

Nope mate, the inlet cam with the VVT deactivated is 16 degrees advanced, only with enough oil pressure and >1700rpm does the dephaser solenoid activate retarding the inlet cam by 16 degrees.

Heres a link to catcams profiles look at the info bit

http://www.catcams.be/800x600/mainframe.htm?english

[Ashy]

You learn something new every day!

Why do people use yellow text on white background?!?

You can't fcuking read it!!!

[SP33DY]

Just clicked that link and its a dudd, heres the info cut and paste

information & important remarks:

#The VVT system on the intake camshaft changes the cam timing (and so the lift at TDC):
- 1st intake valve: 124° (disengaged) // 108° (engaged)
- 2nd intake valve: 128° (disengaged) // 112° (engaged)
- 1st exhaust valve: 108° (no VVT)
- 2nd exhaust valve: 104° (no VVT)

Please make sure there is enough distance between valve and piston when the VVT system is engaged.

[Scoff]

Yes, the timing is a bit odd in the VVT off position but actually it can work quite well with the turbo and higher boost. Advancing the inlet back toward the VVT "on" position brings mid range up a lot but you end up with a slight lope at idle.

[Matt Cole]

The only problem is there for non VVT cams so if you could use your current design with the added benefit of adjustability it would do away with the need to upgrade to VVT delete cams.

Obviously when using the OE timing tools it will time the cams 16 degrees advanced, so to get it back to a VVT enabled situation your gonna need a minimum of 16 degrees of adjustment.

Heres the ones i have

http://www.k-tecracing.com/show_product.asp?id=2374&appid=2

You wont be selling them to me now i guess!:crap::coffee:


:D

[Matt Cole]

Nope mate, the inlet cam with the VVT deactivated is 16 degrees advanced, only with enough oil pressure and >1700rpm does the dephaser solenoid activate retarding the inlet cam by 16 degrees.

Heres a link to catcams profiles look at the info bit

http://www.catcams.be/800x600/mainframe.htm?english


the number 5 is a majic number!:D

[Andrew Cooke]

the standard timing position is 16 deg retarded and the VVT advances the cam 16 deg. When I measure the cams it's relative to the straight across installed position.

[Ashy]

the standard timing position is 16 deg retarded and the VVT advances the cam 16 deg. When I measure the cams it's relative to the straight across installed position.

So was I right?! :scratch:

Heres a few pics of my VVT delete setup.

The oil ways in the end of the cam that feed the pulley measure 3.8mm dia. So I god some stainless pins ground to 3.83mm dia with a slight lead in. They were a nice tight fit and pressed nicely into position.

http://www.r4f1.btinternet.co.uk/172/DSC_0333.jpg

http://www.r4f1.btinternet.co.uk/172/DSC_0338.jpg

Then the pulley bolt needed to be plugged. The bore was 5mm dia, perfect for tapping M6. So once it was tapped a stainless steel grub screw was lock-tighted in place.

http://www.r4f1.btinternet.co.uk/172/DSC_0339.jpg

Bolted up, just need to fit shorter M6 bolts.

http://www.r4f1.btinternet.co.uk/172/DSC_0345.jpg

So now its time to get stuck into it in the garage. See how far we get today :)

[SP33DY]

Nope mate it's how I explained I just got my advances and retards round the wrong way round :confused:

[Andrew Cooke]

I was just about to say that I thought Steve was getting his advance/retard mixed - easily done...

basically, if you want it in the low overlap position time the cams straight across as per the manual.

[Ashy]

Got quite a bit done today...

Front Subframe, powder coated and polybushed.

http://www.r4f1.btinternet.co.uk/172/DSC_0350.jpg

Engine built up and VW box adaptor plate fitted.

http://www.r4f1.btinternet.co.uk/172/DSC_0352.jpg

Flywheel bolted.

http://www.r4f1.btinternet.co.uk/172/DSC_0357.jpg

This is how she stands now, ready for the box to be fitted tomorrow.

http://www.r4f1.btinternet.co.uk/172/DSC_0358.jpg

[Ashy]

Good days graft today, engines now in.

http://www.r4f1.btinternet.co.uk/172/DSC_0367.jpg

http://www.r4f1.btinternet.co.uk/172/DSC_0369.jpg

Trouble is the old exhaust manifold now fouls the gear selector. Looks like I'm gona need to build a new exhaust manifold and downpipe... The question is do I update the turbo whilst I'm on?!?

[T.K]

What a great project this is. :agree:

[Big Steve - Raider]

Looks Fabulous Ashy! :niceone:

The colour looks bright orange in these latest pictures? Is it the picture or is the car orange?

Just looking at your Brake Servo, it doesn't look like a 5 unit? Is it a larger one off something else?

[Robbo]

that orange paint looks great

[Ashy]

Haha, orange paint!! Nah its just the pictures, it does look red in the flesh!

The brake servo is from a 172 / 182 it fits perfectly and its much bigger than the Gtt one :)

[benj88]

Nice work mate :agree:

[Ashy]

Small update this week...

New brakes turned up :cool: Was supprised how big the calipers were... Just need to get the front end built up then I can try them on :)

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/DSC_0427.jpg

Also new turbo arrived... So I can start building my manifold, here it is in the bay on my fixture so I can get the position right then transfer it onto a spare head to build it up...

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/DSC_0435.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/DSC_0436.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/DSC_0437.jpg

Got a weeks holiday coming up so hopefully Ill break the back of it then :)

[Andrew Cooke]

nice looking turbo:)

when you're bored of it throw it my way :cool:

[tom t]

immense work! nice tubby is it a gt35?

[Ashy]

New GAZ Coilovers fitted and Hi-Spec Brakes :)

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Wheels/DSC_0438.jpg

I was worried that the drive shafts would need to be modified as my gearbox sits differently to Scoff's old one... But they fit like a glove! Mint.

My steering rack is away being re-conditioned, due back Wed / Thurs so then I should be able to drop it down and roll it around! :cool:

[philg]

Getting there mate, I might have pop down next weekend and have a gander.

[Ashy]

Cool mate, feel free :)

[Kris M]

Few nice bits of engineering there Ashy, good man :agree: :)

[Ashy]

Next up, Steering Rack...

Thanks to Phil G for putting me in touch with Quick Start who carried out the reconditioning of my rack... Dropped it of last sat and got the call to say it was ready today!

Looks spot on, just goto get round to fitting it now :)

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/steering%20rack.jpg

[Ashy]

Took my last few lieu days this week to get some garage time in and try to get this project moving. The biggest task is to build a new exhaust manifold and downpipe, so with 2x172 manifolds cut into bits a chop saw, grinder and welder at the ready I was all set.

Old engine setup as fixture.

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/fixture.jpg

First Attempt - but the second runner wasn't right, I wanted to make the runners equal lengths (within reason). The other 3 measured 500 - 550mm each and this one was just 350mm so decided to re-hash it.

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/IMAG0281.jpg

Didn't get many pics of the other stages - heres the runners all welded up.

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/tubes.jpg

All tacked up in position.

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/tacked%20up.jpg

Rear View

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/tacked%20up1.jpg

Manifold complete

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/welded%20manifold.jpg

Manifold in position -

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/mani%20rear.jpg

The reason for putting the turbo on an angle is to give as much room as possible at the back for the down pipe... Thats the plan anyway?!

[Big Steve - Raider]

:eek: Noodle Doodle!!

Nice job Ashy :niceone:

[Matt Cole]

Nice one marrow. Looks very good. How come you divided the runners? you fancying twin scroll soon!:D

[philg]

love the mainfold, great work, no probs on the rack, happy to help :)

If weather is good sunday i might have a run down, im going to bend your ear to make me a manifold to lol :D

[HAndy]

really great build,should be awsome power output to:cool:

[Gibbo69]

Great build ... well in matey :)

[andybond]

There is some serious mechanical talent in this place.

You all a bunch of ugly funts - but gifted with a spanner.

[Dave Reed]

Great work :agree:

Quick question, why does the engine look to be slightly angled down (cam belt end)? Or is it just the pics..

[Ashy]

Great work :agree:

Quick question, why does the engine look to be slightly angled down (cam belt end)? Or is it just the pics..

Yeah it is, its just the way it worked out with the new mounts on the gearbox end.. I built it slightly high expecting the mounts to give a bit more than they did... I'm not too bothered at this stage but may pack up the top mount to level it out if needed.

[Ashy]

Quick update, managed to get a few hours in the garage over Christmas and got quite a bit done. THe plan was to build a 3" downpipe, side exit and fit my external wastegate!

So here goes...

Starting on the downpipe elbow.

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/DSC_0486.JPG

Finished Downpipe

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/DSC_0487.JPG

Another Angle

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/DSC_0488.JPG

Downpipe fitted.

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/DSC_0491.JPG

External Wastegate fitted

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/DSC_0554.JPG

Another Angle

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/DSC_0550.JPG

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/DSC_0557.JPG

Just need to shot blast the inside of the manifold to clean any loose debris out and I can then heat wrap and fit them. :)

[V Man]

Looks Ace G.
Downpipe looks the schnizzle.
You finished all the welding now?

[Ashy]

Looks Ace G.
Downpipe looks the schnizzle.
You finished all the welding now?

Yo G, aye nearly, just got a hanger to weld on and I'm pretty much done... The beasts been faultless as usual :)

[philg]

Down pipe looks first class, but i can not believe all the **** bits of exhaust and screwdrivers lying around in a freshly painted car you butcher :laugh::cooter:

[philg]

Just had another look at your work bench to, god i wont sleep tonight mate, i was going to pop down sometime and have a looksy, i will have have a good tidy up for ya when im down :D

[Ashy]

Dont be so soft ya big fairy! Feel free to pop over and tidy my garage though if it'll make you feel better ;)

[philg]

Dont be so soft ya big fairy! Feel free to pop over and tidy my garage though if it'll make you feel better ;)


:laugh: I will definitely get through early next year mate, just wont take mine out in the rain :ashamed: hopefully brigsy will get out the gym long enough to get some good n/e meets sorted.

Cans of Carling's under the car to omg, you should see my garage, everything in its place lol

Car is looking sweet to, but you need to rip of pascal and get some black Porsche rims :smokin:

[Woznaldo]

Lovin' your work Ashy. Top job on the Ex Manifold and Turbo Downpipe. These VW Gearbox swaps are catching on....

[Big Steve - Raider]

hopefully brigsy will get out the gym long enough to get some good n/e meets sorted.

:laugh::laugh:

http://www.palyne.com/talk/Smileys/palyne/weightlifting.gif

[Scoff]

The exhaust looks about the same as mine ashy. Is the silencer from MIJ ? I use one of those, 18" long I think. 3" straight through, 5" OD. It's a bit louder than I wanted in road-going mode but it sounds quite nice :)

[Kris M]

Cracking engineering during the project mate :agree:

[Bass J]

sat and read this thread just there ...top marks!

Makes me wish i knew how to weld! :smokin: will be watching this thread in the future :smokin::smokin:

[Ashy]

The exhaust looks about the same as mine ashy. Is the silencer from MIJ ? I use one of those, 18" long I think. 3" straight through, 5" OD. It's a bit louder than I wanted in road-going mode but it sounds quite nice :)

mmmm interesting, yes its am MIJ one mate, but i only went for the 12" long version :eek:

I did wonder how loud it would be.... maybe I'll have to fit another!!

[123-gtt]

ashy looking the dogs marrow, so when you doing mine?:D

[Tony Walker]

[quote=Ashy;30331]One of the problems with the NA engine was movement, it rocked about too much on the gtt mounts, so I had to brace it with a bit of a pikey stabiliser bar onto the strut top.... So once the engine was removed for the turbo conversion I decided to weld in a clio top mount...


You probably allready kno but the clio sport top mounts are pretty prone for splitting and clunking maybe look at the 225 mount if thats possible?

[Ashy]

One of the problems with the NA engine was movement, it rocked about too much on the gtt mounts, so I had to brace it with a bit of a pikey stabiliser bar onto the strut top.... So once the engine was removed for the turbo conversion I decided to weld in a clio top mount...


You probably allready kno but the clio sport top mounts are pretty prone for splitting and clunking maybe look at the 225 mount if thats possible?

I don't think its going to move much at all with the engine mounts! I've got plenty of clio top mounts lying around so won't be a problem if I kill a few :)

[Tony Walker]

lol :)

[Ashy]

Not really getting much done at the moment with the early arrival of our new baby...

However i've designed a new inlet manifold which I'm in the progress of making!

http://www.r4f1.btinternet.co.uk/172/manifold.JPG

[Matt Cole]

Leading the way marrow, 'Yorkgeordie puudding Tuning' :D

[Ashy]

Well, not done much recently but today I decided to pull the 5 outa the garage (as it hasn't been out in a few months) and give it a wash...

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/DSC_0725a.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/DSC_0727a.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/DSC_0729a.jpg

These aren't the wheels I was planning on using but they actually realy suit the car, maybe Reno got it right with the Trophy?

I'm really happy with how she's coming along... Just wish I could jump in and go for a spin :(

[Os8472]

Damn she's lookin fine fella, nice work

[Mudslinger]

Looking very nice ashy :agree:

[Matt Cole]

Wheels lock spot on marrow!:agree:

[Ashy]

Making good progress on the inlet manifold(s) heres a few pics of the current status... Just goto make a fixture to hold it all in the right place whilst its welded, then I should be good to go!

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Inlet%20Manifold/DSC_0756.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Inlet%20Manifold/DSC_0759.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Inlet%20Manifold/DSC_0763.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Inlet%20Manifold/DSC_0781.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Inlet%20Manifold/DSC_0783.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Inlet%20Manifold/DSC_0784.jpg

[Matt@CodeRedMotorsports]

Lovely bit of work.
Just a quickie, is there any benefit from firing the injectors into the roof of the port? As in, having the injectors on the underside of the inlet runners? (I'm always unsure of the fastest flow to carry the fuel), or is it better to have them fire fuel into the port as standard for best atomisation on the back of the valves....:crap:

[Scoff]

I feel like i've seen a manifold like that before somewhere :)

Nice work :) I tacked mine together with the mig. Aluminium wire and argon, then ground them back so as not to make it hard to tig over.

[Ashy]

I feel like i've seen a manifold like that before somewhere :)

Nice work :) I tacked mine together with the mig. Aluminium wire and argon, then ground them back so as not to make it hard to tig over.


You know me mate, don't like to re-invent the wheel ;)

I've tried ali welding with my mig before and it just made a right mess of it... Might see if I can borrow a portable TIG set from work...

[Scoff]

You know me mate, don't like to re-invent the wheel ;)

I've tried ali welding with my mig before and it just made a right mess of it... Might see if I can borrow a portable TIG set from work...


It'll do it mate, you want clean metal, a load of current and a load of wire speed ! It's not usually pretty but that's what flap wheels are for ;)

[Ashy]

Making progress, first one is tacked up for a trial fit...

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Inlet%20Manifold/DSC_0779.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Inlet%20Manifold/DSC_0780.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Inlet%20Manifold/DSC_0788.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Inlet%20Manifold/DSC_0787.jpg

Starting to see the light at the end of the tunnel now! :cool:

[Scoff]

Looking good :)

[Matt Cole]

:agree:

[philg]

looks great, i wish i could do more stuff like this, can not wait to see it :)

[Brigsy]

Proper job :agree:

[Brizza]

Ashy, just had a look through all this and looks superb, from the engine to the dash, looks brilliant! where the shiny callipers a simple fit? I'm sure compared to everything else it was but had to ask, also in your dash pics for some reason there appears to be loads of pics of my 5 when it was in the bodyshop last year! ;)

[Ashy]

Ashy, just had a look through all this and looks superb, from the engine to the dash, looks brilliant! where the shiny callipers a simple fit? I'm sure compared to everything else it was but had to ask, also in your dash pics for some reason there appears to be loads of pics of my 5 when it was in the bodyshop last year! ;)


The calipers just bolt on mate, simple as that!

I don't know why the pictures get jumbled up, I think it was when the website moved servers? Theres loads like that!

Glad you like it, just be nice to get it finished!

[Ashy]

little update....

Modified my radiator to move the outlet so it doesnt interfere with the turbo oil return...

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/rad.jpg

and FPR arrived in the post! Big thanks to SteveT2!!

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Engine/reg.jpg

[Ashy]

First two manifolds now welded... Gona be a busy weekend :)

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Inlet%20Manifold/DSC_0816.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Inlet%20Manifold/DSC_0814.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Inlet%20Manifold/DSC_0821.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Inlet%20Manifold/DSC_0823.jpg

[Kris M]

Looks spot on Ashy :agree::)

[James5]

Ashy looking good:agree: why 2 manifolds?

[allanr5gtt]

are you selling the spare manifold?

[Ashy]

Duno yet mate, I've actually made 3 of them...

Ones for me and ones for Matt C, the flange is designed to fit either a 172 / 182 / 225 cylinder head. The third one is a spare for me (as I'm building another engine) but I may sell it if I decide not to use it....

Also I have the designs available so could make anoter batch if there was enough interest.

[Josie172cup]

Duno yet mate, I've actually made 3 of them...

Ones for me and ones for Matt C, the flange is designed to fit either a 172 / 182 / 225 cylinder head. The third one is a spare for me (as I'm building another engine) but I may sell it if I decide not to use it....

Also I have the designs available so could make anoter batch if there was enough interest.

Dibs on that spare engine :D

[Ashy]

Quick update, got a week off work so started tinkering today, hopefully get somewhere near finished this week...

Heres a few pics

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/final%20build/DSC_1067.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/final%20build/DSC_1074.jpg

[Tony Walker]

Looks fantastic mate, :devil: credit to the club :agree:

[mattk]

Looks awesome mate, hope you get close to finishing this week :goodJob::goodJob::goodJob:

[James5]

Looking very very good Ashy :agree:

[tubbyG]

stunning....... brilliant craftmanship on show here :smokin:

[Woznaldo]

stunning....... brilliant craftmanship on show here :smokin:

Ditto :agree:

[Ashy]

Thanks guys, small update from today's tinkering.

I needed to re-think the crank sensore pickup due to the fact that i'm using the VW flywheel. So I had a 36-1 wheel produced at work to blt onto my inlet cam pulley..

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/final%20build/DSC_1076.jpg

Inlet cam pulley before:

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/final%20build/DSC_1077.jpg

Inlet cam pulley after:

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/final%20build/DSC_1083.jpg

Engine view, plumbed in the intercooler, and some of the water pipes... Just a few small things to do tomorrow then I may get to plug the ECU in and see if things look OK to start her up. :eek:

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/final%20build/DSC_1078.jpg

[Brigsy]

Superb job mate :agree:

[Tony Walker]

:D you have to post a vid of it running:agree:

[Tony Walker]

just noticed your belt, there only meant to run in one direction(apparently) not sure how true that is but ive allways thought the writing on the belt should face you when putting it on. Just something to check maybe?(something i was taught by oldschool lecturers lol)

[Ashy]

Interesting, I don't know, I thought modern belts were multi directional, the only time you should fit directionally would be if the belt was marked up with directional arrows or if you were re-using an old belt and you needed to make sure it went back on the same way.

There are no directional arrows on the belt and i've just checked the Clio Manual (http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/172_pdf%5B1%5D.pdf) (just incase) it doesn't mention it!

:eek: :confused: :scratch:

I'll not be able to sleep tonight now :cry:

[Tony Walker]

Sorry, you are right in saying that some belts have directional arrows on them, i just have allways put them with the writing facing me. Its probably fine but thought id mention it before you go ahead and run it.

[Matt@CodeRedMotorsports]

Lovely work ashy.:smokin:
Ditto tony with the cam belt, also, are you using cam speed for tdc sensor? I'm guessing you have a correction in the inj comp (not teaching you to suck eggs here) as cams turn half the speed of the crank, so normally you would need a 72/2 tooth wheel on a camshaft.

[Ashy]

Lovely work ashy.:smokin:
Ditto tony with the cam belt, also, are you using cam speed for tdc sensor? I'm guessing you have a correction in the inj comp (not teaching you to suck eggs here) as cams turn half the speed of the crank, so normally you would need a 72/2 tooth wheel on a camshaft.

Now then Matt, yes I'm taking the TDC reading from the inlet cam, I haven't checked DTA SWIN yet but I'm sure it'll be able to handle it.

When you say Ditto on the timing belt are you thinking its wrong or multi directional... :confused:

[Matt@CodeRedMotorsports]

Re cambelt, I'm old so have always done the belt so you can read the writing when facing the engine. Not scare mongering in any way mate, I'll check some renault tech notes in a mo, see if there is any info there.

[Ashy]

Re cambelt, I'm old so have always done the belt so you can read the writing when facing the engine. Not scare mongering in any way mate, I'll check some renault tech notes in a mo, see if there is any info there.

Thanks Matt.

[Ashy]

Nearly ready to turn the key.... Any info yet? :scared:

[Matt@CodeRedMotorsports]

No tech notes on direction apart from if it has direction arrows on it near the part no.
So I think you are ok!!;)

[Ashy]

No tech notes on direction apart from if it has direction arrows on it near the part no.
So I think you are ok!!;)

Good news, thanks mate, its a genuine Reno belt so thats a relief!

[mattk]

Hope its all going well mate :cool:

[Ashy]

Hope its all going well mate :cool:

Yes thanks, shes now running :agree: :cool:

http://www.youtube.com/watch?v=HCRRkvks6Vg&feature=youtu.be (http://www.youtube.com/watch?v=HCRRkvks6Vg&feature=youtu.be)

[Tony Walker]

wooohoooooooo:agree:

[GT Josh]

Amazing work mate :agree::smokin:

[123-gtt]

Good lad ash marrow,I'm up this weekend,might call round if your free :agree::disagree:

[Ashy]

Yo, aye pop over mate, I've not got anything major planned but just drop us a text to see if I'm in and I'll stick the kettle on!! See if you can drag old Bertie out too :agree:

[philg]

good stuff ash :)

[Big Steve - Raider]

Smashin! :D

Looking forward to seeing this bad boy finished & running! :niceone:

[Ashy]

All back together now, just need to bleed the brakes and the gear linkages need adjusting... Other than that its nearly ready for an MOT :eek:

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/DSC_0079.jpg


http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/DSC_0080.jpg

[James5]

Ashy ooking good, quiet a few red 5's coming out at the mo:agree:

What's going on with the grill?

[Ashy]

What's going on with the grill?

Just needs tweaking, the rad fan is sitting behind it and maybe its touching? Didn't notice until I saw my own photo's :sad2: Its not as obvious in the flesh... I'll be having a look tomorrow :)

[Brigsy]

Grill should be fixed on outside of slam panel that will probably sort it, looks well though mate!

[Ashy]

Grill should be fixed on outside of slam panel that will probably sort it, looks well though mate!

Aye normaly it would, I've removed the lip on the back of the slam panel to give more clearance for the rad, so was just trying different mounting methods.

[Matt Cole]

Nice one marrow. Awesome!:agree:

[Woznaldo]

GTTs in red are my least favourite (mainly because the paint is hard to maintain) but, your car and Pascal's are making me seriously reconsider this opinion!

Looking freakin great! :cool:

[T.K]

Wowzers trousers! This looks truly excellent. :agree:

[Ashy]

MOT booked for sat :eek:

[philg]

Im sure it will sail through.

[Ashy]

Failed last week, appearently new MOT rules don't allow spot / stitch welding on replacement panels! So I had to grind all the underseal off and fully seam weld my inner sills!

I did that last weekend and it went back in yesterday, she now has a full 12 month ticket :)

Just waiting until next friday and I'll be taxing her! :D

[DaveL485]

Failed last week, appearently new MOT rules don't allow spot / stitch welding on replacement panels!

You can't spot weld the panels that are spot welded on from the factory :sad2:

Pity its not pre 1960's, you dont bloody need an MOT at all then! :eek:

[Ashy]

Quick update, big thanks to Scoff (EFI Parts) for spending all day Sunday mapping my car, what a top jobs he's done. Thanks mate.

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/001.jpg

[Ashy]

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/002.jpg

[Robbo]

nice one ash tray:)

[Andyturbo!]

Great figures ash! And top job mr scoff :agree:

[Coops]

thats some serious power right there :-) good work and nice once mad scientist:cool:

[Os8472]

Awesome numbers fella, this is gunna be an animal on track :agree:

[Matt Cole]

Job done marrow!:agree: Got to be pleased with that :D

[Ashy]

Job done marrow!:agree: Got to be pleased with that :D

Yes mate, very pleased :)

Got a few bits and bobs to do to make her perfect, then I plan just to enjoy driving a 5 for once rather than lying under it! :laugh:

[c7borg]

Yes mate, very pleased :)

Got a few bits and bobs to do to make her perfect, then I plan just to enjoy driving a 5 for once rather than lying under it! :laugh:

Well done mate, that is some stonking power!! if I had a bit more luck with the F4R I might have been turbo'd by now but I've turned to the dark side and bought a mk2 golf with a 20vt engine.. exactly what you say I rather be driving that lying under it :)

[TNT ANDY]

Nice one Ash, you goto be very happy with that. I'd love to know what thay must feel like. Well done again, that must have be- a much more pleasurable experience than I had.

[Ashy]

Nice one Ash, you goto be very happy with that. I'd love to know what thay must feel like. Well done again, that must have be- a much more pleasurable experience than I had.

I'll let you know when I've had a brave pill and tried it at full throttle.... :scared:

I heard you had a mare mate, new cam on the cards?

[Brigsy]

Awesome result ashy:agree:

[James5]

Niall, Top work looks like it paid off with all that time and effort fantastic power output, going to be quiet a handful on trackdays:agree:

[Coops]

I'll let you know when I've had a brave pill and tried it at full throttle.... :scared:

I heard you had a mare mate, new cam on the cards?

balls to brave pill, suck it up and mash that loud pedal! enjoy it whilst its working :laugh: :agree:

[GT Josh]

Nice nice Ashy. Be careful you dont get sucked into that turbo. It could fit a small country inside that bad boy! :devil:

[Ashy]

Minor Update....

Had a few issues with wishbones bending / flexing so I thought I'd try to strengthen the front end...

Subframe and wishbones blasted

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Subframe/1.jpeg

Wishbone mounting points

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Subframe/2.JPG

Top side seam welded.

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Subframe/4.JPG

Wishbone Sleeves welded in place

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Subframe/5.jpeg

Subframe and wishbones, gussets in place, strengtheners over wishbone mounting points.

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Subframe/6.JPG

Underside of the subframe with additional skins and bracing.

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Subframe/7.jpeg

View from other side.

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Subframe/8.JPG

Next step is the wishbone to subframe triangulation....

[Goobie]

Thats one crazy subframe there mate! :cool: Any more updates on this? :)

[Ashy]

Thats one crazy subframe there mate! :cool: Any more updates on this? :)

Slow progress I'm affraid, just been tinkering over winter ready to be back on the road when it warms up a bit....

Finished the subframe off...

Tie Bar from the wishbone to subframe

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Subframe/tie%20bar.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Subframe/gusset.jpg

After Coating.

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Subframe/coated.jpg

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Subframe/coated1.jpg

And re-did the engine mounts on the gearbox and added a sixth one from the drivers side chassis leg to the back of the block.

http://www.rtoc.org/files/Technical%20Files/Ashy%20172%20turbo/The%20Rebuild%202010%20-%202011/Subframe/mounts.jpg

Nice and solid now :)

Engines back in just need to fit it all back together and plumb it all in :agree:

[Tony Walker]

Fantastic, what was happening to the components to need this work?

[turbo ted]

awsome job there ashy on that subframe i will be copying that idea and doing to my r5 to try keep my car from swisting apart when ever i pull my finger out and finish my vw gearbox conversion:)