R5 - 172 Turbo Project **Updated**

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.

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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.

https://www.rtoc.org/files/Technical%...o/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

https://www.rtoc.org/boards/picture.p...pictureid=3264

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

https://www.rtoc.org/files/Technical%...o/Image069.jpg
https://www.rtoc.org/boards/picture.p...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/image...es/smiley1.gif

So I set about re-building engine number 3

Machined the pistons down to drop the compression -

https://www.rtoc.org/files/Technical%...o/Image004.jpg
https://www.rtoc.org/boards/picture.p...pictureid=3266

Machined the flywheel to take my multiplate clutch -

https://www.rtoc.org/files/Technical%...o/Image015.jpg
https://www.rtoc.org/boards/picture.p...pictureid=3267

Stripped the block & Painted it yellow -

https://www.rtoc.org/files/Technical%.../DSCF2486a.JPG
https://www.rtoc.org/boards/picture.p...pictureid=3269

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

https://www.rtoc.org/files/Technical%.../DSCF2499a.JPG
https://www.rtoc.org/boards/picture.p...pictureid=3270

Knocked up a manifold and downpipe to suit a T3

https://www.rtoc.org/files/Technical%...20turbo/1a.JPG

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...

https://www.rtoc.org/files/Technical%...o/DSCF2784.JPG


Welded In

https://www.rtoc.org/files/Technical%...o/DSCF2843.JPG

Primed

https://www.rtoc.org/files/Technical%...o/DSCF2845.JPG

And Painted

https://www.rtoc.org/files/Technical%...o/DSCF2848.JPG

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.

https://www.rtoc.org/files/Technical%.../DSCF2983a.JPG

https://www.rtoc.org/files/Technical%...o/DSCF3174.JPG

Fitted that to my new engine

https://www.rtoc.org/files/Technical%.../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

Good job Ash!

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

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

https://www.rtoc.org/files/Technical%...urbo/dash1.JPG

Finished Up

https://www.rtoc.org/files/Technical%.../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 incase anyone wants to try it.

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)

https://www.rtoc.org/files/Technical%.../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

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

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:

Quote:

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Originally Posted by Spooky

Good job Ash!

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

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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.

Quote:

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Originally Posted by Bodell

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:

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

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:

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

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

Ashey that is blood good work mate, keep it up

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

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


:worship:

Looks great Ashy. :agree:

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
:)

do u fancy doing the same to mine m8 ? lol

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.

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!!

https://www.rtoc.org/boards/picture.p...ictureid=10212

Looking forward to an interesting 2010 :)

Cool is that a GT30?

Quote:

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Originally Posted by Logg

Cool is that a GT30?

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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?

Quote:

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Originally Posted by Andrew Cooke

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?

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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.

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

Latest pics bud?

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.

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 :)

Quote:

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Originally Posted by 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 :)

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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?

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 ?

Quote:

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Originally Posted by 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 ?

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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?

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

Quote:

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Originally Posted by fcdgary

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

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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...

https://www.rtoc.org/files/Technical%...o/SAM_8593.JPG

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?

Quote:

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Originally Posted by Ashy

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?

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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.

news of this superb project of GT RS ???

would you have a video of your GT ? ;)

Quote:

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Originally Posted by xenon

news of this superb project of GT RS ???

would you have a video of your GT ? ;)

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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...

https://www.rtoc.org/boards/picture.p...ictureid=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

:)

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

https://www.rtoc.org/files/Technical%.../DSC_0724a.jpg


The drivers side was just nasty....

https://www.rtoc.org/files/Technical%.../DSC_0727a.jpg

So out it came....

https://www.rtoc.org/files/Technical%.../DSC_0779a.jpg

Cleaned and painted ready for the new surround

https://www.rtoc.org/files/Technical%.../DSC_0782a.jpg


New surround tacked in place

https://www.rtoc.org/files/Technical%.../DSC_0792a.jpg

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...

https://www.rtoc.org/files/Technical%.../DSC_0768a.jpg

https://www.rtoc.org/files/Technical%.../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...

https://www.rtoc.org/files/Technical%.../DSC_0771a.jpg

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

https://www.rtoc.org/files/Technical%.../DSC_0784a.jpg


Then Spotted it into position...

https://www.rtoc.org/files/Technical%.../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...

https://www.rtoc.org/files/Technical%.../DSC_0775a.jpg

And welded into position

https://www.rtoc.org/files/Technical%.../DSC_0785a.jpg


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

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

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

Great work as ever :)

Proper job mate :agree:

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:

Quote:

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Originally Posted by jesus in the seat of a 5

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

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:laugh::laugh:

:cooter:

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


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

phil

Very nice body repairs, good work

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

Quote:

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Originally Posted by Sparkie

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

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

I've started a THREAD in group buys if any one wants any repair panels.

Cheers Ashy.

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

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