My White 5 gt turbo project

[Fordy]

First post!

So i took a gamble and brought the car off my cousin as a non runner, no mot or tax, water mixing with oil project

Spec is pretty much unknown but have found a few things:
Alloy header tank
ktec alloy carb top
mocal oil cooler
alloy degassing camber
ktec bored out turbo elbow
bigger alloy intercooler
samco silicone hoses everywhere
engine rebuilt back in 2006 new pistons+liners, bottom end rebuild
scorpion straight through exhaust system
clifford g5 alarm
Ecotek valve (removed as soon as i saw it)

This is how the car turned up on my door step after being towed,
Carb and turbo had both been removed and put in the footwell






then i started work on the engine to get the liner seals changed and inspect the rest for damage









Whilst waiting for parts to turn up from renault i decided to take the front bumper, front archs and side skirts.
Found a few medium size rusted through sections in the drivers outer sill and a small hole in the passenger side outer sill.

So far have cut out the rusted sections and put in new metal and welded it, seam sealed and painted with paint, got to do the rear of the drivers sill as the inner sill needs a bit of welding but need to drop the tank as its too close for my liking

Replaced both front wheel bearings and bottom ball joints as they were knackered

Then my bits from renault turned up

new heatshields as mine are missing
new headgasket kit
new rear window square trims as mine are falling apart
new sideskirt clips as most of mine have broke
Metre of brake servo hose as some knob has fitted a ecotek valve in mine
New coolant
Sump painted black by my brother
Also found out the whole car has dynamat everywhere







Rebuilt the carb
Dinner trays are good for carb rebuilds :mrgreen: found out some muppet had got the accel pump spring wrong way around so it was sitting on the diaphram and would of split it sooner or later


Then i got the engine all back together after cleaning the liner platforms (Drill wire brush attachment and flat screwdriver works wonders) new liner seals fitted, new headgasket

After much internet searching i found out where each samco hose should be
Engine bay now its fully functional but slightly smokey from turbo oil seal


Turned him around so i can start work on the back end so took pics of the front end all rust treated and painted black





Bolted the front bumper and pushed the broken grill back in place to look better for the moment


Now i got to fix up the back end
drop fuel tank
do small bit of welding on sills
fix the fuel pump and filter on properly
fix a fuel pipe leak
make a new reserve tank strap
raise back end as currently sitting far too low

Got to sort out the interior aswell as its a bit of a mess :roll:

Then hopefully get it to work for a mot and i just need to get the turbo rebuilt and the car onto the rolling road for a fueling check and boost increase :mrgreen:

[Yellow]

The white ones just keep popping up. Good work mate, get her on the road and enjoy.

[philg]

nice and looks very oem to

[g10far]

Nice work, glad to see another one back to its former glory, keep us updated!

[Fordy]

New poster! (less than 10 posts)

did a bit of filler and prep work where i had to weld in a new bit of metal on the top of the sill the other day during the week



all primered ready for a rub down and lick of paint :nodyes:

And had a decent amount of progress today

Sill has been painted


Drivers and passenger rear sections of sill holes has been fixed and strengthened so much its a new jacking point


Then the front archs, sills, floor pan, boot floor pan basically everywhere under the car has been waxoyl'd super thick :mrgreen:




My reserve tank strap had rusted away and snapped and i wasnt going to pay £30+ delivery for one :shock:
So i went all blue peter on it 8) Mine cost £0 :P

Cut away snapped strap from brackets



Cut out length of metal from brothers crash austin mini



Clean brackets ready for welding, Spot welded new metal strap to brackets, welding outside in the wind with a gas mig turned out half decent



Temporary fit on car, bend strap to right place and measure the second bracket and mark where it needs to be welded on to get a nice tight fitting strap



Spot weld second bracket onto metal strap and you should have something like this



Then it got painted in etch and chassis black paint, and a nice sticky foam strip was cut to length to stop it rubbing through when its all bolted up


Then after arseing about with the exhaust to get it a perfect fit, took off the rear bumper started poking some holes and found some rather nice rusty holes to weld up So glad i brought a new reel of mig wire and gas bottle today

Provisional mot date is beginning of october fingers crossed if i don't go rust hunting again ops:

[car.crash]

nice project, looks like your doing a great job

[Fordy]

New poster! (less than 10 posts)

started working again now the snows over

Before


My little helper making sure i dont grind my fingers again



And After




Doesn't look like much but we've done a fair bit.

Removed the tailgate as its scrap but kept all the wiring safe.
Removed the rear seats, drivers seat, boot carpet and under back seat carpet.
Removed the show roll cage.
Fixed the rust hole on the rear bumper mount and fuel filler neck mounting.
Fixed the captive nut so the bolt that holds the drivers seat frame to the body so it actaully screws into something and the seat dont flap about . :lol:
Hammered off all the renault sound deadening from the boot floor and rear arch sides.

But i got pokey screwdriver happy and found another 2 rust holes

So i've crossed a few things of my to do list but added a few aswell doh!


The worst rusty hole less than 1 inch away from the rear seat belt mounting point
Some of the weld went **** near to the end as i ran out of gas and the gas regulator packed up :x

This is just the inside part of the panel i've fixed, got to do the part in the wheel arch tonight


Oh and you can see where i removed some of the sound deadening on the arch and floor


Rear seat backs repainted black


Interior going back in




Shopping this morning got some new engine bits


Took the rear windows out to change the 3 little rubber bits and well i'll let the pictures do the talking.......



My newly paint floor is going to get ruined even tho it'll be recovered in sound deadening anyways



Looks like the welder is coming out again..... surely there cannot be anymore rust after this?

[philg]

Good effort, keep at it. Its all worth it in the end

phil

[Big Steve - Raider]

Major Bummer about the Rust!

But keep up the good work matey!! You're doing a Grand Job!!

[Fordy]

New poster! (less than 10 posts)



















Then started to fix all the messed up wiring loom and poor clifford g5 installation that was hanging down everywhere, so out came the dash and started re-tapeing the whole thing back into shape.
Removed all the scotch lock's and crap solder joints and replaced with heatshrink crimp connectors 8)

[Fordy]

New poster! (less than 10 posts)

ok the brakes wont bleed properly :roll: so i went out and brought a new master cylinder as it only cost £27 and the rear bias valve seems to be working fine
oh and a easy bleed kit as these like to be pressure bled



Then got cracking on the wheel refurbing



And the apprentice is doing bodywork stuff





first time i used the camera since christmas ops:

Just need to order tyres, flush the engine oil, fit a new battery and sort insurance and then its mot time :mrgreen:

[Fordy]

New poster! (less than 10 posts)

Well my brother has today and tomorrow off work for his birthday
so i was expecting him to play on his pc all day or something but..... instead he has gone and done a **** load of bodywork preping for me :mrgreen:

He shall be rewarded by supplying him curry form the local takeaway

[Fordy]

New poster! (less than 10 posts)



















big thanks to Phase I 16 V Turbo aka http://www.gt-turbo-spares.co.uk for the parts

[Fordy]

New poster! (less than 10 posts)

good news
got a new brake compensator coming for thursday and got some 8mm microbore copper pipe

also my brother brought these home today :mrgreen:

before picture of badges with lacquer peeling off and looking rather tired




After



Simple to do, In person they are great and shiney 8)

My brother has said if people cover the cost of return postage and offer a few beer tokens, he'll do other peoples in his spare time, letters will have to be a brushed style finish but background can be most colours

[Fordy]

new rear brake compensator valve as i found mine was leaking,
copper fuel lines as my standard steel lines had cracked,
new rubber hose for good measure,
and a load of jubilee clips again for good measure,



Compensator went on fine without a problem......But ..... I snapped a bleed nipple in the drivers rear caliper.... DOH! couldn't drill it out double DOH....
So off to the millfield motor factors for a new one for a lovely price of £70 and it came with a new pad carrier aswell

But now i have 2 new rear calipers, brakes that bleed properly and actaully stop. Also new fuel lines that don't leak out v-power quicker than it goes in lol






Then I put in some engine flush to help get any water out of the engine/ oil cooler as theoil cooler hoses wont undo without breaking the line and cooler, so its had a flush and new oil fitted after a cheeky road test up and down the road to make sure it stops lol







Then we got bored and a night free from the gf means as much time as we want to play.
So my bro finishes sanding the passenger side down and i got bored.....

Soooo i started ripping the black trim off the bumper, the brother wasn't too pleased as this now means he has alot more sanding and prep work to do muhahahaha

[raj]

your putting some work in there mate

WARNING: i dont know if anyone else has noticed but that oil pump thats fitted to your engine is NOT a gtt type. its from a campus. your bottom end wont like that at all. get it swapped

THIS is the gtt type

[Bigfoot]

You do realise that those tyres are going to scrub more than likely, when going 15" you really do need 195/45r15

Superb work there, cant wait to see the finish look of it, do like a nice clean white 5, you going to be putting the original decals on?

[Big Steve - Raider]

So off to the millfield motor factors for a new one......

I Just read this part of your thread & thought "Surely he can't mean THE Magical Milfield Autoparts???"

A quick look of your profile & I see your in Sawtry!!!

I'm only in St Neots mate & all my family are in Peterborough

Nice to see a well sorted 5 is so nearby!!

I'll have to have a mosey on over sometime & have a look in the flesh, and I'll add you to the list for the convoy to National Day!!

I like what your brother has done to your badges & reckon I could be tempted to see what he'd do to mine!?

You're doing a F'ckin awesome job on the car though mate, Great thread, keep it up!

[Fordy]

as long as the wheels dont scrub the inner archs with half a turn before full lock i'd be happier, tyres wont be lasting long as it'll be abuised on trackdays

didnt know about the oil pump tho oil pressure is fine on the dash when hot, but if the engine does blow it'll be rebuilt/changed for a higher power build


big steve,
you wouldnt believe how much millfield have saved my life and wallet when buying new parts, master cylinder £27, the compensator came to £80 and caliper £70, bleed nipples few pennys so a tidy saving from buying online

if your badges are the metal ones he can do the same as mine or maybe something fancier but you'd have to ask him. To get them off the car without bending them, use some welding wire to cut it off the car careful of the locating pins on the badge tho

national day and frog of the pod are my plans once the car is finished so i'll defo be going to both and be nice to convoy with someone as i dont know anyone yet

[djinuk]

looking really good now , that rear badge is , what exactly has your bro done, im going to guess , painted and then flatted back with a block, then lacquered?

[Fordy]

looking really good now , that rear badge is , what exactly has your bro done, im going to guess , painted and then flatted back with a block, then lacquered?

pretty much fella, but we nitromors'd it back to pure metal and started fresh

[TNT ANDY]

That's just given me an idea - I have a large conservatory, which currently has no parts in it.

[Fordy]

That's just given me an idea - I have a large conservatory, which currently has no parts in it.

haha they do come in handy the amount of stuff you can dry store in them

quite a productive weekend, the bro has done well even if he did look like a albino earlier





front bumper hasnt been touched other than ripping out the black rubbers.

thats most of the work we can do before getting it mot'd so i just got to put a drivers interior trim back on during the week and swap the wheels over for mot friendly ones,

Fingers crossed i make it to the mot station without having to call out rac to save me

[BriC]

Those tyres will almost definitely scrub! Car is looking good though

[Fordy]

out of interest what tyre/wheel combo doesnt scubb the chassis leg?

[djinuk]

is that aersol high build dude??

If so you may have problems, it often reacts like buggery, and its so damn thin in them cans it either does nothing orrrr.... it just rubs though when you flat it...

invest in some 2k stuff matey

[Fordy]

is that aersol high build dude??

If so you may have problems, it often reacts like buggery, and its so damn thin in them cans it either does nothing orrrr.... it just rubs though when you flat it...

invest in some 2k stuff matey

yup only out of a can for the moment to stop anything getting into the filler when it gets driven to the mot, most will be sanded off

brother is going to get some proper filler spray stuff from work that needs a 2mm gun nozzle to spray it

have experienced the reactions before on another cr when painting over halfords paint, needless to say it wasnt pretty when the proper paint went on over the top

[BriC]

out of interest what tyre/wheel combo doesnt scubb the chassis leg?

Those wheels with 195/45/15 would be fine.

195/45/15 tyres have near as makes no difference the same rolling radius as the original tyre size.

[benj88]

Great work mate, the finish on the wheels looks class

[Wallace]

Gonna be yet another lovely minty mint 5 on the road

Good work mate, some serious effort gone into that..........

Keen to see the next update

[Trevhib]

Loving this, well done indeed, keep the pics coming along with the progress

[philg]

Coming along great

[Fordy]

well the new wheels are on and looking sexy also checked for scrubbing as i dont like scrubbers

the rears are 100% fine even with my brother jumping in the boot

And the front clear fine when the car is jacked up.
When on the floor, they clear.
The front of the tyre misses the chassis leg fine but the back is kinda close possibly cardboard thickness maybe a touch thicker but for a mot they will be fine.

Down the road with the tyre flexing i recon it may scrub slightly nothing some 10mm spacers and longer bolts cant fix i'm sure

Also fitted some new number plates to make it look good

[r5adz]

looking really good m8. I know it's a small thing but im so impressed with the badges. I was looking at mine wondering how to bring them up to scratch. Can't wait to see it finished

[R5TURBORON]

loving this project keep up the good work

[Fordy]

Well log story short,
friday i set off to the mot station and i got possibly half a mile away from my house,
gave it some boost in 2nd gear and didn't watch the boost gauge,
pulled up the a roundabout and cough cough cough yup running on 3 cylinders and smoking worse than ever with no power at all,
So drove it home at 40mph and a ozone killing cloud of smoke behind me.

compression, sparks and fuel all fine.....

So i blew the head gasket or a inlet gasket

Rather than mess about i stripped the engine down and this time going to build it properly rather than in 5 minutes


new turbo, piston rings, oil pump, liner seals, head gasket, head bolts, head skimmed and all the valves relapped in

the head has already had new guides by the looks of things and the valves look new too but it had a bend in the centre when checked with the straight edge so needed skimming

Got the head back from being skimmed today, and i've done the valve lapping

Spare cylinder head is screwed, det marks a plenty, corrosion pitting in the head and 3 or 4 valve seats beyond repair

few pics from the phone when stripping it down again








other pics currently uploading

[Fordy]

[Fordy]

Came home today find the last pieces of the puzzle i've been waiting for so now i'll post pictures up

So a run down of parts:
New Standard Turbo
Refurbished renault 5 gt turbo oil pump
Piston rings - brand matched to recent new pistons and liners
Renault valve stem seals
Uprated headgasket set "blue seal"
Conrod bearings in standard size
Exhaust mount
New oversized door pins


BIG Thanks go out to
Mike at Gt-turbo-spares for sorting out most of the parts, He Truely is a legend every time i've ordered bits

And to everyone on here warning me about the campus oil pump and offering their spare cheaply

[Wallace]

Nice nice nice Coming along mate

Once you've finished, its surely got to be a meet for us "local" guys,your only an hour away, Big Steve Raiders up the road & Purplerob is almost my neighbour

Keep the updates and pics coming mate and we'll get a meet sorted

And yes Mike is an absolute diamond isn't he - haven't forgotten i owe you a beer Mike

[Fordy]

i'd be up for a meet sometime could even take some shots of the cars now the weather is getting nicer

Once its on the road mot'd and taxed i'll be paying up for frog of the pod and national day

[Fordy]

Bottom end is all done and the sump back on sealing over night

Gave the piston tops a quick going over with scotchbrite to bring them back up clean

Old big ends


Liners and pistons in




Decided to use my little daddy 3/8 torque wrench on the big end nuts





Old piston ring massacre

[Trevhib]

Nice one Raj for spotting the oil pump situation and to Fordy for getting it sorted when the opportunity came.

RTOC is all about the resto projects at the moment!

[Fordy]

Nice one Raj for spotting the oil pump situation and to Fordy for getting it sorted when the opportunity came.

RTOC is all about the resto projects at the moment!

Only planned the campus pump to last untilll after the mot but i didnt even make it to the mot before the engine went pop

And my thinking is a new turbo + a campus pump = bad times so it had to go

Head is pretty much built up only little bits left to put back on

BUT!

I broke a one way valve on the inlet manifold

Took it out to check it works fine and change the copper washer, put it back in and tried tightening it and it wouldnt tighten it just snapped :x

So i need to go over my cousins to get one off his 6 spare inlet manifolds he's got :lol:

[Fordy]

Getting closer to being finished

Altho somehow the ht king lead has broke

And also i'm missing part of the oil return which i assume is still in my old turbo that got sent to cgb.....arse!

Was going to try get it mot'd on saturday but i doubt i'll get the part back from cgb in time





Broken king lead


My working conditions lol need to do some house cleaning soon me thinks

[Wallace]

You don't mess around do you

Notice you've got a brand spanking new turbo - have you considered an in-line filter in the oil feed?

A lot of others recommend them and it will save any swarf of ****e ruining your fresh turbo.................just a thought!

Good luck with completing it

[Fordy]

You don't mess around do you

Notice you've got a brand spanking new turbo - have you considered an in-line filter in the oil feed?

A lot of others recommend them and it will save any swarf of ****e ruining your fresh turbo.................just a thought!

Good luck with completing it

I was thinking about an inline filter but with the rubber feed hose is cracking and stuff, i was going to get a braided pipe made when needed

Funds are at a major low so any little extra's will have to wait till next pay day

I just want to drive it for more than 1/2 a mile then i'll be happy

[Tony Walker]

Take a look in my profile at the T2 housing i made for bedding engine in. oil feed i just pushed in to the return and put a clip on it. Its worth it for the turbos sake.

[Fordy]

Take a look in my profile at the T2 housing i made for bedding engine in. oil feed i just pushed in to the return and put a clip on it. Its worth it for the turbos sake.

Good idea there fella but i dont have a spare t2 housing

I should think with very regular oil changes in the first 500 miles will be good enough to save the turbo. When the turbo does blow I'll get it rebuilt into a t25/t2

[Fordy]

time for the big update :mrgreen:

drum roll please ..................


Its alive 8) and it runs great, no more smoke, rough idle or milky oil

Also word of warning to everyone
when your little bro is turning the engine over to get fuel into the carb and the pressure up and you have the coil pack ht lead off
DO NOT HOLD THE LEAD to stop it arcing off metal

fook me the coil pack packs a punch :shock: both my arms went straight up and kinda flapped about :lol:

But i may have a minor leak from the flywheel side half moon sump seal
Or it might be where i split some oil out when the turbo oil feed was off in a bottle to make sure i had oil moving around with the new oil pump. But thats a simple fix which will get done once i've put 50-100ish miles on it and need to change the oil next

Now i'm getting 4 bar oil pressure whilst cranking down to 2.5ish when the fan cuts in 8)

Did get a little video but its nothing special will upload soon

[Big Steve - Raider]

Its alive