something a bit diffrent

[Jaff]

New poster! (less than 10 posts)

Hi guys, just joined and being as this is a renault turbo club i guess this qualifies on here

theres loads too it so please be patient while i upload them from another forum

i bought my car on the 1st of April 2008 for £3800!!! (a lot i know! part exed a ford escort for £400 tho) anyway shes an x reg (00) 1.6 16v sport alize, when i had her she had just reached 30k genuine miles and the garage changed timing belt brakes and gave it a full service for me.

This is not long after, completley standard.



after a few weeks i started to get cracking on how i wanted her to look.
•1st were the alloy wheels (wolfrace prosprint)
•then came the tinted windows
•longlife backbox
•black lens repeaters
•aerotwin wipers
•some renault mudguards
•after wrestling for 2 months with my torsion bar i managed to lower her and i bought springs for the front uprated the dampers all around
•painted calipers and drums white!
•groved disks & crappy green stuff pads
•some HID headlights and led sidelights

•coupe club stickers
•private plate

•silverline indicator bulbs
•and a nice little touch for my boy... his 1st trainers hanging from my rear view


so this is how she looked afterwards



plans at the time were...


exterior...
•Laguna splitter
•spats front and rear
•respray the front bumper
•astra mk 4 spoiler
•possibly a full respray in the distant future


interior...
•nice sound system


perfformance...
Refurb the whole braking system, including rear drum to disk conversion
lower more on the front


engine...
•bought this a few months ago (F7R with spare engine)



will be tuning the spare engine and building it up and swapping it into my car



Engine performance...
•ported and polished head
•3 angle valve seats
•road race cams
•rebored & honed block
•High compression pistons
•lightened flywheel and crank
•cold air feed
•Full longlife system including custom manifold
•omex ECU


started collecting things to complete the exterior...


astra mk 4 spoiler


spats
reinforced (fibreglass) laguna splitter


i also received some EBC rear disks and braided brake hoses ready for the drum to disk conversion at the rear



started work on the F7R head, stripped the valves from it and gave it a quick blast with a jetwash



Bokked in to the bodyshop to have all the planned work carried out
a before picture...


after going to the bodyshop to have the front bumper and splitter resprayed door handles and spats resprayed and a new astra mk 4 spoiler fitted, i gave her a quick clean today and she now looks like this....






managed to get the brake disks more or less prepped ready for fitting when i get around to it


and i went and took a load of stuff that i dont need off the donor car to sell on,
shes starting to look a little sorry for herself now...


took the head up to AP-D today should have it back in about 2-3 weeks,(<pahahahaha)
while i was up there i seen scotts car and decided it was in need of some attention so i took a picture of it with mine lol...


also took a pic of the font calipers all ready to go on with new rubbers and paint

[Jaff]

New poster! (less than 10 posts)

De-wipered


after trying to straighten my steering wheel out the other week and consequently having to change my track rod ends, my wheels decided they didnt want to go in a straight line and would rather toe in towards eachother (its what u get for lowering ur car and not being able to use old fashioned tracking guages lol) anyway my tracking is so far out the outside of my tyres are being ripped to shreds, so yesterday i decided to adjust the track rod ends slightly (guessing) to rectify it a bit and i had to put my standard wheels back on because my front tyres were slightly illegal!
so anyway she now looks like this...



then finally!! this morning i got some paint in the post so i now had evrything i needed to sort the front end out.
so i set about earlier stripping down the front end,
picture before...


picture during...


pictures after to follow soon. then im going to get it tracked properly
will also have some pics of her on new springs, and she should be sitting just how i want her then

also ive been to see about refurbing some alloys...
my 17's will be done soon with a bit of luck and will be wrapped in toyo TR1's more than likley to be my summer wheels.
my 16's are being refurbed in the next few weeks and wrapped in rainsports no doubt to be my winter wheels

i carried on with the work i started yesterday, today.

1st i stripped my shock absorbers down and painted all the bits that were going rusty and flaking...


then when i reassembled them i put my new springs on also

very pleased with the way they came out
comparison...


then i went a bit wild with the paint and started cleaning evrything up lol heres a few befores and afters...



all the bits ready for nearside, to go back on all painted and shiney ...


and the end result (without brakes)...


very happy with the way she sits now aswell looks just right atm, cant wait to get her bk on my 17's to look spot on again

will be taking her down to be tracked in the morning and i will get some more pictures up of the new lowerage

sneak peak of my winter wheels, currently being refurbed by a mate...




alarm arived today


look at all these wires


well carried on what i started months ago today, stripping the block...
just need to get the sump and flywheel off now and then its ready to be cleaned up and machined

some pics....(didnt get any before pics sorry )




also took some updated pics of the doner car...
really looking sorry for itself now



little update...
failed its mot on tyres today, also just scrapped through its emmissions as i have a crack just after the middle box (damn my low car lol hit it on something at some point) so...
just ordered 4 new toyo tr1's for £240 ish delivered, the 17's are going to be refurbished tomorow

Another little update...
rang craig today, cylinder head still aint ready!!! he said ring him again end of next week...
no worries anyway its not like i can do any more to the engine atm because i took my wheels to be refurbed today, so that will skint me for a bit.
i didnt get any before pics of the wheels but i do have some i took a couple of weeks ago so when i get them back ill get some before and after pictures up
as for the exhaust its being welded by my mate (who is a life saver!!!) and at the same time hell hopefully be fitting my alarm system and remapping my car

had these today

[Jaff]

New poster! (less than 10 posts)

Got my wheels back today well impressed with them I must say, pictures tomorow when I've cleaned the soap stuff they use putting the tyres on with, off!
And my alarm is going on tomorow too

half fitted my alarm today, need a bit more info before it can be finished off, sorry still no pictures of the wheels. and tbh im starting to lose intrest

some pics of the alarm installation...



well its taken me a while and i still havent done it properly lol...
was in tesco earlier and decided to get some pictures up of her lowered on my refurbished 17's...
ignore the dirt, its done nothin but rain the last few days and i havent had chance to clean it

this is how the wheel sits in the arch 1st, which is perffect imo...


after getting my wheels back i managed some free time today to just give her a quick clean, nothing special, will hopefully be getting the paint corrected on it shortly.

anyway heres a quick pic of the quality on the wheels...


hey arent perffect because i scuffed them so bad in places (only 2 iirc) that the guy couldent get them out as they were too deep. even now tho they are still not noticable

then as i was out i just took a couple of quick snaps on my phone






quick update, been paining this afternoon
these are the hubs off the F7R to put on my car so i can have rear disks
before...


after some red oxide and black paint (on on the left has only had 1 coat)


finished article...


will do my brakes soon, i have to its annoying me not being done now

finally changed my exhaust centre section yesterday, was really starting to pish me off, no pictures of the new bits (just a standard centre box) but i took 2 of the old box with the rust and the holes ...



ANNOYED!!!
started ther car up this morning and i thought id been transported back a week, my exhaust was blowing again, i thought no worries i know what this is its just the clamp that holds the centre section onto the cat. we hadnt replaced this when we replaced the centre section and was on my list of things to do as its not really that important.

so after quitting college today (thats for another discussion tho) i bought a new clamp came home jacked the car up. before i even get chance to look at the clamp some fluffy white substance catches my eye hangin from the bottom of my car, curiosity got the better of me so i grabbed it thinking it was just something that got caught whilst i was driving.... wrong!!!

the centre (brand new) box that i fitted saturday has split open spewing its white fluffy guts all over the place and causing the horrendous noise my car made 1st thing this morning! im not impressed, i now have decided to just get a stainless centre section rather than renew it, for a stupidly large amount of £150 from longlife.

and to top it off the guy whos doing the roof wrap wont answer his phone

picture of the brand new box after less than 100 miles. its been sent off on warranty so i have 2 weeks to wait untill i can get my cash back


got a nice stainless centre section and small silencer now with a lifetime warranty so happy days, still looking for leather and might get my air filter now i dunno yet

new vinyl roof
few pics of it going on...







another quick update... my exhaust started banging when i started the car up the other day, so down to longlife today to get it sorted... very happy, got him to weld a bracket half way down the car so the middle section is supported
few (rubbish) pics of the bracket...



Quick update, got the roof lining out of my scrapper yesterday, was shabby to say the least but its intact and isnt broken or sagging anywhere so its all good...


after 2 seconds work it now looks like this...


and is ready for some new fabric

also received a new engine cover to tidy the bay up a bit


Just finished putting the foam on my new headlining, not perffect but it doesent matter because the vinyl is going over the top of it and it should look ok then


sneak preview...


run out of evostick can't finish it tonight now lol, looks ok atm see how it comes up Monday now


Quick pics of my parcel shelf... Its not perffect, neither is the roof lining as the glue creases it but it don't look too bad.


In the middle of painting my speaker covers Matt black too, should be back in Wednesday. Then if it all turns out looking good I'm going to start stripping the plastics out and painting them black too

finished...

[Jaff]

New poster! (less than 10 posts)

Finally done my brakes today
grooved disks all round, more green stuff pads, new cables and fluid and some braided brake hoses
looks much better

finished my interior today, just in time for FCS
here are a few pictures...





dashboard is being beta tested atm and will be done properly as will the headlinging

made a big decision today... F7R will no longer be going into the car Naturally aspirated.
she will be turboed and hopefully touching 250 BHP. this is the far easier and cheaper option to get the power than the N/A route

Well today i finally fitted my Air filter, the strutt brace has been on a few weeks and the engine cover a bit longer.

the strutt brace and other bits under the bonnet need a good clean but their ok for now.

As for the filter, ive deffinitly noticed a bit of performance squeezed out of it (minimal). it deffinitly picks up a lot better now. the strutt brace is ood too its much tighter round the twisties now

here are some picts of the bay as it is now






wired a sub and amp into my car today with a bit of help from daviedavie

not working atm because im haveing a bit of a problem with it, im sure itl get sorted soon

thanks to adz for both the sub and the amp im sure ill be enjoying them soon...

when the sub was sent to me the box had a bit of damage on it but nothing too bad, so i used some carpet from the back of the seats in my shed car to recover it and make it look presentable and blend into the boot the cover is being sprayed by daviedavie, the same colour as my winter wheels lol

heres how it looks intboot...


and then i mounted the amp on my parcel shelf because it looks the tits there
(its missing a cover on the side atm due to the problems im haveing so the exposed wires will be hidden in time...


i also decided to take the rear plastics off to give them another coat of paint because it had started peeling where id pressed to hard to put it back in (the clip behind was broken)so they will be resprayed next week

also i ordered a new driveshaft today so ill fit that sunday and clean around dowwn there again. stupid grease

EDIT: just went out to the car at 11PM!!! because it was just annoying me that much... bad earth, bit of sandpaper job done

so saturday i changed the driveshaft, had it at a bargain £64 brand new (everywhere else wanted £80 odd for a reconned one + a surcharge)
from euro car parts my new favourite motor factors

so now i dont have any wheel wobble at 70 ish and no knocking when pulling off and breaking so i was a happy chappy
i also got a bit exited when i pulled the old one off because the ABS ring came off with it due to it being cracked, and i thought it may sort my ABS light out but no such luck
anyway, massive diffrence and im going to do the otherside + gearbox oil while im at it in the near futre. ill also put the right reluctor rings on the rear when i get a chance




then yesterday i went to town with the cleaning cleanned in all the nooks and crannys and took my front grilles out and badges off. front grilles will be spreyed back to the right colour not grey!!! and the badges will hopefully be replaced if their cheap enough.
washed it with auto glym polished it with super resin and waxed it with megs carnabua wax. now all i need to do is decide wether to debadge the side wings???

i want to move the numberplate after this pic...



hen today i finally finished stripping the s**tter engine out box out carpet out, just have to take the rear bumper off and the subframe and its being scrapped then

pics to follow


bit of a delay but i finally have some today



its deffinitly seen better days

Over the weekend I resprayed my front grilles because they were letting the front of the car down! I'm still not sure on them tbh not sure I like the lacquer look... Opinions?





Will have to do the scuttle panel and wiper arms now too :lol:

[Jaff]

New poster! (less than 10 posts)

got my top dash back ready for trax on thursday fitted it and added a coupe badge, this is only blu-taked on atm tho as i dont know wether or not to keep it.




well i had the shock of my life this morning!!!

after going up to see craig last week about my cylinder head he promised me he would chase up the machineist doing my cylinder head by midweek next week (yesterday). he was going to either take it away from the machineshop and take it to another one to get the work done or tell the guy who has it now to get on with it. then he would ring me to let me know whats going on.

now going on past experiences i wasent expecting a phonecall at all and fully expected myself to take another trip up there on monday next week.

then came the shock!!! he rings me this morning telling me...
hes chased up the guy doing the work.
its going to be done by midweek next week or its going somewhere else
and he needs the valves to have some work done on them free of charge.

now i dont know what he means by this last bit because i was still in awe at the fact he had rang me so i didnt ask him all the questions i should have so does anyone know what he could want them for?

anyway after this i decided to crack on and clean the valves, springs etc. ready to take them up to him tomorrow.

so here are the results, not the best but a lot better...

how theyve been stored since i stripped them...


Exhaust before...


Exhaust after...


Inlet before...


Inlet after....


has these delivered today .


those and cartax have skinted me for the month mind but its worth it

hopefully get a call off AP-D tomorow now

Been collecting a few bits the last few days...
Got some brembo 4 pots and some disks ...



And a pro alloy intercooler


Bit of a clean and a lick of paint/polish they should come up really nice

Also I think I'm going to retro fit a spare seat Leon 6 speed gearbox that I have to the engine just for something more reliable and for kicks

Also I know it means nothing to you lot but I'm getting my cylinder head back next week... Lol... Maybe

9 months and 3 days after i dropped it off i have picked it up!!!

for those of you that dont bilieve me...


i however can bilieve it! because my bank balance is seriously depleated!
expensive lesson learnt, wont be asking him to do any work for me again!

on another note on my way to pick it up and my gearbox mount vertical bolt sheared!!! again!!!

begining to think i have an underlying problem somewhere.

Ok then been busy the last week or two, first I took my ported cylinder head into work to clean all the crap out and get it nice and clean...


Here's a pic of the work Craig carried out...
Inlet


Exhaust


Then I set about lapping the valves in! What a gay job to do!


Here's the results...


Then today I finished putting all the valves back in! Yet another gay job! Those stupid little collets do my chunking head in
2 done...


All done...


And my workspace the misses loves me!


next is to find some gaskets to put the cams and stuff in and the head is near enough done then. Ordering some low compression pistons on Friday woohoo

Also took the current engine to the RR day as a nice comparison between the before and after

She made 95 whp which equates to aproximatley 116 bhp which I'm happy enough with for now here she is on the rollers...


cleaned the camshaft carriers today!!! my god they were dirty!

before on the left after on the right...


happy enough with the results got rid of most of the burnt on oil.

ordered a Head Gasket set today too so that should be in tomorrow, and im ordering the pistons tomorrow so my xmas deadline for the engine built up is looking promising, providing i dont make the mistake of taking the block to some cowboy machineist

had a delivery today...


got exited when i seen the size and shape of the package...


woohoo pistons are here!!!



cant bilieve how lite they are! 83mm diameter should see me up to nearly a 2.1 litre engine

courtesy of TSR perfformance, they specialize in VAG stuff but are a distributor for Wossner pistons, got them for £512 delivered where wossner themselves wanted £560

result

after xmas now the block is off for a rebore and hone, and ill go searching for a decent headgasket and it should be built up by january

whacked them on today.

2 new uniroyal rainsport 2's on the front, part worns on the back on my dinards that came off my scrapper all cleaned up and painted...


better late than never but gonna acompany them with some orange mirror covers and badges


Been playing with di-noc again...


And here's how it looks in place...


Looks much better with less Grey there now I'm sure youl all agree

Gonna do the drivers airbag when I get some more double sided sticky tape then to finish off the interior before fcs I have to dye the spare carpet I have and redo the headlining and parcel shelf. Will also be on some new wheels for fcs hopefully

finished stripping the block today crank looks good no scores or anything so bit of a result! cracked the plastic pump guard in the sump tho !!! pished off about that!

anyway ill let the pictures do the talking...

sump off...








getting the crank mic'ed tomorrow in work to check it and taking that bloody heavy flywheel off!

engine should be built up next month when i get some cash together

my hands are also ripped to shreds too so im happy...

watch for an update tomorrow, hopeffully im going to get the block up to mine to blast it with a karcher ready to be taken to the machine shop

[Jaff]

New poster! (less than 10 posts)

New poster! (less than 10 posts)

well ive been fretting all winter about new wheels for the summer time and i just couldent decide what to do.

i didnt want to put my wolfrace ones back on because they were getting on my nerves and they needed 2 new tyres which i couldent be bothered to sort.

so i was on another site yesterday and seen some oz superleggeras for sale for £320 delivered with no tyres that were in ok condition and i thought bugger it ill buy them. as theyd been for sale for a while i thought id get them no problem and asked the guy if i could pay when i get paid on friday. as sods law would have it the day i enquired about them is the day he fecking sells them, so i missed out.

so anyway i decided to search the web for another set (i wasent very hopefull).

i ended up finding a set of 16's for £350 with good tyres (toyo tr1's, which i would have bought anyway) and in better condition than the ones previously.

i bought them anyway! lol


arriving next week

been busy today, ive mocked up the brembos on a spare F7R hub (has the same bolt spacing as the K4M hubs) heres what ive come up with...


i found spare 300mm disks in the scrap metal bin at work (result!!!) so i used them to mock up the disk on the hub, cut away the lower brake bolt hanger to get the caliper to sit correctly around the disk. by doing this i could see where i need to drill and tap the hub again, and what sort of shape brackets i need to fit the calipers securley.

now i just need to find some decent steel to make some brackets then see if it will be feasable to work them with the fiat coupe disks i have waiting to be used (these need the center bore machined out, which shouldent be a problem)

Then...

i got home to find a delivery waiting


they are very shabby behind the face but the face itself will come up nice with a good de-tarirng and polish. although i am tempted to go out and buy a dremmel now and refurb them opinions?

anyway i put them against the car to have some sort of idea and they look far better than the old 17's i had! what do you think?



3 wheels have what look like nearly new toyo proxes tr1's which is great but one seems to have worn unevely so i may change it.

cant go wrong for £350 delivered


painted the block
should benice and undrstated in the bay now



well i took her down daviedavies today as the mot is out today and it was going to fail so i made the tough decision to take it off road to start the engine work

im quite sad tbh but im trying to think of the bigger picture and getting on with things. i will be driving this badboy about in the mean time...


4X4 FTMFW!!!

anyway the car is tucked up ready for work on monday, progress will be slow to begin with but should start to pick up soon im hoping to get it all up and running by xmas

here is her new home for the next few months...

[Jaff]

New poster! (less than 10 posts)

Then it starts to get intresting lol.

will post the remaining bits later after the F1, apologies if it dopesnt make a lot of sense, like i said ive copied and pasted from other forums

comments welcome as always

[bod 182]

Good work mate

[Jaff]

Good work mate

Thanks

Although you ain't seen nothing yet

[Os8472]

Nice work there fella, will u be coming to our national day at Blyton park this year?

I've got a lightened and balanced flywheel if your interested

[Jaff]

Lol car isn't in a state to move ATM mate, I'll update this with the progress over the last year in a bit

Flywheel will be no good to me as I have a vag box in it now

[Jaff]

bought an omex 600 standalone managment the other day for an absolute steal so thats something to keep me busy while i still collect a few bits for the engine.

t3 turbo off a sierra and some piper pulleys and its just gaskets and bearings to buy then along with a rebore before the engine is built up. if you see any turbos or pulleys that may do the job id appreciate a link

big thanks to daviedavie and let the project finaly begin

o i started today lol. as i decided to buy a ***** rather than a bloody car she wasent playing ball today

started by taking the back bumper off...


then proceded to take the backbox off and heat sheilds, but i couldent get the cat bolts off so i couldent get the whole thing off

then i went to take the rear axle off... still not playing ball so the axle is half off now lol, just need to get at the bolts from inside the car!

am i right in saying i need to get in through the door cards to get at these?

anyway back down on wednesday no doubt... pics of some progress...


ngenious (pikey) axle stands to get the axle off


front bumper and inlet track off the car..


stored...


tucked away for some more abuse soon...



well shes fooked me off again today!

exhaust wouldent come off! took us 5 hours to get the rear axle and the cat off! what an absoluto ***** of a job!!!

anyway more pics from today

grinding the cat nuts off...




my ingenious solution to holding the engine forward


axle off ready to clean and paint, along with a new lick of paint on the callipers


had to take the rear seats out to gain acces to the bolts holding the axles on..


I love creme eggs


and my brake fluid catchers lol...


painting tomorrow

[Jaff]

done some more today, she was playing nice today too so it was a pleasure to work on her

i think i have paint poisoning now but meh, its all for a good cause

so we took the tank out...Hello!!!




gave it a clean

and the remaining exhaust heat sheilds and proceded to sand and paint everything with red oxide paint to prevent rust in the future, ready to paint with hammerite next week so its easy to clean.

Masking up...




spraying…





then we done the rest of the underneath including the wheel arches
ignore the shocks im getting new ones

wheel arches before...


stupid tortion bars being in a stupid place made me bend my sill and now its gone rusty


how do you eat yours?


some pictures of me getting high...




and the result...


yes thats my head

and the car...



ready for painting black next week

also had a delivery today


= the plug and a load of wire to go with it

DAVIES WORK

right, lil update today, as jaff is currently sunning himself at a bbq.. (uncommited is what i call it ) as i wanted to do some work to mine, and his car has exploded everywhere in my garage, i had to do some so i had some bloody room to move

started to wire brush down all the bits that have come off and are, well, rusty as hell.








hamerite them black next, after i have done all the other bits laying around

ME AGAIN
started hammeriting today! what a pain!

also primed the axle and other bits ready to go back on when theyre painted too.
we run out of hammerite, so theres a bit left to do, including a second coat!

rear sprayed gloss or satin black...


then the underneath hamerited




creme egg!!!



other bits..


and axle...
before


during...



after...


and the dust on my car


well yesterday i went down to the car again to do a few bits and peices.
didnt get much done just finished doing the first coat underneath and gave the axle and other bits a coat

pics...



how mature…


creme egg!!!!


end result...



cant seem to find any pictures of the axle and stuff but its only a first coat on that anyway. as sods law would have it when getting the abs sensors out i got the broken one out no problem but the good one had to be butchered out ghey!

anyway also had a delivery last week...


walbro fuel pump for a bargain, to provide enough jungle juice to the big boost

also dropped the block off to a reliable machineist yesterday for a rebore and hone

should have that back next week

also while i was up there i mocked daviedavies bumper up to my car to see if i like it, i do lol so think ill be blending in my splitter but leaving the line not smoothing it out like he has and maybe chopping the grille out and ill be doing a couple of extra things because ill have intercoolerz!!!! plus some big brakes that will need cooling ha!


aaannnnddd ive chopped the rover in for something more french and better on fuel because im dull like that

to this


ve called it baby boost because its giving me a taste of things to come only in small doses

we had some fun changing the belts on it on sunday too



the mess..



missed catching the coolant haha...

[Jaff]

well spent a good 12 hours sorting the car out yesterday! i came home and went straight to bed it was gruelling

story of the day...
second coat on the meg
play with the rear bumper
go out to fetch the fuel tank off the s**tter and get some spring compressors
get high in the car!
lower daviedavies coupe
put the rear axle back on my car
roll it out and wash the dust off it
go home lol

ill let the pictures do the talking...




creme egg!!!


wheel arch..


the mess...



he 2 fuel pumps that are going to give me a headache over the next few weeks...



car out for a wash...




we were both like this by now...


done some more work today...

engine out, subframe off... thats pretty much it!
pics...



jaffa cke!!! because tesco dont sell cheap creame eggs anymore!!!
[img]
http://i577.photobucket.com/albums/ss211/daviedavie2009/jaff%20turbo%20project/30042011194.jpg[/img]

out with the old...



build the new ...


nice shiney honed bores ...



also got renault bearings, and a good head gasket along with the pistons and rods so this should be built soon

felt like this afterwards...


subframe and associated bits....


and how we left it...



ohh and the piece of exhaust that had me ryan, and daviedavie swearing for 4 hours a few weeks ago...


more stuff arriving in the post soon

spent a day down the garage with daviedavie again yesterday. managed to get a bit done. sprayed the middle of the car red oxide, painted various engine bits and removed the engine bay wiring loom along with some other stuff. theres still a bit more in the bay to do yet but hat will be done in good time

pics...
cam carriers


masking the cylinder head off...


jaffs turbo... powered by...

CREME EGG!!!


paining...



ooks 10000 x better!

my delivery from the other day...


getting the sodding loom out!!!


makes me want to cry lookiing at this...


then the priming of the underside...

before...


durning...


after...


and i was once again a ginge

[Jaff]

Today whilst daviedavie put the first coat of black under the car i procedded to build part of the engine. polished the crank, oil pump and rod bearing surffaces ready to be built then dropped the pistons in...

crank...


pistons and rods...


together in holy matrimony...


cleaning the block face up...


4 pots...

sexy!!!

powered by creme egg of course...


undersie...
[img]
http://i577.photobucket.com/albums/ss211/daviedavie2009/jaff%20turbo%20project/05052011270.jpg[/img]

then a quick pic of the first coat of black underneath...


we also stripped the subframe and bits to sort out and clean/paint/powdercoat etc. no pics of this atm

theres also been a develpoment down the garage with pictures soon... we call it the fail wall! its there to remind us of the (no doubt) many failures we will encounter it already has things from my car on there

it of work done today, still arguing with renault for the correct bearings but ive managed to source the correct ones anyway. so wil build the bottom end up when i get them.

the rest is built now tho

had to take the pistons out again, cleaned the block thouroughly...


back in and gasket on



head on




also got a new attachment for my karcher that ive been meaning to try out and we had a chance today on my subframe, as demonstrated by daviedavie...


sandblasting attachment
subframe before...


during...



and the bit thats been done...


needless to say im very happy with it and the rest will be done when we get mroe sand

also made a little purchase today...


bottom end got built today and i started thinking about the wiring, not looking forward to that!

building the bottom end...



the correct bearings






waiting for my turbo to arrive and ive found some vernier pulleys i may buy

got some goodies the last few days...



turbo isnt as big as i wanted but it will do the job to get my target for now untill i get a better one next year and the pullies are second hand but a bargain so i couldent leave them

also had a development in the progress of the engine today that will be confirmed by the end of the month wait and see

done a bit more on the car/engine the past 2 days

this includes:
modifying my fuel pump carrier to have a reg at the rail
build the basic engine
took both wings off
started my secret mod
made brackets for my bonnet strutts
tarted up the turbo and some other engine bits
gathered most of the engine bits ready to be prepped
made some enquiries into powdercoating

only a few pics...

secret mod...



well ive been flat out all week doing various things. the secret mod is now as good as done, the engine has all but a few pieces sitting next to it ready to be rebuilt and run in in mine and daviedavies recent purchase...


the engine will be run in the week after FCS with no turbo on it so when the time comes to putting the engine in my car its a case of getting it mapped and off you go

this car is then set for scrap once its purpose has been served, so as usual pm me for any parts, theres not much left once weve finished with it but there could be something random that someone wants...


as for the enigne...


and all the bits minus the belts etc that are in a box under the table.



ive been waiting for the oil pump cradle to be fixed to finish building the bottom end, if you look top left of this picture you can see a mount for the pump has snapped off when i took it out. so i araldyted this together the other day and im now waiting for this to dry before putting it in...


this is the manifold ill be using, its a stainless one off a nissan 200sx which just needs the flange cut off and a new one machined and welded back on to fit to the F7R and it will suspend the turbo in an ideal place


ohh speaking of welding...

secret mod anyone?

well between FCS ive been slowly butchering things as usual

first heres the current state of affairs in garage a la davie...


to get the F7R out davie has used his noggin and the anti christ to great effect...


helps us be lazy and not push

so i got the engine out of the F7R ready to put my engine in for the run in milage

this is the mess we have to work in



while the F7R had the engine out i couldent help myself and i mocked up the turbo onto the manifold then mocked it up in the bay...

WINNING cant wait to fit it into my car now

so far ive half stripped the F7R ready to use the parts on the turbo engine and started to build the turbo engine...




parts on the floor ready to be cleaned and fitted, not having dirty s**tty stuff all over my nice clean block and head

back down tomorrow to finish the build then wednesday or thursday ill put it in the car ready for a friday blast/boring run around


since the last update the engine has done about 800 miles, would have been well over 1000 had the car not let us down in derby by blowing a power steering pipe.



4 hours later it was back in the garage in ammanford ready for the engine to be taken out. the decision was made by the power steering pipe that the car will be scrapped and not salvaged.


now that the F7R is gone i can crack on with finishing my car as im begining to miss coupe ownership. on the to do list before the enigne goes in is...

send off running gear to be powdercoated so i can put the car on 4 wheels again
finish my clio 197 rear diffuser off, this requires more welding and some undersealing then cuttin the spare bumper and mounting it
paint the bay and under the wings.

while ill be doing these, amongst waiting for parts to arrive and paints to dry ill be working on the engine also. first thing to do is to butcher the manifold i have and get it to fit the F7R once ive done that i can mount the turbo and make the oil return also drill the sump or block. then i can buy an oil feed line too and mock that up so thats the main engine work left to do done.

the rest of the engine work includes changing the timing belt because i stupidly put the wrong cam seals in before first start up and the belt got contaminated then general tarting up and making it look the part.

id also like to give a big thanks daviedavie and ryan (rtsportdti) for helping me and staying up untill stupid o clock in the morning to iron out some of the teething issues we had with the engine. things like the constant oil leak from the rear crank shaft seal(the one behind the gearbox and flywheel!) huge fuel leak from the fuel return and leaking exhaust manifolds. needless to say i would never have been able to do all this in time without their help

all in all i was very pleased with the engine. considering it was my first build and even though it went evrything other than smothly it still pulled as standard and went like a rocket once i had put a few miles on it held great oil pressure and started on the button every time cant wait to get it into my car boosted and producing some good power figures

anyone who wants to read more about our days out in the car or see more pictures of the car in our week of madness you can see some in these 3 threads...
http://www.renaulton...est-drive-ever/
http://www.renaulton...drive-ever-pt2/
http://www.renaulton...drive-ever-pt3/

the doner car has now been scrapped and the engine is sitting in davies garage if anyones intrested in it?


if not im gonna ask davie nicley if i can butcher the block to see if i can get a meggy 225 box to fit somehow because im not happy with the thought of changing gearboxes every week. im convinced i can make it fit but time will tell.

[Jaff]

not much more to update on but when i get some stuff powder coated things will start moving forward again then and things will be going back on the car, which will please me and davie immensley as its getting a bit packed in his garage now. when things start going back on its a good sign that were getting there! so watch this space!

ohh and i bought a forge dump valve

Well evryone knows what this is by now so i thought id show some of the work that involved in doing this sort of thing! went down to garage a la davie and there was no one about, so i ransacked his house and found...


the lazy b*****d!

so after waking him up we both went out the garage, cleaned up a bit,
it would seem we have an abundance of wheels...


moved the car forward a bit so i could work on the back and set to work.
the task is to get this...


onto the back of my car, not as easy as it first seemed!!!

up until now i have

taken the bumper off
married the diffuser up to the car
marked what needed removing
and removed the bits!

it started off that i was only going to cut the bottom of the wheel well off and weld a plate on the bottom. leaving enough room in the wheel well for a space saver or something. then me and davie noticed to get the dual exhaust exit to have the diffuser live up to its potential there would be quite a lot more modification to do it properly. my motto with this car since the day it went into davies garage is "if your going to do it, do it properly!"

so out came the grinder!

first i cut out the floor of the wheel well and due to the curve of the well and the fact it isnt central in the car i c**ked up and cut it squint, not to worry i chopped the rest out leaving about 8 inches at the back of the car about 5 inches deep. if you cant picture this it will come clear in a second...

with the boot floor practically gone it was quite upsetting seeing what id done to my car but it was too late to go back now.

so i gave my mate a ring, he brought his wleder down and set about welding the plates of 1.6mm steel i had cut to shape into the boot floor. today weve been cleaning up the majority of it because the welds werent great due to the ammount of underseal on the underneath of the car reacting during the welding process. there are still a few holes to be filled and then cleaned up and the slope of the wheel well is still there that needs to be cut off but its nearly there now, the car at least has a boot floor again

here are some pics to help you understand the shape and diffrence of my boot floor compared to a normall floor...

normall floor with wheel well...

my floor with small storage area...



this is a picture that gives you the idea of how much the wheel well sticks out from underneath the rear slam pannel...


this is too much for the rake of the diffuser to sit flush on the bumper!

so this is what mine now looks like...



ooks cleaner imo

more pics of underneath...


note the lip on the circumfrance of the old wheel well is still there and needs to be ground off! but a nice space for some exhaust pipes and maybe a centre/back box to provide some proper exhaust also like i mentioned before, i saved a few inches at the back of the car for a little storage space, nice little tool cubby hole and some tyre weld or similar, ideal size ...


more updates during the week, getting some seam sealer soon so i can seal it all up ready for paint, hopefully the diffuser will be mounted on a bumper next week then mounted on the car

so i took a handfull of stuff to a local powder coaters to see their handy work...


as you can see my misses still loves me by letting me put car parts all over her worktops
turned out very well, theyve also been primered in a zinc coating for an extra layer of protection so im well happy with them for the price and i will be taking the rest off tomorrow to be done too

ive also picked up a bit of 12mm stainless steel to make my manifold flange out of...


Top quality steel this is! cost me a fortune for what it is and had to have it special ordered from birmingham. the guys down at express metals, swansea were superb and managed to find me this and get it to me the day after i enquired about it so i was well happy

ive found a company that will cut the shape out for me, it was harder than i thought because no one wanted to touch it and it was looking increasinly like i was going to do it myself with a pillar drill every dinner time lol.

now its being machined by CNC machines so it should be of good quality

also my welder is coming up on the 1st or 2nd of august to finish off my boot, so that can be seam sealed fully and painted and finished awaiting the diffuser to be mounted which may end up in the bodyshop at this rate.

I couldent help myself when i brought the 300mm disks down to the garage either...


im also in the process of buying a mocal 13 row oil cooler with a thermostatic sandwich plate to keep my oil temps down and i will soon be searching for a load of silicon pipes. target is to have the bay painted and engine test fitted with the turbo by the time daveski and simon pop down in the middle of august, then we should really see some progress
i should have enough money to keep a steady flow of updates between now and then even with my apprenticeship end date looming and it looking increasingly likley that i wont be paid for 8 weeks and my last pay being substandard

either way im looking to partly strip and rebuild the engine again to put a turbo oil drain in and put some vernier pulleys on (+ a new fecking timing belt kit! damn oil leak!) before simon and dave come down so i have plenty of work left to do.

does anyone know anything about treating bolts so they look good and stay looking good rather than going rusty and/or dull. something like polarising but something i can do myself?

been busy with the spraying...

wings...



gets very dirty up there!



primered



finished...




taking evrything out of the bay...



the bay before...



painting the scuttle...





then the bay...



and after...





just waiting for payday to get the subframe and stuff powdercoated now and my mate to come and finish the welding on the back, bit of seal sealer and paint and then she will be going back on 4 wheels ready to have the engine fitted.

next few updates should be some final engine work and then shes going in cant bilieve how close its getting now!

will get better pics when the paint has fully dried

Had my mate over again this week to finish off welding my boot, it is now done and sealed up just needs to be flattened back, seam sealed and painted and the boot is done. just a case of fitting the diffuser to the bumper and both to the car then which SHOULD be a piece of cake after the rest of it!



also fabricated some brackets and had them welded on to the car to support the bonnet strutt i installed...


i liked them so much on the pug and have wanted them for ages so i thought why not!

earlier on this week i dropped my manifold flange off to the engineering company i found localy and for the sum of £20 i picked it up today with the holes in exactly the right place to accept the rest of the manifold. it just needs to be shaped and welded now. this will be done when the engine gets its first test fit in the car which will happen when i get the rest of the powdercoated stuff back from the powdercoaters should have them back end of next week or start of the week after next all being well

pics of the manifold flange...


getting closer and closer to the wiring now :'( which i supose also means closer to finishing it

i also SHOULD have a nice suspension setup coming to me if i get my job at the end of the month to really sort the car out

some pics of the bay now the paint has dried properly...




im well happy with the finish personally bits will be slowly going back in in the next week or so (sorry about the poor quality in some of them)

and me looking at a fire under my car with some close up pictures of the paint finish


more updates when my powdercoated bits come back or when i finish my boot

ohh and i also bought a mocal 16-row oil cooler with thermostatic sandwich plate and braided hoses the other day. no pics because its second hand and dripping with oil in the boot of the pug

[Jaff]

Finished the inside of the boot out yesterday

just need some more seam sealer, some underseal and paint for underneath and then the back fo the car is done exept the actual fitting of the bumper/diffuser

pics...










more soon

been arseing about with gearboxes today amidst finishing off the seamsealing of the underneath of my car

just need to underseal, and repaint the undernath now and evrything goes back together then helped by the fact that my powdercoated bits are ready to be picked up tomorrow

anyway todays antics included making lots of bits of cardboard look like they have chicken pox by poking "strategic" holes through them

after 4 attempts of trying to get a template for an adaptor plate and failing we gave up for today and im persuing others who may already have a copy of the template

/cheating

anyway, just for you non bilievers...


t fits just fine on the engine, will fit widthwise in the bay even with the adaptor plate, the only issue i can possibly see is that it MAY catch the subframe with the diff housing because its simply mahoosive compared to the JC5 and is visibly stronger! but im confident that this is just a minor obsticle

pics of my powdercoated shizz friday and hopefully more progress with the gearbox, with maybe even a test fit in the bay

so exited!

[Os8472]

You boys like ya cream eggs don't ya lol

Nice work there bud

The tubular manifold, you say it's of a 200sx, is that the 1.8lte or 2.0ltr engined 200sx?

[Jaff]

not sure tbh mate i think its the 2.0. bought it off a mate in work whos mate has a 200sx and he bought a few diffrent manifolds to try. let me have one he didnt use

and yes creame eggs rule :P

[Jaff]

found some more pictures of the progress i made on the rear diffuser making various shapes out of some steel and cutting the car out...












and a picture of the diffuser taped in position to check where i can mount it and wha may need to be chopped off to accomodate stuff like the shocks, brake lines and a dual exhaust...


Test fitted the engine and the vag gearbox today seem to fit fine roughly atm. cant get it spot on without the adaptor plate, but i seem to have enough clearance around it for evrything needed. just need to make a new mount and stuff for it all to sit properly.
got some pictures of it fitted onto my spare engine in the bay... http://i985.photobucket.com/albums/a...0829-00331.jpg







should have my bolt treatment tomorrow or hopefully soon so i can then build my engine up and put a lot of stuff back on the car.

here is the majority of it


done some more work on the car yesterday.

i properly undersealed the back end, so now its just a case of painting the underneath again and theres no more work to do on the back appart from fitting the diffuser to the bumper.

i also had a go at doing that yesterday too but my idea along with some expanding foam didnt really work that well but im going to try again before i give up and take it to a bodyshop. no pictures as that foam got everywhere!

i also had a final fitment of the manifold and the turbo in the bay to see where i have the space. i need to make a new actuator bracket and possibly turn the core of the turbo. this is how it will sit in the bay



the space between the turbo and the bulkhead, sort of...



bay needs another coat of paint because ive scratched it a bit at the back, and i seem to have missed a few bits

more proigress saturday hopefully

Made some progress with the diffuser today, been sniffing fibreglass all day lol.

diffuser fitted and partially fibreglassed...






the middle bit needs redoing due to the shape of the bumper and diffuser being diffrent

and ive attached spats on the bumper and started blending in the spats to the diffuser and the bumper, but i dont have any pics of this i will get some next time...




well having given up last week on marrying these 2 items together due to my lack of skill with bodywork etc. i went arond some bodyshops to pay to get it done.

1 day of searching and 3 bodyshops looking at me funny and i decided i was getting nowhere so i was gonna have to suck it up and do it myself! and after 2 days messing about they were finally together today with only a bit left to do...

before it was stuck together and just offered up to each other... well having given up last week on marrying these 2 items together due to my lack of skill with bodywork etc. i went arond some bodyshops to pay to get it done.

1 day of searching and 3 bodyshops looking at me funny and i decided i was getting nowhere so i was gonna have to suck it up and do it myself! and after 2 days messing about they were finally together today with only a bit left to do...

before it was stuck together and just offered up to each other...


and done minus the spats and a bit more filler...


well after god knows how many hours on this little venture the end is near!

fibreglassed the spats to the bumper to give me the extra length to the bumper that i needed and made some makeshift bits for the gap between the spats and the diffuser giving me roughly the shape i want for the bottom of the bumper leaving me with this...



ingore the ginger :lol:

Then i slapped a load of filler on it and sanded it roughly.

i havent gone nuts with this stage im going to take it to the bodyshop in a few weeks to have the finishing touches on it, i.e filler and painted properly as im likley to **** up the filling process.

then i had to fit it to the car for a test




now all that is needed is a few brackets on the car to hold the underneath of the diffuser up, somewhere here...


and to sort out the little issue of the filler pipe...

here is non filler side...


and on the filler side you can see the filler pipe is slightly blocking the exhaust exit


so thats the next 2 issues to sort then some heatsheilding for a custom exhaust and i can start with the more exiting things

[Jaff]

had a visit from a ginger englishman and his "mate" yesterday with some presents for me

ill let the pics do the talking for now...






megane cup racer suspension

complete with adjustable camber on the strutt mounts, solid top mounts, height adjustment, remote resevoir inserts for the fronts, fully adjustable rear strutts incuding remote resevoir complete and a couple of spare pairs of springs to boot too

should give me some good road holding ability if i can deal with the harsh ride im hoping it wont be much worse than my previous setup in that department

just need to find some hubs now as ive been let down by a member on here after paying for a pair and IDE hubs ARE DIFFERENT!!!

finally had chance to get into the welding shop at work today with one of the boys who has a key so i got to work on sorting the manifold out



nissan 200sx stainless steel manifold, cut inbetween the pipes with a plasma cutter...


warmed the 3 pipes that needed bending one at a time...


then bent them into shapoe of my manifold flange and cut off the remaining peices of the nissan flange off...



ground down each pipe so they sit foughly flat...



then offer the new flange into its new place..


number 3 pipe from the left has been adjusted up since i took this picture so theyre all lined up correctly now


just waiting for some stainless welding rods to be delivered into work now so my mate can tig them up and i have a manifold
the flange will be cleaned up when i have more spare time in work too

been a busy boy the last few days.



ive dropped my OZ's off to the alloy wheel man for a refurb whilst using the tyres on the F7R dinards on my runabout.



ive also been to see the machinist about making my adaptor plate for my gearbox but that needs more work because the cad drawing isnt really up to scratch.


im also informed that the first batch of flywheels for the gearbox conversion is done and pending scoffs approval i should be getting mine soon



ive also been to renault to buy:



various nuts and bolts so i can bolt the front up,
thermostat housing
water pump
inlet manifold gasket
exhaust manifold gasket


and i bought some morrette headlights to see if i like them on my car


more spending soon

so ive been busy drawing on autocad the last few days and ive managed to draw an adaptor plate for the VAG gearbox. ive turned the box to the correct angle to use the inspection hole as a sensor position that will read the flywheel (which i should have soon!) trigger pattern.



to make sure its all good davie printed off a copy and we attached it to some 6mm wood (the adaptor plate will be 6mm also) and cut it out so evrything will be as it should be when the plate is made out of steel.
[img]http://i985.photobucket.com/albums/ae339/jaffman09/IMG_0046.jpg

then we set about putting it in the car with the spare engine.



adaptor plate on the engine..






and the bit of the block that will have to be chopped to accomodate the inner CV...


now im hoping there will be enough room to put the steering rack in, so i will try that next week. ill also be drilling the block for the oil return and mocking up the manifold ready for welding!



i also put the polybushes in the wishbones but i need to adjust these...


Right no pictures but i thought id tell evryone what ive been doing the last few days...

first things fist, i went to express metals and ordered some 6mm steel. still waiting for the phonecall for that to arrive.

then i ordered a t- peice off ebay for my oil feed, will go to pirtek to get a braided pipe made once i have this, should be here in the next few dyas.

then i went to renault and spent a small fortune!

ive ordered-

timing belt covers
oil filler cap seal
4 new nuts to hold the rear axle on
a new drivers side scuttle panel
4 new wishbone mounting bolts with related nuts and washers
4 new strutt mounting bolts with nuts
new waterpump
new exhaust gasket
new inlet gasket
new thermostat housing
4 new drop links and bolts for the ARB
"rocker cover" gasket
2 new front wheel bearings

and as a christmas present to myself, a new genuine renault phase 2 RS splitter

ive also bought some nimbus heat sheild to tart the bay up a bit.

waiting on news of the flywheels on friday and the steel when it comes will be making me a new engine mount, new brake carriers and of course the adaptor plate for the gearbox

need a timing belt kit also

i can see the end now

so ive been busy over the past few weeks getting evrything i need to finish this. i have 90% of the stuff, the rest will have to wait.



anyway just had this in the post



flywheel for my VAG box conversion


also picture of my RS splitter


and some nimbus heatshield i have (need to get more of this) to cover the bare bulkhead...


So I started on my hydro clutch today. I'd already bought a master cylinder*


all I needed now was to fit it to the car. So...

Take 1 hole saw


And drill 1 hole in the required spot...


Then bolt it up (forgive me I haven't got any pictures of it bolted in place)*


This is what you get inside the car...


Now I just need to attach it to my pedal. I had to get a flexible joint in there somewhere though to ensure free movement and flexibility. Cue genius idea!

Take 1 boot strutt from a daewoo matiz (who said they were useless?!?)...



And remove the flexible metal ball joint on the end...


and bolt the ball joint to the pedal...No pics of this yet as its on the car and I need to join the joint to the shaft of the master cylinder tomorrow. So pics of it hopefully finished tomorrow and some more diffuser work *

Been down the car again today i didnt manage to sort the clutch pedal out as it requires a bit more thinking. at the moment it looks like ill have to cut come of the pedal box off but im unsure as to wether this is a good idea and wether it would compromise the strenght of the pedal box.



in other news ive run out of m8 bolts so i couldnt finish all the mountings i needed today but i managed to put a bar across the back of the car from chassis rail to chassis rail. this bar gives me something to have the exhaust backbox hanging on, something that will hold the fuel filler pipe up out the way and something that adds a bit of strength back into the car after having a lot removed when i took the wheel well out.

i also made some brackets to mount the diffuser underneath but didnt get a chance to mount these because the drill battery run flat and like i said i ran out of m8 bolts!



the only thing left that i wanted to do today was mount the intercooler or at least work out how it was going to be mounted. in the end i had to admit defeat and accepted that my big cooler wont fit so ill have to make do with the smaller one for now untill i get one made thats a bit bigger but not too big.



now i need some opinions... i cant decide wether i want the stealth look or the in yo face look so i have 2 pics here so you lot can help me make up my mind...



here is the standard bumper, it will have an RS splitter on the bottom of it so will be lower than that so no risk of the cooler being too low etc.


and here is davies bumper on my car which has the grille cut out so it shows more of the cooler. obviously this is how low the bumper will be but it will have the RS splitter too not the guna one. it will also be blue for those simpletons


opinions?



im back down there tomorrow to mount the oil cooler somewhere, finish getting the diffuser on the car and ill put the RS splitter on the front bumper so both bumpers are then ready for paint

had a very productive day today

managed to fix my clutch pedal problem. turns out i was putting the bolt in the wrong hole! weve all been there lads!

so anyway it works a treat ...


then i finished the back of the car off, mounted the diffuser and bumper properly..



plenty of room for an exhaust in there


i also mounted the oil cooler and intercooler in position...


and so i set to work on the front bumper.

all i needed to do was fit the RS splitter and mount it to the car to make sure evrything fit ok.
to fit the RS splitter renault sugest you fit foam pads between the bumper and splitter. couldnt find any sticky back foam anywhere that was thin enough to do the job until i was in tesco and i spotted these...



I had to cut the sails off the boats and i couldnt use the planes as they were too big but i got some cars and trucks on there

anyway i got it fitted and put it on the car...


as you can see ive decided on keeping the grille but ive moved the cooler as far forward as possible so you can still see a bit of the cooler.

in the middle of the stealth and the in yo face look

happy with todays efforts, also got news on my wheels that i sent off to be refurbed before xmas, they will be ready monday, adaptor plate should be ready wednesday so engine is in soon

[matty j]

Looks good buddy

[Coops]

nice work mate, very detailed thread :-)

[Jaff]

Thanks guys more to come later, my finger started hurting last night lol

[Jaff]

been collecting more stuff. coming together nicley now

welded the manifold up...


or we got so far and we ran out of gas so will finish it off soon.

also picked up my gearbox adaptor plate and engine mount...


and some brake hangers for the brembos...


also received some F7R hubs to fit my bearings, brakes and new suspension too


got a 3 bar map sensor...


and a fuel rail on its way so i can then order injectors and a fuel pump so i can actually start the engine lol.

got my wheels back from being refurbed... these are lush!!!


and got a second sub and a new HU for the interios



So the spare engine is in with the gearbox, flywheel, clutch, manifold and turbo on its mounts *

All fits fine with plenty of space to spare and my n/s mount idea worked a treat *

Anyway pictures...

First of all my brakes *


Will get the new hubs i got off *gaz stripped cut powder coated and rebuilt soon so I can put it on 4 wheels again *

And to the engine...

Adaptor plate and flywheel on...



And in the bay on its hanging mounts (temporary fittings atm) and I've measured up underneath so I can utilise the dogbone mount *


Plenty of room for the turbo...*


And a route for the cold air in to the turbo and out to the intercooler around the 'other side of the engine *



Also found the rat in the garage that has been there for a while and scared him out lol. Thing was bigger than my dog and I laughed my ass off watching it scurry out the garage :lol:

No pics unfortunately as it was just too quick!*

Next up build the low comp engine up properly and prep the bay for evrything *

well the plan today was to buold the engine up but im still unable to drill the block so i started doing other bits and bobs.

started on the dash anyway...

made some makeshif dash pods and radio surround and stuck them on the dash


fibreglassed





needs more work!

wasent happy with mark1 so i got my other spare dash and started mark 2...

anyway here is mark 2 half completed...







guages still need to be sanded almost flush with the rest of the dash, then filler it and sand to shape ready to paint/wrap


a lot better already i think

nearly finished the dash ...


didnt get a lot done yesterday even though i was there froim 1 till 10 because we started cleaning the garage (it was in DESPERATE need of a clean!) and i didnt start on the dash till half 5.

so just a few refinements on the middle guage atop the dash and its ready to be wrapped

also stared working on the hubs to put the brakes on had to call it a day with the drilling though as it was getting late!

i also need a bit of help regarding fuel rails/injectors/pressure regulators etc. if anyone can offer any?

so it started on tuesday with an absolute mare! evrything i touched went wrong and i didnt get much done. got the engine back out at least anyway

i also had the manifold near enough finished, up untill the thermal trip cut the tig out so that was the end of play then. when i got to davies he was being usless but he redeemed himself later on after me throwing a tantrum about evrything going wrong by painting my gearbox

then wednesday i had a better day, i managed to finish one of my hubs ready to be powder coated, they jusst need to be stripped down now because i have new bearing etc. i also used all my nimbus heat sheild up covering the fuel filler pipe, because i cba to move it lol. i also covered half of the firewall with it. i then just mucked about doing little jobs so nothing to write about really.

thursday was a good day too, the manifold is finished, both hubs are ready for powder coating and i took the dash build i made out of the scrap dash.

the bad news that ruined an otherwise good day?

i cracked the dash nothing unfixable tho, just needs another tub of fooking fibreglass to finish it off. i have the dinoc ready

pics saturday


so as proimised pictures from this week...

but before we get to the formalities i have an announcment...

theyre baaaaaaaaaccccckkkkkk...


anyway my hubs with brembo 4 pot carriers...


only have 8.8 grade bolts holding these on, should i get some tougher bolts?

made a bit of a booboo with these too as the scrap disks i found that i used to mock up the brakes were 297mm, the ones off the fiat are 302mm... hence theyre too big! so theyre either getting machined down or im getting some grand scenic 300mm disks which if im lucky will be smack on 300 mm or a bit less but we will see.

anyway, my bad ...



but, all fixed now and near enough ready for wrapping



and my manifold...









the manifold flange may need to be surface ground tho which is a shame because i thought i may get away with it but we will see

more next week.

todays antics involved taking my dash out, taking the centre bit out of it and putting my newly wrapped centre bit back on it.

got as far as mocking it all up now it just needs fixing in place.

pics...

centre bit...


and mouinted but not secured in the dash...


nd most of the relevant bits put in place, including some wrapped dials too





not sure about what to do with the grey now...

bumpers also went for spraying today, should get them back monday

also started working out a bit of wiring yesterday! all fun... not!

[Jaff]

so been doing some wiring today.

cba with it all tbh!...



on another note tho, ive put some sound proofing in the boot, not quite finished yet, ill do the rest when i move the car forward...


and went to see how my bumpers were doing today and i came across this...


i nearly wet myself with exitment tbh!

so i had my bumpers back today the guy had a bit of a battle with the front bumper due to the previous paint job. so its not perffect atm but it will be going back to the guy when its on the car for remedial work. anyway ill let the pictures do the talking...

for information the blue is renault monaco blue which must be the best colour ever! the black is BMW carbon black. this black really compliments the blue due to its blue tint in it. in the light this paint comes to life and it goes brilliantly with monaco blue.

here is a picture of carbon black in the light...


im sure youl aggree it looks great!

had the front grilles done in this colour too...



should help set off the front end because i decided to keep the splitter black (pictures later)

anyway the back...



the colours just gel together beautifully





im so pleased with this


and the front...


colours going together well again...


now a decision i think ive made but would like some more opinions anyway...






i also refitted the engine again! this time though i got the gear selector working and a rear mount fabbed up no pictures of this unfortunatley as i used up all my battery taking pictures of my bumper

enjoy

[Jaff]

made some more progress yesterday, the gearbox now has a selector fitted and works seamlessly




also started building up my engine again just got to find a place to make me an oil drain pipe today and ill finish it off ready to put it in.

i also fitted my injectors to the rail and the fuel pump was a big win as the pump fit straight into the cradle, electrical clip and all with no fussing. just need some proper fuel pipe now to finish it and put it back where it belongs.


anyone know if coolant hose is good enough to carry fuel in the tank?

i also got this through the post today for £4.99 which is going to be installed in the car somewhere


plug and play at last

Done a bit more today. Built the majority of the engine. Just need to sort the adaptor plate out now and I can put it in the car


Here's a pic of the oil feed and return to the turbo that was requested...


Feed...


And the return (this isn't long enough I made a mistake and need another one)


Goes into the top of the sump like so...


nearly ready to go back on 4 wheels now got the brakes fitting perffectly with new bearings in the hubs...



now i just hoppe the wheels fit over them haha

calipers being painted...


needs some refining atm tho lol theres no rush for these atm, hubs had a coat of paint yesterday so when i go back down there they should be ready to be bolted together if i can get the wishbone powerflex sleves welded before then.

engine is just about ready now too...



buggered a powersteering pump up so have to fix that then i can bolt the front together and it can go in here...


then its just odds and sods to do after the wiring

just had my driveshafts and new radiator through the post too


car is a complete frankenstein now lol, VW gearbox, clio diffuser, MR2 radiator amongst other stuff lol

She's on 4 wheels massive milestone for me. Not completely ready yet though I still have to change the inserts on the front dampers and get some driveshafts made but it's a rolling shell again at least


Tried getting a picture of the diffuser in the light but I'm no photographer so I ended up with this...


Does look great tho! Just needs some nice tail pipes to finish it off


Anyway Thought id mark the occasion by giving it a well deserved clean, it was a but dirty lol


Who knew the thing was blue!



Back in its bed for now anyway.


More work to do tomorrow and hopefully the engine will be in for the final time over the weekend

bee struggling to sort the clutch line out the past few days but i think i now finally have the correct stuff to get it completed!

that means the engine can go in and stay there thank god! its pretty much built now..



power steering pipes are in, manifold is wrapped, davie made a bracket to support the turbo and manifold to hopefully prevent it cracking, calipers are being a pain, dont know wether to strip them down and refurb them have them powdercoated then rebuilt or try and find an arange paint... the one ive had from ebay has been s**te!

down again tomorrow when the engine will hopefully go in so i can measure up some boost and coolant pipes and some driveshafts. i will need a new radiator tho as the MR2 one was too big my bad lol

Finally sorted the clutch out yesterday! 3rd time lucky! Forgot some fluid to test it tho so will have to wait till later for that now.

Put the engine in anyway, just waiting for the mount to come back from the powder coaters for it to sit where it should, the crane is holding it in place atm.


Just odds and sods to do now before wiring it up, I should have a base map coming soon so I can test it all out


Nearly there now

Right small update. Not been well the last few weeks so things have slowed down but today I got moving again.

Got the engine out to alter the flywheel slightly, done that and put the gearbox back on.

Got an alloy radiator and mounted that, took a fair amount of time because it wasn't a straight fit.

Clutch is sorted just needs bleeding

Driveshafts need to be made , will get this done when the local company have checked the Renault shafts.

And my basemap is ready so as soon as I wire it up it can be started

Put the engine back in today too so it's looking good again last time it goes in hopefully, just odds and sods left to do now.
No pictures unfortunately as some chimp threw his van into a power line outside the garage so we had no power or light from about 8 which happened to be when we were half way through putting the engine in! That was an experience lol!

Will update soon with some pictures

Driveshafts went away yesterday to be made should have them back soon

No pictures because nothing has really happened

Had the driveshafts back today


Happy with them will be going on the car maybe later so it will finally be drivable again once it gets wired up

Yeah I may have to cut a bit of the car again...


Anyone able to help, I have a set of adjustable front strutts and I have some remote inserts that I want to swap into them. I've got the bottom nut off the strutt and the insert will slide up and down the bottom assembly but it won't come off fully. Do I have to take this assembly off the bottom (I have tried its fooking tight!)?



Ignore the mess lol.

Davie took a picture of the camber on the car as it was sat loosely on the suspension to use a new app he has lol...


Wont be having it that extreme lol

He also tried and I quote "some artsy pictures" lol



Anyway been speaking to scoff and we've come to the conclusion that I'll finish the car ready for an mot take it up to him and give him the pile of wires, switches and plugs to sort and get it running. Gives me peace of mind and it's easier for him so once the car goes for an exhaust I'll book it in with him.

Light I can see it at the end of that tunnel!

Bit of an update, car is going for an exhaust next week if I can find a car trailer
mot is booked, just needs a confirmation date
dash and associated interior has gone to be flocked (bargain price too with someone fairly local)
Davie has also been working hard on my iPod/iphone dock in the centre console. It's a fit and forget thing because of my radio. In other words plug the phone in out of the way then control it with the stereo.

This is where we put it...


The dock...


Is just fibreglassed between where the gear gaitor goes (the big hole in the first picture) and where the tray used to be. Now it's a bed for the phone to lay down on.

Looks bad in the pictures but it's all even and when it's flocked it will look a lot better

Any help available for a trailer an he suspension?

Car went of its exhaust today...


Picked up my flocked items yesterday complete bargain! £145 for this lot and the guy was fairly local too so I just filled the BMW and drove down to hm

dash



Door cards front and rear



A,b and c pillars + other bits to finish the interior off



And the centre console which Davie has put an iPhone mount into, quite proud of him for this because it looks very good...


can you spot the iPhone?


Here is it


Now all I have to do when I get in the car is plug the phone in and forget about it because it can all be controlled from the radio

Here's a look without the phone and of the docking station


Underneath


Cable goes from there to stereo .

We also decided to make the most of my car being away and having an empty garage by cleaning it. So far after about 4 hours we have cleaned the pit and this side...



And the remaining mess lol!


Well I went down The garage today to put my dash back together ready to go in the car when I get it back (tomorrow hopefully) anyway turns out I've left an important part in the car so we couldn't do that. So saves wasting a trip we went about fashioning a pair of cold air feeds into the fog lights.

Here's how we did it...


Take 1 of Davies fog lights...


Strip it apart...


Put it together without the glass and the bulb holder and reflector...


Slap in some fibreglass...



And some filler...



Add some paint to check for imperfections...


Add a Lairy colour and test fit...


Well happy will get them done in carbon black when I feel like it lol


Comments welcome

[Jaff]

Doesn't look like the car will make FCS now unfortunately its just too close to call atm. Car is still in longlife, no date set for its homecoming yet.

Anyway while we have had space in the garage we putmy dash back together, minus a few bits



And I've started spraying my spats and my cold air feed "trumpets" in carbon black too (I love that colour!!!)



Just need a car to put them on now lol.

Some close ups of the colour after 2 or 3 coats...




poor pics taken by an iPod touch but you get the idea

Few more coats and some lacquer and they're ready then I have nothing to do until the car comes back which I hope will be tomorrow

Then I can get some pics of it all together

Got my car back yesterday happy with the exhaust. Here are some pictures

Down pipe


She's very close!!!



Flexi and 200 cell cat



That clamp will have to be turned! Lol


Back box


And 2.5 inch inward rolled tailpipes



Waiting to be collected and put on the trailer



I also fitted the dash back in and got a few of the wires back to where they belong so progress there too, pictures when it's all in


Done some more yesterday btw, dash near enough in properly...


And made some lights for the intake. People will hate this I know but I don't care I like it


Day off today because the misses needs some attention lol

So been busy the last few days. Got my new jack today.


Sick of using the bottle jack! Now it's easy

So I used it to fit my suspension on the back...



Anyone know what I'm supposed to do with the torsion bars now I have these strutts in? I can't find out what the cup racers used to do.

Also finally got 90% of the pipes I need, most of the coolant is there so I've mocked them up, just need to get the right clips now




Sorted a few brackets out and other bits that belong in the bay like the clutch reservoir and the fuse box. Still have a clutch leak, it's peeing me off now! And I got a power steering pipe made which sits perfectly now.

After a bit of help with the turbo coolant too. Anyone know if this is too close?

[Jaff]

and thats you lot up to date

any help from you lot is appreciated, comments and critisisms always welcome and i will kepp it updated

im off to massage my fingers now as theyre a bit sore after all that copy and pasting lol

[Coops]

top bombing fella, so close to a startup you must be able to smell the fumes ;-)

how much oomph you looking for? 300 range or 400+ like turbo ted man?

[Jaff]

top bombing fella, so close to a startup you must be able to smell the fumes ;-)

how much oomph you looking for? 300 range or 400+ like turbo ted man?

Yes! Would be done by now if I hadn't been let down by so may people! But there we are getting close now.

As it happens I've based my figures on what you get lol. I'm expecting about 280-300 not 100% on the turbo tbh (a future upgrade ) but should do me for now

It's up to scoff to get the best out of it

[HAndy]

great project, a lot of hard work and time gone into it
hope you get what your after and enjoy the car

[Coops]

cool man!

tbh in a track/road orientated FWD car 300bhp is pretty much all you'll ever need! mine scares the living daylights out of me still, after 5 years (in a good way obviously!)

keep up the good work and I look forward to seeing it run!

[Tutuur]

picture overload on the network here

good to see you here too Jaff! still shame it just won't make it to FCS!
why not go for 400's, your engine and geartrain is upto it. maybe set a low and high boost map for the occasional fun run's

[Coops]

yeah 300bhp is no fun at all, need the extra 100 for a real fun run

[Tutuur]

lol, no offcourse not but you can't deny extra horses are always welcome

[Coops]

amen! I pray to the gods off boost, let there be wheelspin

[Jaff]

Ha tutuur it's easy when your spending somebody else's money isn't it

I had a plan to begin with which was have 2 maps, high boost low boost but that seems to have been left to my right foot to decide as time goes on ha!

I may upgrade at some point but as coops said 300 is plenty I'm sure for a road car, anymore is just for showing off and bragging rights lol

[allanr5gtt]

good thread bud
i see your useing fiat coupe 300mm disc. are they fiat coupe 20v turbo brembo's? as i thought the 20v turbo had 305mm disc?
also where did you get your flywheel and adaptor plates made? as this is something i would like to do in the near furture.

keep up the hard work well done

[Jaff]

Cheers, Yes they are fiat coupe brembos and yes your right standard disks for fiat are 304mm.
Cocked me up when measuring up lol but I'm using megane grand scenic disks which are 300mm so works well.

The plate I made a cad drawing myself and had machined by a local company, and the flywheel I had off scoff.

[allanr5gtt]

thats handy as i have a set coupe brembo's i'm my stock pile. did you have any issus's with getting your wheels to clear the cailper's? and will there be any safety issus using 300mm disc's instead of the 304mm?

[Jaff]

Honest answer... I haven't tried yet lol. But the math says they will fit under the 16's I have.

Shouldn't be any problem it's only 4mm lol the mounting to the hub was the biggest pain

[xenon]

work makes and superb!!
highly photographs final of the car finished!

[Jaff]

All pretty much done in the bay now. Wires tidied ready for scoff, pas reservoir has been secured, just actuator and oil feed to the turbo to sort again before I move on to the remaining crap lol

[matty j]

does look awesome buddy

[Jaff]

Thanks looking forward now

[Jaff]

I've decided to wire the thing up myself!
Decided its not beyond my capabilities and if I do it I know what's what if anything goes wrong.
So anyway not much to show as wires are just wires but so far I have this...


Also the gauges are now wired in and I've found a nice place for my boost controller

Wires everywhere!!!!
Ashtray closed (will be di-noc'ed to match the rest)


Pop up controller FTW! Wire that in this week and the rest of the car if I get my orders
Done some more today. It's not a lot to most but I'm massively proud of how well I'm doing ATM
As it stands only the sensors, fan, coil pack and some other bits and bobs inside the car to wire up and she be ready to start
Some pics to show how it's gone from mess to tidy in the bay



May need another piece of cf as I'm not 100% happy with that one


Done a bit more over the past few days. Interior is basically complete now, it's all wired up now anyway so it just needs tidying and putting back together..
Radio, gauges, boost gauge all working

New headlining and boot floor done in suade...


Can just about make out the floor in this picture done...

Subs kick out some punch too the inner chav coming out in me lol
And the whole interior blending together well

Anyway done all that whilst I was waiting for stuff for the wiring, today managed to get it done up to wiring the sensors in. In other words I've routed the cable and now I need to put plugs on the end of them lol.
Shuld be nicely inconspicuous in the bay

Having big trouble with the coolant gauge ATM tho so that's been taking up most of my time!
Finally had my brake calipers back today. Put some stickers on em. Will put them on the car when I get chance...



sexy brakes!

Next obstacle ...
Bloody wheels don't fit! 15mm spacers required each side. So no pictures of the wheels on lol.
Done a few other bits too like running fuel lines down the side of the engine, putting aux belt on, running the abs cables to the block.
More stuff to get through soon

[Jaff]

Small update

Thought I'd try my hand at a bit of welding, been meaning to give it a crack for a while and me needing an actuator bracket provided the perfect opertunity for me.

So problem was where the standard bracket sits its butted right up against the bulkhead and wouldnt house the actuator properly so I needed to extend the bracket.

I done it by cutting the bracket up, welding 2 bits of angle iron to it to extend it then a flat plate on the end to house the actuator and some threatening vanes to the sides.




Not bad considering I've never welded before it's a bit cleaner now too since I've ground a few of the welds down to make more space .

Anyway im even more pleased that the only spare 2 inches I have in the bay is now being filled by my bracket and an actuator



Not bad considering I've never welded before it's a bit cleaner now too since I've ground a few of the welds down to make more space .

Anyway im even more pleased that the only spare 2 inches I have in the bay is now being filled by my bracket and an actuator




Just got to expand the arm slightly now and paint the bracket and it's job done

Finally finished with everything with regards to the turbo now after fighting with the oil feed for the past few weeks

Also got some tyres delivered today, got another docking station to fix the broken one in the car and my mate welded another lambda boss on the exhaust for me last week (not quite ready to tog weld yet lol)


Fitted my painted bracket today. Does the job perfectly I couldn't have done it better if I had tried tbh I've been very lucky! Will get pictures of it tomorrow but it's nothing special to look at

Also more sexy brakes...


Got some refurbed calipers and painted them... In the kitchen of course


Put my new genuine disks on with pads too so all it needs now is the new brake line (currently been painted and drying) and an abs sensor and that side is done, will do the other side tomorrow

[Jaff]

New seats...



Also made a bracket for the crank sensor.



Currently. It cranks but won't fecking start more work required before I'm kicked out of the garage next week!

[Tutuur]

wow picture overload :P

still no succes with the standalone mate? that sucks!!
i'll be on the rollers 27 oct. to see if i can break 300bhp