205 dt sleeper, engine in :)

[Paul_13]

Here's the story of my 5 door derv runabout.

Pretty much been in the family since new with only 1 additional owner but my Dad bought it back off him.

Originally started with the lovely beige interior which was quickly disposed off!

At an early age of ownership the front running gear was swapped to 1.9 gti running gear, which proves to be one hell of a lot more stable than base model!

I also swapped the front brake calipers to 1.9 gti items as the 1.6 brakes had given up the ghost and when the pad locking bar went walkies on the way to driving to work in Brighton it was time for their farewell!

Out with old

(NA 1.8 D with 182k on the clock and still going strong!)







Some very perished fuel lines



Lovely veggie goodness!



Don't any pictures of the new engine installed, but basically the specs are:

1.9 Dturbo engine out of a 405, Bosch pump T2 turbo and I believe possibly a Hdi box.

Here's a pic of halway through the gov mod:This basically replaces a spring on the cradle which limits the fuel delivery over certain rpm. Most people shim them but Ryan had put a stiffer spring in and I was basically the guinea pig of his modification It's worked well! Full on fuel all through the rev range.

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Next was the LDA pin modification (boost pin)
New ground down version vs. old



Where it came from



The spindle was adjusted so there was more travel on the throttle and because of this I needed more travel on the pedal, so a quick modification was needed!

Excuse the bodged boost hose! Also bent the accelerator pedal to gain more travel!





The air filter I had on there was a bit restrictive



Thought I could smell a burning smell! This was resting on the turbo



The plan was to use this front mount intercooler off a BMW e94

[ginge191]

any pictures of the rest of the car

nice little project though

[Paul_13]

Had a bit of a hiccup when I decided to tighten the wastegate arm on the actuator. I'd manage to flatten the thread on the arm.

So I had to take the actuator off and take it to work to fix it. I ended cutting the flattened part off and threading the "eyelet" back on which resulted in 31 psi of boost through the poor turbo when I turned up the fuel up!

Needless to say it felt rather rapid at this point, only downside is the top mount interwarmer was hot enough to fry an egg on! (As i had not fitted the front mount)

I sourced a fmic adapter as the sale of the Xantia manifold fell through

Next modification was to get rid of the restrictive fuel filter setup and increase the banjo size.

Ordered a 10mm banjo off ebay and a 10mm fuel filter.

My reason for doing this is the inlet hose to the bosch pump is around 7mm in diameter and if you are running veg oil becomes a bit restrictive.



Off came the fuel filter housing



The new fuel filter and banjo setup



The difference is night and day, it doesnt feel strangled up the rev range and pulls considerably better!

I thought i'd get rid of the plastic pipe which feeds the intake of the turbo and replace it with a less restrictive setup (eventually)

I bought a reducer 90' bend off of Ebay and a bit of flexi hose and an air filter. Excuse the long flexi hose it's a temporary measure while I get the FMIC sorted.

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Wait you impatient bastard!

[4WayDiablo]

Awesome project fella!
Looks like you are eager to get it going well!

[Paul_13]

My rad lowering bracket, a piece of 20 x 40mm unistrut from work with a couple of 90' cleats and some 12mm bolts and nordlocks.







15" steelies which look awesome!



But came off a day later as they rubbed soo bad

[Piggy]

wana see the car!

[306Puggy]

Pretty interesting, I like you attention to detail It must fly with that lump in a 205! Must feel like being in a bean can though! I should look at my fuel lines as well, might solve some of my starting/running issues on veg.

[Paul_13]

Lowered the rad and makes a huge difference to the inlet temps , I can actually put my hand on the intercooler after a sprinted drive and not burn my hand! Bought some slim line fans off of ebay and they've done the job nicely!



Next I moved onto mocking up the BMW front mount, now if I had a GTI valance fitted it wouldn't be a problem! But because I'm trying to fit everything behind a base model valance, it's a task and a half!







I don't think the police at work would appreciate this!

[padge]

they would just think its the rad, just with grill removed..

[306Puggy]

Says the voice of experience The police at work I hear you say. I guess you are civilian staff at a police station then?

[Tom]

This is epic, keep the updates coming!

[strictly_perv]

Glad you finally got round to it!
Sadly mine suffered engine failure (again) so have sold up.
It's Max BTW, I had the white Dturbo from the 205drivers.

[Paul_13]

After deciding that the BMW would not fit I opted to go for a universal cooler



I couldn't find another that fitted comfortably, but this one will do the job the adequately!
Plus a few silicone hoses off eBay I have a front mount which will fit!



I bought a random filter from the local motor factors. It's only 8mm connections and I wasn't too pleased with this. I've been after a 10mm inline filter and have really struggled to find one until now. http://www.inlinefil...etal/FFG-FF5079 Got a few of these on order now

A few bits turned up in the post:









Here's a quick mockup of the front mount setup



And pretty much installed:













And a hint of whats going on next!

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Glad you finally got round to it!
Sadly mine suffered engine failure (again) so have sold up.
It's Max BTW, I had the white Dturbo from the 205drivers.

I know who you are ;P
You and Ryan gave me the bug to put a dturbo engine in!
Shame you got rid of it mate!
What happened to the engine?

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Says the voice of experience The police at work I hear you say. I guess you are civilian staff at a police station then?

Some thing much more sinister!
Nothing to do with police stations! More places of top secretness!

[vlj]

Very good read!

[procta]

coming on really well! you need some aftermarket or 406 wheel trims to go on that, depends on how OEM you want to go. my sleeper is proper OEM spec, with the oem extra spots too.

[Paul_13]

10mm fuel filter fitted, ready for testing. Was an absoulte arse to find one but we'll see how it goes. I had an 8mm 106 gti filter on there for a bit and that was fine until it blocked.

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I've got some 1.6 gti sprayed black, Max will recognise these!

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Was tempted to put a rear spoiler and GTI front valance on with driving lights etc but I wanted to keep the base model looks.

RRyan is building me up an 11mm pump and that will be going on in the next few weeks.

Also getting a td04 turbo to go on. Need to f*ck about with adapter plates and actuators first.

Might stick a home brew 3" exhaust on

[Piggy]

glad to see you got a more suitable filter in line there...seemed bit silly initially to go up to 10mm and then stick a tiny filter which the veg would clog up!!

love how sleeper it is...please keep it that way!

[Paul_13]

The 10mm filter is suitable for a 9mm pump (gov'd and home made lda pin) and a t2 running 31 psi (possibly more)
The beauty with the other filtres is that you could take them apart and clean them. They did flow pretty well.

[silverzx]

Nice work mate. Good to see another DERV 1.9 205!

[Paul_13]

Firefly? Off 205 drivers?

[silverzx]

Firefly? Off 205 drivers?

Yeah, bit quiet over there I find...!

[devils_fuel]

Firefly? Off 205 drivers?

Yeah, bit quiet over there I find...!

Firefly...Gaylord !!!

[td_dan]

Looking good mate love both your 205s

[Paul_13]

Looking good mate love both your 205s

Thanks

[aggyj17]

Nice work mate. Good to see another DERV 1.9 205!

And mine dont count??

[Pugmarshall]

Nice conversion, I likey!

I've got an XUD9 205 and it's strange how many things we've done similar!

[silverzx]

Nice work mate. Good to see another DERV 1.9 205!

And mine dont count??

Uh, I lose track of whos got one. Need to make a 205 group.

Firefly? Off 205 drivers?

Yeah, bit quiet over there I find...!

Firefly...Gaylord !!!

Apparently silverzx was forbidden / not unique!

[devils_fuel]

Nice work mate. Good to see another DERV 1.9 205!

And mine dont count??

Uh, I lose track of whos got one. Need to make a 205 group.

Yeah, bit quiet over there I find...!

Firefly...Gaylord !!!

Apparently silverzx was forbidden / not unique!

..GAY

[THE_Liam]

This looks frigging epic!

[kernow_joe]

205 ftw! loving the sleeper spec of this!