stef's 205 gti6 supercharged

[Stef205]

if i can run the same boost as the low boost rotrex and out power them ill be very happy. At the same time its not the main reason for the bigger charger.

[Stef205]

So the new charger turned up today and like a child i couldnt wait to get it unwrapped and out the box.
First thing i noticed was its size and its weight!, i may have to re think my mounting plan.
Away like a child i rushed out to the car whipped the bonnet up and sat it on top the m45 to get a eye.


As you can see its "slightly" bigger but it will go in once ive finished.
I then moved on to taking a good look over it, i already knew about some case damage which i will address, It does look like some chav has tried fitting it to his nova at somepoint and cut the casing away with his teeth! Anyway ill stick it on the mill and mill the remaining of the damaged mounting away and have a friend weld a new piece of tube in.
The picture below shows the damage.


This picture gives a idea of its size!


The inlet side looks alot more usable with regards to fixing with 2 m8 threads either side, so i should be able to make a reasonable fixing.

Am i the only one that thinks it looks like a pair of eyes and a mouth?
The rotors apear to be in good condition which is a relief.


I then moved on to start breaking it down as i will be rebuilding it as i dont know its history, Ive a list of bearing and seal numbers so i will get those ordered shortly.
Removed the oil filler plug to check for any oil, couldnt see any which may have been removed for transportation, carried on and removed the snout to find a genuine eaton coupler and some signs of oil.

All seems to be good, the coupler will be replaced for a modified version.
Tomorrow ill remove the rotors from the casing and give them a look over.

Iam sorry for anyone who hasnt been able to contain them self, please dont feel bad Niall lost his ability to control him self talking about it!

All for now
Stef

[RetroPug]

That's massive...it looks like you're trying to fit a second engine in there.
Glad it seems to be in good order.

[fatlapit]

Isit not too big??

[Stef205]

Isit not too big??

no it will go in there, havent decided on my pulley setup yet

[Kezzieboy]

Fuarrk me that's huge, you hero! Such an epic project

[Stef205]

Fuarrk me that's huge, you hero! Such an epic project

Ha thanks!

Today I only had a small amount of time on the charger today. I got the rotors removed from the casing. I found oil residue inside and over the rotors this could only be the rotor seals weaping, regardless these will be changed.


Got the case clean and removed the rear case needle bearings. I can now get it on the mill to start the repair work.



I managed to get another aux mounting to modify as I didn't want to cut up the mounting from the m45. Hopefully I'll start some proper work on it Monday.

Stef

[Stef205]

Small progress today with the car, i started to do a test fit and mock up of the new inlet along with fitting the braided hoses and adaptors.



Went in very easy with no hastle, ive got to modify the inlet side boost pipe as the new inlet is slightly shorter in reach at the throttle body. Ive just to sort out the fuel lines and source a slim fuel filter with an fittings. I should be on the mill tomorrow to skim the mounting face of the inlet for piece of mind after alot of welding.

Stef

[Niall]

Looks shit. That charger is far too small you f*cking ponce


/notjealous

[Stef205]

Looks shit. That charger is far too small you f*cking ponce


/notjealous

Is that the way you treat all new people?
your sh*t so im told! Does that .5 bhp mean alot to your results? Aww thats cute!

[dashmader]

this 205 is so cool, must go like a tunder

[Stef205]

Been busy the last day or so, after test fitting the new inlet i noticed the inlet side boost pipe would need modification so i set out adapting it as the tb on the new inlet doesnt have as much reach.


The big moment came to start finding a suitable place for the m90 to sit. I knew it was never going to be easy but knew it could be done. So i strapped it to the inlet to get a eye on things. Firstly we opted for it to sit upright, but on further inspection it was going to foul the alternator.


So after alot of rethinking and head scrathing we got the first mount tacked in, looked great and left it for the day as my head was fried.



The next day i a fresh look and noticed that i couldnt get the outlet plate on it with moving the rad, so the mounts came off and we opted for a new postion.
We rotated the charger round slighyly and this allowed us the room we needed.

Ive now got it sitting on 2 mounts, i am very limited to mounting points with the m90 there are only 3 unlike the m45 with about 5.

I managed to get on the mill today with the inlet to skim the mounting face. It was warpped very slightly at the ends between number 1 and 4, after taking a few thou off its nice and true again.



Stef

[Piggy]

Nice inlet...who did all that welding for you?

This is looking awesome dood....keep at it!!

[Stef205]

My good friend over a JEK Fabrications near chard. Hes abosoultly amazing at what he does, he also modified the rail for me.

[akuma406]

Companion, this 205 is scary jajajaja
I want to see another video with new updates

[Midnightclub]

Awesome stuff, love this build

[Stef205]

Companion, this 205 is scary jajajaja
I want to see another video with new updates

Ha thanks, it sounds broken rather than scary! I ll get some more videos done soon!

Awesome stuff, love this build

Thanks!


Didnt have much time on the car today, due to work commitments. I managed to get my fuel lines finally done, I must of had them over 4 months now collecting dust! Im having to use a aftermarket fpr now as the inlet is now that short the stock fpr would hit the inlet and not bolt down. This is my first time using braided hose and an fittings. As for fitting i already bought a jig for the vice to allow easy use when fitting the unions to the pipes. I can now be glad of no more julbliee clips did nothing but leak for me.
I decided to replace the stock filter with a high flow filter and with slightly more filtering, i decided to keep it in the stock position.



Stef

[RetroPug]

Possibly my favourite project on the forum. Always enjoy the updates. Keep at it!

[Piggy]

Sexy fuel lines!!!

[Stef205]

Today i finished off the modified boost pipe, and got all the charger mountings finished. Pressurized the fuel rail and hoses for the first time, fpr working as it should, ive a slight weep out of one of the welded an fittings that is on the rail. The charger is due to go to my friends to be repaired so i will get him to sort the rail at the same time. The inlet is having some vacuum take offs welded in then that can be bolted on to stay.


Stef

[akuma406]

Go !!!! monster stef
It is very difficult to adjust the electronics when working with a compressor?
Use of electronic oem XU9? no map sensor?

[Stef205]

Go !!!! monster stef
It is very difficult to adjust the electronics when working with a compressor?
Use of electronic oem XU9? no map sensor?

its run on a standalone aftermarket managment omex 600, i has a map sensor again its aftermarket as the oem sensor can not read positive pressure. I leave all the mapping to sandy brown.

[Stef205]

I havent been able to do much to the car lately as the charger casing is being repaired and the inlet is having some vacuum take offs welded into it.
Ive made a temporary tensioner untill Niall kindly sends me one of his spares.


Ive started work on the outlet for the charger, ive spent a good month now looking for a suitable one and as the m90 is really only used in the states finding one is hard. So i opted for a jag xjr6 outlet, funny enough they used a m90 but the casing is alot different, so ive chopped the mounting flange of it neatly with a hacksaw and "hopefully" Niall is sending me a cad file of a the m90 outlet so i can have it cut out. I then plan to weld the jag outlet to the plate.


Should move along well once i have everything returned

Stef

[Stef205]

long over due update, I had the charger casing repaired by a friend. I can now get the third mounting fabricated.


I then started to mock up the outlet from the charger and straight away i knew i had a issue, the outlet elbow i was planning to use fouled the bonnet.
My only option was to move the charger and remount it into a different position.



We moved the charger positioning which gained us alot more space for the outlet, i also made up a more suitable slam pannel, the previous one was made from cheese and didnt give much support or strength.





Im waiting for the water cutters to finish my inlet and outlet plates then ill start fabricating those. I recieved my pulley and hub from smoothflow pulleys which was a custom job being that my charger should have a 8 rib pulley and not a 6 rib, never the less nicely made.



I should have more regular updates now that i have everything back, progression to stream nicely now.

Stef

[Grant]

Great progress dude! Can't wait to see the final results on this.

[allanallen]

Only just spotted your thread stef! Told you the m90 was a beast!

Is that a 6rib pulley for the charger then? What ratio have you gone for?

[Stef205]

Great progress dude! Can't wait to see the final results on this.

Thanks Grant

Only just spotted your thread stef! Told you the m90 was a beast!

Is that a 6rib pulley for the charger then? What ratio have you gone for?

Ha i knew you wasnt lieing mate! The 6 rib pulley is for the charger, and im having a smaller crank pulley made by stew at baker. Im aiming for 9-10psi at the redline so should be the same as a low boost rotrex, providing my caluclations are right. 1.31:1 ratio
But should i build a engine in the future that can cope with more boost, extra pulleys are peanuts to fit the hub. But my aim is more efficiency and less heat.

[Stef205]

today i got the mountings finished off and fitted the new pulley and hub. Fitment was really good with no issues what so ever. I mayhave to change one of the fuel line fittings to a 90 bend as its possible when the bonnet is shut it may touch the pulley.







tomorrow i start looking at possible boost pipes and inlet to the charger.

Stef

[Stef205]

slow progress over the last few days mainly due to that im waiting on other people for parts. I mocked up the inlet to the charger and got a idea of where most things would lay.


I noticed that the idle control valve would foul the piping to the charger, I had thought about removing the valve all together but after a quick chat to sandy he advised i keep it. Ive started to relocate it out of the way.



ill be ordering my crank pulley this week and should be able to get a belt sorted for it.

Stef

[jammapic]

That's a whole heap of engine crammed into a tiny space! :-)

Looks good.