stef's 205 gti6 supercharged

[7057sam]

Should come down on the 12th aswell for forge

Would be great to see it on track finally.

[Stef205]

i dont do action days for many reasons! full of idiots mainly

[Stef205]

Not much has happened on the 205 for abit mainly due to being snowed under with axles again! Ive have recently taken in more inspiration and look to be adding more to the car soon.

I had been in designing a dummy pulley to divert the aux belt that would sit on the sump hangers but after taking with rich_w he has come up with a design and he got a few made up. Granted not normally my style of buying a production item as i like to make my own stuff but he could produce them cheaper than i could make it.





Nicely designed and made this will allow me now to use the oem auto tensioner as the rallye setup just cant handle it.

Ive also been toying with a new cage and design that im planning at some point. Also im waiting delivery to start my tubular wishbones which should have caster and camber adjustment. But before that can happy i need to finish my swirl pot and find a quicker rack!

Stef

[Stef205]

Its been a while since i updated this. Car is doing well returning good mpg better than oem in fact.

Ive been in need of new rear discs for some time, the current ones have turned blue from the heat and running the rears harder than normal doesnt help so i had a friend cut some waves into some brembo discs to try reduce the heat whether it works or not there cool :


Ive been meaning to change my passengers harness from those dangerous 2" Chinese straps to a more substantial type. I finally got in gear and ordered another rsa 3" 6 point harness to match the drivers side. Nicely made and even come with a sheet on how to "correctly" fit them and at what angles etc also included is 6x eyelites which is handy. Now my passengers can ride along with out fear of death



Been real slack with the cleaning of the car lately and shamelessly havent opened the bonnet in over 2 months, quick level check and a clean and good to go again.




Still waiting on my boost pipes!!  

Decided to check the plugs to see what has been going on.




Look pretty good to me :

Stef

[Piggy]

Good work

[Stef205]

Thanks piggy.


Ive been battling with a fluctuating fuel map for sometime now and id finnaly had enough of it, some days it was perfect other days rich as arseholes. After various datalogs and late nights studding the data and chats with guy at omex we finnally think we have sussed it! Turns out lambda feedback was on somehow causing the fuel map to rely on the wideband sensor. :/ Turned it off and noticeably i knew id have to rescale the map. I did a few hours out on the road on my own slowly adjusting things stopping in layby after layby finding various different roads to suit the load points i was looking for.




Left is old right is new

As you can see its progressively changed and now is much more stable and reliable. I dont believe theres any more to gain from my ignition table in fact ive had to take some power out from the bottom end and going from my plugs it seems on par. Im due to go out with a friend on the weekend with it and let him drive it while i perfect it alittle more while in the passenger seat. I do believe the map is trying to tell me my injectors are running out of puff and where the charger peaks, Im no way an expert in this but have been shown and taugh abit thanks to sandy and will be getting him to check over it once finished.

Stef

[bashbarnard]

Always wanted to learn to do this. You can clearly see difference in the graphs. No idea what im looking at but looks smoother now so i suspect thats good. Well done. As always awesome work.

[Matt]

Same as bash I have no idea what I'm looking at. But looks like a smoother power delivery. And ironed out a power spike (probably wrong) at 4k?

Good work though mate! I love this car

[Stef205]

the problem with eatons is that they may give the same pressure all the time but they dont give the same flow consistently so its not always a spike its probably where the charger gave more at that particulate point. Most of my correction maps (ie air,coolant,battery) where all over the place so they now do bare minimum to stop any interference.

[Stef205]

Did a few little odd jobs today and a general check over. Been noticing my boost gauge has been sticking lately and not zeroing so i stripped it and sprayed some wd in and its seem to come back to life.
Finally fitted my wavy discs hopefully they will be an improvement but only time will tell and gave the calipers a touch up.


Stef

[Stef205]

Ive now finished smoothing the map out, let a good friend drive the car while i sat in the wrong seat and adjusted. Car needed more fuel in the lower rpm at load really pushing the injectors now but still at 3bar dont want to up the pressure due to spray patterns and efficiency. Map is lot smoother and mpg has increased from around 25 to 35mpg! Im checking the plugs regularly for any tell tell signs but seem to be burning nice. The car runs a nice 13.0:1 afr on driving, a nice 12.5:1 as it creaps into boost and 12.0:1 on boost. Afr's are much more consistent and having turned off or reduced most of the correction maps.

I snapped up a xsara vts rack off the gti forum the price was reasonable and came with new track rods. Was a low mileage item but me being me i wanted to rebuild it anyway, seals looked crusty and a slight weep in places. Picked up everything i needed from simply bearings and stripped it down.



I plan to take advantage of the powersteering and retro fit it to the car with the saxo pump i bought awhile ago.

The next thing i bought is something id always wanted since they came about after sitting in a car with one i knew i had to have one!







Real engineering porn in my eyes and a true work of art. Cant wait to get it fitted!


Stef

[bashbarnard]

That looks epic. Glad to hear the maps better and the mpg are just a bonus i guess. Always wanted one of those

[7057sam]

Stop spending money on shinies and get it on track

Have fun fitting the satchshift but it will definitely be worth it.

[Stef205]

i really dont know why people struggle to fit them?! its easy with common sense. It will be on track when im confident its ready. Money spent well only makes it quicker on track.

[Poodle]

I presume that converts the lever to sequential-style action? Looks like my kind of funky, do love a bit of engineering porn.

[Niall]

I presume that converts the lever to sequential-style action? Looks like my kind of funky, do love a bit of engineering porn.

nope. What it does is gives you a stupidly accurate and precise gear shift.

[Matt]

Love the wavy brakes! And the shifter looks absolutely porn!

Haven't read this thread properly but looks like an absolute weapon. Better mpg than the rallye too, I'm jealous!

[Stef205]

yup as niall says very accurate shifting second gear atm is under my armpit

[Poodle]

Ah ok, so it replaces linkages, balljoint and the lot then?

[Stef205]

converts 80% of it to rose joint there is 2 ball joints on it but thats down to the gearbox selector that cant be changed

[Poodle]

I'm with you, that's pretty cool. I want one now lol.

This is rapidly turning into an absolute weapon, can't wait for the next video update.

[Stef205]

ive a drag event this saturday so i should have some after.

[Eeyore]

So many tasty parts!

[Blandy]

Satchshift is awesome best mod I've done to mine

[Matt]

Looking forward to vids! Wanna see how this shifts

[Stef205]

this is a link to my youtube channel there are some videos on there. Some are fairly old now but you get the idea.

https://www.youtube.com/user/stef205gti/videos

[Matt]

Just watched a couple, it definatley shifts!

Absolutely love the sound of it! That supercharger whine is incredible

[Stef205]

Sadly i was unable to do the drag event not because of car issues or issues with my self but dvla! i had forgotten that i had recently renewed my license and they had yet to return it! never mind.

So i used the day to get the satchshift in and setup to suit me. The install was easy and pretty straight forward, straight away the difference is night and day. Real happy with it.



Had to ditch the radio which may not sound like a issue but still is a daily for me, never the less ive a plan for that.

Spent the rest of the day giving it a real deep clean having not cleaned it in over 2 months it was due.





Got home and ended up doing the 106 aswell



Ive hopefully a new bumper design coming soon along with all new pipe work and a new intercooler. Currently collecting parts for pas and designing a way to mount a 106 pump in the bay.

Stef

[Stef205]

today i started to install the saxo/106 powersteering pump into the car. I had lots of ideas of where i thought of putting the pump from down behind the radiator to under the boot floor but after a few glasses of thinking juice (pepsi) i came up with an idea of mounting it behind the battery in an upright position. Firstly i was unsure if it would work upright so some bench testing came into play again. Bench test proved it would work upright and would happily self bleed. I welded 2x m8 joining nuts to the outer motor case very carefully then bolted to the inner strut body with a spacer from a dw10 exhaust manifold.



Next was to get the battery back in which fitted perfectly still and wire the pump in. I had already carefully removed the pump wiring from the donor vehicle carefully without cutting to much of it. I had decided to wire it as it would be in the 106 and have it come on with the engine running, doing this by having the relay switch via the 12v dash feed from the alternator. Then i wired in the main power feed with a fuse holder and screwed it to the strut body. I was unsure what size fuse to use so i did some various testing out on our 106 and at the worst i saw a draw of 43amps so ive settled for a 50amp fuse. At the same time i modified the reservoir bracket and bolted it to the top strut.

Im awaiting hoses for the pump to rack so ive left the fuse out for now and then i will fit the rebuilt xsara rack.

Quite happy with how it turned out almost as if it grew there.



Stef

[Niall]

You may have to change that to a 60A fuse at some point. That's what they came with as standard.