Hi, building VNT'd 205 Sleeper in Chesterfield...

[399road]

This is what the dash looks like now. A bit Fast and Furious.


Another under bonnet picture. There's a few more pipes and bits gone on after this one was taken but it shows location of turbo and boost pipework. The next manifold I make will mount the turbo higher to allow a better angle for the oil return pipe to run back to the sump. It would also make access to the underside of the turbo easier. Need to talk James into a manifold building session next. This one will be fine for my 205. Tomorrow I'm mounting the scavenge pump in front if the gearbox and then a bit more road testing.

[399road]

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Few more pictures from tonight. One is showing the turbo's oil scavenge pump which I've mounted under the end of the gearbox. It has another pipe with a breather filter on it drawing air in with the trickle of return oil to prevent it sucking oil out of the turbo's bearings. Another shows the boot mounted battery and the last one shows the trimmed grill to fit around the boost pipes. The 3" exhaust I've made is shown in one picture and fits really nice down the back of the engine and box and clears the gear linkages by miles. A proper road test is this weekend's priority as I've only nipped it up the road and it's already breaking traction on half throttle haha.

[toseland]

this looks VERY mental...

could we get a project thread up? maybe one of the mods could help!

[Mattcheese31]

Would you like this moving into projects chap?

[399road]

Would you like this moving into projects chap?

Yes please matey. Thanks....Luke .

[399road]

Been for a proper road test in the 205 today with James in passenger seat. I never went past half throttle and it still felt dangerous. He's turned the boost down for now and the only issue with it was its expansion bottle cap leaking. The car seems to put the power down pretty well in a straight line, but do it on a bend and you'd better hold on tight. James is picking up a rad cap this week so I'll park it up again till it can hold its coolant. We were both dead impressed by it.

[procta]

that's very neat!! only thing that would give the game away is the gauges on the dash, id have tried to locate them somewhere out of sight.
with mine, the dash itself looks completely standard, I even left the choke cable in place.
I fitted a centre console and fitted 3 gauges there, so if some one takes a glance through the window, they will see a poverty spec dash.

[399road]

that's very neat!! only thing that would give the game away is the gauges on the dash, id have tried to locate them somewhere out of sight.
with mine, the dash itself looks completely standard, I even left the choke cable in place.
I fitted a centre console and fitted 3 gauges there, so if some one takes a glance through the window, they will see a poverty spec dash.

You're right mate, but the dash isn't finished yet. I agree they'd be better somewhere else and I can't read any of them while I'm driving. I'm planning on another section of 205 dash on hinges that flips down over them so the local "chemically dependant" don't think it's owt special when they're peering through my windows, checking my ash tray for coppers   .

[399road]

The car is finished and had a drive up to James' garage earlier this afternoon. It behaved perfectly and I opened it up a bit more on the bypass. Still soft pedalling it, I got it up to 80 in no time at all and it coped with the rush of power really well. The hdi gearbox is a massive improvement but the gearchange is a bit crap still. Maybe my linkages are a bit tired? Anyway it's held its oil and there were no puddles underneath at James, so I reckon it's all good. It's doing 1.4 bar of turbo at the moment with that home made mechanical VNT controller and there's no smoke under acceleration so really, everything's unstressed for a running in session. It can have a couple of hundred miles like this and then get some 15w40 and the boost/fuel turned up.

[399road]

Other cars blown into the weeds by the little 205 this last week during running in around Chesterfield.
MR2 ( got angry once he'd caught up on some bends so I gave him a repeat prescription on the next straight )
2 x Mk4 Golf GTIs ( got cheering and waving from those lads )
Mercedes 230 Kompressor ( wasn't impressed one bit )
Audi TT ( dropped right back afterwards to avoid embarrasment )
Audi A4 ( see above )

I still haven't been past 2/3 throttle either and the fueling is low. The boost is still too high and we're struggling to lower it but it goes like a Lambo.

[procta]

Other cars blown into the weeds by the little 205 this last week during running in around Chesterfield.
MR2 ( got angry once he'd caught up on some bends so I gave him a repeat prescription on the next straight )
2 x Mk4 Golf GTIs ( got cheering and waving from those lads )
Mercedes 230 Kompressor ( wasn't impressed one bit )
Audi TT ( dropped right back afterwards to avoid embarrasment )
Audi A4 ( see above )

I still haven't been past 2/3 throttle either and the fueling is low. The boost is still too high and we're struggling to lower it but it goes like a Lambo.

Its very, very funny isn't it, when they see some old 20 year old plus poverty spec car, and try and take the piss out of you.  Until they get their arses handed to them!
hell I have raised with gta 16v and the 1.1s,
Best ones for me are:-
A ford focus at the lights years ago, thinking he could over take me, and got well embarrassed, as he wouldn't look over, after I hung him out to dry.  led him into a false since of security, my dad was ill with laughter over that one. He shouted at the lad, Yes its a 1.8!!  That one was with the GTa 16v shell.  

A Peugeot 206, that fella tried to under take me, but got a nasty shock when I dropped a gear and let the thing go.
you think he was in reverse.
A corsa 1.2 xsi tried to have me at the lights, he never even got a look in. ( well he did fall for the  1.1s badge on the back)
A Peugeot van, one that some lads mod on here, one of those tried to undertake me, and then got pissed off, and tried to sit off the arse, but got a nasty shock when I put the power on.
A modifed ford focus backed right off, after a failing to try and catch me. 
Only thing I have had, was a lad and his lass in a new clio, have a very surprised look on their faces and starting to laugh,  The lad with wide open eyes said " no where and hell that's a 1.1s!"  His lass was ill with laughter. 
That could have been due to the fact that they couldn't catch me either.
I seem to get Nissan Qashqai , and the micra lot wanting to try it on more often now.

[399road]

Sleepers rule matey. My old Escort was badged up as a 1300 but was a full race 1700 with 160 horses. I smoked allsorts with that one. Your Metro sounds cool. I've got my eye on a dark green two door Allegro that's ripe for the sleeper treatment

[procta]

Sleepers rule matey. My old Escort was badged up as a 1300 but was a full race 1700 with 160 horses. I smoked allsorts with that one. Your Metro sounds cool. I've got my eye on a dark green two door Allegro that's ripe for the sleeper treatment

They do, you cannot beat poverty specd sleepers, with a couple of OEM extras.
The metro is a laugh mind, and is one car that gets shunned sadly, but I think yours is a better all round sleeper.
have a look at the thread sometime if want. Or Pm me if you want to know more.

[399road]

I'll have a look at your Metro thread. I've made a cover for those dash gauges too.

[procta]

good that you have sorted the gauges, I did think about fitting a hiding change light into the dash clocks too, ( I might still do that)
I am toying with the idea of upgrading the anti roll bar at the back too, as some one has made a set.
Bar that its nearly sorted,

[allye]

Fantastic build! Sleepers are the best, I'd even half consider my old goodwood a sleeper with the V6. Best one was a blat with a tuned 1.8t skoda, we went 140+ (it would go north of 150 quite happily) on a dual carriage way, went single lane and widows down;

"What the hells in that!?"

"A V6!"

[Dum-Dum]

Liking your work, thing the green hoses might be a bit of a giveaway. Personally I'd suggest some 14" steels so you can get some bigger brakes (Just 206/306 HDi stuff with the 266mm discs) on and it'll still look like a sleeper. If you want a set I have some.

[399road]

Thanks, but the green hoses are now stealthed too. I slid some black gloves over them with the fingers cut off. I thought about 14s a while ago, but still prefer the look of the skinny 13s and it puts the power down really well so far. Might be a different story when the fuelling gets wound up though. I think the actuator's diaphragm is split now because it runs 34psi and won't wind down. It just boosts and boosts its head off and it won't last long doing that.

[procta]

uprate your tyres when you in crease your power, mine is sitting on 175s/ 60 /13s I could go for 185s but there isn't much tyre choice. not sure what they do in the 195s but its the back end for me that would be trouble. Due to the radius arms. So it would have to be a smaller tyre wall and a wider tyre. But I want to keep the car looking stock as possible, If you look at the car from the side, it looks like a 1.1s as I bought new 1.1s trims. Keeps it looking that bit extra poverty spec.

[399road]

Nah. Downrate the tyres haha. 135 13s should liven it up a bit once I get used to the power and they're less thsn £15 each for some Polski ditchfinders.

[zx_volcane]

Hope to see this in the flesh soon

[ginge191]

absolutely love this.
My aim is to have something very similar to this! Top work!

[399road]

Got 250 running in miles on it so far, but still got too much boost and a dribbling expansion bottle cap. Also developed a few new knocks and bangs from engine mounts now everything's settled down. I've got another stronger actuator to replace the split Impreza one. It's off the same Ferrari reach stacker ( Scania engined ) that my metal boost pipework came off and came with a huge, but seized Holset which I found in the scrap pile at one of the container ports I work at. The actuator's rod is 8mm thick! Need to remove turbo to rework linkages for that new actuator, though another Impreza one would be a load easier.

[Dum-Dum]

That has got to be a beast of a Holset, what is it?

[allye]

What header tank is that from? When 205 metal ones die you replace with a harder sprung plastic cap and that normally sorts things out.

[399road]

That has got to be a beast of a Holset, what is it?

Holset has no tags on it. Part number on actuator bracket is 7622403asm and actuator is 4037622 if you can make anything of those numbers. All I know is it's huge.

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What header tank is that from? When 205 metal ones die you replace with a harder sprung plastic cap and that normally sorts things out.

Header tank is from a Rover 75. It's a great fit but a stupid design and good quality caps that fit properly are tricky to find. This latest 140 cap with uprated Viton seals and the top pipe blanked off is my last attempt at making this header tank work.

[399road]

James has now got the boost under control and I've ended up junking that cable and lever vnt controller, replacing it with a shortened vnt lever on the turbo and another Impreza actuator acting directly on it. It's doing the same job my set up did, but is easier to adjust. It's also had a change of boost controller to a Dawes valve off ebay ( sold by Mumby developements ). He's turned the fuelling up and set the boost ar 1.8 bar for now. It now boosts nice and smooth from idle and makes all the right noises. It's still putting the power down really well too.

[399road]

Bit of an update. The 205 is still going strong and has only been defeated by one car - a C63 AMG! Not bad for an old smoker. Was hoping to dyno it at Mattcheese's dyno day Saturday but it's been postponed until later this year. Got a GTI subframe to fit next and also whip axle over to Stef205's for a rebuild and lowering. I've bought another old Opel which needs a few jobs doing too, but I'll try and finish the Peugeot first..... Luke.

[procta]

Nice to hear it still going strong! Mine is in bit at the moment,

[Chris_90]

Still not seem this about, can't wait to see it smoking off tho not that I'd see it for long on my bx nad but still be awesome to see it.