stef's 205 gti6 supercharged

[Mighty306]

So that's what the HDi crank was for.  It looks really great Stef, and like it's going to be a lot of fun.  (Just a little jealous!).  What were you looking to get out of the changes to the head?

[Stef205]

Oh. My.

When I thought I couldn't love your 205 any more ....

Going to be hard getting back into it after 6 months of evo.  

Wow, what a build! Disgustingly clean.

Thanks, Not sure it will stay clean.

So that's what the HDi crank was for.  It looks really great Stef, and like it's going to be a lot of fun.  (Just a little jealous!).  What were you looking to get out of the changes to the head?

HA! yes thats what it was for. More flow should allow more timing and less chance of detonation etc. I now nearly have 3 times more lift at tdc than i did on the std camshafts.

---

Tonight i assembled the bilstien coilovers. 



Will get them fitted at some point.

[Mighty306]

That explains why the ECU doesn't like the changes!  Looking forward to hearing how it goes once remapped.  Like s**t off a shovel I suspect!!

[Stef205]

That explains why the ECU doesn't like the changes!  Looking forward to hearing how it goes once remapped.  Like s**t off a shovel I suspect!!

Never expected it to like it



Fitted new brake lines and remounted and repositioned the pas pump, originally stood up but it wasnt happy. 

Car is now on four wheels again, a few more tweaks then its off to mapping. 

Stef

[Mighty306]

Looking good!  Will be keeping an eye out for updates.

[Eeyore]

Just seen the update and what an update it is. Looks great mate!

[Stef205]

The day before mapping, I drained the oil from the engine as it was only used to run the engine for the first time and to get it through its first lot of heat cycles. 
Drain and refilled with mobil 10w/60 and a genuine oil filter. 
Untitled by stefan golesworthy, on Flickr

Oil choices can be very opinionated but ive used this stuff since owning the car and its served me well with no failures or issues so i just continue to use it.

Untitled by stefan golesworthy, on Flickr


Loaded up and headed for Cornwall!

Arrived at ARM bmw and motorsport and what a place! 

As always nothing goes to plan and tbh i never expected it to with a new setup. As we got into the higher pulls and higher loads suddenly we had a real rough idling issue, after about 30mins of looking for a air leak we discovered the exhaust cam pulley had slipped! luckily i had built the engine with plenty of valve to piston clearance so a case of moving the cam back and all was good again! With that said it happened about 3 times again only after full hard pulls. 

I then moved the belt and the pulley to the end of its adjustment so it couldnt move even if it tried which worked! Sandy then continued to work his magic which then saw us welcoming the 205 into the 300hp club! something id never expected to see! completely shocked. 

We called it a day with the map pretty much there i was told there was more in it but for now its enough lol. The car had been completely transformed and is very drive-able and a animal when needed. 




Sadly the gopro failed and the only video i have was filmed on a android potato!

Stef

[Mighty306]

Holy s**t, you've created a monster Stef.  Must be fun trying to put all that power down on a damp road!!!!

Thank god the slipping pulley didn't do anything to the top end. Must've been a heart in mouth moment.

[Stef205]

Lucky very lucky, hopefully ive sorted it now ill probably look for some aftermarket pulleys in the future.

Sandy has welcomed another session as he said there is more in the car but i said its enough for me!

[Mighty306]

Been looking back through your pics on Flickr again.  Really interesting stuff.  The centre bolt on the later J4RS cam pulleys is cranked down pretty hard ...it really must take a lot to make them slip.

Also, was looking at the other changes you've made.  Original pistons but with shorter con rods by the looks of it?  Different supercharger too?  I assume some of the head work is top secret as it seems to be photoshopped over.  Was also curious why your pistons have names?!!

Is this going to make it up to Castle Coombe some time?  I can't be the only one eager to see it in action.

Sorry ....too many questions!!

[Stef205]

Been looking back through your pics on Flickr again.  Really interesting stuff.  The centre bolt on the later J4RS cam pulleys is cranked down pretty hard ...it really must take a lot to make them slip.

Also, was looking at the other changes you've made.  Original pistons but with shorter con rods by the looks of it?  Different supercharger too?  I assume some of the head work is top secret as it seems to be photoshopped over.  Was also curious why your pistons have names?!!

Is this going to make it up to Castle Coombe some time?  I can't be the only one eager to see it in action.

Sorry ....too many questions!!

dont read to much into my flickr its all over the place since i migrated from photobucket. Im not on std pistons, rods or crank now. The head work is hidden on request of sandy so i have to respect his wishes. Naming of the pistons was bit of fun bewteen me and a friend those pistons didnt get used come the end.

[Piggy]

Ooooof!

[Stef205]

Been driving it around for a bit now all seems well UNTILL...........

I had developed at tap/knock at the top end - sounded like a common tappet so traced it down to the inlet side started removing parts, removed the timing cover to find that the cover was hold the inlet pulley bolt in! Naturally thought the worst got the bore scope down each cylinder to check if we had kissed any valves. Luckily we hadnt! I had built the engine with a fair amount of clearance. So the inlet pulley had be smacking up and down on its adjustment hence the knock sound i guess, Retimed it all, thoughly cleaned the inner threads and the pulley bolt and a good dose of thread lock and tightened to FT! Torque settings had gone out the window at this point!
Turned the key with fear to hear the sound of a smooth and non tapping engine!

Anyway here a quick blast im still learning to deal with the power and at the time the tracking was to cock. 4,000rpm seems to be the scary point

https://www.youtube.com/watch?v=gWgJveDLiRM

Stef

[Mighty306]

Another close call! Glad you got away with it. I guess you're going to become a bit paranoid about that pulley bolt now.

It sounds good n looks fast. Does it top the Evo experience?!

[Piggy]

Mental.

[Stef205]

 Does it top the Evo experience?!

evo is in its own class 4wd lazy to drive and fast

---

Mental.

me or the car

[Piggy]

Youre off the chart idiotic... But the luck that engine had with that pulley is mental ...as is that video

[Stef205]

thank full the engine has about 4-5mm of valve clearance at tdc.

Im hoping to get it running on some meth soon, even tho its hardly got any ignition in the top end atm it will help raise the aki and reduce inlet temps further.

[Stef205]

Still here

Car is in bits again 

Was driving well untill i heard some thing snap instantly followed by the car attempting to drag me to the nearest hedge.
At first a suspected snapped shaft or inner joint ( Regularlar thing now) Car on the ramp shafts out and inspected to find they were all good. Next the box came out and removed the diff. Opened that up to find damaged internals. From what ive seen the preload spring snapped thus scoring all 10 clutch plates  

Now awaiting plates from 3j, Joys of a modified car i guess

[Blandy]

What setting do you have your 3j set to out of interest?

[Stef205]

40/90 75ftlb preload

[Magenta Sunset]

multi-plate clutch?

[Stef205]

Untitled by stefan golesworthy, on Flickr

Untitled by stefan golesworthy, on Flickr

Untitled by stefan golesworthy, on Flickr

[Stef205]

I ve known that the clutch has been struggling to hold power at times. I removed the clutch to find good evidence of this. It was always going to be a trial and error experiment. 

Untitled by stefan golesworthy, on Flickr


I got onto the phone to my friend and had a good conversation about what we would try next. After a good discussion we agreed it was the pressure plate at fault. With that we both agreed he would made a twin diaphragm pressure plate and a new friction plate with tougher springs again. Hopefully it holds now and we can slowly introduce more power into the engine. 

The new clutch arrived, like normal he had done a brilliant job. 

Untitled by stefan golesworthy, on Flickr



Untitled by stefan golesworthy, on Flickr

Im still setting the preload on the diff, it requires a few more shims to get it right luckily ive managed to bench test the break strength before fitting it to the car. 

Stef

[Stef205]

Finally got the diff settings where i wanted them with roughly 75-85 ftlb of preload, Turns out 3j had redesigned a few plate and reduced the thickness on some. With that it was put back in the box and refitted to the car. 

Untitled by stefan golesworthy, on Flickr

slowly becoming a car again. 

Untitled by stefan golesworthy, on Flickr

With that i decided to investigate a small oil leak that had developed, Appeared to be coming from the exhaust cam oil seal which is annoying as it was all new. 

Engine timed and all needed was removed, cleaned the cam ladder and now waiting on a new seal. 

Untitled by stefan golesworthy, on Flickr 


stef

[Mighty306]

Was sorry to see this had to come off the road Stef.  The price to be paid for having too much fun I guess?! Good to have updates on it though & to see it's coming back together with a few upgrades. Cheers!

[Stef205]

stumbled into this the other day, remembered i still owned it, washed it then put it back in the corner.

[Eeyore]

stumbled into this the other day, remembered i still owned it, washed it then put it back in the corner.

classic supercharged owner

[Mighty306]

Even if it hasn't been running I'm sure it's still very pretty to look at! Guess the Evo is still keeping you entertained then?!

[Stef205]

205 has been in daily use for a good 3 weeks so far. I'm doing some tidying on the evo atm.