stef's 205 gti6 supercharged

[Mighty306]

Stef, someone stole your wheels!  

Nice to hear the 205 is getting a look-in. Is that cam sprocket all sorted & happy now after you used the 'FT' torque setting + locktite?!

P.S. I bet work on the Evo is slow ….it just doesn't stop f*ing raining. Need to do some wok on my car but no way am I sitting in a soaking gutter in the pouring rain!

[Stef205]

 Is that cam sprocket all sorted & happy now after you used the 'FT' torque setting + locktite?!

Well, the belt has been fitted with the cam pulley's at there stops on the adjustment to stop them moving even if they tried. Touch wood so far its been good!


We hope to fit the hydro clutch setup this year, last year i made a full pedal box to accommodate a master cylinder, believe its from a 206 as its very small in size so will tuck behind the engine and clear the manifold. The clutch can remain the same but will have to swap to a be1 bearing and will replace the top mounted be3 clutch arm with a be1 arm which will come out the front of the box and mated to a vr6 slave cylinder. A 406 reservoir to provide fluid rather than two separate tanks. Hopefully this will all work, if not the theory is there.

Still stuggling to get it to drive nicely, while its not helpfully running 350hp through the front wheel it darts around and it becomes very scary even and low speeds and throttle. Still got a few things to try yet!

[Stef205]

Update

While i rarely have to drive it or work on it atm with now axle work being my full time job i managed to get some time to finally get the clutch conversion started.
Loaded it on the trailer and got it down to the workshop.

Within 30 minutes the box was on the floor 

The be3 clutch arm, fork, guides and bearing was removed.

https://www.dropbox.com/s/hmwnqy6e0560l6...9.jpg?dl=0

next was to install a be1 pivot ball

https://www.dropbox.com/s/7d1k7b23ywe4kh...1.jpg?dl=0

The bolt holes in the gearbox needed to be drill out as they are a stupid m7 thread, once drilled out i helicoiled to a m8 thread. I chose a helicoil as i didnt really trust a alui thread.

i offered up the slave which the be1 arm, roughly gauging where the arm would be sat at full reach. I knew the slave mounting pcd holes would not match the gearbox side  which was the case. 

https://www.dropbox.com/s/ftsruzz6z2gk83...3.jpg?dl=0

With needing to fill the holes up i stripped the slave down. It came apart very easy which is one of the reason i chose to use it.

Clamped it down to a piece of steel and fired the tig up and filled the holes.

https://www.dropbox.com/s/x7mnekbcg219zn...8.jpg?dl=0

https://www.dropbox.com/s/y4s1nuik1jitxf...5.jpg?dl=0

I needed to space the slave from the gearbox so 30mm spacers made from some old inner tie rod made the perfect spacers! HA!

https://www.dropbox.com/s/sd7wq03yw429yj...2.jpg?dl=0

With the gearbox side of things finished to a point, i returned my attention to the pedal box. 
First job was to remove the old pedal box, with a gurt 16v lump and a massive blower in the bay things wasnt going to be straight forward. I refused to remove the engine straight and plain  
We refitted the box then removed the blower and both engine mounts, rad and some pipe work. Then proceeded to pull the engine as far forward as possible. The internet states it cant be done, but with the help of some unorthodox methods it came out with ease. 

https://www.dropbox.com/s/thr0vfnu5999cz...3.jpg?dl=0

Internet was wrong  

Reminding my self on what i had built over a year ago, I stripped the servo from the pedal box and removed the clutch master. I decided to use a base model servo as they are somewhat smaller.

https://www.dropbox.com/s/6yti5y4mrl9gpd...0.jpg?dl=0
https://www.dropbox.com/s/ibv1ez06gizrj9...7.jpg?dl=0

With the pedal box in, i mounted the clutch master and with the engine mounts back on i was happy with the clearance to the engine, considering it was all bench made.

https://www.dropbox.com/s/xzc4vsuclavkcm...9.jpg?dl=0

I had intended to use a 406 brake reservoir but in the end i used a bike brake reservoir which seemed to work out ok.

https://www.dropbox.com/s/o9u2z926lm9nw9...3.jpg?dl=0

clutch line to the slave was made from some brake pipe and a random 406 front brake hose, i managed to clip it well and followed the 306 pas pipe route.

Heres a short video of it working 

https://www.dropbox.com/s/rtodzkjcgibjgq...2.mp4?dl=0

It all bled easy as gave great results first time around with no alterations needed to the slave spacing. First drive was brilliant with the clutch feeling nice and somewhat lighter! 
Guess time will tell how reliable is all is. 

Parts used 
206 clutch master
Vr6 slave
be1 clutch arm
base model servo 
brembo bike reservoir 

Hope this might be of use to others

Stef 

[Mighty306]

You've been busy Stef. Top work as always & interesting to see the conversion done. Thanks for sharing!

[Stef205]

It was time to address the common inner wing panel, Only the passenger side has seem to suffered. Got the drill out and started to drill all the spot welds out. A few hours later i had a hole. 



Managed to get in contact with a lad that has made a few panels for others, Exchanged a few pennies with him and he got with the fabbing. 

While doing a few rust repairs i came to the conclusion the car really ort to have a better cage in it. While there nothing wrong with omp cage i just wanted something abit more approved. The omp cage was fitted when the car really wasnt that serious or quick so it only made sense now.
Got on the internet and found a good used safety device c12 cage with a factory optional x brace and harness bars. 

 
Naturally this meant cutting the old omp mounts out   Luckily jake had just bought a nice plasma cutter.   So after a good afternoons work the old mounts was cut out. Messy and tedious! 



I plated the area not only to tidy it up but to give the new cage feet a nice area to be welded to 



I plan to do some extra bracing to the cage and hopefully some triangulation at the front as well as a tunnel brace. 

more soon 

Stef

[Mighty306]

Nice. You got plans to track the car some more when life starts to return to normal?

[Stef205]

absolutely, got access to a trailer now.

[Stef205]

managed to get the new cage in, with the new feet tacked in place. What an nightmare this design of cage is to get in and straight with the body as it has so many pieces to it unlike the omp cage. Anyway its in and loosely fitted for the moment.



The front feet are a little weird in design, i guess its originally designed to follow the floor shape but ive never seen a 205 with a perfect floor. I opted for this with a thick backing plate under the floor which sits against the sill lip.



The inner wing panel arrived that i had made by a nice lad i found on instagram. 





It just fell into place which was nice!



Spot welded back in then seam sealed up ready for paint.


Stef

[Stef205]

Car still going, better than ever if im honest. Over the years ive moved the car with the times. Ditched alot of old junk and slowly made the car abit more "serious like"

One major improvement was the change of the ecu, We ditched the omex mainly as the car just out grew it. We decided to go with a Maxx ecu race, having seen these in action at a friends place and having hands on with the tuning software and seeing its capabilities i was sold on it.
We advanced to fully sequential ignition and fueling, drive by wire throttle, staged methanol injection, engine protection features like oil pressure, temp, battery pretty much every protection its there. Wireless switching for various things via a tablet which also displays data removing the need for gauges. I wired the ecu on its own fresh wiring circuit thanks to a maxx ecu fuse box which is wired straight to the battery and we also removed any unneeded wires within the car. In short term the ecu can do anything we need.

Engine has pretty much remained the same but with the ability to control it abit finer now, we added methanol injection to control air temps when on track and to prevent any knock despite a good knock control table. We also gave it the "party pulley" I still stand by that i was pressured into fitting it. With that we fitted some new bosch 550cc injectors. Power wise it made 309whp on a very harsh dyno dynamics but ive neither worried about figures to speak. It drives, its safe, good enough.

Heater box was ditched for one of those track heaters as the oem heater never delivered heat to the screen despite many repair attempts.

Cage was updated to a safety device cage with a few more bars, with the car getting quicker it made sense. Powder coated in the mandatory red.

Brake system is currently going through a major overhaul, still running the nissan skyline calipers up front and gti6 rears we managed to set fire to them at combe one day With that ive decided to bin it all, I didnt want to suffer again or experience brake loss at 140mph+ towards avon rise. As most will know im not one for buying stuff off the shelf so i made some brackets and fitted some wilwood 4 pots to the rear, yes the rear with some modified 207 stub axles in the lathe and some spacers here and there and we now have a vented rear set up. Surprisingly not much weight gain and abut 3mm added track width - win in my eyes, Theyve also got some lovely handbrake levers built with in the caliper to please my mot man. Although it will be backed up by hydraulic.
Fronts im still awaiting to arrive but again probably ott but meh. I looked around for awhile and also drew some brackets but in the end decided on some ksport 6 pots and some btcc pads, i plan on doing some serious endos and skids at the local maccy d's so well worth it!
There was no question the servo had to be ditched especially to supply fluid to those calipers, a bias pedal box is now in the works.

Exhaust is something ive struggled with not only with noise but actually getting it to survive more than a few years. I ripped it all off and made a new system 3" downpipe which traverses into a 2.5 system with a long repackable silencer in the middle feeding a big 8"x24" round rear repackable silencer with a out come of a respectable 92db

Since most of this ive really actually enjoyed driving it and has made it drivable again, i secretly fell out of love with it for some time but managed to find the love again, in the summer days its a real hard choice which to drive 205 or evo even climbing over scaffolding.
On a serious note i do owe alot of credit to Stephen at p v engineering, even after supplying the ecu, sensors etc the after care support was amazing, always had time to explain and guide me where needed. After supplying him with his jaffer jakes for the year he mapped it with minimal issues even with a broke leg!

Photos i havent uploaded to anywhere since the downfall of photobucket and my tightness of willing to pay for it
Although i do upload most stuff to instagram so if you want to bore your self photos can be seen there @stef205


Stef

[Mighty306]

Great to hear from you Stef & to have an update on the car. Glad to hear you're loving it again. One of my 306's (the blaze yellow one) succumbed to rust & sat unused (bug hole in n/s wheen arch) for most of the winter. Used the GF's car when needs be but she's having to go in to the office again now so have got an old Fiesta (she calls it the 'fester'!) as a stop-gap. Amazingly it started straight away when I put a fully charged battery on it. Just robbing some parts off the blaze now before it goes to the scrappy. Getting on with sorting one of the others is imminent ....work on the house has been a priority for the last year or two. Miss having an old Pug to razz around in!