stef's 205 gti6 supercharged

[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