My track car is using one intended for a 205 afaik, made by direnza. Was a brand new purchase on an ebay auction and I got it for circa £80 from memory. New but it now's are a bit more expensive but just keep your eyes peeled. Doesn't have a header tank built in though, so just something to consider.

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Goldie the track car.

I have two 10" fans side by side on mine. Plenty good enough for road use, and not too bad on track. I have a laminova fitted with mine which sticks a load more heat into the coolant too.

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Goldie the track car.

I fitted a baker bm adapter thing to my thermostat so i've just used 32mm flexible silicon for the top hose (the direnza rad has the take off angled down and towards the offside, so i've fitted my laminova along the back of the radiator, but if you know someone who can tig ally then you could have the old take off removed and a new one fitted for a better angle to suit your xsara).
The bottom hose is basically a standard bottom hose with the push fit part chopped off and pushed the rubber over the swaged take off.
I should mention that i had to re drill the cross member to get the radiator to fit my 306, i think i just used a hole saw or a step drill and re-used the old rubber grommet things to help insulate the radiator from vibration, and used rubber bobbins along the top to mount it to a bit of aluminium angle which spans across between the two legs above the radiator. I think i've put some pics of my setup in my project thread.

I sacrificed my heat exchanger as i am tight on room in that area of the engine bay now, and the laminova is essentially just a massive one of them anyway. I think there are tapped holes in the ends of the radiator so you could potentially fit adapters of have small take-off's welded on to incorporate the heat exchanger, and have some sort of tee on the top hose to also suit that.

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Goldie the track car.

Bit of a bump, does anyone have photos of how they've fitted a 205 rad? I'm thinking about putting one in mine soon to allow clearance for an air box.

Parts list would be:

Rad: http://www.ebay.co.uk/itm/BRAND-NEW-RADIATOR-PEUGEOT-205-1-6-GTI-1-9-GTI-DIESEL-NON-TURBO-NO-AIR-CON-/282665233534?fits=Car+Make%3APeugeot%7CModel%3A205&hash=item41d0292c7e:g:uGsAAOSw32lYpCVR

Expansion tank: http://www.ebay.co.uk/itm/peugeot-205-1-9-1-6-gti-Cti-expansion-water-coolant-bottle-round-type-sensor-/253159337424?hash=item3af178edd0:g:Y1QAAOSw4DJYiQdM

XSI thermostat housing

Pipework?

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Rallye Race Car

What does Damien and carl chambers run? Afaik do they not run a aftermarket gti6 rad that gives a bit more rooom?

Damien uses one of these: http://www.ebay.co.uk/itm/ALUMINUM-ALLOY-RADIATOR-FOR-PEUGEOT-306-GTI-CITROEN-CITRO%C3%8BN-XSARA-ZX/252439924702?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2060353.m1438.l2649

Photos would be great Martin!

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Rallye Race Car

I normally use Imgur, don't think it even requires an account to upload!

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Rallye Race Car

I think so, would certainly make life easier if it did! There are no dimensions though so can't tell how much shorter it is and I don't think Damien uses an air box

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Rallye Race Car

i was using a modified renault 5 turbo rad for years 70mm wide core, Sat on the gearbox side gave plenty of space for itbs.

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1990 205 gti6 supercharged

So it's a standard 205 Gti expansion tank.

I had a set of BBM silicone hoses that I used a few bits out of and chopped around. I made a T piece with one part being smaller than the other 2. That came off the thermostat housing. It joined to a made up copper rail along the back of the block as I didn't need a heater take off.

I used an aluminium joiner on the other end to join to a 90 degree bend off the bottom of the expansion tank.

The thermostat housing is off a 16v xsi. As it only has one outlet on the rear.

It then has a BBM alloy adapter so it can fit the 205 slip fit pipe for the top pipe to the rad. I used the top pipe off a 16v xsi again which I cut the ends off to make slip fit. This was a good shape to leave a big space on top of the gearbox as the pipe routes out of the way.

From the rear of the engine water block I used a standard pipe cut down, then an alloy joiner to a silicone 90 degree bend to be a slip fit onto the bottom of the rad.

One of the top pipes on the expansion tank was blocked off, while another had a silicone pipe which is standard 205 size to be the return from the top of the rad above the alternator. And then the other top of the expansion tank is the overflow leading to the floor.

Then the fan setup is 2 pulling fans on the rear of the rad.

I hope that's some help and not too boring!

Obviously my solution was mainly to plumb it all in without the extra heater matrix pipe work.

Damien's solution looks to be the best but it doesn't really look any smaller than the standard GTi6 rad so not sure how much space it would have for an air box like: https://www.maximotorsport.com/products.php?directory=products/Peugeot/Peugeot%20306/Airbox/306%20Evo%202%20Polyester

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Rallye Race Car

You 100% won’t fit a maxi air box in with mine ....I sold mine because a maxi air box needs 100% correct angle / length Inlet ....my one off Satchel inlet wasent the correct angle or length so I just sold the Airbox ...put the thickest latest alloy Rad I could find in ...
The big advantages with the Maxi air box is no hot air from the rad gets sucked in but I wasent going to get a new Satchel one off inlet made just to fit one ?...god knows what that would cost ?

Ive been toying with making a Kevlar scoop surround to direct clean fresh air into my ITG ....I will get that bonded onto my grill above the Rad fitted now ...that way no hot air will get sucked in ?.....similar to my alloy plate design with my 205 rad before my Sandy Engine ...it will 100% work as well plus cheaper / easier access ...Tony Palfrey said for me to make a template ....he will make it no probs ...

Also getting some radiator / Kevlar surrounds make for behind my F2000 front bumper to direct cold air to my Rad / oil cooler / Stop air escaping around the sides Etc etc