Finally got around to fitting the new clutch. Got the box out within 15mins (sad i know) Pulled the oem clutch off showed clear signed of heat and was extremely glazed. Decided to inspect the flywheel for any issues, Apon inspection we found lots of stress cracks and lots of high spots. I wasnt happy about putting it back so got on and sorted another. Big thanks to rich!, really didnt want to buy a s/h unit as ive see loads with high spots along with heat marks from oem clutches. Also fitted some new flywheel bolts from peugeot. Nice touch from ttv is the pressure bolts have now been upped to a decent bolt size m8 instead of peugeots stupid m7!





Flywheel has made a real noticeable difference, Omex has delt with the change well and idle is as smooth as it was before. Clutch is nice and wouldnt know it was a paddle but bites alot harder, worthy upgrade!

Stef

________________________________________

1990 205 gti6 supercharged

The vxr injectors make much of a difference then? Wondering if they would be a straight swap on mine or would need a completely fresh map.... I know it wouldn't be perfect without mapping obviously...

________________________________________

Black power baby! SUUUUUPERCHARGED
Seat Leon FR TDI 190BHP 300lbft daily gti-6 killer :p
12x 306's owned so far

Cambelts, clutches, service work carried out on All makes and models, Peugeot Citroen / mitsubishi specialist.
Pug planet / Citroen Lexia diagnostics / code reads available.

What clutch are you using?

Defiantly need to get me one of those flywheels. Only reason I didn't get one last week when I had my box off was in case the omex on mine needed any tweaking. Will get one over the winter though

I had it made, told them what i wanted and they made it.

________________________________________

1990 205 gti6 supercharged

New suspension has turned up :Big Grin

Direct from bilstein 205 grp a bodies with inverted mono tubes with Eibach springs. Big thanks to miles for sorting them for me.





will be sorting top mounts soon.

Stef

________________________________________

1990 205 gti6 supercharged

309 tube, zero toe arms, -1.5 deg camber, 22mm tb's 25mm arb and soon will have the bilstein grp a rears to match the front.

________________________________________

1990 205 gti6 supercharged

Ill try buddy

Had a few minutes at work so fitted the new mintex 1144 pads and brembo discs with new fluid. Can already feel the difference only time will tell.



Stef

________________________________________

1990 205 gti6 supercharged

Would it be worth strengthening them with some triangulation either side? Might make it a bit more awkward getting a spanner or socket on the bolt but it would help prevent them breaking again so easily. You could even weld in the triangulation so it makes the hexagon captive, ruling out the need for a spanner/socket on that side of the bolt.

________________________________________

Goldie the track car.

Yeah ill do something with them at somepoint, I have welded the bolts to the brackets already but a better bracket design will be better.

________________________________________

1990 205 gti6 supercharged

Had been nursing the engine for a while, started pushing water out and started to run hotter. Decided it was time to pull it out. 
The original plan was just to lift the head and repair what was needed.

Untitled by stefan golesworthy, on Flickr
Which in turn changed to this.

Untitled by stefan golesworthy, on Flickr


Now it had become a full engine build and a engine bay tidy and repaint.   :itwasntme: 

Engine strip began

Untitled by stefan golesworthy, on Flickr

Yes a FIBRE gasket! I did 40k on this 35k with boost!

Untitled by stefan golesworthy, on Flickr

Head and valves seemed ok.

The head was then sent to sandy to work his magic

in the mean time the block was fully stripped and inspected, Big ends where in top shape but the mains had taken a small blow. 
It really wasnt worth spending money on a cast crank so i raided the spare hdi engine for its forged crank

quick test fit of the 88mm crank

Untitled by stefan golesworthy, on Flickr

xu5/7/9 thurst washers need to use this crank in a xu10 block.

block was cleaned and gave it a slight hone. The block wasnt scored or did it have any lip at the top it was mearly to score bore up.
Untitled by stefan golesworthy, on Flickr

genuine peugeot mains fitted to the block

Untitled by stefan golesworthy, on Flickr

Untitled by stefan golesworthy, on Flickr

Pistons in and mated to the crank with some arp bolts. 

Head returned from sandy 

Untitled by stefan golesworthy, on Flickr

About as much as i can show you
The head also received new valve guides, and serdi valve seats head was skimmed abit more than expected but wont effect the build. 
head was put back on with a genuine gasket, genuine bolts and added some newman camshafts to the mix.


Untitled by stefan golesworthy, on Flickr
secretly there just boxes

The standard exhaust manifold was modified, the flange appeared to be the restricting part as it really funnel necks down. I removed the flange and opened the collector to match the exhaust sizing i plan to use. 
The mandatory v-band was added 
Untitled by stefan golesworthy, on Flickr

Untitled by stefan golesworthy, on Flickr



Wont stay that clean im sure.

I turned my attention to the engine bay. 
I fully stripped all the paint off the bay with industrial paint stripper as it was easier. Then my good friend that paints at mclaren came down and painted the bay for me. Not bad considering the conditions. 

Untitled by stefan golesworthy, on Flickr
fuel lines were replaced to ali lines and clipped to the bulkhead.

Untitled by stefan golesworthy, on Flickr
engine was lifted back in, surprisingly i didnt scratch anything :

Untitled by stefan golesworthy, on Flickr

Oil cooler was moved to sit behind the fog light hole in the valance. 

started the exhaust build

Untitled by stefan golesworthy, on Flickr

Untitled by stefan golesworthy, on Flickr

Untitled by stefan golesworthy, on Flickr

Untitled by stefan golesworthy, on Flickr

Untitled by stefan golesworthy, on Flickr

The engine started for the first time, Ecu naturally isnt happy. Ill be getting it back down to sandy at some point. 

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. 

Untitled by stefan golesworthy, on Flickr

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

Stef

________________________________________

1990 205 gti6 supercharged

Its around 10.5-10.8:1 its hard to say the head was skimmed past the normal point. Im now running less boost about .6bar mainly due to the increased cc i guess pulley setup is still the same and the least boost it will run.

________________________________________

1990 205 gti6 supercharged

Brilliant Updates Stef

Keep them coming