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Author Subject: High Boost Rotrex conversion
fletch

Track Head

Location: The nearest Shell garage

Registered: 12 Jun 2004

Posts: 12,273

Status: Offline

Post #1
Thought it was about time I started one of these threads Happy

Intro

About three and a half years ago, before I got the trackday bug to distract me, I was thinking about more power in the 6. I tried Nitrous, which I actually quite enjoyed, but began looking for a more sustainable boost in power. Having seen the Ecosse conversions using the Opcon 'charger (and the price!) as well as contemplating a T16 conversion, I decided there wasn't enough power per
Posted 23rd Dec 2008 at 04:42
fletch

Track Head

Location: The nearest Shell garage

Registered: 12 Jun 2004

Posts: 12,273

Status: Offline

Post #2
Heres some of the shiny bits I collected up ready for the rebuild Wizard







Posted 23rd Dec 2008 at 05:01
roland rat

Yeeeah Rat fans!

Location: Swansea

Registered: 29 Nov 2006

Posts: 22,282

Status: Offline

Post #3
Laugh i remember coming home all excited from work to see what had been delivered when i was building my s/c 6.

Looks to be an awesome project mate Thumbs up
Posted 23rd Dec 2008 at 05:02
stu

Seasoned Pro

Location: Milton Keynes

Registered: 22 Aug 2006

Posts: 5,525

Status: Offline

Post #4
roland rat wrote:
Looks to be an awesome project mate Thumbs up


+1

Look forward to further updates! Cool
Posted 23rd Dec 2008 at 05:05
fletch

Track Head

Location: The nearest Shell garage

Registered: 12 Jun 2004

Posts: 12,273

Status: Offline

Post #5
Rebuild

My bare block came back having been overbored to 86.5mm. This was accurate, measured using an inside mic with no wear at the top of the bore. I also had the Ancillary bracket cut down, and the head came back skimmed and cleaned.








Bearing tunnel:



I decided to tart up the block while it was in pieces, so set about priming and painting it.




At this point in the build I moved house, and shortly after, helped in the in-laws move house.

Anyone who has moved, knows the hassle and work that needs doing before everything is settled in
and so the build was put on hold Sad
Posted 23rd Dec 2008 at 16:14
rallyestyle

Seasoned Pro

Location: London

Registered: 23 Jul 2003

Posts: 14,989

Status: Offline

Post #6
Keep it going buddy, looking very nice indeed Smile

Who do you get to do all your engine work/fabrication?

________________________________________

Just Drive It
Posted 23rd Dec 2008 at 17:22
fletch

Track Head

Location: The nearest Shell garage

Registered: 12 Jun 2004

Posts: 12,273

Status: Offline

Post #7
rallyestyle wrote:
Keep it going buddy, looking very nice indeed Smile

Who do you get to do all your engine work/fabrication?


The machine work was subcontracted by Lynx Garage as I was down there quite often for various reasons. Not sure what fabrication you mean though?
Posted 23rd Dec 2008 at 19:00
rallyestyle

Seasoned Pro

Location: London

Registered: 23 Jul 2003

Posts: 14,989

Status: Offline

Post #8
fletch wrote:
rallyestyle wrote:
Keep it going buddy, looking very nice indeed Smile

Who do you get to do all your engine work/fabrication?


The machine work was subcontracted by Lynx Garage as I was down there quite often for various reasons. Not sure what fabrication you mean though?


Poor choice of words really as its pretty much the opposite to what i meant, rephrased... who hacked apart your ancillaries bracket? Laugh Im guessing Lynx too Yes

________________________________________

Just Drive It
Posted 23rd Dec 2008 at 19:17
fletch

Track Head

Location: The nearest Shell garage

Registered: 12 Jun 2004

Posts: 12,273

Status: Offline

Post #9
With seemingly endless birthdays, moves, holidays, weekends away etc and me getting depressed at the lack of progress I decided (and told the missus Laugh) much of the next few months was to be spent finishing off the build.

I set about building the bottom end:



Bearing clearances were then measured and checked.

Shells and Crankshaft were put in place and the main bearings torqued down.

Time to crack out the shiny bits Cool

Pistons were fitted to the rods with gudgeon pins in place.



Next up the rings...



I didn't want to hide these away in the block as they are beautiful bits of kit, but the engine wouldn't really work well without them... Meh



Fitting the pistons to the cylinders...






Big ends with L19 ARP bolts torqued up. (These bolts have a tensile strength of ~40,000psi more than ARP2000 bolts Crazy)



Engine was turned over and everything was moving nicely.

Now was the time to crack out the multiple bags of bolts I labelled up over a year ago Unsure



Some of the labels had deteriorated Laugh
Posted 23rd Dec 2008 at 19:33
paul. Banned!

Location: nottingham

Registered: 24 Nov 2008

Posts: 11

Status: Offline

Post #10
hi mate dont want to sound a pan but your pistons are in the wrong way the arrow is to the rear of the engine
Posted 24th Dec 2008 at 01:50
rikky

Forum Pikey

Location: cheshire

Registered: 28 Feb 2004

Posts: 26,785

Status: Offline

Post #11
paul. wrote:
hi mate dont want to sound a pan but your pistons are in the wrong way the arrow is to the rear of the engine


http://www.306gti6.com/forum/showthread.php?id=91000&page=1

________________________________________

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306 slam panel esso stickers | 306 yellow / orange / pension fund red side door badges
306 red '6' 3d-printed badges (old part no 866503) | gti6 inlet manifold badges | 306 rear boot badges (p2/p3)
winner of Extraction of toys from prams with outstanding vigour award 2009 [source: gti6 owners club]
Posted 24th Dec 2008 at 01:59
n.g.k

Seasoned Pro

Location: Peoples Republic Of Cork

Registered: 03 Feb 2008

Posts: 6,200

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Post #12
Owned

________________________________________

Inside you are face!

Tune Of The Month
Posted 24th Dec 2008 at 02:15
read88

Regular

Location: Farnham

Registered: 23 Nov 2008

Posts: 112

Status: Offline

Post #13
Mate, ur in crawley??? Listen, im desperate to get a GTI-6 at some point, and i do wanna supercharge it eventually as well, low boost tho.. im only about 20 mins away from u fella, do u mind if i give u a hand with this project, i don't know jack-shit about engines, but im pretty desperate to learn a bit more.. but im pretty strong and healthy n I'm good at taking orders, give me a bell mate anytime n ill come up n give u a hand!
Regards,

Ben

________________________________________

Media.
Posted 24th Dec 2008 at 02:30
nuss306

Regular

Location: Mansfield

Registered: 16 Jul 2008

Posts: 184

Status: Offline

Post #14
Hiya mate looks an excellent rebuild and will be interested on seeing it completed and seeing what power you get from it.
Keep up the good work! Cool

________________________________________

Vauxhall (c20let) powered peugeot 306 2.0 16v turbo, aka - PUGLET
Posted 24th Dec 2008 at 02:42
birk

Seasoned Pro

Location: Doncaster

Registered: 24 Oct 2005

Posts: 7,032

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Post #15
about 400bhp i suspect

________________________________________

Dimma + Gt35 turbo = Ninja
Solid rear beam mounts £130
07889376885
Dan
Posted 24th Dec 2008 at 02:47
fletch

Track Head

Location: The nearest Shell garage

Registered: 12 Jun 2004

Posts: 12,273

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Post #16
paul. wrote:
hi mate dont want to sound a pan but your pistons are in the wrong way the arrow is to the rear of the engine

Paul i made the orientation decision based on rich's experience. He installed them this way and they came out with no wear on the skirt or piston slap. So we will see how they fare.
Posted 24th Dec 2008 at 03:06
midlife

Seasoned Pro

Location: Colne, Lancashire

Registered: 13 Mar 2006

Posts: 7,544

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Post #17
birk wrote:
about 400bhp i suspect


No shit SherlockLaugh my ass off


Loving the write up, keep it upThumbs up

Cool

________________________________________

Get used to seeing the yellow one !!!MehMehMehMehMeh
Team 330Cool
Team "no front end or engine"
Team "LIMITED EDITION" I live for the 306 stickerSmug
Team 0-60 in 6.44 & standing qtr in 14.808 @ 94.55mph all with std engineSmug
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Posted 24th Dec 2008 at 03:02
roland rat

Yeeeah Rat fans!

Location: Swansea

Registered: 29 Nov 2006

Posts: 22,282

Status: Offline

Post #18
Do i see a set of 4-pots in your shiny box of tricks? Cool
Posted 24th Dec 2008 at 03:07
pedro_de_la_cruz

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Location: London

Registered: 14 Mar 2007

Posts: 2,555

Status: Offline

Post #19
did Rich go for 86.5mm overbore too?

great project there mate, that feeling when its all finished and you take it for its maiden drive (even if you are running it in) is going to be memorable!

________________________________________

*R.I.P Pete Sims*
Posted 24th Dec 2008 at 03:12
midlife

Seasoned Pro

Location: Colne, Lancashire

Registered: 13 Mar 2006

Posts: 7,544

Status: Offline

Post #20
roland rat wrote:
Do i see a set of 4-pots in your shiny box of tricks? Cool


I was thinking the exact same thing, they look big buggers, what breed are they thenDunno

Cool

________________________________________

Get used to seeing the yellow one !!!MehMehMehMehMeh
Team 330Cool
Team "no front end or engine"
Team "LIMITED EDITION" I live for the 306 stickerSmug
Team 0-60 in 6.44 & standing qtr in 14.808 @ 94.55mph all with std engineSmug
203bhp Corolla T-Sport daily driver stealthier than Kwai Chang Caine
Posted 24th Dec 2008 at 03:16
fletch

Track Head

Location: The nearest Shell garage

Registered: 12 Jun 2004

Posts: 12,273

Status: Offline

Post #21
midlife wrote:
roland rat wrote:
Do i see a set of 4-pots in your shiny box of tricks? Cool


I was thinking the exact same thing, they look big buggers, what breed are they thenDunno

Cool


Just 406 V6 Brembo calipers lads:

Posted 24th Dec 2008 at 05:08
fletch

Track Head

Location: The nearest Shell garage

Registered: 12 Jun 2004

Posts: 12,273

Status: Offline

Post #22
Windage tray, Oil pump, crank seals, woodruff keys were all refitted.



Ancillaries bracket was fitted to the block and then the Alternator, SC bracket, and Rotrex were test fitted.






In parallel to the bottom end build, I was building up the cylinder head, that had come back from the Machinist skimmed and cleaned up.

New stem seals:





When fitting the valves to the Cylinder head I discovered one of the inlet valves was bent.

The valve guides looked ok, so I replaced the valve and continued by lapping in all the valves just to make sure they seated properly.

Next up was the tappets, cam carriers and cams. I fitted the timing cover, seals and pulleys, ready to drop onto the block.








Posted 24th Dec 2008 at 05:45
thugpuggin

Seasoned Pro

Location: Bristol

Registered: 10 Apr 2004

Posts: 26,784

Status: Offline

Post #23
I may have missed a bit of this that is glaringly obvious Matt but which one is this going in? Diablo.

Looks a good work in progress btwThumbs up. Keep at it and get it al done.

________________________________________

Black X Reg PIII.VGTi 6 A4212 pt 1 A4212 pt 2 Searching the streets of Bristol for 1.36p/day.

Joint Kent Leader

Posted 24th Dec 2008 at 05:56
mattg4321

Seasoned Pro

Location: Nr Brighton

Registered: 21 Dec 2005

Posts: 2,228

Status: Offline

Post #24
i reckon it'll be going in the black one Yes

looks awesome matt - keep up the good work, let me know if u need a spare pair of hands and ill do my best to help you out

________________________________________

Ex 6 owner - now S2000 Cool

Posted 24th Dec 2008 at 05:59
midlife

Seasoned Pro

Location: Colne, Lancashire

Registered: 13 Mar 2006

Posts: 7,544

Status: Offline

Post #25
fletch wrote:
midlife wrote:
roland rat wrote:
Do i see a set of 4-pots in your shiny box of tricks? Cool


I was thinking the exact same thing, they look big buggers, what breed are they thenDunno

Cool


Just 406 V6 Brembo calipers lads:



Ahhh, it was the bolts in the crossover pipe holes that threw meDoh

Cool

________________________________________

Get used to seeing the yellow one !!!MehMehMehMehMeh
Team 330Cool
Team "no front end or engine"
Team "LIMITED EDITION" I live for the 306 stickerSmug
Team 0-60 in 6.44 & standing qtr in 14.808 @ 94.55mph all with std engineSmug
203bhp Corolla T-Sport daily driver stealthier than Kwai Chang Caine
Posted 24th Dec 2008 at 06:14

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