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Author Subject: Dutch 306 Gti Supercharged
Wilde Haren

Newbie

Location: Utrecht

Registered: 10 Sep 2018

Posts: 28

Status: Offline

Post #1
Hi guys,

It's nearly two years ago that I decided to do what I've dreamed of since I got my first cherry red Le Mans with Gti6 engine; supercharge it. Got a golden Gti body three years ago to fit my Citroen RFS engine in, much better looking and a lot less rust! So, much saving and scrounging parts later I ended up with all the parts needed. Many thanks to Rich W and a few of the forum members here! I wanted to keep both power steering and AC so I got me two 106 epas pumps and a same side intercooler and spend many weekends figuring out how to put it all together.

First week of March 2020 (a week before Corona hit here in the Netherlands) I started work with my trusty mechanic.
Two weeks later, she runs! Build pics below.


Inner bumper


Cutting out bits of bumper to make room for the intercooler


Trial fit of the first intercooler, this one was way too big and I coudn't fit my outer bumper over it so I went with a smaller one later on. Also you can see the first (open) version of the fan shroud here, I went with a closed version later as this builds up more pressure at the front of the radiator resulting in better cooling.


Horizontally mounted the 106 epas pump as low as possible


Some ugly but functional welding, resused the ABS bracket screw


Somewhat oversized intercooler, bigger is better and who knows what the future brings Big grin


Bends still fit!


Yes, my fan shroud is ugly but it works


Mounted the Rotrex cooler sideways, didn't use the extension at the top


Had the 2.5" exhaust fitted first. Unfortunately extremely loud and boomy



Taken things apart


Most pricy part ever gets to go on first


Polished the inlet manifold a bit


Air filter has already done a few miles as I used it in my homemade intake so could access the epas pump location a bit easier


Wire stuff, so much fun (go to do that twice as I made a mistake somewhere)


Pipes looking very tidy!


Added an aluminium strip at the top of the radiator as most cool air seemed to slip out that way instead of going though the radiator


Put some pipes in the bends, difference is huge. Both visually as in throttle response.


At 84.5% of the first and longest and slowest 100km of all times


Checking if nothing is leaking while there's some daylight left


Mounted the oilcooler for the second time, first time the lines got in the way of the bumper; rookie mistake


It barely fits, as do most of the extra parts ;-)
Posted 7th Apr 2020 at 12:57
miki4

Regular

Location: Cologne

Registered: 09 Nov 2015

Posts: 389

Status: Offline

Post #2
Top work Sander! I'm also collecting the last parts for my supercharging project right now. Engine oil cooler + bigger charger oil cooler as the 10 row is under-dimensioned, I've read more than once. I bought my kit from Rich E in summer 2018 and finally I almost prepared everything to begin with the build. Thanks for the pics, these will be helpful for me. Thumbs up

Where did you get your inlet manifold from? Is it the one mechanical_repairs offered several years ago or is ist self-built?

Michael

Posted 28th Mar 2020 at 14:18
Wilde Haren

Newbie

Location: Utrecht

Registered: 10 Sep 2018

Posts: 28

Status: Offline

Post #3
Feel free to ask for tips while it's still fresh in my mind!

The intake I got from a guy from the UK on Facebook, he had a bunch made a while back and this was the last one.

I hope the SC cooler will do the trick for a low boost setup, I wouldn't know where to fit a bigger one Big grin
How many rows does yours have?
Posted 28th Mar 2020 at 14:23
Day666

Seasoned Pro

Location: Bristol

Registered: 20 Apr 2013

Posts: 5,212

Status: Offline

Post #4
Fantastic Sander keep the updates coming m8 Thumbs up
Posted 28th Mar 2020 at 17:56
Joep

Regular

Location: Urmond (The Netherlands)

Registered: 19 Sep 2013

Posts: 467

Status: Offline

Post #5
Cool to see you here too, Sander! When a dyno day will be organized by the Dutch Peugeot GTI Club, you have to be there Wink

________________________________________

My car park:
'96 Sigma Blue XSi6
'98 Diablo Red GTi6
'99 Onyx Black S16

All RFS powered!

Plus various other Peugeots
Posted 28th Mar 2020 at 19:52
Wilde Haren

Newbie

Location: Utrecht

Registered: 10 Sep 2018

Posts: 28

Status: Offline

Post #6
Thanks guys! I don't have any updates planned, just improvements ;-)
Probably a better exhaust as this one is too loud & boomy and probably too restrictive.
Maybe a bigger restrictor, I hear going from 38mm to 39mm can be done safely.

@Joep; lets hope that happens soon! Last time it registered a healthy 170 horses & 200Nm much like the other RFS engines there that day.

I use it as a daily driver and compete with it in the Dutch Wimedo auto slalom / autocross competition, so I'm trying to find the sweet spot between daily driveability and squeezing as much torque and grip out of it for the track days.

As such, it already has:
- a 406 Brembo / Tarrox / DS2500 brake setup
- strut brace
- BakerBM adjustable top mounts set to -2.5 degrees negative camber
- BakerBM group N engine mounts (only the top ones)
- ApX adjustable coilovers, lowered it a bit allround
- Citroen (C5?) aluminium "aluminies" 15" rims with Federal 595 RS-R semi slicks for the track days
- 12mm spacers front and 16mm spacers rear for a better look
- 20mm spacers front on track days to make the rim clear the calipers
- Almost forget the Quaife diff, best upgrade of them all!

Posted 29th Mar 2020 at 14:35
Joep

Regular

Location: Urmond (The Netherlands)

Registered: 19 Sep 2013

Posts: 467

Status: Offline

Post #7
Yep. Let's hope so! Still need to find out how much horse power and torque the XSI6 has.

Also looking forward to meeting all Peugeot GTi enthusiasts again. Will you go to PugFest?

Is your GTi6 high or low boost?

________________________________________

My car park:
'96 Sigma Blue XSi6
'98 Diablo Red GTi6
'99 Onyx Black S16

All RFS powered!

Plus various other Peugeots
Posted 29th Mar 2020 at 11:17
blandy

Seasoned Pro

Location: Bucks

Registered: 25 Feb 2007

Posts: 2,437

Status: Offline

Post #8
Looks neat in there, very subtle
Posted 29th Mar 2020 at 14:39
Wilde Haren

Newbie

Location: Utrecht

Registered: 10 Sep 2018

Posts: 28

Status: Offline

Post #9
Low boost, plenty for now although I have a feeling it won't be enough for my taste. I want more low-down and mid-range torque.

Never been to PugFest, don't like those kind of dogs ;-)


When & where is it? Might be or get cancelled or postponed now ...
Posted 29th Mar 2020 at 14:41
Wilde Haren

Newbie

Location: Utrecht

Registered: 10 Sep 2018

Posts: 28

Status: Offline

Post #10
Thanks Blandy, I'm happy with how it looks too. Simple shiny & black Big grin
Posted 29th Mar 2020 at 14:42
Joep

Regular

Location: Urmond (The Netherlands)

Registered: 19 Sep 2013

Posts: 467

Status: Offline

Post #11
PugFest will be June 27/28... not cancelled (yet). Will be at Prescott Hill.

________________________________________

My car park:
'96 Sigma Blue XSi6
'98 Diablo Red GTi6
'99 Onyx Black S16

All RFS powered!

Plus various other Peugeots
Posted 29th Mar 2020 at 15:08
Wilde Haren

Newbie

Location: Utrecht

Registered: 10 Sep 2018

Posts: 28

Status: Offline

Post #12
PugFest, I'll have to think about it. I was supposed to go on holiday around that time but nothing is a sure thing these days. Looks like a nice roadtrip though!
Posted 29th Mar 2020 at 16:59
miki4

Regular

Location: Cologne

Registered: 09 Nov 2015

Posts: 389

Status: Offline

Post #13
Hi Sander, how's the car going? Wink

Is your intercooler off the shelf? Can you give me the measurements of it, please? Why did you go down the road of a twin pass one?

Do you see the possibility to route the 2" intercooler piping left and right (or either side) of the rad and condenser with the EPAS in place and without cutting away anything?
Posted 5th Apr 2020 at 10:24
Wilde Haren

Newbie

Location: Utrecht

Registered: 10 Sep 2018

Posts: 28

Status: Offline

Post #14
Car is doing fine after 500km but I'm having issues with the exhaust. A local 'expert' gave me rather small muffler in the middle and a turbo style (chambered) muffler in the back, made a lot of noise and the drone on the highway was terrible. Went back to complain and their solution was to put a 2" equally small muffler in the middle and a 2" restrictor after the rear muffler. Supposedly this would keep the noise down and help with torque low down. So now I basically have a 2" exhaust that's indead less noisy but also noticeably less powerful. Looking for another company to do my exhaust now, one that specializes in supercharger conversions.

Intercooler is off the shelve; 450x230x65mm with 2.25" pipes. I got my stuff from Fmic.eu since they are the only ones in Europe supplying one sided superchargers for a decent price.

The IC maybe a bit oversized for low boost but this way I'm ready for any other upgrades I might do in the future. It cools perfectly. The hot side measures 75 degrees Celcius on the outside of the pipe, the cold side measures 20 degrees. The hot pipe is placed after the radiator so it might pick up some extra heat from that. However looking at this Wikipedia article 70 degrees is about the right air temperature for a low boost supercharger on the hot side of things.

I managed to squeeze 2.25" inch pipes + silicone joiners in between the radiator / aircon condensor and the frame. I did have to cut out a piece of metal from the thing that holds the headlights and I had to bend the edges of the frame somewhat. I also removed some bits of plastic from the radiator and removed a brace for one of the aircon pipes. I also made a custom fan shroud for my 10" Spal slimline fans to place the fans as close to the condensor as possible and I had to bend a few brackets for the condensor so I could move it 1 to 2cm closer to the radiator. Finally I cut a lot of plastic from the inside of the bumper. All this to make room the for the intercooler. I've added some pictures of the bumper cutting in the original post.

I went with the one sided intercooler because there's absolutely NO room on the left if you want to keep both aircon and power steering. The 106 EPAS pump is relatively cheap to acquire (my local wrecker had two) but placing it is a custom job as is the wiring. It is heavy though so I placed it as low as possible, also because the IC pipes needed to go up and over the pump.

So yes, you can go the right side way but you have to do a small amount of cutting and bending.
Posted 7th Apr 2020 at 16:54
rudolf

Seasoned Pro

Location: Skelmersdale

Registered: 07 Apr 2004

Posts: 2,769

Status: Offline

Post #15
Who made your inlet manifold?

________________________________________

S Reg Diablo standardsSpec SORNED
R Reg Nile standard spec written off then repaired
X Reg Astor in need of TLC
R Reg Nile to restore
Set of Lions to fit.
Posted 7th Apr 2020 at 17:56
Wilde Haren

Newbie

Location: Utrecht

Registered: 10 Sep 2018

Posts: 28

Status: Offline

Post #16
Some guy in the UK made a batch and I was lucky enough to get the last one. Round looks better than the square one in my opinion. With a bit of sanding and polishing it looks even better. Maybe ask around on the forum or FB to see id someone has one.
Posted 8th Apr 2020 at 17:13
mechanical_repairs

Seasoned Pro

Location: leicester

Registered: 10 Jan 2005

Posts: 12,122

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Post #17
Wilde Haren wrote:
Some guy in the UK made a batch and I was lucky enough to get the last one. Round looks better than the square one in my opinion. With a bit of sanding and polishing it looks even better. Maybe ask around on the forum or FB to see id someone has one.



Nice build, great to see them still getting used.

I would be the one you bought the inlet manifold from, not been on here for ages, just popped in as well theres not much else going on in the world at the minute other than a virus.

Stay safe.

Carl

________________________________________

C.G.Cars of Leicester, Peugeot/Citroen/Renault specialist Tel: 01162 624498/07799 405184 WWW.CGCARSLEICESTER.CO.UK
36 narborough road south, Leicester LE3 2fn

MOT station now open, tests £35 with a free retest.
Recovery available with a recovery unit, for those not so local jobs

Also offer the loan of a free courtesy car 306 dturbo
Posted 9th Apr 2020 at 08:36
miki4

Regular

Location: Cologne

Registered: 09 Nov 2015

Posts: 389

Status: Offline

Post #18
Thanks for your thorough explanation. Really helps me with the preparation. Is it absolutely not possible to go through the left side with one ic pipe like in this setup?

http://www.306gti6.com/forum/showthread.php?id=106502&page=1

I ask because I already have a single pass intercooler. Where do you see the problem? If I need to cut metal anyway, I can do that on the left side as well to get around the condenser. Or is there no room due to the aircon pump?

Regarding your exhaust: Did you have a look at the Jetex cat-back system? Afaik this is the quietest aftermarket 'sport' exhaust system for the '6. It is 2,5" although I've read that it has a bottleneck of 2,25 inch somewhere near the cat. You can buy it from Friedrich Motorsport with EG approval and a tail pipe of your choice. They have a 15% discount code until 13 April.

https://shop.friedrich-motorsport.de/peugeot/306-limousine-break-xs-xsi-gti-rallye-1993-2002/schraegheck/2.0l-89kw-2.0l-16v-97110112120kw/1990/gr.a-anlage-peugeot-306-xsi/xs/gti/rallye?c=1648

Posted 10th Apr 2020 at 10:36
Wilde Haren

Newbie

Location: Utrecht

Registered: 10 Sep 2018

Posts: 28

Status: Offline

Post #19
Hi Carl! Yes, your intake, great work. Didn't want to drop names as you told me this was the last one.

Miki, I looked into Carls way of building it but I couldn't find enough room on the left side of the rad. Right seemed easier to do. Couldn't go the standard route (underneath) due to the aicon. Couldn't go left because of aircon and you can't cut the rad ;-)

Exhaust; already spent the money so I'll have to sort it with the exhaust guy. Wish I had known about the Jetex though ... I'm going to try some really big Simons mufflers next as they are easy to come by, not too expensive and known to be quiet.
Posted 12th Apr 2020 at 14:08
Wilde Haren

Newbie

Location: Utrecht

Registered: 10 Sep 2018

Posts: 28

Status: Offline

Post #20
So, contacted my exhaust guy to complain about the noise and he's convinced a quiet 2.5" free flowing exhaust has mufflers that are 2" internally. Looking for pictures of 2.5" exhausts to prove him wrong 😅 So please share you pics! I'm thinking of Jetex / Blueflame levels of quiet.
Posted 4th May 2020 at 14:07
Joep

Regular

Location: Urmond (The Netherlands)

Registered: 19 Sep 2013

Posts: 467

Status: Offline

Post #21
A fast car needs to be loud! Wink

________________________________________

My car park:
'96 Sigma Blue XSi6
'98 Diablo Red GTi6
'99 Onyx Black S16

All RFS powered!

Plus various other Peugeots
Posted 4th May 2020 at 15:58
Day666

Seasoned Pro

Location: Bristol

Registered: 20 Apr 2013

Posts: 5,212

Status: Offline

Post #22
Joep wrote:
A fast car needs to be loud! Wink


Not for track days LOL
My twin box Edwards Manifold /exhaust is 89dbs but my induction sound is like 180 Crazy
Posted 4th May 2020 at 18:38
Wilde Haren

Newbie

Location: Utrecht

Registered: 10 Sep 2018

Posts: 28

Status: Offline

Post #23
It's daily, needs be driveable without earplugs.
Induction sound, what's that? Haven't heard it yet ;-)
Posted 6th May 2020 at 10:01
Day666

Seasoned Pro

Location: Bristol

Registered: 20 Apr 2013

Posts: 5,212

Status: Offline

Post #24
Wilde Haren wrote:
It's daily, needs be driveable without earplugs.
Induction sound, what's that? Haven't heard it yet ;-)


Fair point on both LOL
Here’s mine without Sequencial

https://vimeo.com/271302562?ref=em-share
Posted 6th May 2020 at 11:01
Day666

Seasoned Pro

Location: Bristol

Registered: 20 Apr 2013

Posts: 5,212

Status: Offline

Posted 6th May 2020 at 11:02

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