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Author Subject: More to do supercharged Rallye
mechanical_repairs

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Location: leicester

Registered: 10 Jan 2005

Posts: 12,122

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Post #1
Well got a load of my stuff back from the powder coaters today so i am now slowly starting to build up my rallye, first things first the inlet manifold-



A few more bits i had done whilst i was there-




Then here is what is needed to be fitted plus more, ie the intercooler and i also need to get a place to fabricate all the boost pipes as these didnt come with the kit-






Well thats it so far, i will get the car here tomorrow and get cracking, will add pictures as i go along. Had to post this up as i think it looks great.


Well now on to the mucky bit so to speak where you get your hands dirty, here is what i started with-



A lovely nice clean engine bay, although i still got dirty and had to wash my hands-



Well off comes the nice and shiney inlet manifold (these are for sale by the way in various colours)-



Then on to removing the power steering pump and grinding off the lugs that are used to attach the pump, this by the way was a misson as i wasnt removing the mounting from the block-



Well after cutting and swearing etc and getting abuse from this dick head, the lad who works with me-


I test fitted the charger and made sure everything was lining up as it should (still not at this stage spun the charger outlet round yet-



Another pic from a different angle-



After the that i spun the charger outlet around so it was in the correct position and started bolting on the inlet manifold, first off i removed the rag that had stopped the crap going down into the cylinders and blew all the fileings away that had been made when cutting the engine mount-



Another picture of the manifold, i think it looks great-



It was then a case of putting all the sensors on and sorting out where the wires would be routed etc, also started to bolt the brakets on and the throttle body to the charger-




A few more bits and pieces fitted-



I then set about putting the power steering pump down onto the sump, a case of moving a metal pipe round on the pump itself then mounting up the the brackets supplied in the kit, power steering fluid by the way is horrible!

Started with this-




Then eventually, got this-



Decided to see if i could use the original power steering pipe and to my surprise it fitted, just a case of seeing if it will be ok-




Had a little trouble mounting the alternator braket, as the car is a rallye the sump has never had any bolts fitted to the sump so the threads were a little tight, got the lower bolt in more or less all the way then the bloody thing snapped, job for later now Sad

Well done a bit more, mainly sorted the wiring out as the sensors etc have been moved so the looms needed to be extended, not a job i enjoy soldering but it went quite well and luckily i have all the correct colour wires to make it look a nice and neat job, also found some plastic tubing to put the wires into, just makes it look that bit neater-





Just got to start putting the oil feed in for the charger and then the fans etc and mount the intercooler, then hopefully thats about your lot. Oh and need to find somewhere to make up all my boost piping, i am struggling with that.

Well today i removed the slam panel and before i started any mechanical work i decided to break out the polish and clean up a few years of crap around the panel edges LOL

I used g3 machine polish as it seems Peugeot only based up the engine bay so all the muck and grime over the years seemed to stick into the paint, this will also be why the car has rusty bits here and there Sad





I then set about fitting and mounting up the oil cooler and all the pipe work, once i had removed the power steering pipes the brackets that used to hold the pipes flipped upside down where perfect for holding the oil coolerLOL



As you can see the intercooler was fitted as a trial and was wedged in place, after a walk around the garage scratching my balls, i came across a couple of inlet manifold brackets and these slightly bent fitted well and looked perfect-




Well with the intercooler mounted and secured in place all i have left to do is the cooling fans (which are on order) and get all the pipe work made up.

Spoke to a local chap today and i have the car booked in on friday for the pipes so by the weekend i should have a fun toy Cool

I am really impressed with the kit and i have decided that Rich is one very clever chap, everything you need is done in detail and its very easy to assemble, no real specialist tools are needed too. A real work of art.

Just cant wait to get it on the road!!!

Will take some finished pictures when its all back together and the engine bay has been cleaned, its a bit dirty now, mainly power steering fluid, think i tripped and split it on the resevoir instead of in it!!

Today the cooling fans turned up to my suprise so i removed the intercooler and set about putting these together, being a rallye the car only has one single fan but as the engine is being worked that little harder i decided to fit a pair and wire them together-



Then once they were fitted i reinstalled the intercooler-



Tested out the fans by bridging the contacts and all was good, then set about putting the front grill on to see if it would all line up and hey presto, you would never know-



Then test fitted the bumper, its just slid on-



The only thing you notice thats a little different is thisLOL-




The car is now stuck back in the corner untill i can get the pipe work sorted next to its little brother the 205-




Thats it for now, just the pipe work left.
Thanks for taking the time to read all my babble.



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 20th Oct 2010 at 20:01
SteviePut

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Location: Down south

Registered: 20 Oct 2005

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Post #2
Good progress CarlWink Laugh my ass off

________________________________________

My old man wrote me a letter from prison once. It said if you don't want to end up in here, stay away from crime, women and drugs. Trouble is, that don't leave you much else to do, does it?
Posted 30th May 2008 at 00:33
petegti6

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Location: Solihull & Market Harborough

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Post #3
SteviePut wrote:
Good progress CarlWink Laugh my ass off


LOL

Are you building a low comp engine for it or going for the lower boost conversion.

Should be mint anyway Smile

________________________________________

Cress87 wrote:
This place is getting beyond a joke. There's been an enormous influx of bellends signing up recently


Team 205 1.9 GTi

Team: Hmm™
Posted 30th May 2008 at 00:37
SteviePut

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Post #4
It's the low boost version IIRC

________________________________________

My old man wrote me a letter from prison once. It said if you don't want to end up in here, stay away from crime, women and drugs. Trouble is, that don't leave you much else to do, does it?
Posted 30th May 2008 at 00:40
rich-6

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Location: Bottoming out!

Registered: 06 May 2007

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Post #5
mechanical_repairs wrote:
Well thats it so far



Laugh my ass off Start reading and thinking this is good Hmm then the next line that appears.

________________________________________

Cool

RIP Pete Sims
Posted 30th May 2008 at 00:41
lotek

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Location: Berkshire

Registered: 04 Dec 2007

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Post #6
how hard would it be for a average person to do this conversion?

ive toyed with the idea , even thort about using a different charger to bring costs down, also im to immature for 400bhp haha.

but the main thing is would i be competant enough to undertake it?

is there like a installation guide with pics /diagrams etc ,on the net anywhere, so i can gauge how much work there really is and if id be happy to do it???
Posted 30th May 2008 at 00:41
rich-6

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Post #7
It depends how confident you feel about doing it, I'd have a go, however i wouldnt feel up to stripping the engine down to go for the high boost conversion

________________________________________

Cool

RIP Pete Sims
Posted 30th May 2008 at 00:43
khj100

Senior User

Location: York

Registered: 30 Mar 2003

Posts: 11,171

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Post #8
Rich supplies a really good fitting guide with all the information you need.

________________________________________

Trackday, trackday, trackday Hyper
Posted 30th May 2008 at 00:45
lotek

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Post #9
so Realisticaly what parts would i need?? and what would i have to do to go for the low boost??


Posted 30th May 2008 at 00:45
mechanical_repairs

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Location: leicester

Registered: 10 Jan 2005

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Post #10
Its only a low boost one for now as i want to get to grips with it that way for now, although being in Rich w's did make me think!


There will be a load more pics tomorrow, sorry guys/gals.

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 30th May 2008 at 00:46
gazzerdaman

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Post #11
Low Boost Kit would be

-Rich's Kit
-Rotrex Charger
-Intercooler & Pipes

You could not use Rich's kit if you wanted to use a different supercharger

________________________________________

Gary

Cherry Red GTi 6
Posted 30th May 2008 at 00:47
khj100

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Location: York

Registered: 30 Mar 2003

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Post #12
Have a read of Rich's threads on what's contained in the kit - plenty of info out there. At very least, can we keep this off Carl's progress thread Thumbs up

________________________________________

Trackday, trackday, trackday Hyper
Posted 30th May 2008 at 00:52
lotek

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Post #13
khj100 wrote:
Have a read of Rich's threads on what's contained in the kit - plenty of info out there. At very least, can we keep this off Carl's progress thread Thumbs up




agreed, sorry guys....Wink
Posted 30th May 2008 at 00:55
chris_306gti6!

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Location: Truro

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Post #14
good luck carl - when do you plan to have it done by?

hopefully i'll have mine done by next weekend
Posted 30th May 2008 at 15:59
supertwisted

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Post #15
Looks good Carl, I'll follow this thread with interest.

By the way, you've spilt oil on your carpet. Smile

________________________________________

Bianca White 306 Rallye - with Limited Edition detachable door handle.
Posted 30th May 2008 at 18:03
rich_w

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Post #16
Loving your powder coating these days aren't you Laugh

Good effort on removing the 'LYNX POWER' from the manifold though Whistle

Just pull your finger out and get it done Thumbs up


BTW, mines running properly now, was the external fuel pump beginning to fail, it's back on form now Devil

Shame I couldn't take peeps out when it was running right Sad

________________________________________

Contact Details:

rich@lynxpowerengineering.co.uk
07732 822546

Posted 30th May 2008 at 18:14
millic333

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Post #17

Was a real shame Rich - would have loved to have gone in it.

Maybe the next one if you can make it!

________________________________________

sharland wrote:
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CARL.
Posted 30th May 2008 at 18:34
justinaccurate

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Post #18
Haha carl - powder coating it before you've fitted it and know its all working

Tart! Razz

I expect to see this finished tomorrow knowing the speed you do normal jobs Wink
Posted 30th May 2008 at 18:34
mechanical_repairs

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Location: leicester

Registered: 10 Jan 2005

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Post #19
justinaccurate wrote:
Haha carl - powder coating it before you've fitted it and know its all working

Tart! Razz

I expect to see this finished tomorrow knowing the speed you do normal jobs Wink


Well i have had a good day on it today, all thats left now is the intercooler and getting the pipe work done.

Have to say the kit feels like a bolt on that Peugeot made themselves, it is spot on.


The above to be continued, have other matters on the go at the minute.
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 31st May 2008 at 00:56
chris with a pug

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Post #20
I was thinking about getting my bracket powder coated but rich said not a great idea as it goes soft when hot and comes loose
Posted 31st May 2008 at 01:07
mechanical_repairs

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Location: leicester

Registered: 10 Jan 2005

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Post #21
chris with a pug wrote:
I was thinking about getting my bracket powder coated but rich said not a great idea as it goes soft when hot and comes loose



Well we shall see, lets hope not LOL


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 31st May 2008 at 01:26
chris_306gti6!

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Location: Truro

Registered: 24 Sep 2006

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Post #22
good progress carl. should a really nice rapid motor
Posted 31st May 2008 at 01:27
mechanical_repairs

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Location: leicester

Registered: 10 Jan 2005

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Post #23
rich_w wrote:
Loving your powder coating these days aren't you Laugh

Good effort on removing the 'LYNX POWER' from the manifold though Whistle

Just pull your finger out and get it done Thumbs up


BTW, mines running properly now, was the external fuel pump beginning to fail, it's back on form now Devil

Shame I couldn't take peeps out when it was running right Sad


Yours is an animal and i am glad you got it running right now, cars when they arnt performing as hey should are a pain in the ass esp when you have put so much time and effort in like you have.

Love the kit mate its a perfect fit and goes together so well.

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 31st May 2008 at 01:58
stu

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Location: Milton Keynes

Registered: 22 Aug 2006

Posts: 5,525

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Post #24
Good work Carl! Thumbs up

Love reading threads like these. Smile
Posted 31st May 2008 at 23:07
chris_306gti6!

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Location: Truro

Registered: 24 Sep 2006

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Post #25
anything else been done today?
Posted 31st May 2008 at 23:23

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