Peugeot 205 GTI 8v track/sprint car
Posted: January 20th, 2008, 10:07 pm
Here is my blog of my route to perfection. I have copied al lthe recent additions from another forum..in the future i'll update this thread as per the other forums. It would be great to get advice/comments from a different community. I'm no expert, learning all the time, and appreciate constructive feedback..
I have provided a background to the car itself and latest engine build previously on this site, here's the link
mid dec/07:
I picked up the car from des-developments friday night and the following has been done recently:
1 - Trumpets fabricated to accept injectors (going 8 injectors very soon)
2 - New airbox for better increased space at front of car, with side feed
3 - Minor Oil leak sorted
4 - Fit new OE fuel pump - new pump delivers much more fuel as a result..worth knowing for other peeps!
5 - Exhaust tested to get to the bottom of the mysterious mid range torque dips - outcome was Des-d Group n (v2) system performs better that peugeot sport and standard system, and is not the cause of the dips.
The exhaust manifold was then highlighted as the only possible reason for the dips. Several long telephone conversations with longmans and ab motorsport led to some interesting information regarding the longmans/maniflow manifolds, turns out there is 3 systems on offer:
1 - road car oriented with crude length primaries (the one I currently have) - apprently only good for 160 bhp according to ab motorsport, but with a race cam i've seen 204 bhp on my car. Costs roughly £200
2 - track/rally oriented version with semi equal headers. Costs roughly £270
3 - race oriented version, not off the shelf version, equal length headers and design optimised by longmans on the dyno. Only available directly from longmans and costs £460. So i ordered on of these before xmas, expect it to arrive mid jan.
The 2 weeks will be rather busy, I have the following jobs on:
Make a new dash
Wrap the new airbox with cool-it or similar heat protection
Fit a cold Air Feed
Lower rad a smidge
Fit colin satchell trumpet spacers
Fit spa-design mirrors i've had for so long i can't remember
spec a dta loom to be made
fit a DTA s40
Here are the pics of the new airbox
24/12/07:
made progress on wiring in the new oil pressure sender today to feed the new gauge.
I learnt a lot recently regarding how todo things properly, and not use the cheap halfords type bullet connectors. So here are some pics of my handy work:
stripped wire:
heatseal pre-insulated terminals (heat shrinkable with water proof adhesive):
End crimpted with a decent insulated crimping tool:
End heated, and placing braided sleeving underneath the seal for that professional look:
Some heatshrink to finish it off:
Both ends finished:
That will certainly do the job :D
Old and new senders
Also here are some pics of the fabricated trumpets to accept a set of outer injectors, ready for my 8 injector setup:
26/12/07:
today I started to test the fitment of the new airbox with the colin satchell spacers i've had for ages
here I have trial fitted 2 sets to extend the inlet tract by 60mm
Started to sort out the crappy wiring. I'll have a new engine management loom soon, so might as well tidy up the other wiring too while I have the time, and now the tools.
The starter/alternator area was looking rather sorry for itself, here are some before and after pics:
before:
After:
Here was the earthing and fan control area before and after:
After (blocks removed, cut lenghs and sealed connectors):
Last update of today..this time regarding the trumpet spacers I bought ages ago. With the new airbox and manifold specifically built and altered to allow the inlet tract length to be lenghened, it was time to see how many spacers I can indeed run..
First I tried 3 x 20mm spacers
I've trial fitted only 2 sets out of 4..
Then tried the bonnet on..
oh dear, the bonnet is clearly being help up meaning they are too high..unacceptable!
So I took 1 of the 20mm spacers off to see if that helped..
Looked ok from the side..
And with the bonnet on...
Looked good, definitely not touching. So I used some playdo to see how much clearance there was..
About 20mm i'd giess from this:
So I think i'll settle with just the 4 spacers, which will give me an inlet tract length increase from roughly 320mm to 360mm
Next i'll start to work out what size filter I can get away with
27/12/07:
Started working on the new dash today.
Buy one of these:
Decide it's still too bulky, so remove the top and integrate with the ABC carbon sheet to create this:
Here's the surround painted and in place (temporary)
I'll add the oil and water temp gauges tomorrow and the new warning lights:
Sean
I finished off cutting the new dash today.
Here's what the finished product looks like:
I have to replace the hazard light with a generic orange lamp for low fuel, and then wire the inappropriate in
Accurate readings here we come..
wired up to test...
here's a pic and video of the new dash in action:
VIDEO (2mb)
The rev counter I think is reading double the real revs currently, will look into it tomorrow
As I now know all the wiring I need for my new dash, therefore I know what is surplus to requirement. So I've removed all the tape from the looms and am currently removing the old stuff. Plenty coming out..good weight reduction and fuse board simplification :D
Some new parts arrived today.
Cool-it thermal barrier for the new airbox:
More fuel hose and fittings to go from 4 to 8 injectors:
Cool It Thermo Tec heat barrier covered airbox. Should help keep temps down..
My long awaited filter arrived today.
It had to be large enough not to be restrictive, be small enough to actually fit, and be angled to aid fitting. It took a while but I managed to find one that fitted the bill.
Here it is:
might have to cut some more from the gill to get more fresh air
Unexpectidly my longmans race manifold turned up today; wasn't expecting it for another 2 weeks.
It was one inappropriate of a jigsaw to put together but think i've got it roughly looking right.
I will now send it off to be ceramic coated and then put on before the dta mapping starts. Looks rather different than my current version :D
I have provided a background to the car itself and latest engine build previously on this site, here's the link
mid dec/07:
I picked up the car from des-developments friday night and the following has been done recently:
1 - Trumpets fabricated to accept injectors (going 8 injectors very soon)
2 - New airbox for better increased space at front of car, with side feed
3 - Minor Oil leak sorted
4 - Fit new OE fuel pump - new pump delivers much more fuel as a result..worth knowing for other peeps!
5 - Exhaust tested to get to the bottom of the mysterious mid range torque dips - outcome was Des-d Group n (v2) system performs better that peugeot sport and standard system, and is not the cause of the dips.
The exhaust manifold was then highlighted as the only possible reason for the dips. Several long telephone conversations with longmans and ab motorsport led to some interesting information regarding the longmans/maniflow manifolds, turns out there is 3 systems on offer:
1 - road car oriented with crude length primaries (the one I currently have) - apprently only good for 160 bhp according to ab motorsport, but with a race cam i've seen 204 bhp on my car. Costs roughly £200
2 - track/rally oriented version with semi equal headers. Costs roughly £270
3 - race oriented version, not off the shelf version, equal length headers and design optimised by longmans on the dyno. Only available directly from longmans and costs £460. So i ordered on of these before xmas, expect it to arrive mid jan.
The 2 weeks will be rather busy, I have the following jobs on:
Make a new dash
Wrap the new airbox with cool-it or similar heat protection
Fit a cold Air Feed
Lower rad a smidge
Fit colin satchell trumpet spacers
Fit spa-design mirrors i've had for so long i can't remember
spec a dta loom to be made
fit a DTA s40
Here are the pics of the new airbox
24/12/07:
made progress on wiring in the new oil pressure sender today to feed the new gauge.
I learnt a lot recently regarding how todo things properly, and not use the cheap halfords type bullet connectors. So here are some pics of my handy work:
stripped wire:
heatseal pre-insulated terminals (heat shrinkable with water proof adhesive):
End crimpted with a decent insulated crimping tool:
End heated, and placing braided sleeving underneath the seal for that professional look:
Some heatshrink to finish it off:
Both ends finished:
That will certainly do the job :D
Old and new senders
Also here are some pics of the fabricated trumpets to accept a set of outer injectors, ready for my 8 injector setup:
26/12/07:
today I started to test the fitment of the new airbox with the colin satchell spacers i've had for ages
here I have trial fitted 2 sets to extend the inlet tract by 60mm
Started to sort out the crappy wiring. I'll have a new engine management loom soon, so might as well tidy up the other wiring too while I have the time, and now the tools.
The starter/alternator area was looking rather sorry for itself, here are some before and after pics:
before:
After:
Here was the earthing and fan control area before and after:
After (blocks removed, cut lenghs and sealed connectors):
Last update of today..this time regarding the trumpet spacers I bought ages ago. With the new airbox and manifold specifically built and altered to allow the inlet tract length to be lenghened, it was time to see how many spacers I can indeed run..
First I tried 3 x 20mm spacers
I've trial fitted only 2 sets out of 4..
Then tried the bonnet on..
oh dear, the bonnet is clearly being help up meaning they are too high..unacceptable!
So I took 1 of the 20mm spacers off to see if that helped..
Looked ok from the side..
And with the bonnet on...
Looked good, definitely not touching. So I used some playdo to see how much clearance there was..
About 20mm i'd giess from this:
So I think i'll settle with just the 4 spacers, which will give me an inlet tract length increase from roughly 320mm to 360mm
Next i'll start to work out what size filter I can get away with
27/12/07:
Started working on the new dash today.
Buy one of these:
Decide it's still too bulky, so remove the top and integrate with the ABC carbon sheet to create this:
Here's the surround painted and in place (temporary)
I'll add the oil and water temp gauges tomorrow and the new warning lights:
Sean
I finished off cutting the new dash today.
Here's what the finished product looks like:
I have to replace the hazard light with a generic orange lamp for low fuel, and then wire the inappropriate in
Accurate readings here we come..
wired up to test...
here's a pic and video of the new dash in action:
VIDEO (2mb)
The rev counter I think is reading double the real revs currently, will look into it tomorrow
As I now know all the wiring I need for my new dash, therefore I know what is surplus to requirement. So I've removed all the tape from the looms and am currently removing the old stuff. Plenty coming out..good weight reduction and fuse board simplification :D
Some new parts arrived today.
Cool-it thermal barrier for the new airbox:
More fuel hose and fittings to go from 4 to 8 injectors:
Cool It Thermo Tec heat barrier covered airbox. Should help keep temps down..
My long awaited filter arrived today.
It had to be large enough not to be restrictive, be small enough to actually fit, and be angled to aid fitting. It took a while but I managed to find one that fitted the bill.
Here it is:
might have to cut some more from the gill to get more fresh air
Unexpectidly my longmans race manifold turned up today; wasn't expecting it for another 2 weeks.
It was one inappropriate of a jigsaw to put together but think i've got it roughly looking right.
I will now send it off to be ceramic coated and then put on before the dta mapping starts. Looks rather different than my current version :D