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Clio Clio 197 with forged Megane r26 engine
- Thread starter stephenvenning
- Start date
DaveL485
Staff member
My Dad is a footballist, so we never really did the car/DIY thing. Luckily I learned a lot of bits and bobs and some common sense from my Grandad who was a Draughtsman and engineer which was enough to set me on the "Learn by your mistakes" course...that explains some of the scars and close escapes haha 
stephenvenning
Well-Known Member
Very handy having such a knowledgable dad, but I achieved all this pretty much on my own.
Did some final contouring today and then polished the surface.
Did some final contouring today and then polished the surface.
stephenvenning
Well-Known Member
Thanks mate
stephenvenning
Well-Known Member
Blended it with 400 grit paper and then 600 grit. Then used autosol and a cloth to polish it. Yeah it is, would make a great desk ornament!
DaveL485
Staff member
Actual elbow grease? I bet you have forearms like Quagmire after he discovered internet smut
Norwich Nick
Well-Known Member
Forearms like @TNT!hammondActual elbow grease? I bet you have forearms like Quagmire after he discovered internet smut
Any progress @stephenvenning ?
stephenvenning
Well-Known Member
Actual elbow grease? I bet you have forearms like Quagmire after he discovered internet smut
I just put it in the lathe and held a rag and the polish on it, no elbow grease needed
stephenvenning
Well-Known Member
A little bit of progress, I'll update this soon with more pictures. It's mainly gearbox bits at the moment.
stephenvenning
Well-Known Member
UPDATE:
I havent updated this in a while due to being very busy with the engine and getting ready for the conversion.
First on my list was to get the turbo finished and get the hot side machined for the larger HL turbine wheel. The was done the same as the compressor was machined. The radius was measured and was 7mm, a tool was then made up. The housing was fixed into a 4 jaw lathe chuck with the fixture Ive made. It was then "clocked" to ensure the centre of the hole was lined up with the centre of rotation of the lathe within 0.01mm. The hole was then opened up to 46.9mm allowing 1.2mm total clearance. The inducer hole was then machined to 52.4mm. Now using the radius tool I slowly cut the contour, much harder this time than on the compressor housing due to the turbine housing being made out of much harder cast iron. Once the desired contour was achieved it was blended with sand paper like before.
The turbo is now pretty much done, just need to weld the inlet pipe on, spray it black and assemble it.
I had a big parts order also this week, Ive ordered an 60mm core intercooler, quaife ATB LSD, forge boost pipes, scorpion 3 inch downpipe, milltek centre section, engine service parts, ARP head stud kit, helix stage 3 clutch and cover and a billet lightened flywheel. Ill also be ordering all the fuel system next week.
One thing that has been playing on my mind is the hassle of sending my block out for machining and getting all the clearances right then assebling it to correct spec. I could do it but I dont really have the time considering the car is coming off the road at the end of the month. Therefore Ive sent the block off for assembly at engine dynamics. The specs will be as following:
Kings racing bearings
ZRP h beam rods
wossner pistons
ARP cap bolts
New oil pump
New oil squirters
Blueprinted and balanced crank.
Should hopefully get it back in 2-3 weeks. Then I can assemble the whole engine
Finally Ive now installed all the bearings and seals into the gearbox casings, just need to gearbox internals to arrive back from shot peening and I can finish the gearbox.
Pictures as always:
Thanks guys
I havent updated this in a while due to being very busy with the engine and getting ready for the conversion.
First on my list was to get the turbo finished and get the hot side machined for the larger HL turbine wheel. The was done the same as the compressor was machined. The radius was measured and was 7mm, a tool was then made up. The housing was fixed into a 4 jaw lathe chuck with the fixture Ive made. It was then "clocked" to ensure the centre of the hole was lined up with the centre of rotation of the lathe within 0.01mm. The hole was then opened up to 46.9mm allowing 1.2mm total clearance. The inducer hole was then machined to 52.4mm. Now using the radius tool I slowly cut the contour, much harder this time than on the compressor housing due to the turbine housing being made out of much harder cast iron. Once the desired contour was achieved it was blended with sand paper like before.
The turbo is now pretty much done, just need to weld the inlet pipe on, spray it black and assemble it.
I had a big parts order also this week, Ive ordered an 60mm core intercooler, quaife ATB LSD, forge boost pipes, scorpion 3 inch downpipe, milltek centre section, engine service parts, ARP head stud kit, helix stage 3 clutch and cover and a billet lightened flywheel. Ill also be ordering all the fuel system next week.
One thing that has been playing on my mind is the hassle of sending my block out for machining and getting all the clearances right then assebling it to correct spec. I could do it but I dont really have the time considering the car is coming off the road at the end of the month. Therefore Ive sent the block off for assembly at engine dynamics. The specs will be as following:
Kings racing bearings
ZRP h beam rods
wossner pistons
ARP cap bolts
New oil pump
New oil squirters
Blueprinted and balanced crank.
Should hopefully get it back in 2-3 weeks. Then I can assemble the whole engine
Finally Ive now installed all the bearings and seals into the gearbox casings, just need to gearbox internals to arrive back from shot peening and I can finish the gearbox.
Pictures as always:
Thanks guys
Looks very well done as usual @stephenvenning
Awesome @stephenvenning 
stephenvenning
Well-Known Member
Thats a hefty purchasing week haha
Yeah I know, fuelling system has been ordered now too lol should be soon, probs be a week or so until I get the parts back from shotpeening
stephenvenning
Well-Known Member
UPDATE:
Right Turbo is now finished! On Monday I welded the outlet pipe back on the compressor housing and painted it in high temperature black paint. The turbo was then assembled, the Actuator was painted in the same gun metal colour the rocker cover is in. Really pleased with how it looks, it spins freely and should produce around 2 BAR boost t around 380hp with supporting mods.
Also Ive oredered the fuel system, Ive gone with a fuel labs swirl pot, bosch 044 pump and sytec regulator, with all teflon braided lines and torques compression fittings. They should have been here wednesday but Demon Tweeks are being a pain :/ Also had some DEI titanium heat wrap coming so I can wrap the downpipe to keep temps down a little.
Gearbox parts will be here next week, cant wait to get the box assembled!
Thanks as always
Right Turbo is now finished! On Monday I welded the outlet pipe back on the compressor housing and painted it in high temperature black paint. The turbo was then assembled, the Actuator was painted in the same gun metal colour the rocker cover is in. Really pleased with how it looks, it spins freely and should produce around 2 BAR boost t around 380hp with supporting mods.
Also Ive oredered the fuel system, Ive gone with a fuel labs swirl pot, bosch 044 pump and sytec regulator, with all teflon braided lines and torques compression fittings. They should have been here wednesday but Demon Tweeks are being a pain :/ Also had some DEI titanium heat wrap coming so I can wrap the downpipe to keep temps down a little.
Gearbox parts will be here next week, cant wait to get the box assembled!
Thanks as always
stephenvenning
Well-Known Member
Thanks mate, yeah it is very satisfying, just hope it all works now lol
stephenvenning
Well-Known Member
UPDATE:
Right the car is off the road! Insurance ran out on Saturday, had a great blast out for my last NA drive in the clio, it was then parked up and is looking very sorry for itself. Today I began stripping out the interior so I can access the fuel pump sender easily and do a nice fuel system boot install. Next problem is how I go about getting the sender out so I can plumb a return line in, do I cut the hole bigger but this is pretty dodgy as sparks and fuel don't normally mix
this then leaves me with the option of having to bite the bullet and drop the tank out, a ball ache of a job without a ramp. Decisions, decisions....
Anyway this is all stuff that can be sorted later.
With all the exhaust system bought i.e downpipe and megane centre section I began wrapping the downpipe in DEI titanium heat wrap. If i do say so myself it didnt turn out too bad for a first go, the missus was on hand to do the zip ties up while I held the wrap tight
hopefully this will keep temps down. Also shot blasted the exhaust manifold and sprayed in very high temp DEI paint.
I pick the engine block up Tuesday from Engine Dynamics, then Ill get the engine built and then Ill take the engine out of the clio and while thats out Ill polybush the front and sort out suspension and fix the knocking steering rack. Lots to do..
Pics as always:
Thanks as always.
Right the car is off the road! Insurance ran out on Saturday, had a great blast out for my last NA drive in the clio, it was then parked up and is looking very sorry for itself. Today I began stripping out the interior so I can access the fuel pump sender easily and do a nice fuel system boot install. Next problem is how I go about getting the sender out so I can plumb a return line in, do I cut the hole bigger but this is pretty dodgy as sparks and fuel don't normally mix
this then leaves me with the option of having to bite the bullet and drop the tank out, a ball ache of a job without a ramp. Decisions, decisions....Anyway this is all stuff that can be sorted later.
With all the exhaust system bought i.e downpipe and megane centre section I began wrapping the downpipe in DEI titanium heat wrap. If i do say so myself it didnt turn out too bad for a first go, the missus was on hand to do the zip ties up while I held the wrap tight
hopefully this will keep temps down. Also shot blasted the exhaust manifold and sprayed in very high temp DEI paint.I pick the engine block up Tuesday from Engine Dynamics, then Ill get the engine built and then Ill take the engine out of the clio and while thats out Ill polybush the front and sort out suspension and fix the knocking steering rack. Lots to do..
Pics as always:
Thanks as always.
