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5 GT Turbo my mid engined, rwd, cossie powered GTT updated 27/5

stu21t

Active Member
well I thought I would start a thread on here.
bear with me as these post are all copied from another site...


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engine
2litre 16v 2wd sierra cosworth engine
t3 turbo
bosch 803 injectors
21 psi boost
grp a coil
grp a regulater
grp a headgasket
4x4 inlet manifold
vernier pulleys
huge pace ally radiator
ally swirl pot
ally header tank
2 fans running 2 stage switch + override
2 charge coolers, 2 pumps, 2 swirlpots
huge pace ally pre rad
ally grp a oil breather system
bosch 044 fuel pump
-6 fuel lines and fittings
pro alloy foam filled fuel tank
un1 gearbox
ap cossie/reno clutch
oil cooler
level 8 management
running approx 340 bhp lb/ft


chassis
ford rs200 rear spaceframe
engine/suspension all bolted to cradle
full welded in roll cage tagged to body everywhere and to space frame
std r5 front end upto where rear seat used to start in floor


rear suspension
rs 200 setup inc.
4 coilovers
double wishbones
tie bars
race polybushes
2wd cossie hubs
all adjustable in every direction


front suspension
avo coilovers
race polybushes
r5 hubs with ford stud adapters

brakes
ap 4 pots up front 330 mm discs
wilwood 4 pots at rear 300mm disds
group n corsa bias pedal box (adjustable in dash)
-4 braided lines throughout
hydraulic handbrake

std bodywork outside
fully stripped inside


2 corbeau revolution seats
homemade ally dash housing clocks and relays/fuses
cable gearchange
plastic windows
billet compomotive mo's (very strong (and expensive))
kerb weight under 1000kgs
probably loads ive forgotten, anything u wanna know just ask


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small update
new engine

long studded 200 block
l+b bottom end
std comp mahle pistons
high pressure oil pump
polished and ported head
bd10 exh
bd14 inlet
piper valve springs
4x4 plenum with spacer
greys
3bar
t34.63

new toys for the l8 ecu
anti lag
launch control
wasted spark

wideband lambda and gauge

repainted all the insides in matt black cleaned up lots of untidy stuff
doubled up all the panels around the engine filled them with insulation
heat matted all the panels, floor, baulkhead

new alloy floor pan with louvre vents to cool rad pipes running through old exhaust tunnel

alloy door cards matt black

tidied up all the old engine bay

will have lots of pics once its back up and running.

heres a few new pics of the car in white, nothing exciting



stripping/prepping it in my garage



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how i DROVE to the paint oven

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how i DROVE it home

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going back together

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and nearly done

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when putting it back together i also fitted loads of new parts
new headlights,
new numberplate lights
new indicators
polished the plastic windows
cleaned all the rubber trims
filled/smoothed/meshed and vented the bumpers
new door cards
new front grille
polished rear lights


and a little while ago i had it on power engineerings rollers and it made
380bhp, 351lbs/ft trq @ 1.55 bar, thats 320 bhp at the wheels
the fuel pressure was causing issues so could go for more but i think ive sorted that now so should be able to up the boost to 2bar
hopefully be around 400 bhp
will post specs and a graph once ive sorted it and done a new RR session

im getting there
 
got bored and had a spare 1/2 hour so spur of the moment i painted the wheels black.

take the wheels off,
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get a few bits out of the garage,
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rubbed down
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mist coated
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all painted
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and back on the car
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much better
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then though it would be rude not to take a pic of 3 of my toys on the drive.

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update,
as it now sits in my garage

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the engines back out,
just for some cleaning, painting, rewiring.
i cant afford the stuff i wanted to do to it, due to some jobs cancelling on me in these shitty times.

i need a new waterpump as this ones packed up,
gunna get a std exhaust cam for it,
and some general tidying up.
so nothing exciting really.

not exactly much room to work,
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__________________
 
tonights progress
engine totaly pulled out,
stripped loads of bits off the engine ready for cleaning/replacing

exhaust manifold off to be ceramic coated,
new waterpump,
new cam,

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pics arent great cos taken off my phone and no flash.
 

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how it sits now.

just before the start of show seaon and the fun that comes with it and ive stripped it to the bones. lol

gearbox is out to be stripped, inspected, cleaned and repainted.
rear suspension is off for a cleanup
drive shafts need cv joints repacking and cleaning then paint


ive also done some more welding and paneling to the engine covers to seal it better, and done a load of cleaning/painting already.

hopefully i will get it back together soon, its booked to go on a stand at the rsoc central day in the middle of april so i better get a move on.
__________________
 
YEA BOY
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engines back in.

after a full strip/rebuild/paint of the whole back end, inc. suspension, gearbox, engine its finally going back together

got a few more bits to do/order then its ready for the rollers again.
passionford.com_forum_images_smilies_icon_biggrin.gifpassionford.com_forum_images_smilies_icon_biggrin.gifpassionford.com_forum_images_smilies_icon_biggrin.gif
__________________
 
bad new peeps.
i got the car running on sunday
got it all back together on monday and went for a test drive on tuesday and it broke. lol

the cam cover gasket blew between the cams and spark plugs resulting in this
img.photobucket.com_albums_v313_stu21t_IMG_0518.webp

the oil ran out of the fronnt and back breather holes of the cam cover, and onto the cambelt and flywheel
meaning the whole fucking thing is now dripping in oil.

and then i lost all gears, it popped out of reverse while i was parking and then i couldnt get any gears.
im hoping the oil has caused the clutch to stick to the flywheel.


lets hope i can get it back together quick enough to get it mot'd on saturday for central day on sunday


other than that it was ok.

some more update pics:
under floor panel with vents for cooling
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gearbox stripped
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rebuilt
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__________________
 
just came in for dinner so thought id do an update. lol
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its all cleaned up,
i just used blue paper towel, and once it was as clean as i could get it i kept diluting it with degreaser till it was all gone.

jimbo, thanks for the offer but i have 1 on its way to me, should be here tomorow.


and



img.photobucket.com_albums_v313_stu21t_IMG_0524.webp


ive taken the clutch out already. lol
it looks quite clean but im gunna give it a clean up anyway and start to put it back together now.
i WILL make it on sunday. lol
 
thats me done for the night
found a few problems.
the spline on the clutch centre plate was all burred up, so i had to file that down so it was all clean.

also i have a small metal adaptor that goes in the back of the crank where the pilot bearing goes, that adapts the renault un1 box to fit.
that had clearance probs so ive grinded that down for more room.

then sanded and cleaned the clutch cover, plate and flywheel.

now the clutch and box are all back in and bolted up.

tomorow i will get the hydraulics back in and bled, exhaust back on, and as long as the gasket turns up i will do the camcover and get it back out for another test drive
 
update,
the reason i missed central day,
the clutch centre plate popped off the gearbox splines and rounded off the teeth on the plate, meaning i had a spinning engine and clutch but not gearbox.
im not too sure why this happened, i know my input shaft isnt aslong as a std cossie 1 but its been ok up until now,

so i have sent the paddle back to ap, via an authorised dealer passionford.com_forum_images_smilies_icon_rolleyes.gif (wont let me send it back direct)
and its getting a new spline/hub, hopefully with a spline that sticks out more into the box.

while its out ive taken my flywheel and cover plate to be skimmed, so when it comes back i will have a brand new clutch setup,
also getting a spare clutch master cylinder sleeved down from 28mm to 22mm, this should give me more throw at the release bearing, and a lighter pedal.
and for some reason i had 2 3mm plates between the engine and gearbox, to give the release bearing a bit of space to release, but i will be removing them to bring the box closer to the engine. this will help with disengagement and also give me more spline contact.
hopefully will get this all done in a couple of weeks ready to tax it at the start of may.
_________________

another bad update

after sending off the centre plate over a week ago.
ive now been told that ap wont repair it passionford.com_forum_images_smilies_wall.gif even tho when i rang and asked they told me they could passionford.com_forum_images_smilies_wall.gif
they want to sell me a new 1 @£200, and that could fail like this 1 did.
im now in talks with helix to see if they can make me a new 6 paddle centre plate with an extended spline.

also the man who was supposed to skim the flywheel and cover plate, hasnt, because he is very busy.

so for now i have got them back and put it all back together with the std centre plate i had in the car first time round, which is still in good condition.
i got as far as assembling everything and got it all back up and running, last night, but i need to bleed the clutch.
thats WAS gunna be tonights job.

but
at work today i was barrowing concrete from the street up the drive, round the back to concrete a patio slab.
and at 1 point the scaffold board i was on gave way, and i went over on my ankle, hurt like hell and is all swollen, problem is i had to finish the job, so i carried on working barrowing concrete for over an hour, then had to level the footings and clean/tidy up.
since i got home its been on ice, strapped up, i cant even put any weight on it.

so no clutch bleeding or test driving tonight. lol
 
well update
i had today off cos of my fucked ankle,
so when i got bored of resting my foot, i went in the garage and bled the clutch and adjusted the pedal.
it worked passionford.com_forum_images_smilies_icon_biggrin.gif
so i drove out of the garage and washed the car, but my foots not well enough to dare driving it properly.
lets hope tomorows ok, then i can test drive it and tax it.
i hope the clutch holds

YEA BABY
just got 1 of these

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so now road legal(ish) lol for 6 months

also ordered an itg foam air filter and some hoses/ducting so will have an air filter for the 1st time ever. lol

have also done some more drilling of the rear bumper to let more heat out, its a bit less subtle but should heat getting the temp down.

still waiting on my new clutch slave to but have been told i might get it at the end of the week.

im off for a little drive as ive got tax. lol
 
well i bought a new ITG filter, its huge, with a 102mm outlet on it, and some nice new hoses
and fitted some more underbody cooling vents.


AND......

ive stripped the turbo. lol
1 step forwards...2 steps back.

ive always had a low boost problem on the car, as in i cant get any high boost.
it was spiking at 1.5ish and dropping back to 1.2ish bar.

turns out my wastegate penny was warped, the shaft had play in it to so the penny was only sealing about 20%

so ive stripped it all apart and am going to see if i can get the new parts to repair it myself.
then should have 2 bar boost and less lag.

should make for a more fun drive then. lol
 
well, a little update.

i fitted a new wastegate assembly to the .63 housing and
OH MY GODpassionford.com_forum_images_smilies_icon_biggrin.gif

its a whole new car.
i now get an almost instant 2.2bar boost spike and holding 2bar almost to the limiter passionford.com_forum_images_smilies_icon_biggrin.gif
it is soo lively its nuts.

last year with a laggy 1.5bar spike 1.2ish held, i got wheel spin in 1st gear, none in 2nd.
now i can face the pavement in 3rd. lmao its great.

only thing now is the clutch is slipping, so i need to get a new spline fitted to replace the damaged 1 in my ap6 paddle, and get that back in the car.
even with a slipping clutch i took my m8 out and scared the shit out of him, and hes been in it before.
with the anti lag on its an animal through the bends.

and a couple of silly pics i took yesterday before i went out.

extra vents in the rear bumper...
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massive itg filter with 100mm pipework, dropping to 70 at the turbo
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vents in the floor... now got 4 4"by2" and 2 6"by2" forward facing vents, some with hoses to direct the air around the engine
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and my new favourite addition
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speaker covers. hopefully will fool passers by and other motorists passionford.com_forum_images_smilies_bigcry.gif
 
cheers guys.
as ever im having more issues with it.

untold amounts of clutch problems, but i think i can see the light at the end of the tunnel now.
bot 2 centre plates to chose from, and need a new master, then hopefully will have the clutch troubles sorted.


the charge coolers are out, ive tested them and 1 has a leak. its been filling the water side with 2 bar of boost, so thats being sent off for repair.

and the gearbox is out and strippped.
im getting some teeth removed from the synchros to make it change gear better at high revs.

when it comes back it should be a lot better.
i will also fit some bonnet vents, prob, erst ones, and use bonnet pins to raise the back of the bonnet to help get more air flow through the rads at the front, should help a little with charge temps
 
well after a year of sitting in my garage on axle stands with no gearbox, i finally got round to sorting the car out passionford.com_forum_images_smilies_icon_mrgreen.gif
its all back together with a rebuilt box with some new mods
other than that its the same as before
and it only has 1 charge cooler now so will have to turn the boost down so charge temps are low enough.
but at least its working again.

im going for an mot tomorrow which hopefully it WILL pass,
then i can tax it tomorrow or Monday
passionford.com_forum_images_smilies_smile011.gif
Of course lol
Mot'd at lunch, came home and gave it a wash, put some bonnet pins on the back of the bonnet to raise it 2" to help let heat out.
So far it all seems ok
BUT with just 1 charge cooler and only runnin 0.7bar it gets up to 50 degrees inlet temps, so i cant turn the boost up any more. passionford.com_forum_images_smilies_bigcry.gif
Got a few bits to do tomorrow to tidy it up. But it is useable again
passionford.com_forum_images_smilies_smile011.gif
well a small boring update....
the cars back on its feet for the first time in ages.
its on its 4/5/6th gearbox, i cant remember which. lol

basically i was having trouble in selecting 2nd gear at high revs, i tried a few different things to sort it but couldnt.
i eventually gave in and decided to sent it to a pro.

i sent it to mach1transmissions who has been specialising in un1 gearboxes for kit cars for years.

he stripped it and said he couldnt find anything physically wrong. (which is good and bad news cos it means i didnt fuck up the build, but bad cos we dont know how to fix it properly lol)

i sent him 3 boxes to build the best one out of the lot.
it now has a new diff with a different ratio giving me longer gears, new synchro hub for 1/2, new stronger synchros springs 1/2, blah blah blah...

its all back in the car now and i will be test drving it tomorrow.
im still only running 10psi at the mo until i can sort a charge cooler
but at least its heading in the right direction.

shame the tax runs out on monday lol
small video clip of my 5 all back together.


http://www.youtube.com/watch?v=2oMe2aHEWmI


the 2 switches with the red label underneath are ANTILAG and LAUNCH CONTROL passionford.com_forum_images_smilies_smile011.gifpassionford.com_forum_images_smilies_smile011.gifpassionford.com_forum_images_smilies_smile011.gif
love them switches.


will get a proper vid one sunny day with a decent camera instead of my phone. and will get some of it on the move and with the switches on. lol
__________________
 
right time for a funny update

i had cut some 4" round holes in the bootlid (behind the number plate so as not to be seen) and engine covers to let some more heat out
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i decided to change it a little so i marked out the numberplate and cut out a large rectangle hole slightly smaller than the plate

img.photobucket.com_albums_v313_stu21t_6608c1a7.webp

did the same in the engine covers

img.photobucket.com_albums_v313_stu21t_53354829.webp

got some ally sheeting (an old door card id run over lol)

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cut a strip out of it and folded it to the size of the hole i cut out

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bent a lip round the edge

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then slotted it in the hole like a letter box lol

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then i got some 22mm copper plumbing fittings (end feed end caps) cut them down a bit and cut a short bit of pipe so i could solder it all together to make some spacers
then attatched a piano hinge to the spacers
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spacers and piano hinge fitted to bootlid

img.photobucket.com_albums_v313_stu21t_06bbc6f6.webp

then fitted the plate to the hinge lol
now the rear plate is covering the hole and has a space at the top to let heat out at stand still and low speeds and can open fully to let more heat out as i go faster lol

i might attach a spring to the base of the plate so i can control what speed it opens at, or have it fixed shut or wedged open for off road driving lol
img.photobucket.com_albums_v313_stu21t_bde70037.webp

partly open

img.photobucket.com_albums_v313_stu21t_8f425216.webp

and fully open lol
img.photobucket.com_albums_v313_stu21t_07b910ee.webp

the metal box that goes through the bootlid has got a rubber gasket on it and seals against the engine covers so it doesnt let fumes into the car


added bit of comedy value to i think lol

all of its a bit agricultural but i use the tools/materials avainlable to me. and it works lol. looks better now its all tidy and painted
the pics were taken more at the mock up stage lol
 
went for a long test drive last night.
everything seems good passionford.com_forum_images_smilies_icon_mrgreen.gif
did a few standing starts and although im only running 10psi so no power lol it changes into 2nd the best it has for a long time.
so all seems good.

one thing i did notice tho is that now ive got the rear suspension working properly the front seems quite bouncy, and there seems to be a lot of body roll.
i need to work out what spring ratings i should be running. any1 got any ideas?

actually yes
ive bought a new charge cooler, pump and pipework
ive got an AH fabrications cooler, 25mm pipework and a davies craig engine water pump.

old pump/pipe vs new pump/pipe
img.photobucket.com_albums_v313_stu21t_9d30b8c4.webp

new cooler
img.photobucket.com_albums_v313_stu21t_a9e4907f.webp

img.photobucket.com_albums_v313_stu21t_7bc9bf3c.webp

its in temporarily so i can test it will work ok.
then it will be off for new end tanks and inlets
i will then make some heatshields out of nimbus g2, heatwrap the manifold and exhaust again and get a turbo jacket for it.

then im back to 2 bar passionford.com_forum_images_smilies_icon_biggrin.gif
 
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