19 Project Turbo Shed - sponsored by Bosch PWS850-125

[andybond]

Loving your work here !

 

[DaveL485]

I regret nothing.

Good choice. You do your best work when you have a taste for it.

 

[Neal R19]

So I got the downpipe and front pipe welded up by my mate Ed:




This was done with his old MMA welder that he dragged out of a skip and is using as a scratch start TIG set.



Result is not pro level for sure but pretty good considering.





I then just MIGed the flexi up. Not quite as pretty but who cares?



Next step is to make the bracing brackets for it but that can wait until I next drop the engine out of the car.

In the end I decided to borrow the stainless system off my 16V. She's a garage queen anyway, she won't need it. Then just got a suitable flange cut from 8mm 304 and MIGed it onto the end.





Fitted to the car



Bosh!

Also connected up a clio header tank.

Megane bottom hose:



Got hold of a clio 172 bottom hose:



Chopped them both around a bit and ended up with this to give me the extra branch that goe up to the lower stub on the coolant tank:




Also connected the top stub of the tank to the thermostat housing with another hose from a clio



Just need to attach the clio tank to the bulkhead.

 

[Neal R19]

Also piped up my intercooler with alloy mandrel bends and silicon joiners



Had to ditch the washer bottle to route one of the boost pipes. Will look for a smaller one (clio again?) to fit next to the pipe or something.




Had to shorten some of them and re-swage. Homemade swaging tool:



Can't take credit for this idea, I saw it somewhere else on the net. It's INCREDIBLY laborious doing this by hand but it does work. Sped up a bit when I started using a hammer. Sped up even more when I started crushing it in the vice.

With that all done I thought fuck it, let's give it a go! Connected up the megane fuel tank sat in the back where the rear bench would be and pressed the button.

Didn't work. Fuel pump wouldn't run. Scratched my head for a while and started tracing wiring. Figured out that the fuel pump is earthed through one of the rear light clusters which obviously isn't there anymore. So I stripped back that bit of loom and re-routed that earth.

Pressed the button again:



Sweet. Only ran it for a few seconds as it has no coolant in it. Pretty major milestone but still loads to do.

 

[andybond]

Whoooo ! Its ALIVE !

 

[DaveL485]

Frightening.

In a good way.

 

[Metzy]

Just read this from start to finnish, what an awesome project :ay: for how many Scenic bits you've used you may aswell of just started with one of them but i'm glad you didn't as there's still a remote chance i may be one of the 1st if i ever get back to mine :ag:

How far are you thinking of going on loom stripping? i know the current is temporary to get it running (a good idea and where i struggled with my project years ago slimming it down from the start) but realistically its running now with a full canbus system so realistically to use the clocks and ignition etc you need everything else etc to save it having the christmas tree dashbourd, or even it causing restrictions etc

Wayne

 

[DaveL485]

**Tapping fingers impatiently**

 

[Neal R19]

Right then, been working on a few bits and bobs recently. One of those things is drivehafts.

I’m using clio 172 hubs (same as later mk1 meganes) so I need to use the outer CVs to match. Inner CVs are obviously the megane 225 ones that go with the gearbox.

Top is the megane 225 shafts (with intermediate section on the O/S shaft. Bottom is a pair of scenic dci shafts. I picked these as they use a larger 35 spline outer CV joint type. Also for some variants of megane/clio/scenic shafts replacement CVs are not available, only complete shafts. This type is available from SKF. The shaft is also a closer match to the diameter of the 225 shafts (32 spline inners)



Stripped 'em down and marked 'em up so I don't get confused. Not that there's any way I could - both outers will be identical and so will the inners, only the lengths will differ one side to the other. I HATE working with CV joints... that bloody manky grease gets everywhere.




Chopped all 4 shafts in half. Meg 225 ones are solid, mk1 megane ones are hollow.




Then trimmed and trial fitted to get the right length. Put the tripods mid-depth in the cup with the hubs jacked up to normal ride height and checked everything was OK at full suspension droop/full steering lock etc. All good.






Busted out the gasless MIG and boshed the bits together with my custom alignment jig. AKA a bit of angle iron.




Then I can send them off to get them replicated as new one piece bars. Sadly there’s no cheapskate way of making these if I want them to last more than 5 minutes. Just have to put my hand in my pocket. About £400 all in

 

[andybond]

£400. Ouch!

 

[Neal R19]

£400. Ouch!

Yeah. I was thinking since one is hollow and the other solid, I could turn the solid one down to fit inside the hollow one, weld round to join them and then drill through the sleeved section for a big feck off cotter pin (or two) and maybe weld that/them in too. But I have a feeling that wouldn't last long. Would cause mega damage when it lets go as well.

 

[Brigsy]

Maybe look at machining the shafts to the same thickness and sleeving with a tube then welding ? A coded or good welder would be able to do that no worries - not the kind of thing you can do with a cheap mig set but will be plenty strong with the right tools for the job. Seen it done on many high powered conversions no issues.

 

[Duncan Grier]

Who did you go to for that price? Was that including new cv's etc

I have had mixed results with joining by the power of glue. Machining a sleeve to join the 2 and taken to a welding god are still going strong in 270bhp turbo setup

DG

 

[Neal R19]

That's from Berrisford's... new bare shafts, no CVs etc.

 

[Duncan Grier]

Give Dave mac propshafts in Coventry a call. Sure even Joe public prices are nearer £300 for a custom S155 steel shaft. Ask to speak to John if he is available

 

[Neal R19]

Give Dave mac propshafts in Coventry a call. Sure even Joe public prices are nearer £300 for a custom S155 steel shaft. Ask to speak to John if he is available

Will do, cheers

 

[Neal R19]

Spoke to John.

£295.

Each.

Plus VAT.

:ai:

 

[Duncan Grier]

Sounds like the price has crept up a touch but still cheaper and cough cough maybe take the cash out and agree paying cash in advance rather than on your card

DG

 

[Duncan Grier]

Used to be £250 each but know they were having to pay a bit more for material

I can vouch for quality and service from the team if that helped. I have always had a copy of the drawings with any made also

DG

 

[Neal R19]

Berrisfords is £160+VAT each, so when I say "£400 all in" that's for the pair! I'm going to ring around a couple more places but I think I'll go with that.

Local place here in Bristol that I went in to were quoting £600 each FFS!