19 Project Turbo Shed - sponsored by Bosch PWS850-125

[Duncan Grier]

Was the bend a 1D? Only option to gain more I have seen is the jetex welded tight 90deg or but of cut and shut / Dave's suggestion or poss squish it making shape oval. Or twin smallar diameter pipe you can position better bit that would be a pita

I need to make a tight turbo elbow on friend 7 stylee with sr20det lump to clear chassis. Nothing is ever straight forward

Good progress

DG

 

[Brigsy]

If you want more clearance could use the megane servo/bulkhead etc as its mounted on the passenger side. Seen a clio done the same with megane f4r fitted

 

[Neal R19]

If you want more clearance could use the megane servo/bulkhead etc as its mounted on the passenger side. Seen a clio done the same with megane f4r fitted

I thought about that and in fact kept the whole megane setup from the donor - pedal box bits, transfer bar and the full width bolt in bulkhead plate itself (had to burn all the adhesive/sealant away to get it out!).

BIG job to make that work though! I think I've seen the clio you're talking about, my concern is that the whole thing is reliant on the stiffness of the bulkhead - the megane shell/bulkhead is heavily reinforced for the purpose with beam sections folded/welded in. The 19's is much more like papier mache.

 

[Neal R19]

Was the bend a 1D? Only option to gain more I have seen is the jetex welded tight 90deg or but of cut and shut / Dave's suggestion or poss squish it making shape oval. Or twin smallar diameter pipe you can position better bit that would be a pita

I need to make a tight turbo elbow on friend 7 stylee with sr20det lump to clear chassis. Nothing is ever straight forward

Good progress

DG

Can't remember the radius but the actual clearance to the manifold is the limiting factor anyway.

 

[Duncan Grier]

Bugger, no doubt you will find the best solution available

DG

 

[Neal R19]

Bit more done over the weekend, modified by front pipe to clear the ARB, filled with coolant (well, plain water) and ran it for a bit.

Then got snip happy with the wire cutters. Chopped quite a lot of loom out



Still starts with all that cut out so nothing important What's left is starting to get a lot less daunting to look at



Still quite a bit more to get chopped out of there!

Only particular problem I'm having is I just can't get the clutch working. I've bled it forward, backwards, up, down and and sideways. There's a bit of resistance right at the bottom but it doesn't disengage. That'll be the main focus this weekend I suppose.

 

[DaveL485]

Do I recall there being a knack to the clutches on these of some sort? Having to pre-fill the slave or something? @Brigsy ?

 

[Brigsy]

The megane setup is a bit of a bastard to bleed. Is it running the meg pedal etc ?

 

[andybond]

Do I recall there being a knack to the clutches on these of some sort? Having to pre-fill the slave or something? @Brigsy ?

Yes , prefill the servo and then its still a pain. Sometime CLIP is needed to purge.

However , I have alos heard , prefill , fill the rest of the system and then push pedal down and wedge it down overnight and that sorts it ..

 

[Brigsy]

You dont need clip for bleeding the clutch @andybond i think you are getting confused with the brakes (you dont fill the servo either lol). Prefill the concentric slave is recommended however should get it with a power bleed regardless.

 

[Brigsy]

I know the concentric slave cylinders sometimes do not like being re used/bled too check no fluid is leaking too.

 

[andybond]

You dont need clip for bleeding the clutch @andybond i think you are getting confused with the brakes (you dont fill the servo either lol). Prefill the concentric slave is recommended however should get it with a power bleed regardless.

You might be right. Let me do some digging. I think it was the brakes and the ABS thingy that knackered?

Specky filled my slave when changed out the clutch ..

 

[Brigsy]

No electrics on the hydraulic clutch setup. Need clip to bleed brakes if you let the original megane abs block if air has got in or drained of fluid. This is on a different setup so should be sound

 

[andybond]

No electrics on the hydraulic clutch setup. Need clip to bleed brakes if you let the original megane abs block if air has got in or drained of fluid. This is on a different setup so should be sound

Wonder if I can do a sneaky edit ..

The hold the clutch down thing is defiantly right though

 

[Brigsy]

Pedal down works. Many years ago i bled an xantia activa sealed hydraulic clutch setup with no bleed nipples, pedal down overnight with reservior top off worked grand.

 

[Neal R19]

It's a scenic RX4 pedal box, modified to accept the Megane 225 master cylinder, so pedal cut and rewelded to position the actuating pin correctly. Bit of a lash up on the face of it, however I did take a bit of time over it to make sure that the master cylinder experiences the same travel as when fitted in the megane so I'm pretty sure that side of things is fine.

I also pre filled the slave by putting the end in brake fluid and pumping it full, then capped it off. The excess fluid pissed out when I bolted the box back up to the engine. So I'm pretty sure there's no air there.

I'll try the wedging the pedal down thing, thanks chaps.

 

[Neal R19]

Modified my front pipe this weekend..

Before:



After:



MIG welded by me this time so a bit less pretty now than it was, but it should be strong enough, it's gas tight and clears the ARB.

The flexi is now a lot further away from the engine than I'd like it really but whatever, we'll see how it goes. It something cracks I'll weld it up again.

Also got the clutch working. No pics but I cut the top of the pedal and relocated the actuating pin to give a few more mm of travel. Now the pedal hard stop is the master cylinder bottoming out which isnt necessarily great but I can put another physical stop in at some point. So I was able to move the car up and down the drive under its own power.

Getting there!

 

[DaveL485]

So I was able to move the car up and down the drive under its own power.

Thats always a great feeling victory for me after undertaking big surgery....well done mate

 

[andybond]

The light at the end of the tunnel is no longer a train heading your way

 

[Neal R19]

Still plugging away at this.

Cut up the exhaust heatshield from the megane to make a heatshield for the shifter box under the car:




Put all the dash and interior back in and chopped out loads more redundant wiring loom, there's very little left now, should be easily concealable under the centre console or tucked up behind the standard fusebox.



I've wired it to start off the central locking switch (one from the spares box, this car never had central locking, just a blanking plate):




I'm running some of the original engine loom in parallel to get the temp gauge and oil level gauge working as per standard, I put a standard 19 temp sender in the top hose, so that all works fine now.




Then on Sunday a mate came round and we bled the brakes up properly and went round the block. Excerpt:



Already getting a taste for some boosty boosty :ag:

As expected, the steering at low speed is a bit heavy!

Only a few jobs left before I can chuck it through an MOT!