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5 GT Turbo Time to get my old 5 GTT back on the road...

rabbitstew

Active Member
Hi All,

Im a long time 5 GTT Owner, having bought my first one in around 1994 and after owning and tuning a couple ive had my current 1988 Phase 2 one since about 1995/1996. I bought it as a shed back then and decided to tune it up how I wanted it. Id never been one for mad bodykits, so kept the car looking as standard as possible but did all the tuning under the bonnet. Back then it was a pretty mental car and very little local to me could even come close to it performance wise. I had loads of fun over the years until it became a bit impractical for work, so I took the car off the road in about 2001/2002 and its been in my garage ever since. Family commitments and DIY on various houses unfortunately took up all my spare time over the years.

Anyway, after finding myself with a few spare hours each week over the last 12 months I started working with the spanners on my Yamaha R1 and Ducati 996 and got them running nicely. I soon found I had got the bug back to get all greasy in the garage and decided to finally start giving my 5 some love. Im lucky in that ive always been handy with the spanners and over the years ive built up quite a good collection of tools so I will be doing all the work myself which will help cut down some of the costs. I had started turning the car into a track car back in about 2003/2004 so a lot of the OE interior trim has long since been ditched, so rather than try to turn it back into an OE car, I will replace all the knackered bits with performance pieces. The bodywork/styling I will keep stock as I like it. Standard bodykit, bumpers, spoiler. The wheels are not OE as I upgraded them to 15" at some point in the past and the suspension sits a bit lower on Jamex springs with Spax adjustable shocks. Interior long since went and ive already a proper 6 point cage, harnesses and buckets, so they will stay for the time being.

The first thing I noticed in getting back into the 5GTT scene is that things had moved on seriously since I was into the 5 tuning scene back in 1993/1994. Back then the RGTT owners club was fairly small and me & other guys used to spend ages on the phone talking about tuning tips and ideas we had come up with. The main company back then was GT Tuning and people such as K-Tec wasnt even a name to us back then. It was well before the mad "Ali G" Max Power type days of people using mad bodykits and colours etc. I remember most people back in the old days tended to go for what was commonly called a "stage 1" level of tune. Of course each manufactorer had different ideas and claims, but roughly speaking "stage 1" meant a bleed value to increase boost from about 8psi to 14psi, a strap for your intercooler to stop the plastic ends blowing off, and a bigger carb jet... typically a 135 main jet. You`d normally bung a different exhaust on and air filter. On the road the difference was quite noticeable and cheap. I remember I went a stage further with a T25 hybrid turbo (wish I could remember what spec it was now!) and subsequent heavy duty clutch to handle the power, and then after chatting to another guy in the owners club I got in touch with Portformance who ported out/gasflowed the head, carb and manifolds on my car. They got about 17% more flow through the engine and on the road I noticed immediately that at standard boost the car felt like it was running 14/15psi but it was much more responsive. To sort out the fueling at 20psi the recommendation from the tuners at the time was to just bung a big 160 mains jet into the heavily bored out/gasflowed stock carb (which apparently is all frowned on these days). I was worried about overfueling but at idle it passed the MOT emission test fine and on the road it seemed okay. Although the soot in the tailpipe would tell me its running a bit rich.

Anyway roll on to 2014 and I start googling and im amazed now at how things have moved on, EFI injection systems welded to stock manifolds, electronic boost values, so you can plug an ECU into it all and map it how you want, AFR gauges. Even engine transplants with clio units.... Some cars putting out 300/500 bhp now... mad and all very exciting to me! All the "old school" tuning seems to be out of the window now and a whole new era actually came in and went in the time my cars been in the garage off the road.

My plan really atm is to get the car back on the road, through its MOT and replacing everything which needs to be done with performance bits. So, ive new brakes, bearings, ball joints, brake pads, calipers, brake lines, brake hoses, brake bias valve, brake master cylinder, wishbone mounts, seat mounts, fuel lines, fuel pump, plus all the service bits like new plugs, leads, dizzy cap, fuel filter, oil filter, air filter etc... Then as the old radiator is knackered ive a double capacity alloy one, a big alloy front mounted intercooler, a mocal oil cooler, new pipes, silicone hoses, water pump, alternator, starter motor, new 2.5inch exhaust system, new alloy carb top and thats about it. Only bit im not touching atm is the engine/head/carb as I want to get it on a rolling road in its "old school" spec to see exactly what power it was kicking out. Estimates at the time were around the 200bhp mark with the work on it, but we all know that unless you have the rolling road print out it could be anything! Once I have a base line figure and can see how healthy the old lump is, I can decide what approach to take going forward. I have however bought an AFR gauge/sensor which I will plug in as im dying to now how good/bad my carb set up is!

The other big challenge I have is the dreaded rust. Having left the car outside parked up against the side of my house for about 12 months, upon jacking the car up to look at the front suspension it soon became apparent that the passengers side underside isnt great. So ive had to weld in new front jacking point and do some sill repairs as I work back to wards the rear wheel.... where I can see that the rear jacking point is also looking a bit worse for wear.

Anyhow thats an intro to me, im on other forums, so you may recognise my username from there. Ive also setup a blog so you can follow my build progress and see photos - link is in my signature.

Looking forward to getting to know everyone.
 
Now thats an introduction !

Welcome along !

Are you ok if I move this thread into the project classic section so I can follow progress and it doesnt get lost in the hellos ?
 
Now thats an introduction !

Welcome along !

Are you ok if I move this thread into the project classic section so I can follow progress and it doesnt get lost in the hellos ?

No problem! :)

Still very hard to get my head around the fact that my car is now a "classic" it was modern when I bought it!!!!!!
 
lol classic and getting older by the day. great intro, get a resto thread up, oh and welcome along
 
Welcome to TurboRenault.co.uk Rabbit!! It was lovely to read your opening thread and remember the tuning scene as it was when I started out with 5 GTT's! :) I look forwards to seeing your progress.
 
great introduction. Do you have any photos of your car.
Welcome by the way

Got loads on the blog in my signature!

Welcome to TurboRenault.co.uk Rabbit!! It was lovely to read your opening thread and remember the tuning scene as it was when I started out with 5 GTT's! :) I look forwards to seeing your progress.

Cheers, its amazing how much things have moved on. Glad im not the only "oldie" on here!!! :)
 
Hey just read the blog. I'm most impressed about using the infrared locking thing with your watch back in the day. Didn't know that. :yes3.gif:
 
Hey just read the blog. I'm most impressed about using the infrared locking thing with your watch back in the day. Didn't know that. :yes3.gif:

Yep it was cool, like kinda knight rider. Not many cars which you can press a button on your watch to open the doors!!!!
 
I've got a spare sky remote. I'm gonna try and do it

Not sure if a sky remote would work, but certainly any "learning" normal remote will do it. You press button on the remote to "learn" then point the 5 key ring at it and press the button. The remote control will learn the infra-red code as its the same as your telly uses!

I wonder if im the only person who has done this?! Could be handy if you loose your 5 key fob, although carrying around a telly remote to get into your car is a bit inconvenient!
 
Been making some reasonable progress on the car since I started. A quite a few times though ive had that "wtf am i doing" feeling run through my head. Usually after discovering another rusty part of the car which needs welding, or whenever I look at the growing total on my costs spreadsheet. Fortunately the cost my wife thinks its costing is about 1/10th of the actual current cost. In actual fact looking at it now I might have been better off just buying a decent road worthy 5, fitting the performance bits off mine into it and breaking mine for parts. With the cost of some parts these days they could have probably have paid for the cost of the new car and id be back on the road for free.

But then again, I think im saving this one from the scrapyard in the sky and also have a lot of sentimental attachment to it. I also figure, by time im finished 80% of the car will probably be brand new and I couldnt buy a new car for the money this restoration is costing me.... either way I seem to be able to justify it in my head..... :D

So, ive managed to finish one front corner on the car. Welding done in that corner, new jacking point fitted, new brake calliper, brake disc, braided brake hose, pads, wheel bearing, ball joint, tie rod, polly bushes on wishbone & ARB. THen that corner alll undersealed and painted up. Ive moved further down the side of the car - the sill needed a bit of welding under the passengers door and im now at the back passenger corner of the car. Ive stripped the brakes off and pipes. Found some more welding needed around the rear jacking point & sill in that area. Ive taken the spare wheel cage off and can see the bias valve is pretty rusty so ive a new one of them to go on, along with new rear disc, new calliper, pads, bearing, handbrake cable, braided hose & brake lines.

I can see that the rear bumper mount is also pretty rotten, so the back bumper will need to come off so I can weld that up.

As the welding was getting me fedup, i made a bit of a start under the bonnet also. Removed the old rotted copper cored radiator out, old intercooler, fan, indicators & headlamp. I cleaned up around the front of the car and repainted that with some satin black paint. Fitted new double capacity alloy radiator - involved making new mounting hole for one of the legs of it as im moving it 9 inches to the right. Had a polished alloy bit of tube made up to extend the silicone top hose to allow for this. I flushed the cooling system out with the old garden hose pipe - amazing what rusty crap came out. I fitted the new oil cooler on top of the front cross member. Looks nice although now I realise that it will be hidden behind the bumper and no air will get onto it. I will either have to remount higher up (although the top panel under the bonnet doesnt look very strong) or cut some holes in the bumper. Im steering towards the latter option - cut some 50mm holes in the bumper above the number plate like the cup cars had.

Other than that, ive cut the old header bracket off the car and rewelded it into the bulk head on the drivers side so I can put the header tank in there. Will need to cut some holes in the bulk head to reroute the plumping in there. The car had an old car alarm there, which im pretty sure i never used to use, so ive cut it out. I only hope that it doesnt have some sort of immobiliser on that alarm it else i`ll never get it started. Im pretty sure it doesnt as I had a Cobra immobiliser fitted shortly after I got the car, so fingers crossed.

I also made a start at getting the perc fan out although i need to wait until I move the car out a bit from its current position in the garage so i can get to the mounting bolts which look like they are under the drivers side wheel arch.

Interior ive not touched yet except weld a couple of mounting plates in for the roll cage. I did actually sit in the drivers seat for the first time in about 4 years. I was quite shocked. It felt like such a weird place to be after being used to "modern" cars for so long. The steering wheel felt so thin, the plastics were all square and hard. The heavy duty clutch was well, mega heavy (soft clutch pedal conversion sitting in my pile of bits to do). The thing which surprised me the most was that the whole cabin felt mega tiny. I dont remember it being that small back when i used it as a daily, but i guess ive been used to slightly bigger cars since.

Im now debating where to put the gauges. Ive already got a boost gauge to the right of the rev counter, but ive got a new AEM boost gauge and AEM AFR gauge and a mocal oil temp/pressure dual gauge. Ive worked out if i remove the heater, i can mount them perfectly in the space where the clock & heater controls go. 24cm wide, each gauge is about 6cm and that leaves a nice cap between them. But I wonder if that will be too low. I want to be able to just turn my eyes and see them without moving my head. The alternative would be to remove the air vents above the storage compartment and mount them in there. Im just making up a mounting plate for them so i can offer up into both and see.

I also need to workout where to plumb the oil pressure gauge into. It looks like ive got a nice T-piece for it, so im thinking if i remove the one way valve below the turbo oil feed pipe, maybe it will fit in there. The oil temp sensor looks like its 1inch long... so im not sure where to fit that. I have read people mounting it at the back of the sump but i dont fancy messing about with that atm. There is a bung ive noticed under the alternator which looks like it will screw out and something can go in there, but i wonder is that for oil or water - and is the oil temp sensor too long to fit in there. I`ve also heard people just screw it in place of the sump plug.... not sure if its the same thread or not or if thats a good idea. Any ideas?

As always, pics and more details on my blog!
 
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