[Car_Restoration] 205 Gti6 Build And Car Restoration Again...

[Pugmanian Devil 1]

Hi all

 

I don't have much time to write up everything but here are a collection of pictures that best tell the story, will try write up more about the work and spec's when i am not so busy with work

 

 

More pictures to come with a full write up..

[omega 82]

^{very very nice}

^{I can tell by the pics that this a cheap restoration}

[Pugmanian Devil 1]

Abit of history on the car,

 

I am a good friend of Dino's (J19DNO sorrento green mi16 Pug back in the day before he turned to the darkside and fell in love with BMW's )

 

I have owned the car for around 9 years and every year I just cant seem to leave it alone, been a mechanic by trade I just feel I need to take it apart and do something new with it,

this is how it looked after engine build number 4 and how it was before I started this year..

The obsession started for me a year after buying the car from my brother, its not the first time the car has been stripped down and rebuilt, ive never been one to document my builds although so many people tell me I should, So here I am... as ive never done this before and the cars had so many different stages its difficult to know what to write up and when so excuse the order I might be doing things in..

 

 

After many setups I managed to get 189bhp from the 8v engine, to achieve this I had a group A spec head from Brett Sims Motorsport, wossner forged 83.5mm pistons, P.E.C. steel con rods, 45mm throttle boddies, 90mm trumpets, VXR 480cc injectors, 600 Omex ECU and a full race equal length primary maniflow 4-2-1 manifold along with a 2/1/2inch middle and rear box also from maniflow.

It was a lot of fun to drive but want more...thought about putting a turbo on the 8v..but.decided I prefer to just stay NA.

I plan to go all out NA build next year on the gti6 engine but for now I am just tweaking the engine a little bit.. so out came the 8v and here I am

 

For now the bottom end is pretty much standard on the 6 engine, apart from larger cut outs on the pistons done by bridgecraft to fit catcams 4903109.

All the usual stuff has been done, 3-angled valve seats, new ACL big ends, Mahle main bearings, full oil pump rebuild, Arp rod bolts, along with 4.1kg TTV superlight flywheel, lightened crank pulley, re-honed block and hours spent with a wire wheel before painting it in black engine enamel as can be seen.

 

On the 8v stuff I have had the head re-shimmed and fully cleaned & de-carbonised by Brett Sims, the liners re-honed along with new piston rings, ACL bearings and will be putting it all up for sale soon along with the maniflow race manifold, port match inlet manifold for throttle boddies or carbs, so keep an eye out, I also have just bought a set of Avo GTX coilovers to replace the Skip Brown fast road setup that's on the car atm which is also going to be put up for sale, along with the eibach pro springs and new top mounts, group N rubbers and group N engine mounts as ive just got a set of Vibra Technics race mounts to go with the 6 installation.

 

More to come... the car is now in prima which is going to be left to sit for a week for it to sink in nicely before flatting and painting, will keep updating

 

[Pugmanian Devil 1]

managed to start heat wrapping the manifold today although 50ft of titanium exhaust wrap wasn't enough so have ordered more, prior to wrapping I sanded and painted the manifold with ceramic based VHT exhaust paint.

[Pugmanian Devil 1]

Haven't had much time lately to do much more, apart from receiving the steel fuel rail from jenvey today, had to mess around with stand off lengths but was no big deal so managed to get the injectors mounted to the throttle bodies.

 

Vauxhall VXR 480cc injectors @3bar, I will be using a 3.5bar weber fuel reg with aeroquip fittings

 

New fuel rail

 

Old ally fuel rail

 

As you can see the thickness is different of the mounting lugs

 

 

Mounted after making the right length stand offs

 

Quite a large difference in length as can be seen

 

ARP rod bolts fitted then measured con rods in case they required resizing

Hydraulics fully stripped and drowning in De-greaser I have already dressed the tops of the buckets with 240grit sandpaper with plenty of duckoil a tedious task but glad its done, another job off the list

 

 

 

 

 

 

 

[welshpug 1,620]

Injectors a bit ott

[Pugmanian Devil 1]

Yeah they are, in which perhaps I wont be keeping them.

 

These where the injectors that I was using on my 8v engine which increased its torque threw out the rev range massively and its max bhp.

 

When Brett Sims told me to use these my reaction was exactly like yours (a bit big don't you think ) and this was for an 8v, before these I was using a set of green GTi6 injectors on the exact same 8v spec engine, the difference these injectors made was huge, I put it down mainly to the spray pattern of these VXR injectors, the duty cycle setting was sensible in the map and they worked really well even with "deceleration fuel turned on" they were still able to react fast enough.. Hence why I am going to use them on the Gti6 engine. they wont be the last injector I use or try on the Gti6, eventually I plan to run 8 injectors with a 700 series Omex as the 600 cant do it

Edited July 9, 2013 by Pugmanian Devil

[welshpug 1,620]

I doubt very much it was the injectors but the mapping.

[Pugmanian Devil 1]

It was mapped by the same company (track N road) in rainham essex by the two Steves 2 weeks apart

It was the injectors that made the difference not the mapping as we had exhausted every aspect when the engine was using the gti6 injectors, I can say this because we altered +2/-2 degrees for cam timing and ignition timing on high load and the engine just didn't want to make any more torque or power, the first map was spot on.

Modern injector vs older injector, until you try it for yourself and see, I would keep a more open mind.

I am willing to bet that if for instance i was to get this gti6 engine mapped on the standard injectors then swap them for the VXR ones there would be a night and day difference, this car spends more of its time on rolling roads and axle stands than it does on the road...now I am not saying the vxr ones are the most optimum injectors for the 8v build i had or the gti6 build I am currently working on but they certainly wont be the last set of injectors that get used, same as the trumpets

 

Do you have any recommendations as to what injectors would best suit this spec of gti6 build I am always open to suggestions

[Pugmanian Devil 1]

Managed to get a few pictures of how the cars coming along at the body shop

 

Hydraulic lifters assembled and fitted with plenty of oil and joe gibbs engine assembly grease

 

Hours spent wire wheeling the head prior to washing and assembly

 

Alternator pulley painted, the casing itself is getting sprayed red at the bodyshop, I am using a 140amp Alternator (2 Rockford fosgate amps so need the juice)

 

Power steering pipe rubbed down and painted the ends silver

 

More to come...

 

 

[Pugmanian Devil 1]

Managed to get a bit more done today, power steering pump rubbed down and painted with black engine enamel (masking tape is yet to be peeled off)

 

Finally got the manifold finished

 

Bought myself a sandblaster yesterday after getting fed up rubbing down and wire wheeling bumper brackets and other miscellaneous parts, its addictive! here are a few parts i managed to do,

 

 

Hope to be getting the car back from the body shop around mid to early august was told today so might get to catch some of the sunshine

[Pugmanian Devil 1]

Been really busy lately but managed to get more stuff done today.

 

Sand blasted S16 top engine mount

 

 

 

 

[Pugmanian Devil 1]

Painted and fitted to engine block

 

I am unable to upload more than one picture per post even after reducing the pictures file size... can anyone advise on how this can be done because this will take all night lol

[Pugmanian Devil 1]

Alternator casing sandblasted and painted

 

[Pugmanian Devil 1]

140amp alternator assembled ready!

[mechanicalrepairs 8]

Cracking build.

 

 

Carl

[Henry Yorke 269 3 Cars]

Finally turned to 16v Tas?! Well done for keeping off the BMWs despite Dinos influence!

[Pugmanian Devil 1]

Hey Henry how are you doing

After 8v build no.5 I thought it was due a 16v this is only a temporary engine build as next year I plan to either go all out on an N/A build (aiming towards 260bhp) or just forge the bottom end and turbo it again only wanting around 270bhp... but let's not get ahead of ourselves.

 

I could never own a BMW for me nothing compares to the rewarding aspect of a pug, unless a Lamborghini Aventador becomes an option one day then perhaps I will just use the pug as a daily driver

[Pugmanian Devil 1]

Cracking build.

 

 

Carl

 

Thanks Carl always nice to hear such comments

[GLPoomobile 958]

Hi Tas

 

Nice to see this build thread as I remember Dino posting some pics of it during the 8v days and it looked absolutely mint. I remember being so disappointed when Dino stopped feeding updates on here. Looks like your standards haven't slipped since

[kyepan 291]

so much effort!!!!! when you think it will be on the road?

[Pugmanian Devil 1]

so much effort!!!!! when you think it will be on the road?

I am hoping to have it on road by mid September, hopefully sooner!

Soon as it comes back from the body shop which should be by the 3rd week of this month if all goes according to plan. Once its painted I have to go there and drop the rear beam and front subframe so he can then underseal and stone chip all the underside of the car..

 

When I do get it back in my garage the sub frame and a whole load of other bits are coming off to be powder coated so with all this having to be done perhaps mid sept is a bit hmm but we'll see

[Pugmanian Devil 1]

Hi Tas

 

Nice to see this build thread as I remember Dino posting some pics of it during the 8v days and it looked absolutely mint. I remember being so disappointed when Dino stopped feeding updates on here. Looks like your standards haven't slipped since

This car's like wine, just get's better with age!

[Pugmanian Devil 1]

Been a while, soz everyone been really busy lately with work, the cam pulleys I will be using, yet to buy the cams as I am undecided still, am also thinking to get a set of forged pistons now with rods

Edited September 17, 2013 by Pugmanian Devil

[Pugmanian Devil 1]

The middle 2.1/2" maniflow exhaust section i re-painted with ceramic based VHT exhaust paint, then 2 coats of clear coat VHT, also welded in the lambda boss's

 

The car has now been painted, I am going to the body shop tomorrow so will post some pictures up of how it look's, still needs to be flatted down and polished, so much work left to do

Edited September 17, 2013 by Pugmanian Devil