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205 Dimma S16 Turbo Converting To 4X4


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112 replies to this topic

#61
lybker

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This weeks update - I am pushing hard to get the 205 off my lift, as other cars are waiting in line. That means getting all of the understructure finalized and assembled: 

 

First requirement was a reinforcement bracket to support the transferbox. These can be had from ATDperformance at a cost, but anyway - here is my take on this:

 

 

Secondly realizing the enginebay is getting crambed, it took some trial fitments to figure out how to modify the underframe to ensure sufficient strength and enough clearance for the crankshaft. Having finalized modification tonight, next step is clean it all up and apply paint, before final assembly.

 

frustrating is however, it has become clear that I cannot avoid to modify (enlarge) the exhaust tunnel - this is a big step back, as it should have been done before start of the assembly process :-(

 

Will have a good nights sleep trying to figure out what will be the best approach to solve this issue....any good ideas is more than welcome! :-)

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#62
lybker

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progress is being made, however everything is so tight, trialfitting components are frustrating and slow. Even so after 5 adjustments I am ok with the achieved clearance of the front frame vs the center gearbox. Just to fid out there is actually not room for the steering rack, as it hits the driveshaft. I decided in frustration to elevate it by 10mm,but now the steering is somehow tight - I need to redo this once I have found what is the issue.

 

also I found the ARB does not clear the space needed for the driveshaft. Not sure how to sort this, but will remove it for the time being.

 

...and finally - the wheels are back one - I do look forward to the first test drive, even there is still some work to be done first :-)

 

 

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#63
lybker

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Todays thrilling event, was to cut out the middle section, to prepare for enlarging the prop shaft tunnel. I removed a 180mm wide strip, and will instead install a 100mm taller tunnel bended in 1,2mm stainless steel, allowing for the exaust to be placed above the prop shaft. This will also raise the gear linkage and handbrake console, but this should be fine.

 

secondly I will construct an adapter allowing me to fit the modified BMW e39 propshaft directly on the flanges of the center gearbox and differential. The CAD sketch was done tonight and I will print a 3d model to check tolerances tomorrow :-)

 

 

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#64
B1ack_Mi16

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Nice work. I hate cutting in the car like that :D

 

Is that Catia?



#65
lybker

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No its inventor from autodesk.

Believe me, I was quite unhappy about this also, took me a week or so to find the guts to do this. its a real shame, as the chassis is in good condition and rust free :-(

#66
petert

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I use Inventor almost everyday. It's a good package. Love your work. Keep going!

 

I would remove the ARB completely. It's totally unnecessary once you sort out the spring rates.


Edited by petert, 01 March 2017 - 10:29 PM.


#67
Tom Fenton

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Will making the new tunnel in stainless steel not make welding it back to the car a pig? Also stainless as I'm sure you know is prone to cracking when subjected to vibration. I would use mild steel personally here.

#68
lybker

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Trying to keep momentum on the project, I did achieve quite a lot tonight, taking into account I only have time in the workshop after kids are put to bed at 20:00.

 

First i fitted the 3D printed adapter plate and luckily it fits like a glove :-) Next is to have the model, machined in steel and start working on the prop shaft.

 

Second effort was on the new prop shaft tunnel. I cut and bend a 1mm stainless tunnel and after 2 hours of tweaking, welding and sealing, I am pretty happy with the end result. It feels sturdy and tough. To be sure, 3 stabilizers where added to the inside of the tunnel.

 

Missing is surface treatment and reinstallation of the seats. As this stage was a somewhat setback, I just want to get it out of the to-do list ASAP :-)

 

...next days will be slow, maybe thats a good thing....

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#69
lybker

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Even with the bigger tunnel, space is limited. As I am still searching for the rear flange for the final drive, in the meantime I have been working on compacting the gear linkage and modifying the exhaust system.

 

Linkage is done, and the main parts of the exhast is in place. This project is slowly moving towards finalization :-)

 

Still last big missing item is the propshaft, rest is just 100 small items like brake bias valve, oil in the gearboxes etc.

 

I really hope I fitted everything the way it should and reinforced the right locations - as mentioned somewhere earlier, I did detune the engine to 300bhp for starters. Really looking forward to its first track time :-)

 

 

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#70
lybker

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Well the underside is nearing completion, exhaust is now finalized together with the offset gearlinkage and fitted. Space is very limited, and not untill I have the propshaft fitted, will it show clearly if clearance is enough. And this is next step: Waiting for a new rear diff to arriv, collected and shipped by a true Norwegian hero! Really Thanks :-)

 

once this is in, I will be able to prepare the propshaft adapters, measure the gab between the two, and order the propshaft.

 

Next update will not happed untill 2-3 weeks time...I need the break :-)

 

 

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Edited by lybker, 05 April 2017 - 08:42 PM.


#71
lybker

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After spending some time thinking, I decided to construct 2 adapters to bridge from the peugeot standard flange to the bmw drive shaft. The adapters supports the flange on the sides to compensate for the small bolt size. I printed a mockup to test clearance and it confirms a tight fit - but I think it will be ok.

 

Next is to get the adapters machined and finally modify the driveshaft. This will be done by a specialist workshop as I worry about balancing the shaft.

 

Anyway I amthrilled about the outlook to be able to test drive the car sometime in the near future :-) 

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#72
mmt

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Looks really good mate. It is a true Lybker project:-) Looking forward to see the first video of you taming the thing.

#73
lybker

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status - well, I hate to wait. Again the machineshop is delaying progress, as the 3D-printed adapters gets remade in steel. Looking back, half of the time it took to reach this stage of the build has been spent waiting for parts. :-( 

 

So killing time by adding fluids to the driveline is as fun as it gets currently.

 

 

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#74
johniban

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great work 



#75
lybker

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...Finally after 4 months of waiting, the last flange has arrived, and assemby can continue.

 

 

The new propshaft should be ready for pick up tomorrow meaning if all goes as planned, the car should be back on its wheels tomorrow evening, pulling on all 4 - yah!

 

 

 

 

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#76
wicked

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Great! Waiting for parts is always annoying... 

I really like the idea of making a mock up with a 3D printer and then order the final part...  



#77
mmt

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Looks nice. Always a pleasure to see things being engineered out of nothing.

Crossing My fingers for it to work.

#78
lybker

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woop woooop

 

 

Now I am the owner of a 205 4x4!   :D​  :D​  :D​ 

 

The propshaft came today,and it fits perfect, I am so pleased to see all 4 wheels rotating simultaniously ! :-)

 

My "205 To Do" list is down to 

  • bleeding brakes
  • remapping to a lower power output 
  • wheel alignment.

 

Do anyone have a good allround setup for wheel alignment, noting I am not looking to set any laprecords, but instead have a  drivable setup with good grip and easy cornering for trackdays?

 

front caster is as negative as it can be in my setup (unmeassured yet). My initial idea is then to -1½ degree camber rear and -2 to 3 degree in front with a bit toe out on both front and rear axle, with the latter close to neutral - would this work as I hope?

 

Should setup be different for 4x4?

 

 

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#79
petert

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all wheel drive should be the same as fwd, ie front and rear camber should be identical, front caster should be as positive as possible, try +4mm toe on front and +2 toe on the rear. If it's too unstable under heavy breaking reduce rear toe to zero. Enjoy! What a fantastic project. Well done.

Edited by petert, 21 September 2017 - 05:45 AM.


#80
welshpug

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depends very much on tyres.