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sounds of silence

[project] Sos Track 205 16v Turbo Project

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sounds of silence

Ok going to do a build thread on my 205 we are in the middle of building for the beginning of next year.

 

Alot of folk will have seen it this year anyway but i have recently stripped it down to a bare shell to undergo alot of work due to the engine that will be going in it this time .

 

Going to start off when i first got it to the stage it is at now this will be a on going thread for the next few months as it gets built from start to finish and all in house.

 

A pic of the car first of all just a pretty std 1.9 gti .

 

davesos2.jpg

 

then i converted it to a 2.0 8v turbo for the track.

 

engine.jpg

 

at this time it was stripped out , a set of bucket seats and a safety devices multi point weld in cage

 

DSC00191.jpg

 

engine pretty much std except bigger exhaust and 14psi boost from the t25 turbo this putting out around 190 atf .

 

brakes were gti-6 285mm on the front and std 1.9 on the rear .

 

suspension was koni adj all round.

 

cosworth 2wd intercooler modified and fitted to the 205 .

 

End caps cut off and rotated 90 degrees

 

DSC00205.jpg

 

Factory !! :wink:

 

DSC00206.jpg

 

 

sostrackcar.jpg

Edited by sounds of silence

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sounds of silence

Next up a fancied a bit more power having owned a few high powered 205s in the past a wanted a play around with the engine alittle .

 

Biggest problem with the 2.0 8v engine is there has'nt been alot of them tuned in the past so we had to pretty much just make a spec up as we went alittle trial and error but was fun :)

 

newphone008.jpg

 

sent my old turbo away to aet turbos to see what spec i could get made up for the std manifold and to my surprise they said could upgrade to a hybrid T3 (biggest i had heard of on a std manifold was a T28) so i gave them the go ahead and a week later .

 

old turbo against the new one

newphone007.jpg

 

 

 

newphone011.jpg

 

next up was an uprated cam shaft this car from CATCAMS a nice stage 3 cam

 

17072008111.jpg

 

newphone012.jpg

 

now with the bigger turbo and cam i knew i had to go for a stand alone management so i bought KMS management , to go with this i got my hands on a set of cosworth green 803 injectors at this stage the engine looked like this

 

newphone014.jpg

 

after a bit off mapping with the new engine the inlet temp were alittle high so we went for a bigger intercooler this time i opted for a evo one

 

03072008108.jpg

 

31072008115.jpg

 

now at this stage i need to be able to get the power down so we went for a quaife diff and a set of toyo 888's cut slick tyres

 

25072008112.jpg

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sounds of silence

25072008113.jpg

 

so now able to get the power down we now had to be able to stop so decided to upgrade for the gti-6 brakes to a set of hi spec 4 pots and still able to keep the 15" wheels

 

31072008117.jpg

 

That was the car for a while and at that spec we managed to get 230 / 240 bhp at the fly a nice figure and defo good power increase :)

 

2001318889a8229584302l.jpg

 

and not every day runs smoothly , burst water pipe :cry:

 

engine205out.jpg

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sounds of silence

Plans were made for the car to get stripped again this time for the proper build and a nice 2.0 16v turbo engine (same as t16 but better spec'd) and a good few body mods inc seem welding , new cage and light weight panels now hoping for roughly 750kg and 350 bhp.

 

So car goes in looking like this

 

2001318889a8229584302l.jpg

 

to this in no time , engine stripped out

 

resize.jpg

 

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now right back to a bare shell with everything off

 

newphone052.jpg

 

resize3.jpg

 

of course being stuck on one of the lifts is no good so was moved into its possition for the time being and for work to commence .

 

so as it is in the weld and prep area

 

prepbay1.jpg

prepbay2.jpg

prepbay3.jpg

prepbay4.jpg

 

now completely completely striped ready for the engine bay to be seem welded and strengthened

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sounds of silence

This section will show how the engine bay has been seem welded and strengthened.

 

reason for this work is basically a 205 was never designed for hard track use and certainly not for high powered engines as this picture will show the strut top after a bit of hard cornering .

 

see how its started to dome.

 

newphone061.jpg

 

so this is where the strength needs to be added

 

area gets prep'ed

 

newphone077.jpg

 

now plates get tacked into position

 

newphone078.jpg

 

everything gets checked making sure there 100% and then fully seem welded into position

 

newphone079.jpg

 

now while preping the engine bay to seem weld i found a couple of rust patches so decided to cut them out and plate them up properly

 

newphone063.jpg

 

section cut out and ready for a plate to be made and welded in place

 

newphone072.jpg

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sounds of silence

This section will show how the engine bay has been seem welded and strengthened.

 

reason for this work is basically a 205 was never designed for hard track use and certainly not for high powered engines as this picture will show the strut top after a bit of hard cornering .

 

see how its started to dome.

 

newphone061.jpg

 

so this is where the strength needs to be added

 

area gets prep'ed

 

newphone077.jpg

 

now plates get tacked into position

 

newphone078.jpg

 

everything gets checked making sure there 100% and then fully seem welded into position

 

newphone079.jpg

 

now while preping the engine bay to seem weld i found a couple of rust patches so decided to cut them out and plate them up properly

 

newphone063.jpg

 

section cut out and ready for a plate to be made and welded in place

 

newphone072.jpg

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sounds of silence

now its not like you can just go out and buy in a section to replace it , so a section has to made up now for this all that was required was a bit of sheet metal , plasma cutter , square and a hammer :wink:

 

newphone067.jpg

newphone068.jpg

newphone069.jpg

 

now a rough size is cut a shape can then be made to fit

 

newphone070.jpg

 

now must be trial fitted

 

newphone074.jpg

 

and when happy with the fit tack welded into place and then seem welded

 

newphone076.jpg

newphone082.jpg

 

and the rest of the engine bay seem welded

 

newphone081.jpg

DSCN0644.jpg

DSCN0671.jpg

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sounds of silence

we'll engine bay pretty much complete except the cage work which will follow , i moved on to seam welding the inside of the car .

 

For this to be done correct and the cage to be 100% spot on i had to strip the dash completely out and then had to dress up every seam on the car again to be able to start the welding pretty much the same procedure as the engine bay .

 

inside untouched except seats removed

 

newphone060.jpg

 

dash starting to be removed

 

DSC00110.jpg

DSC00109.jpg

 

completely stripped

 

DSC00133.jpg

DSC00135.jpg

 

getting prep'd

 

DSC00128.jpg

DSC00127.jpg

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sounds of silence

then seam welded

 

DSC00129.jpg

DSC00130.jpg

DSC00132.jpg

 

so now car completely seam welded its now time to move on to the new front cage to be made for this we are using 38mm cds tube and getting bent with out HUTH pipe bender.

 

reason for the new front cage is i was wanting it a bit tighter to the A piller and also wanting it to go straight on to the strut tops and cross braced at both doors and behind the seats.

 

first part of the cage in place

 

DSC00138.jpg

DSC00139.jpg

DSC00141.jpg

 

now a perfect fit to the A piller alot happier so now added the first part of the cage to go onto the strut tops.

 

DSC00142.jpg

DSC00143.jpg

DSC00144.jpg

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sounds of silence

Another part of the cage complete but ran out of pipe so will have to get more ordered tomorrow to get the cage finished off .

 

DSC00147.jpg

DSC00146.jpg

DSC00153.jpg

 

 

 

 

and the strut tops completely braced

 

DSC00149.jpg

DSC00150.jpg

DSC00155.jpg

 

then seam welded the subframe , now ready to be powdercoated

 

DSC00154.jpg

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welshpug

Good effort ;)

 

now its not like you can just go out and buy in a section to replace it

 

 

er, yes you can... :)

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sounds of silence

no you cant as there all back order for a month , its not like i didnt try :)

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sounds of silence

was back on the cage again trying to get it finished off , now pretty much 90% complete just a few we bits left to go on .

 

centre bars to support behind the seats

 

DSC00158.jpg

 

DSC00161.jpg

 

then both doors crossed

 

DSC00156.jpg

 

DSC00157.jpg

 

then the final side supports triangulated

 

DSC00170.jpg

 

DSC00163.jpg

 

DSC00171.jpg

 

next up am going to build up a trial engine to fit it in and make sure everything is fitting before it heads into the bodyshop to get prep'd and painted before the proper rebuild :)

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sounds of silence

well managed to make up a test engine today to try out positions for various parts and to make sure of clearance issues which i thought could be a problem , but after its in and everything tested its pretty much perfect to say the least 8)

 

a few teasing pics (now this will make me get the finger out)

 

DSC00172.jpg

 

DSC00173.jpg

 

DSC00176.jpg

 

DSC00177.jpg

 

and a pic to show the room to get in from the cage

 

DSC00175.jpg

 

DSC00174.jpg

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M@tt

thats a fantastic effort mate!!!

 

simialr to what i'd like to do do my Dimma which will be my next project.

 

Out of interest what are material costs like to build a cage like that? also is your pipe bender one of them fancy programmable hydraulic efforts or a manual jobbie?

 

keep up the good work!

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taylorspug

Proper effort there, well done that man! Its nice to see a track car being well thought out and nicely put together, rather than just a random bunch of 'fashionable' bits bolted in.

 

Be very interested in the engine spec when its done too. :)

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sounds of silence
thats a fantastic effort mate!!!

 

simialr to what i'd like to do do my Dimma which will be my next project.

 

Out of interest what are material costs like to build a cage like that? also is your pipe bender one of them fancy programmable hydraulic efforts or a manual jobbie?

 

keep up the good work!

 

cost of materials for the cage were prob around £500 but the man hours is where it is at lol

 

its a proper programmable hydraulic pipe bender mate we use for our exhaust systems etc.

 

and thanks

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sounds of silence

Managed to get the last pieces for the cage in place and thats now all the welding and cage done , next up is the car will be getting fully prep'd for painting this week and will hopefully be painted before the week is out depending on other work . Thought it would have been quiet first few weeks in jan but is not and we are actually fully booked so will just have to find time to squeeze my own in or ill end up running well behind.

 

strangthing plates welded to A pillers and roof

 

DSCF0013.jpg

DSCF0015.jpg

DSCF0018.jpg

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roof also braced

 

DSCF0020.jpg

 

and the last piece was to brace the cage onto the rear suspension points

 

DSCF0023.jpg

DSCF0024.jpg

DSCF0026.jpg

 

the rear beam now fixes up through the floor and the cage to stop any flex this will go nicely with the group A beam we are building for it .

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sounds of silence

well today seen me in to start the preping the car , nothing to drastic needing done but few dents etc normal stuff for a car 20 years old :)

 

DSCF0041.jpg

DSCF0046.jpg

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all filled and ready to prime

 

DSCF0053.jpg

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rest of the car stripped ready to start the paint work now all off the wiring loom , steering column and clutch and throttle cable oh and peddle box and servo ;)

 

now this is total naked 8)

 

DSCF0064.jpg

DSCF0069.jpg

DSCF0062.jpg

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sounds of silence

and on that note a was back in today to start the painting so had to give a few of the boys a shout as the team are still off till monday , so cheers guys :wink:

 

first off moved the car into the booth and panel wiped it all

 

DSCF0070.jpg

DSCF0073.jpg

 

then on to the etch primer

 

DSCF0077.jpg

DSCF0079.jpg

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sounds of silence

then started the high build primer

 

onit 8)

DSCF0084.jpg

DSCF0085.jpg

DSCF0087.jpg

 

then full car primed

 

DSCF0088.jpg

DSCF0089.jpg

DSCF0090.jpg

DSCF0094.jpg

 

now ready to paint woohoo 8)

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M@tt

so have you made you own exhaust manifold as well?

 

any pics??

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sounds of silence

no mate got my hands on a new dp engineering one "welders nightmare" the design of that maniold is superb

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sounds of silence

and for another little update ,

 

today seen the car go into paint , big ups to toffi nice job for first day back :wink: dont say a aint nice to ya :lol:

 

and on that note always bet on black :lol:

 

DSC00192.jpg

DSC00194.jpg

DSC00196.jpg

DSC00197.jpg

 

pictures really dont do it justice imo coz this really s to die for 8)

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sounds of silence

a few pics from last year at the track

 

SOS 1

14062008125.jpg

 

SOS 2

14062008124.jpg

 

SOS 3

14062008123.jpg

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