Running turbo at 0.6Bar

 The Engine is practicly ready to be removed from the car, all thats holding it in place is the engine mountings, gear shifter linkages and driveshafts. All other components, wiring e.t.c have been removed and labelled appropriately. The manifold for the turbocharger is currently being made.

 The bodywork has had a lot stripped off of it and started to have the dents repaired. The tailgate has been totally smoothed off and is in high build primer ready to be rubbed down.

 The interior of the car has got the corbeau seats fitted which took a while to sort out the subframes to fit properly, I have got all the carpet for the rear ready to be cut and put in, The turbo boost gauge has been all wired in ready to use in the centre console and the rear seats have been removed.

 The engine is being removed Saturday 31st may, to start on re-conditioning it and cleaning ready for tuning. Change of plane on the manifold that has been made for the conversion, now im after a Turbo technics style one (email me if anyone knows where to find one). Im thinking about changing the turbocharger that i already have (Which is a garrett T2), for a garrett T25!

- Wednesday 16th june 2003

 The 1.9 engine is out the 205 which i started to strip the head, but i have now found something better than i could expect! Ive been ringing around and found a complete Turbo technics 205 1.9 GTI engine, which i am getting this week!

 The engine is running at 190bhp (as i was told when i rang up), besides the turbo technics conversion it has a piper cam made specially for the turbo, piper vernier pulley and a reprofiled head. What im planning to do is to keep the head of the engine im buying, keep the bottom end that i already have and take the turbo technics pistons out of the bottom end im buying (although i might buy forged pistons?). Im doing this because i know the bottom end works on the engine i already have.

- Sunday 22nd june 2003

 I have now got the turbo technics engine which i have found out hasn't got a vernier cam pulley as i was told! Im not sure about the cam yet. I am trying to find out at the moment if the pistons are forged. All i wanted the engine for was the TT conversion anyway so the other items would have just been a added bonus!

 Im currently starting to recondition the Cylinder head which has had some inlet port modifications, Which is a bonus too!

Cylinder head reconditioning all done, Valves re-ground, Valves cleaned, Valves de-carbonised, Inlet ports cleaned, outlet ports de-carbonised and cleaned, New valve stem oil seals, Head painted in red engine paint and all thoroughly cleaned.

The turbo technics conversion parts have all been taken off the TT engine and are now all in my original 1.9 GTI engine. Parts which have been changed due to overhaul and the conversion are; Pistons out the TT engine, New big end bearings, New piston rings, Wet liners from TT engine, New wet liner seals, New cambelt and sump with oil return pipe on for the turbocharger!

 The engine and Cylinder head are back together now, With a new thicker group A competition head gasket fitted and New Torx head bolts.

 Only the clutch needed to get the engine back into the car!

The Engine has now been put back in the car, At last! The new clutch has been fitted which was easier than i expected! Alot of the engine has been built up; All wiring now connected to the engine, Inlet manifold back on, Throttle body, All water hoses have now been refitted apart from the water connection feed and return to the turbocharger, Most vacuum hoses have been fitted, fuel hoses and fuel components, Radiator, Intercooler, fan and some other things which i can't think of at present.

Ive acquired some Turbo Technics badges from Turbo Technics which will look good on the car once finished. Ive been converting a Peugeot 306 Rear bumper lower part to fit the 205, which is nearly done!

Not a great deal has been fitted to the engine since last time, The Turbocharger is the main part that is fitted to the vehicle. I have now purchased a bailey EVO dump valve for the car which i have yet to fit. I have fitted a one way valve to the pipe that comes of the top of the throttle body and goes to the breather pot, This is to stop charged air leaking out into the breather. I have also brought a magnex exhaust system which i am currently waiting for.

 The engine is increasingly becoming harder to work on, As the parts get in each others way!

I have recently finished fitting all the charge pipes to the engine, The dump valve is all hosed in, I have now got a braided turbo oil feed line which i had special made, The magnex exhaust has arived so i have tried it up but not fixed the front down pipe yet because a special peice has to be made for the turbo. The only things needed for the engine now is the Fuel injector controller, Air filter, breather filter, turbo two stage boost and thats it!

Ive finished boarding up the floor in the rear of the car, all thats left there is the roll cage and two peices of trimmed board for the sides.

I have made most of the custom exhaust downpipe for the turbo conversion only a little to do on that. Still need to fill the gearbox up with oil keep forgetting to do it.

My main concern now is to get the bodywork al ready for painting, I have recently purchased a set of side skirts which i will be customising, Genuine peugeot 205 spoiler which is a aftermarket larger add on and a gutmann grill. I think i will need to purchase a different front bumper as i am having trouble with fitting the custom one due to the intercooler location!

i have also Brought a HKS AIC fuel injector controller which i am waiting to be shipped from abroad!

Today ive Welded up the Passenger door lock and smoothed it. I have welded up a hole which was under the rear seats, welded a eye bolt plate for the harnesses to attach to. Also i have welded up the exhaust downpipe all in place and that fits well, needed a bit of pursuasion.

 The HKS AIC fuel controller arrived on thursday so i have just started to fit that into the vehicle. The top charge pipe and samco hose has alos arrived so i have fitted them between the turbo and air flow meter.

- Thursday 13th November 2003

 Ive purchased a Gasket for my turbo outlet to help seal things up, so all i need to do on the week end is to fit the sections of exhaust in place.

 My sideskirts arrived and my spoiler. The sideskirts are very good and i am very happy with them, the spoiler is good but to fit it ideally you need the original GTI spoiler still fitted which i chucked away!

I have started to underseal all under the arches and underneath the car.

The exhaust downpipe is all fitted, the injector controller is nowfitted although i have to mount it inside the car, The air flow meter is all fixed in place now and i have tried up the sideskirts ready to fit.

 Ive got the engine to idle well and sounds nice when running, also i have heard the dump valve working although i shouldn't have revved it up so much as to hear it (whilst the engine is being run in).

I have ordered the rear valance, the front valance and the bonnet.

I have started doing more to the bodywork repair wise, i have also fitted both side skirts and started to blend them in.

All body parts have arrived and have been tried up to the car, the bodywork is coming on now. The rear screen is going to have to come out again due to the fact that i cannot blend the spoiler with it in.

It will be getting sprayed hopefully on the 20th of December.

- Saturday 20th December 2003

Throughout the past week i have really worked hard to get the bodywork ready for spraying! and thankfully all was achieved in time to get it sprayed today! The colour is still red but it is from a peugeot 206. It looks really good all i have to do now is to fit all the panels back up!

The engine is also going very well, i was unsure what was up with it for a while since the rebuild. i checked the compression this was fine, the injector wiring was fine, the leads and plugs were fine? so i decided to switch around the two centre ht leads, because this is where the problem was considered to be in the centre cylinders. This solved the problem and is now running very well and fast!

Thought i'd put some new pictures up for once seems as i had my hand on a digital camera!

Ive purchased a set of wheels, AZEV 'A' which i am considering spraying white don't know yet? have to decide when they come.

Ive over come problems with regards to bumper and intercooler hitting causing bumper to fit incorrectly and also sorted the grill to get that fitting correctly!

Recently ordered my lowering springs which are -40mm and also purchased some focus style side repeaters which are different! The alloy wheels have yet to arrive, still waiting.

 I have Fitted alot of the vehicle back together including bonnet, doors, tailgate and several trim peices. The passanger door will have to be resprayed due to the fact silicon got in the paint on the door!

 Im thinking of designing and making a one off fron bumper different from the one ive got so it will sit nicer with the intercooler!(which is really doing my head in!)

Ive lowered my car today at the rear end cause ive still yet to recieve the springs for the front!

it looks pretty good but even one spline on the back seems to be alot!

The wheels arrived yesterday and ive started to rub them down ready for painting white.

My lowering springs arrived before the weekend just gone, So they have been fitted to the car. At the moment there sitting a little high but when i get some driving in they should settle down, and bed in.

 Ive polished up most of the car since the respray but will wait till its all finished to give it a wax and valet it.

The passenger door has been resprayed again due to silicon and is now ok. I have fitted all the mouldings except the drivers door centre moulding.

I have brought and started fitting my alarm system which is a scorpion Audi approved system, which if you've got a thatcham 2 immobiliser it bumps the system to category 1 status.

Ive got to get the car ready for a MOT this month so it will be ready for the end of the month!

Finished the n/s front wheel bearings yesterday, also changing the o/s gearbox oil seal and the CV boot. Started to do the other side changed the n/s gearbox oil seal and the n/s CV boot. The reason i didnt change the n/s wheel bearings was due to the fact ive got 2 different size bearings on the front!

i was going to do all the front brakes aswell, but i was sent the totally wrong front discs from Euro car parts! so i havent been very happy!

The wheels have all been sprayed white and have been fitted with tyres. Ive also purchased some 9.5mm wheel spacers allround to cope with the wider wheels, also have brought longer wheel bolts!

Undersealed the underneath of the car with underseal/waxoil.

Both front wheel bearings have now been sorted, all disc brakes and pads have been fitted and the brakes have been bled through.

The alarm is now fitted and working correctly, although to begin with i had a faulty unit!

MOT booked in for the 20th of february, just have to wait and see!

Took the car to have the MOT today it failed!

- N/S front indicators not working

- N/S front suspension ball joint not tight

- Number plate lights not working

- O/S washer jet not clearing screen

ive sorted all now exept ball joint which im doing first thing in the morning and taking back down!

Took back to MOT station, all passed ok!

The car feels really quick even at low boost and not revving it hard! cant wait till its run in!

Ive clocked up over 1000 miles since ive had it on the road to make sure its all run in.

Ive found out that the turbocharger is faulty, the seals and bearings have gone in it! also the exhaust housing has a crack going through it! so it seems to smoke alot after the engines been revved high!

its coming off the road tomorow for a little while to get a new turbo put on it!

i just hope it is the turbo in the end!

Sent the Turbo off to Turbo technics heard back that there are no parts on the turbo that can be re-used! so ived brought a new turbo unit just waiting for it to be built and sent.

Ive also purchased some Antares arches for the car so it will be looking different when next out! More red! hopefully not to much.

The turbo arrived on tuesday so it will be fitted on saturday.

The arches arrived today very good quality and i will see if ive got time to start putting em on, on saturday.

Put the new turbocharger on the car today, found it easier than when i put the old turbo on the first time! had a bit of trouble with the oil return pipes!

took it out for a good run after it had been finished and it doesnt smoke anymore, havent put my foot done as im going to try and run the piston rings in a bit more!

Riveted the antares arches on all thats needed to be done on them now is to grind the heads of the rivets down and smooth the arches into the body!

it will be getting sprayed in the next couple of weeks and is going to be in a group thrash!

The arches have been finished and also i have smoothed off the rear quarter badges, the car has now been resprayed done both sides and looks very red!

I have adjusted the actuator on the turbo as it was boosting to high and is now boosting consistant at 0.6 bar until i get it all set up.

i have purchased a air fuel ratio gauge for it and am going to be buying a lambda sensor for it. the exhaust system is blowing in the middle and will be sorted out shortly.

The air/fuel ratio was fitted tuesday and works pretty good!

The car was rolling roaded today and to begin with was pushing out 152.7BHP and is now pushing out 177.4BHP @ 0.6 bar. i was told it could easily get 15BHP more but the actuator rod needs to be shortened to get the boost.

so at the moment its producing more power than a standard Turbotechnics @ less boost!

Purchased a Antares front valance and also a front splitter to go with it.

will be getting sprayed shortly and fitted to car.

The antares valance is fitted along with the splitter for it and fog lamps!

i think ive nearly come to the end of doing more to this car!

Fitted some lexus style tail lights to the car which look good!

The car has now been reluctantly sold to fund my second project. I would of loved to keep it but unfortunately i needed the money to go further with my current project!

Car featured in a group thrash in a magazine (whilst i owned it).

Performance GTI September/October 2004

( Red car a front left behind 205 T16)