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| Author | Subject: 309 project |
 bobdylan_55
Seasoned Pro  Location: derby Registered: 28 Mar 2009 Posts: 1,466 Status: Offline |
Post #1
hi, some of you may know i currently am doing a bit of a retoration/tuning on a 309 gti. Thought id upload the project thread so far onto here for you all to gander at  Before   started the day just planning on taking the bumpers off to repair them. just after removing the front bumper, rajj decides to persuade me to rag the engine out lol so here are todays pictures in order         [img]http://img21.imageshack.us/img2 ________________________________________ 309 GTi6-T |
 Posted 14th Sep 2009 at 23:06
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MCH_GTi6
formerly mch  Location: Hayle Registered: 09 Sep 2005 Posts: 2,456 Status: Offline |
Post #2
looks a cool project! I like it! keep us updated ________________________________________ Team Moonstone� Ph3 GTI6Team Rallye |
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Posted 14th Sep 2009 at 23:22
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rallyeash
Seasoned Pro  Location: Devizes Registered: 11 Dec 2006 Posts: 4,424 Status: Offline |
Post #3
awsome project made, love it even more being in a 309. what power you hoping from it? should suprise a few people________________________________________ 230 hp 2.1 16v XU 205 rallye on jenveys Project thread here309 3dr K20 Type R |
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Posted 15th Sep 2009 at 13:34
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bobdylan_55
Seasoned Pro Location: derby Registered: 28 Mar 2009 Posts: 1,466 Status: Offline |
Post #4
looking for 350bhp ish, but as it only weighs about 950kg with driver and the bigger 2.0 engine its going to be putting out more like 380bhp per tonne lol, thats more than some well known porsches etc________________________________________ 309 GTi6-T |
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Posted 15th Sep 2009 at 14:32
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birk
Seasoned Pro  Location: Doncaster Registered: 24 Oct 2005 Posts: 7,032 Status: Offline |
Post #5
On standard pistons and rods ? thought turbo's needed high compression?________________________________________ Dimma + Gt35 turbo = Solid rear beam mounts £130 07889376885 Dan |
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Posted 15th Sep 2009 at 17:23
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bobdylan_55
Seasoned Pro Location: derby Registered: 28 Mar 2009 Posts: 1,466 Status: Offline |
Post #6
birk wrote: On standard pistons and rods ? thought turbo's needed high compression? no it needs to be low compression as the turbo adds compression when under boost. standard s16 pistons and rods have commonly been used to reach 400bhp. ________________________________________ 309 GTi6-T |
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Posted 15th Sep 2009 at 17:26
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birk
Seasoned Pro Location: Doncaster Registered: 24 Oct 2005 Posts: 7,032 Status: Offline |
Post #7
Ahh i get you.Interesting, wonder if could get away with a compression plate on my supercharged engine and use standard rods and pistons ? ________________________________________ Dimma + Gt35 turbo =Solid rear beam mounts £130 07889376885 Dan |
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Posted 15th Sep 2009 at 17:29
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bobdylan_55
Seasoned Pro Location: derby Registered: 28 Mar 2009 Posts: 1,466 Status: Offline |
Post #8
maybe, but gti6 pistons are slightly different to s16 pistons, theyre 1mm taller iirc. id not recommend it if going above 300bhp.________________________________________ 309 GTi6-T |
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Posted 15th Sep 2009 at 17:36
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birk
Seasoned Pro Location: Doncaster Registered: 24 Oct 2005 Posts: 7,032 Status: Offline |
Post #9
Thought there would be a flaw in my plan  ill stick with low comp forged pistons and rods when i get some dosh then I'll stop boycotting your thread now aswell Good luck with the build, looks cock on, cant wait to see the finnished outcome  ________________________________________ Dimma + Gt35 turbo =Solid rear beam mounts £130 07889376885 Dan |
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Posted 15th Sep 2009 at 17:46
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rallyeash
Seasoned Pro Location: Devizes Registered: 11 Dec 2006 Posts: 4,424 Status: Offline |
Post #10
bobdylan_55 wrote: maybe, but gti6 pistons are slightly different to s16 pistons, theyre 1mm taller iirc. id not recommend it if going above 300bhp. i thought s16 ones were longer? ________________________________________ 230 hp 2.1 16v XU 205 rallye on jenveys Project thread here309 3dr K20 Type R |
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Posted 15th Sep 2009 at 18:20
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bobdylan_55
Seasoned Pro Location: derby Registered: 28 Mar 2009 Posts: 1,466 Status: Offline |
Post #11
think its the other way around so ive been told. gti6 ones are 1mm taller, rods etc are all the same. ________________________________________ 309 GTi6-T |
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Posted 15th Sep 2009 at 19:27
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allanallen
Seasoned Pro Location: Buxton Registered: 01 May 2007 Posts: 1,399 Status: Offline |
Post #12
This looks an excellent project, nice work with the manifold. Its always nice to see people doing something a bit different/doing the work themselves.whats the advantage of running the j2te block over the j4rs? and what CR have you gone for, looks to be a fairly thick de-comp plate. al ________________________________________ www.bridgecraftmotorsport.co.uk |
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Posted 15th Sep 2009 at 20:01
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bobdylan_55
Seasoned Pro Location: derby Registered: 28 Mar 2009 Posts: 1,466 Status: Offline |
Post #13
allanallen wrote: This looks an excellent project, nice work with the manifold. Its always nice to see people doing something a bit different/doing the work themselves. whats the advantage of running the j2te block over the j4rs? and what CR have you gone for, looks to be a fairly thick de-comp plate. al the j2te block has oil lines as standard for turbo applications, so no need for tapping into sumps or t-ing into oil lines, its also apparently very slightly stronger and can handle more compression (note apparently). the compression has been lowered to approx 8.4:1 ________________________________________ 309 GTi6-T |
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Posted 15th Sep 2009 at 20:29
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allanallen
Seasoned Pro Location: Buxton Registered: 01 May 2007 Posts: 1,399 Status: Offline |
Post #14
bobdylan_55 wrote: allanallen wrote: This looks an excellent project, nice work with the manifold. Its always nice to see people doing something a bit different/doing the work themselves. whats the advantage of running the j2te block over the j4rs? and what CR have you gone for, looks to be a fairly thick de-comp plate. al the j2te block has oil lines as standard for turbo applications, so no need for tapping into sumps or t-ing into oil lines, its also apparently very slightly stronger and can handle more compression (note apparently). the compression has been lowered to approx 8.4:1 gottcha, that saves some mither then. How much was the de-comp plate if you dont mind me asking. cheers allan ________________________________________ www.bridgecraftmotorsport.co.uk |
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Posted 15th Sep 2009 at 20:37
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c.a.r.
Seasoned Pro  Location: Stevenage Registered: 27 Jun 2008 Posts: 2,211 Status: Offline |
Post #15
Isn't that turbo manifold pretty close to the brake lines? Is it already a plan to re-route them?Looks smart, the fabrication work is always nice to see. ________________________________________ '99 1.8 XS - Sold'00 GTi6 - Killed by armco '01 Cabriolet 1.8 - Sold '96 Eunos Roadster 1.8 Import |
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Posted 15th Sep 2009 at 20:47
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bobdylan_55
Seasoned Pro Location: derby Registered: 28 Mar 2009 Posts: 1,466 Status: Offline |
Post #16
the decompression plate was ________________________________________ 309 GTi6-T |
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Posted 15th Sep 2009 at 20:53
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mike rallye
Seasoned Pro Location: mold Registered: 03 Sep 2008 Posts: 1,618 Status: Offline |
Post #17
some excellent work been done. nice to see a 309 been saved and not going to the crusher |
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Posted 16th Sep 2009 at 01:06
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bobdylan_55
Seasoned Pro Location: derby Registered: 28 Mar 2009 Posts: 1,466 Status: Offline |
Post #18
lol the actual car itself is a complete shed, everything on it is seized etc, but its going to undergo a full restoration as part of my uni course so all is good ________________________________________ 309 GTi6-T |
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Posted 16th Sep 2009 at 02:52
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mike rallye
Seasoned Pro Location: mold Registered: 03 Sep 2008 Posts: 1,618 Status: Offline |
Post #19
are you going to be re-fitting the timing covers or leaving them off? |
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Posted 16th Sep 2009 at 02:55
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bobdylan_55
Seasoned Pro Location: derby Registered: 28 Mar 2009 Posts: 1,466 Status: Offline |
Post #20
well the engine is coming out again at some point, but im not sure if ill be fitting them. my brother runs his 106 xsi (all speced up throttle bodies, cammed etc) without a cam cover, and thats used regularly on road and on track (sprints etc) and is fine. might do for reasurance though, also gives me something to paint  ________________________________________ 309 GTi6-T |
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Posted 16th Sep 2009 at 02:59
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chicken_rallye
Regular  Location: Portsmouth Registered: 02 Mar 2009 Posts: 166 Status: Offline |
Post #21
quality looking project i am impressed!always had a soft spot for 309's proper retro and were slightly overlooked wih the 205 good luck and keep the updates coming ________________________________________ tap tap....BOOM!!Now singing sweetly thanks to a fistful of cash and a friendly Rich_w! |
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Posted 20th Sep 2009 at 15:45
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bobdylan_55
Seasoned Pro Location: derby Registered: 28 Mar 2009 Posts: 1,466 Status: Offline |
Post #22
been and made this gasket in the garage this morning. bit tatty around the edges, but it should do the job   its for the exhaust flange on the turbo got my re-positioning adapter for wastegate aswell, just going to go trial fit, so pics in a min ________________________________________ 309 GTi6-T |
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Posted 6th Oct 2009 at 19:56
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bobdylan_55
Seasoned Pro Location: derby Registered: 28 Mar 2009 Posts: 1,466 Status: Offline |
Post #23
wastegate is still a no  stupid bonnet is in way, and head aswell lolthis is the most complete ive seen it since the gutting started about a year ago. got radiator in minus the fan, and then moved it back about an inch and slid it across towards the passenger headlight. This gave me the room the the intercooler piping to go past it as you can see (the blue pipe) and the intercooler fits infront of it, the other pipe will go down near where the horns are and then under the chassis and back up. i have about 65-70mm clearance between rad and intercooler, so anybody know of a slimline in that size?    ________________________________________ 309 GTi6-T |
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Posted 6th Oct 2009 at 19:57
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bobdylan_55
Seasoned Pro Location: derby Registered: 28 Mar 2009 Posts: 1,466 Status: Offline |
Post #24
intercooler bracket made and fitted, pipe work also fitted, however ran out with one pipe left needed only 20cm aswell lol.        ________________________________________ 309 GTi6-T |
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Posted 8th Oct 2009 at 19:54
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rallyeash
Seasoned Pro Location: Devizes Registered: 11 Dec 2006 Posts: 4,424 Status: Offline |
Post #25
pipe works tidy and out the way, nice work  ________________________________________ 230 hp 2.1 16v XU 205 rallye on jenveys Project thread here309 3dr K20 Type R |
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Posted 8th Oct 2009 at 20:00
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