dont feel bad steve your on par with me now ive had 3 chargers

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1990 205 gti6 supercharged

Well, time for another small update, things aren't going as planned for me at the moment

My new dump valve has arrived, but fitted with the wrong spring. (Came with a -10psi fitted, i ordered -2psi for s/c applications). Called up the supplier and they said they'd get back to me but never did, hopefully i'll get hold of them tomorrow and they will have the correct spring in stock and get it sent to me by friday or its going to be one crap trackday.
Regardless of this issue i've carried on with getting everything else fitted, so here are a few pictures.

IMG_5781 by Steve Count, on Flickr

IMG_5782 by Steve Count, on Flickr

IMG_5783 by Steve Count, on Flickr

IMG_5788 by Steve Count, on Flickr

IMG_5785 by Steve Count, on Flickr

The only place i could squeeze it in

And for anyone that likes a little whine, i got a video the other day before the boost pipework was done up. clicky

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Goldie the track car.

Was just watching your Nordschleife video, what's stuck to the bottom of the windscreen?

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Rallye Race Car

The whine sounds a bit louder in that video than in the flesh, hopefully this charger is healthy as i cant afford to go buying a fourth one as a replacement!
It might also be loud because in that video the inlet to the charger goes straight to the air filter, no throttle body in place to quieten it down, and likewise, the outlet just goes through the intercooler and vents to atmosphere, not the engine.

I'm guessing you mean the Nordschleife videos from 2013 Dan? If so the bottom right on the windscreen is a suction mounted phone holder, made life easier using the phone mounted there to control the go pro. To the left of the windscreen is the tax disc holder, but i guess i can remove that now and save a few grams

I've been in touch with them today Stef, correct spring should be with me tomorrow With any luck i'll not have any more issues with the car anymore.
How much boost are you running with yours?
Mind me asking what pulley sizes you run aswell? Just wanting to try and figure out how much air yours will be blowing through the valve at say 7000rpm with the throttle closed, you're now running an M90 arent you?

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Goldie the track car.

Im running a soild 0.8 bar pretty much there from the word go now about .6 at 2k id say. I run a stock c/p 127mm and a stock 3" s/c pulley im spinning mine extremely slow it was this or no boost we tried a 90mm c/p and i made nothing lol. im on a m90 gen 3 but with the later case porting dont ask the difference in performance as im not sure. The m90 flows 1,400cc and the m62 flows 1,000cc but thats based on the gm m62 which has near the same rotor pack as the m90. The merc m62 is a bit of a funny one as it shares the same rotor pack as the m45 nearly its going to be a hard one to judge. Ive a boost calculator here if you want it just message me on faceache and ill send it you. As for filters im now only using a cone and a trumpet sock as it was creating vacuum on the charger could have been the cheap filter i was using.

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1990 205 gti6 supercharged

the tial valve is rated upto "1800bhp" i dont get any inlet gargle so you will be ok. Silly question youve checked for boost leaks and your cam timing ?

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1990 205 gti6 supercharged

Last time I checked the cams were timed to standard settings (drill blanks fitted in fine when locked up).
I haven't checked for boost leaks to be honest, but if it's making 6psi low down surely any leaks would mean that it stayed at 6psi rather than Peter off with revs?
I reckon a lot of it would be to do with the heat as the charger was getting way too hot to touch by hand, when I had this new one running the other day it stayed cool for the few minutes it was running, the previous ones would be quite hot after just a couple of minutes.

What's the best way to check for boost leaks? It's been a long day
When I was checking my manifold for leaks I just kept spraying it with carb cleaner with the engine running and you could hear the engine note change when I sprayed it at a leak (the manifold warped a bit with the welding where it met the head, so i just kept nipping up the bolts a little more to seal it against the ptfe gasket).

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Goldie the track car.

dont laugh but this worked a treat! old pic but it did the job this way i could pressurize it all.

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1990 205 gti6 supercharged

rad looks fine, though the MASSIVE intercooler blocking it wont help

have you checked the charge temps? I noticed theres quite a gap above the rad, filling that in will help, most of the air will try going straight over the top, filling in the sides to the bumper will help too, separatethe lower grille from the fog lamp holes.

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need a part number? get on here - http://public.servicebox.peugeot.com

Bring on the Trumpets.

I still think you need more bonnet catches.

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- Bespoke rollcages/additions/adjustments. Half cages right up to complete custom spaceframes - MSA/FIA spec, CDS, ROPT, T45, etc - PM me
Email me!
Custom-made polybushes available - need an odd size or fitment? - anything from batch work to one-off pieces.

They're all on back order


Yeah it's started to bother me too, i'll look into sorting it if i get chance this weekend.

Don't suppose you know either of them R32 drivers do you Ian? Would be interesting to see if they have project threads and what they've done to their cars.

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Goldie the track car.

Time for another small update.
Not an awful lot has been done to the car since the last trackday, but i've made a little start on sorting some of the older issues and found some fresh ones.

To help sort out the oil temperature on track i decided to get an oil-air cooler to fit between the engine and the laminova. I got a little carried away and went overkill, but my theory is that this should be capable of bringing the oil temperature right down, then the laminova will then put a decent amount of heat back into the oil before it goes through the filter and back into the engine where it will then be circulated. This should also help take some heat out of the coolant and bring that temperature down too.

IMG_6639 by Steve Count, on Flickr

IMG_6638 by Steve Count, on Flickr

IMG_6640 by Steve Count, on Flickr

Very tight squeeze to fit it here, but i couldn't really find anywhere else i could fit it with hopefully decent airflow without having to use a fan. I'm going to make a shroud for this cooler to direct air from the grille/foglight hole.

Another thing i've made a start on is a shroud around the radiator to help force more air through that than just escaping round it and into the wheelarch area or under the engine.
Still plenty to do to finish this but this is the progress so far.

IMG_6602 by Steve Count, on Flickr

Make-shift sheet aluminium bender

IMG_6663 by Steve Count, on Flickr

IMG_6664 by Steve Count, on Flickr

Next up is quite an annoying problem, the third supercharger now appears to be on its way out and sounds like this
YouTube clicky

Looking at the rotor bodies they look to be fine though, and turning by hand i cant feel any backlash or anything untowards.
YouTube clicky

I could really do with taking the inlet manifold off the charger and having a look at the ends of the rotors as thats where the previous two have failed, although both of them just seized solid without any warning sounds before hand.

Anyway, one of the things that i think has caused this failure could be the harsh vibrations that the gears/rotors have to put up with from the crank. Obviously the standard pulley has a rubber damper ring built into it, but my crankshaft pulley is machined from a solid billet of aluminium.
Most eaton superchargers have a coupler fitted inside the snout which helps damp out vibrations but due to mine having an electromagnetic clutch as standard i didnt incorporate any real damping into my pulley setup. The standard clutched system did have a sheet of rubber between the friction plate and the plastic end cap to help with vibration, and the end cap itself being a rubbery plastic will have helped.
Anyway, enough with the waffling on, i'm now in the process of trying to fit an auto tensioner to help reduce belt slap whilst the engine is varying revs etc, and i've started making some adapters so i can fit a polyurethane coupler to help give some damping to the 'charger.

First up i raided the scrap bin at work to make the male and female molds, then smeared them with grease as i'm too tight to buy proper release agents or anything like that

IMG_6620 by Steve Count, on Flickr

Then i mixed up a batch of polyurethane and poured it in.

IMG_6621 by Steve Count, on Flickr

30 mins later it was set.

IMG_6626 by Steve Count, on Flickr

I then made a couple of aluminium plates, one which will bolt to the 'charger pulley and have three dowel pins fitted, the polyurethane coupler will then mate up against this, then the outer alloy plate will have three dowel pins in which fit into the polyurethane coupler, this outer plate will also bolt to the splined adapter which i removed from a spare clutched pulley system.
The parts are all turned now and just need the relevant pcd drilling and tapping etc.

IMG_6666 by Steve Count, on Flickr

IMG_6668 by Steve Count, on Flickr

IMG_6670 by Steve Count, on Flickr

IMG_6671 by Steve Count, on Flickr

I've also diagnosed what the knocking was that could be heard in some of the videos from the last trackday, the rear mounting points for my wishbones had some slack in them where the bolt went through the subframe, it became noticeable when accelerating or braking harshly as it would pull the car to one side or the other. I didn't get an accurate measure of the original hole through the subframe but it appeared to be just under 12mm, which i thought was weird as the standard setup uses an m8 bolt to locate the P bush. Anyway, i made like a shouldered washer at work with a 12mm section turned 3mm long, and a snug bore to my mounting cap screws, and ran a 12mm cone drill through the subframe hole, now the setup has no play in it at all even with the nyloc loose on the capscrew, so that should be that issue sorted.

That's about it for now, hopefully more updates soon as i need it ready for the pscuk curborough day next month.

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Goldie the track car.

Can't wait to see this at Curborough

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Nothing to see here