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Author Subject: 206 turbo
206

Newbie

Location: Belgrade

Registered: 24 Feb 2011

Posts: 42

Status: Offline

Post #1
Hi guys,

thought it might be an interesting project to present.

206 GTI Turbo, EW10J4 - 478BHP. That was the injector limit at the time of mapping, so i didn't want to bother with replacing them, so i left it there. But since the engine has way more potential, and there have been a couple of slightly more powerful 206s around since then, decided to crank the boost up a bit and use E85, which should make around 550BHP.

Started out as a basic tuning project, and gradually turned into a monster Big grin Had so little experience as i started out, learned so much, mostly through my own mistakes - and trust me, there is not a SINGLE thing can happen that has NOT happened with this car, went through it all (list of failures is as long as the list of things i got right): broken pistons, failed gaskets, failed gearboxes, driveshafts, diffs, blown and leaking turbos, engine heads...everything you can think of. Miraclously everything works now, got so many interesting features and unique solutions on the car that it's almost too much to think of everything.

Somebody mentioned there's another ITB+turbo car here, i'd love to hear about that, as it's a rare thing.

I'll follow up with a list of mods...hope i won't bore you with a long read Big grin Some things have changed, some are still to change, but i'll correct from time to time.

A couple of pics - some of them are with an old GT28 turbo, and from previous "evolutions" but generally that's that.

Questions welcome.



Posted 27th Feb 2011 at 00:52
206

Newbie

Location: Belgrade

Registered: 24 Feb 2011

Posts: 42

Status: Offline

Post #2

Engine:

- 1997 EW10J4 standard aluminium block, piston oil cooling added
- forged crank, tri-metal race bearings
- Saenz forged rods
- custom Wiseco forged pistons 9.0:1
- Total Seal Gapless rings
- tri-layer gasket
- ARP fasteners
- Richard Longmann engine head
- mechanical valvetrain, double springs, stainless steel valves
- double oil recirculation setup
- custom 296deg -12.9mm cam
- Jenvey 42mm throttle bodies
- custom aluminium airbox
- custom double-pass IC
- Accusump anti-surge oil reservoir
- Mocal twincore oil to water heat exchanger
- modified oil pump
- modified power steering pump
- turbo oil return electric scavenge pump
- equal-runners exhaust manifold
- Simmons 3” centre and rear exhaust box, metallic race cat
- Bosch 044 fuel pump
- Turbosmart FPR
- Turbosmart WG
- Turbosmart BOV
- Garrett 3071R turbo
- Wizard Of Nos direct port N2O sistem 200+ KS
- 4x788cc injectors
- custom alu twincore radiator
- 12” Kenlowe fan

Power – Dynapack hub dyno:

- 468BHP@7283rpm, 240Kpa, Shell VPower
- 540Nm@5258rpm


Electronics and Electrics:

- NIRA I3+ ECU
- NIRA EGT
- NIRA flatshift
- NIRA launch control
- Wizard Of Nos Max Extreme N2O kontroler
- Innovate XD-16 AFR i lambda controller
- Innovate LC-1
- DEFI Link Meter BF: boost, EGT, fuel pressure, oil pressure, oil temperature, water temperature, tacho
- 4xHID 5000K
- LED rear lights
Transmission:
- custom 184mm flywheel mod
- AP Racing 184mm twin cerametallic plate 700Nm mechanical clutch
- Quaife ATB diff
- Peugeot BE4-5 gearbox, modified bellhousing
- custom made driveshafts, axles and CV joints

Brakes and wheels:

- front: Compbrake B4 4-pot calipers front, Powervane split rotors 286mm
- Black Diamond rear rotors, standard calipers
- modified brake booster, 2 electronically controller mechanical vacuum pumps
- Street: 7x17 BK Racing + 205-45-17 Yokohama AVS Sport
- Race: 6.5x15 BK Racing + Mickey Thompson 205-50-15 Drag Radial

Suspension:

- KW Suspensions coilovers
- Peugeot Sport control arms
- Aluminium + solid rubber engine /gearbox / rear subframe mounts

Interior and exterior:

- Corbeau reclining seats in alcantara
- custom LED dash lighting
- Oracal matt black vinyl wrap
- Oracal 3D carbon hood wrap
Posted 27th Feb 2011 at 00:53
206

Newbie

Location: Belgrade

Registered: 24 Feb 2011

Posts: 42

Status: Offline

Post #3
.

206 has attached the following image:

Posted 27th Feb 2011 at 00:54
206

Newbie

Location: Belgrade

Registered: 24 Feb 2011

Posts: 42

Status: Offline

Post #4
.

206 has attached the following image:

Posted 27th Feb 2011 at 00:56
206

Newbie

Location: Belgrade

Registered: 24 Feb 2011

Posts: 42

Status: Offline

Post #5
.

206 has attached the following image:

Posted 27th Feb 2011 at 00:58
206

Newbie

Location: Belgrade

Registered: 24 Feb 2011

Posts: 42

Status: Offline

Post #6
.

206 has attached the following image:

Posted 27th Feb 2011 at 00:58
206

Newbie

Location: Belgrade

Registered: 24 Feb 2011

Posts: 42

Status: Offline

Post #7
.

206 has attached the following image:

Posted 27th Feb 2011 at 00:58
206

Newbie

Location: Belgrade

Registered: 24 Feb 2011

Posts: 42

Status: Offline

Post #8
.

206 has attached the following image:

Posted 27th Feb 2011 at 00:59
206

Newbie

Location: Belgrade

Registered: 24 Feb 2011

Posts: 42

Status: Offline

Post #9
.

206 has attached the following image:

Posted 27th Feb 2011 at 00:59
SteviePut

Seasoned Pro

Location: Down south

Registered: 20 Oct 2005

Posts: 13,637

Status: Offline

Post #10
Nice project. I bet it's tricky using all that power/torqueLOL

________________________________________

My old man wrote me a letter from prison once. It said if you don't want to end up in here, stay away from crime, women and drugs. Trouble is, that don't leave you much else to do, does it?
Posted 27th Feb 2011 at 02:33
206

Newbie

Location: Belgrade

Registered: 24 Feb 2011

Posts: 42

Status: Offline

Post #11
You'd be surprised how little torque steer there is, and it's surprisingly easy to drive without too much wheelspin. I got a few Youtube videos, look up YT username PeugeotBG and browse the vids.
Posted 27th Feb 2011 at 02:58
206

Newbie

Location: Belgrade

Registered: 24 Feb 2011

Posts: 42

Status: Offline

Post #12
You'd be surprised how little torque steer there is, and it's surprisingly easy to drive without too much wheelspin. I got a few Youtube videos, look up YT username PeugeotBG and browse the vids.
Posted 27th Feb 2011 at 02:58
welshpug!

Capt Pedantic

Location: Bigend, Wales.

Registered: 27 Mar 2007

Posts: 25,839

Status: Offline

Post #13
I'm quite impressed that you are still on the BE gearbox Smile

________________________________________

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

Bring on the Trumpets.

Posted 27th Feb 2011 at 03:07
206

Newbie

Location: Belgrade

Registered: 24 Feb 2011

Posts: 42

Status: Offline

Post #14
Well, i have broken a diff (replaced with a Quaife that will hold forever), an earlier BE3 i've put together, and only recently i've shaved off the 4th gear from the original GTI box (my fault...) - and the 180's BE4 works great, mostly thanks to the small mod i did before installing it.

Main reason the box breaks is not the strength or weakness of the gears, but housing bell flex. So i've placed a steel 10mm plate between the box and the block, and something similar to the block - makes it much more rigid, stabilizes the block as well. No flex, no breaking.
Posted 27th Feb 2011 at 03:57
berger

Seasoned Pro

Location: Bathurst

Registered: 26 Oct 2008

Posts: 1,068

Status: Offline

Post #15
Holy dog poop that is impressive!

________________________________________

Bang'in 7 gram rocks!
I have one gear, GO!
Posted 27th Feb 2011 at 05:58
206

Newbie

Location: Belgrade

Registered: 24 Feb 2011

Posts: 42

Status: Offline

Post #16
Btw, i would've switched to ML if i didn't have the heavy duty driveshafts already made for the BE, and the fact that you can't get a decent LSD for an ML.
Posted 27th Feb 2011 at 06:11
welshpug!

Capt Pedantic

Location: Bigend, Wales.

Registered: 27 Mar 2007

Posts: 25,839

Status: Offline

Post #17
you can, Quaife do one!

Many people will make you one if you ask Wink

________________________________________

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

Bring on the Trumpets.

Posted 27th Feb 2011 at 12:55
musclebeach

Seasoned Pro

Location: Yorkshire

Registered: 13 Aug 2006

Posts: 7,763

Status: Offline

Post #18
That is absolutely stunning! I'm very impressed! I was dubious about a 206 project but not now!!!! Great work!

________________________________________

VW Golf GT TDI 115, 100k nooooooooooooooooooooo!

Posted 27th Feb 2011 at 14:12
adam b

Seasoned Pro

Location: The Nam

Registered: 24 Jan 2006

Posts: 12,828

Status: Offline

Post #19
206 wrote:
Btw, i would've switched to ML if i didn't have the heavy duty driveshafts already made for the BE, and the fact that you can't get a decent LSD for an ML.


You can get a quaife one for the ML boxesWink

________________________________________

Nothing to see here
Posted 27th Feb 2011 at 15:05
206

Newbie

Location: Belgrade

Registered: 24 Feb 2011

Posts: 42

Status: Offline

Post #20
Oh s***...you do realize that you totally f***** me over right now? Big grin I was hoping that i've finally got it finished and that i was done with major mods? Now i don't have an excuse not to put it on...great.

Ok, what box and what Quaife par no? I got a box from the 407 2.2, i think it's the ML5C...
Posted 27th Feb 2011 at 15:43
welshpug!

Capt Pedantic

Location: Bigend, Wales.

Registered: 27 Mar 2007

Posts: 25,839

Status: Offline

Post #21
yup, it was listed for a Boxer van! So likely to be the ML gearbox.

I can't find it on the new catalogue, but if you really want ML box then its worth contacting them, they do list one for a Citroen CX LOL

I'm sure it was Gripper or some similar UK plate diff manufacturer that will make you a diff for whatever you have.

ML6 would be cool, but I think that would probably be too long physically for a 206.

________________________________________

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

Bring on the Trumpets.

Posted 27th Feb 2011 at 15:51
206

Newbie

Location: Belgrade

Registered: 24 Feb 2011

Posts: 42

Status: Offline

Post #22
I've asked Quaife, they said no. Plated diff, no thanks - after having tried the Quaife, torsen is the only thing that works for me.

The ML i have, and i think it is the 6c, is less than 10mm longer - but it would require new driveshafts, new diff and a new clutch, 2500£ minimum. So i think i'll rather change the ocassional broken BE4 at 200£ a piece. Smile

Interesting idea, though.
Posted 27th Feb 2011 at 18:10
cress87

Seasoned Pro

Location: Norwich

Registered: 30 Mar 2007

Posts: 11,360

Status: Offline

Post #23
Looks like am impressive creation. Smile

________________________________________

Ph3 China blue GTi-6 330Ci///M Sport & NC23 CBR400RR Cool

You feed beefburgers to swans. Yes

I may have been speeding Mr Policeman but [a] I live for the 306 and [b] did you see that dog? omfg
Posted 27th Feb 2011 at 18:16
lotek

Seasoned Pro

Location: Berkshire

Registered: 04 Dec 2007

Posts: 6,107

Status: Offline

Post #24
206 wrote:
.
Plated diff, no thanks


can of worms Shut up LOL
Posted 1st Mar 2011 at 15:48
daveyboy

aka Jim Davey

Location: Southampton

Registered: 01 Oct 2007

Posts: 8,648

Status: Offline

Post #25
lotek wrote:
206 wrote:
.
Plated diff, no thanks


can of worms Shut up LOL


If its a daily driver and not a track car I would'nt go for a plate diff either.

________________________________________

R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars
Posted 1st Mar 2011 at 15:51

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