I enjoy reading the numerous project threads so I thought it is time to start my own. This thread has been lifted from Northloop and 205gtidrivers , so it may not read perfectly, but there are plenty of pics so you should be to get the gist of it.

Intro

I am currently supercharging my Gti 6 engined 205, I have run the mainly standard 6 lump for about 4 years now and decided I wanted a bit more oomph!

The car used to produce 187bhp and 137lb/ft as tested at PTS in Luton (which admittedly seems a little optimistic) but I will get a post conversion test there for consistency. My best SQM was 14.7 with a 96mph terminal.

I have bought the Kit from a guy called Richard Walker (Rich_W) who has designed and developed the kit for his own 306, which is currently running over 400bhp and 280lb/ft at 14PSI of boost.
I have opted for a low boost version (7PSI) which has been proven to produce 260bhp and 218lb/ft, which I think you will agree will be plenty for a stripped out 205! Although there is always potential for a little more boost…..

So, first things first I decided to clear out the garage and paint the floor white (I used the remains of an old tin of Dulux! :shame: ) but it has turned out alright so far.





I bought a Forge intercooler and Swirl pot from the autosport show in January for a considerable saving over the rrp:




and a couple of weeks ago I received the heart of the conversion, as Rotrex C30-94 supercharger:



This is what the car looked like Pre op:



I made my own lifting frame from some scaffold borrowed from work, same design as a garden swing I used to have when I was little but much bigger!



Engine and box on the way out, this is the first time I have removed or even seen an engine be removed, it took me all weekend! I was also surprised at the angle it had to go at in order for the gearbox to clear the wing too.



The engine and Box were then taken down to Miles Horne of Pug racing for a gearbox rebuild, as I broke it at Spa last year (it kept popping out of gear, which made Eau Rouge a little more exciting!) and to have the belts and water pump changed.

This is what my trusty fiesta looked like with an additional engine, two gearboxes and a pair of trailing arms in the boot. It has made me question the logic of twin engined conversions, so much extra weight!




Last weekend I jet washed the engine bay ready for taking to the body shop for re painting, I uncovered some pretty nasty rot on the near side wing, which will need replacing

Pre Wash



Post wash



Rotten wing, I was actually able to push a screwdriver through it!




I have also mounted the supercharger bracket and supercharger to the block



I am currently waiting for the new inner wing from Peugeot and then it can hopefully go to the body shop.

Target completion is the 10th of May when I am heading over to the Nurburgring for Sunday TF and then a track day at Spa on the Monday.

Will keep you posted as work progresses.

Garry

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205 GTI6 S

Post 3:

Progress has been quiet of late due to waiting for a new inner wing to be imported from France:

New panel


And then on to the body shop for engine bay painting.
I collected the car on Saturday, I am pretty pleased with the results, nice and clean:

From this:


To this:






Saturday morning me and my brother rebuilt my scaffold lifting frame and collected the car, he kindly towed me back from the bodyshop. it was only 2 miles along country lanes, but I always find it unnerving knowing I have little control and no brakes! :



Engine going in. Is that safe?



I bought and fitted new spark plugs, these are R8 rated which are colder than the standard R6 plugs:



I also fitted my new 440cc Injectors:



You may have seen previously that the inlet manifold was too long, thankfully Richard Walker took it back and shortened the inlet tracts by 30mm and now it fits!



Engine installed and 205 TD radiator mounted, although I will not be able to use this rad as I need to change the charger outlet rotation. In its current configuration the bonnet, yet again, will not close!



This is my intended Intercooler setup, although the charger has now been rotated one notch so the outlet is lower down. To solve this I intend to get radtec rad which is designed for running bodies/ carbs, therefore lower.

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205 GTI6 S

cool post! great project.. keep us posted!

why not moutn the intercooler uptop and have a bulge in the bonnet?

soudns like the bonnet is going to have to be modded anyways?

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EX Rallye owner
Xsara VTS track slag project.

Good stuff Garry, coming on nicely

Just make sure as much of the boost piping as possible is done in alloy rather than silicone. You get upto 14 PSI of vacuum in the pipework, the silicone tends to collapse under these conditions, but it's not a major problem. Would probably just shorten the life of the silicone bits.

[offtopic]

The auto-tensioner pullies are done; my Dad should be picking up the bearings for them today. So I should be able to get this off to you, along with the EVAP blanking plug over the next couple of days.

[/offtopic]

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Contact Details:

rich@lynxpowerengineering.co.uk
07732 822546

You may have noticed on the last picture the charger outlet pipe was sticking up quite alot and subsequently the bonnet wouldn't close. To solve this I have rotated the charger outlet, but this meant that it clashed with the New TD radiator .

So to solve the problem and spend even more money on the project I bought another radiator from Radtec. This has been designed to suit 205's running carbs or bodies and is about 75mm shorter than the standard one but has a 60mm core so its twice as thick.



The quality is excellent and it fits perfectly. Anyway, must get back in the garage and solve the next problem!

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205 GTI6 S

Hi nice project why didnt you run a electric power stearing from a saxo or 106 ?

Same as Kev, those clips do look very useful!....info pwease

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Seat Leon Cupra FR / 306 GTI6 / Breaking 205 GTI6 / Caterham 7 / Mercedes Sprinter 311CDI LWB

Sold: Fisher Fury - Laguna DCI Estate - P1 306 XSI - E30 BMW 325i Baur Convertible - Daihatsu Fourtack - Suzuki GSXR600 - 205 Rallye

Do you have any closer up pictures Wayne?

EDIT: Sorry for the <OT> Garry - will take it to PM, just posted here for Sean's benefit too

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Trackday, trackday, trackday

That will be one interseting car.
Please say your gonna vid your time at nurburgring

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The 6 is complete for fun, stress free driving now…..yeah right

How much was the rad out of interest! i'd like a one similar for my charger!

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Dimma + Gt35 turbo =
Solid rear beam mounts £130
07889376885
Dan

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205 GTI6 S

Another weekend on the car. It was actually quite pleasant sat out in the sunshine, much better than the wind and rain last weekend.

Last weekend I managed to strip the thread from my 13row x 235mm oil cooler I was planning to use on the supercharger cooling circuit. So I bought a 10 row x 115mm cooler from Ebay. I asked for ½’’ BSP fittings, but it arrived with -6An fittings. To save the hassle of sending it back and trying to find a different one I bought new fittings from Think Automotive to suit.



I had already bought a new 19row x 235mm cooler for the engine oil, which fitted nicely behind the fog light cut out. Both of the coolers were mounted using some brackets bought from Focus.



I painted the intercooler using Satin black Stove paint, which is heat resistant and will help hide the intercooler until I get really close! I mounted the intercooler in position using some threaded bar, washers and nuts fixed to the lower brace that runs along the front of the engine bay.



I trial fitted the throttle body and air filter to get an idea of the finished product.





I have also plumbed in the fuel lines, engine oil lines and supercharger oil lines, but I didn’t take any pictures yesterday.

It’s starting to look like a car again now, a great white springs to mind from this angle!



The car has to be completed next weekend ready to be ready to go to DES Developments for a new Group A exhaust, albeit with a 2’’ tail pipe to try and keep the noise down.

On a worrying note, my neighbours have a reported people having a nose around the car when we have been at work. I have taken the wheels of the shell as a precaution, but I am a little concerned to say the least!

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205 GTI6 S

Wow that looks insane good work!

Cant wait for the videos on track.