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| Author | Subject: High Boost Rotrex conversion |
 fletch
Track Head  Location: The nearest Shell garage Registered: 12 Jun 2004 Posts: 12,273 Status: Offline |
Post #1
Thought it was about time I started one of these threads  Intro About three and a half years ago, before I got the trackday bug to distract me, I was thinking about more power in the 6. I tried Nitrous, which I actually quite enjoyed, but began looking for a more sustainable boost in power. Having seen the Ecosse conversions using the Opcon 'charger (and the price!) as well as contemplating a T16 conversion, I decided there wasn't enough power per |
 Posted 23rd Dec 2008 at 04:42
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fletch
Track Head Location: The nearest Shell garage Registered: 12 Jun 2004 Posts: 12,273 Status: Offline |
Post #2
Heres some of the shiny bits I collected up ready for the rebuild         |
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Posted 23rd Dec 2008 at 05:01
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roland rat
Yeeeah Rat fans!  Location: Swansea Registered: 29 Nov 2006 Posts: 22,284 Status: Offline |
Post #3
 i remember coming home all excited from work to see what had been delivered when i was building my s/c 6.Looks to be an awesome project mate  |
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Posted 23rd Dec 2008 at 05:02
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stu
Seasoned Pro  Location: Milton Keynes Registered: 22 Aug 2006 Posts: 5,525 Status: Offline |
Post #4
roland rat wrote: Looks to be an awesome project mate +1 Look forward to further updates!  |
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Posted 23rd Dec 2008 at 05:05
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fletch
Track Head Location: The nearest Shell garage Registered: 12 Jun 2004 Posts: 12,273 Status: Offline |
Post #5
RebuildMy bare block came back having been overbored to 86.5mm. This was accurate, measured using an inside mic with no wear at the top of the bore. I also had the Ancillary bracket cut down, and the head came back skimmed and cleaned.       Bearing tunnel:  I decided to tart up the block while it was in pieces, so set about priming and painting it.   At this point in the build I moved house, and shortly after, helped in the in-laws move house. Anyone who has moved, knows the hassle and work that needs doing before everything is settled in and so the build was put on hold  |
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Posted 23rd Dec 2008 at 16:14
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rallyestyle
Seasoned Pro  Location: London Registered: 23 Jul 2003 Posts: 14,990 Status: Offline |
Post #6
Keep it going buddy, looking very nice indeed  Who do you get to do all your engine work/fabrication? ________________________________________ Just Drive It |
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Posted 23rd Dec 2008 at 17:22
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fletch
Track Head Location: The nearest Shell garage Registered: 12 Jun 2004 Posts: 12,273 Status: Offline |
Post #7
rallyestyle wrote: Keep it going buddy, looking very nice indeed Who do you get to do all your engine work/fabrication? The machine work was subcontracted by Lynx Garage as I was down there quite often for various reasons. Not sure what fabrication you mean though? |
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Posted 23rd Dec 2008 at 19:00
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rallyestyle
Seasoned Pro Location: London Registered: 23 Jul 2003 Posts: 14,990 Status: Offline |
Post #8
fletch wrote: rallyestyle wrote: Keep it going buddy, looking very nice indeed Who do you get to do all your engine work/fabrication? The machine work was subcontracted by Lynx Garage as I was down there quite often for various reasons. Not sure what fabrication you mean though? Poor choice of words really as its pretty much the opposite to what i meant, rephrased... who hacked apart your ancillaries bracket? Im guessing Lynx too  ________________________________________ Just Drive It |
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Posted 23rd Dec 2008 at 19:17
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fletch
Track Head Location: The nearest Shell garage Registered: 12 Jun 2004 Posts: 12,273 Status: Offline |
Post #9
With seemingly endless birthdays, moves, holidays, weekends away etc and me getting depressed at the lack of progress I decided (and told the missus ) much of the next few months was to be spent finishing off the build.I set about building the bottom end:  Bearing clearances were then measured and checked. Shells and Crankshaft were put in place and the main bearings torqued down. Time to crack out the shiny bits Pistons were fitted to the rods with gudgeon pins in place.  Next up the rings...  I didn't want to hide these away in the block as they are beautiful bits of kit, but the engine wouldn't really work well without them...   Fitting the pistons to the cylinders...     Big ends with L19 ARP bolts torqued up. (These bolts have a tensile strength of ~40,000psi more than ARP2000 bolts  ) Engine was turned over and everything was moving nicely. Now was the time to crack out the multiple bags of bolts I labelled up over a year ago   Some of the labels had deteriorated |
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Posted 23rd Dec 2008 at 19:33
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paul.
Banned! Location: nottingham Registered: 24 Nov 2008 Posts: 11 Status: Offline |
Post #10
hi mate dont want to sound a pan but your pistons are in the wrong way the arrow is to the rear of the engine |
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Posted 24th Dec 2008 at 01:50
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rikky
🦔 Location: cheshire Registered: 28 Feb 2004 Posts: 26,796 Status: Online |
Post #11
paul. wrote: hi mate dont want to sound a pan but your pistons are in the wrong way the arrow is to the rear of the engine http://www.306gti6.com/forum/showthread.php?id=91000&page=1 ________________________________________ 306 rallye reproduction decals (full sets/individual decals) | 306 b-pillar textured vinyl weatherstrips306 slam panel esso stickers | 306 yellow / orange / pension fund red side door badges gti6 inlet manifold badges | 306 rear boot badges (p2/p3) winner of Extraction of toys from prams with outstanding vigour award 2009 [source: gti6 owners club] |
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Posted 24th Dec 2008 at 01:59
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n.g.k
Seasoned Pro  Location: Peoples Republic Of Cork Registered: 03 Feb 2008 Posts: 6,200 Status: Offline |
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Posted 24th Dec 2008 at 02:15
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read88
Regular Location: Farnham Registered: 23 Nov 2008 Posts: 112 Status: Offline |
Post #13
Mate, ur in crawley??? Listen, im desperate to get a GTI-6 at some point, and i do wanna supercharge it eventually as well, low boost tho.. im only about 20 mins away from u fella, do u mind if i give u a hand with this project, i don't know jack-shit about engines, but im pretty desperate to learn a bit more.. but im pretty strong and healthy n I'm good at taking orders, give me a bell mate anytime n ill come up n give u a hand! Regards, Ben ________________________________________ Media. |
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Posted 24th Dec 2008 at 02:30
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nuss306
Regular  Location: Mansfield Registered: 16 Jul 2008 Posts: 184 Status: Offline |
Post #14
Hiya mate looks an excellent rebuild and will be interested on seeing it completed and seeing what power you get from it.Keep up the good work! ________________________________________ Vauxhall (c20let) powered peugeot 306 2.0 16v turbo, aka - PUGLET |
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Posted 24th Dec 2008 at 02:42
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birk
Seasoned Pro  Location: Doncaster Registered: 24 Oct 2005 Posts: 7,032 Status: Offline |
Post #15
about 400bhp i suspect________________________________________ Dimma + Gt35 turbo = Solid rear beam mounts £130 07889376885 Dan |
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Posted 24th Dec 2008 at 02:47
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fletch
Track Head Location: The nearest Shell garage Registered: 12 Jun 2004 Posts: 12,273 Status: Offline |
Post #16
paul. wrote: hi mate dont want to sound a pan but your pistons are in the wrong way the arrow is to the rear of the engine Paul i made the orientation decision based on rich's experience. He installed them this way and they came out with no wear on the skirt or piston slap. So we will see how they fare. |
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Posted 24th Dec 2008 at 03:06
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midlife
Seasoned Pro  Location: Colne, Lancashire Registered: 13 Mar 2006 Posts: 7,544 Status: Offline |
Post #17
birk wrote: about 400bhp i suspect No shit Sherlock  Loving the write up, keep it up ________________________________________ Get used to seeing the yellow one !!!Team 330™ Team "no front end or engine" Team "LIMITED EDITION" I live for the 306 sticker  Team 0-60 in 6.44 & standing qtr in 14.808 @ 94.55mph all with std engine 203bhp Corolla T-Sport daily driver stealthier than Kwai Chang Caine |
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Posted 24th Dec 2008 at 03:02
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roland rat
Yeeeah Rat fans! Location: Swansea Registered: 29 Nov 2006 Posts: 22,284 Status: Offline |
Post #18
Do i see a set of 4-pots in your shiny box of tricks? |
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Posted 24th Dec 2008 at 03:07
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pedro_de_la_cruz
Seasoned Pro  Location: London Registered: 14 Mar 2007 Posts: 2,555 Status: Offline |
Post #19
did Rich go for 86.5mm overbore too?great project there mate, that feeling when its all finished and you take it for its maiden drive (even if you are running it in) is going to be memorable! ________________________________________ *R.I.P Pete Sims* |
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Posted 24th Dec 2008 at 03:12
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midlife
Seasoned Pro Location: Colne, Lancashire Registered: 13 Mar 2006 Posts: 7,544 Status: Offline |
Post #20
roland rat wrote: Do i see a set of 4-pots in your shiny box of tricks? I was thinking the exact same thing, they look big buggers, what breed are they then  ________________________________________ Get used to seeing the yellow one !!!Team 330™ Team "no front end or engine" Team "LIMITED EDITION" I live for the 306 sticker Team 0-60 in 6.44 & standing qtr in 14.808 @ 94.55mph all with std engine 203bhp Corolla T-Sport daily driver stealthier than Kwai Chang Caine |
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Posted 24th Dec 2008 at 03:16
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fletch
Track Head Location: The nearest Shell garage Registered: 12 Jun 2004 Posts: 12,273 Status: Offline |
Post #21
midlife wrote: roland rat wrote: Do i see a set of 4-pots in your shiny box of tricks? I was thinking the exact same thing, they look big buggers, what breed are they then Just 406 V6 Brembo calipers lads:  |
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Posted 24th Dec 2008 at 05:08
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fletch
Track Head Location: The nearest Shell garage Registered: 12 Jun 2004 Posts: 12,273 Status: Offline |
Post #22
Windage tray, Oil pump, crank seals, woodruff keys were all refitted. Ancillaries bracket was fitted to the block and then the Alternator, SC bracket, and Rotrex were test fitted.    In parallel to the bottom end build, I was building up the cylinder head, that had come back from the Machinist skimmed and cleaned up. New stem seals:   When fitting the valves to the Cylinder head I discovered one of the inlet valves was bent. The valve guides looked ok, so I replaced the valve and continued by lapping in all the valves just to make sure they seated properly. Next up was the tappets, cam carriers and cams. I fitted the timing cover, seals and pulleys, ready to drop onto the block.         |
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Posted 24th Dec 2008 at 05:45
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thugpuggin
Seasoned Pro  Location: Bristol Registered: 10 Apr 2004 Posts: 26,784 Status: Offline |
Post #23
I may have missed a bit of this that is glaringly obvious Matt but which one is this going in? Diablo.Looks a good work in progress btw . Keep at it and get it al done.________________________________________ Black X Reg PIII.VGTi 6 A4212 pt 1 A4212 pt 2 Searching the streets of Bristol for 1.36p/day.Joint Kent Leader |
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Posted 24th Dec 2008 at 05:56
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mattg4321
Seasoned Pro  Location: Nr Brighton Registered: 21 Dec 2005 Posts: 2,228 Status: Offline |
Post #24
i reckon it'll be going in the black one looks awesome matt - keep up the good work, let me know if u need a spare pair of hands and ill do my best to help you out ________________________________________ Ex 6 owner - now S2000 |
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Posted 24th Dec 2008 at 05:59
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midlife
Seasoned Pro Location: Colne, Lancashire Registered: 13 Mar 2006 Posts: 7,544 Status: Offline |
Post #25
fletch wrote: midlife wrote: roland rat wrote: Do i see a set of 4-pots in your shiny box of tricks? I was thinking the exact same thing, they look big buggers, what breed are they then Just 406 V6 Brembo calipers lads: Ahhh, it was the bolts in the crossover pipe holes that threw me  ________________________________________ Get used to seeing the yellow one !!!Team 330™ Team "no front end or engine" Team "LIMITED EDITION" I live for the 306 sticker Team 0-60 in 6.44 & standing qtr in 14.808 @ 94.55mph all with std engine 203bhp Corolla T-Sport daily driver stealthier than Kwai Chang Caine |
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Posted 24th Dec 2008 at 06:14
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