Tepper
Part of things
Posts: 381
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Sept 24, 2015 19:14:00 GMT
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Just to pick up where Chas left off, I have enjoyed this car massively as a daily driver since buying it - it's been brilliant. I haven't done a huge amount with it other than drive it as Peugeot intended! About a month or so ago the car started showing signs of head gasket failure, so after a bit of thought I figured I may as well try to give the car a bit more poke in the process of getting it sorted. I managed to find a Dolphin Motorsport ported head with bigger valves and a Piper 285 cam and adjustable pulley for reasonable money, the car even managed the 6 hour round trip to pick the bits up without a problem - had to fill up with water halfway but we made it! Long story short we got the head fitted but, as predicted, the car's not too keen on idling anymore due to the cam, although it's great flat out... Obviously I now have to do something sensible to make the car more drivable, improve fuel economy and reduce emissions - so I'll hopefully be fitting this lot at the weekend Kawasaki ZX6R carbs with TPS, DanST manifold, Nodiz 3D mappable ignition and a clever fuel pressure regulator that will let me use the original fuel pump and return. Should be fun and I hope it'll get the most out of the new head/cam. ChasR I hope you don't mind me continuing this thread?
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1989 Peugeot 205 GTi - stolen! 1983 Mazda RX7 1968 Rover P6 - also stolen.
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Tepper
Part of things
Posts: 381
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Sept 27, 2015 16:51:48 GMT
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Got a good bit of work done on the 205 today, didn't manage to get it finished as I'd hoped but it's getting there. A few pictures of the work going on: Old manifold & injection stuff out, starting to pick apart wiring loom ECU out, will be keeping tachymetric relay as it's a nice safety feature Sorting out the wiring loom, identifying all wiring and removing anything made redundant by the new ignition ECU Old injection wiring Extending the loom supplied with the Nodiz using a scrap loom chopped out of a Peugeot 607 - turns out they feature pretty much any wire you can think of! Nodiz loom ready to go but without connectors Putting the Ford ends on the old HT leads to be able to use them with the new coilpack. Got the carbs fitted as well but unfortunately they don't clear the bonnet - I bought the manifold under the impression they would which is a bit annoying. Also made a start on fitting the trigger wheel and getting the throttle cable sorted out. A good weekend's work all in all but plenty more to do...
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1989 Peugeot 205 GTi - stolen! 1983 Mazda RX7 1968 Rover P6 - also stolen.
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Tepper
Part of things
Posts: 381
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Oct 22, 2015 20:23:26 GMT
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Thanks both, jonxs I'd love an XS, the TU is such a fun engine. Picked up the car today after having the exhaust fitted and it sounds amazing! To fit the 4 branch manifold an adapter was needed, so Milltek made one out of the same stainless as the rest of the exhaust and posted it out. Gerald at Viezu Tuning got it all fitted and cut down the Milltek system to suit, it turns out he had to drop the subframe to get the manifold in and he didn't even want to charge me for fitting - I'm very, very happy with the service from both people/companies. It's nice to have someone else deal with those kind of headaches once in a while Anyway, here are some better pictures of the exhaust up on the ramps from Gerald: I'm having to really restrain myself from giving it a bootfull as it's not fully set up yet and I don't want to damage the engine by running it too lean or anything like that. It's taking a lot of self control Fortunately the car's booked in for a rolling road session on the 3rd at M-Tech down in Westbury. They're based in the same premises as Motorsport Electronics, who manufacture the Nodiz ignition ECU I'm using, so hopefully it'll be smooth sailing getting it all dialled in. Safe to say I'm looking forward to seeing what it'll do.
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1989 Peugeot 205 GTi - stolen! 1983 Mazda RX7 1968 Rover P6 - also stolen.
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Tepper
Part of things
Posts: 381
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Oct 26, 2015 20:58:19 GMT
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Nothing major to report, I chopped as much as I could off the manifold the other day as advised by Dan and unfortunately there's still a clearance issue, so I think it'll have to go back to the drawing board. The bonnet does shut, but it's rubbing against the carbs and the air filter baseplate. Also, thanks to the Nodiz and a £15 HTC phone I now have this: Fancy! Air temperature reading is a load of curse word as I am not running a sensor for that. The main reason for getting this set up is so I can make sure everything's behaving itself before going on the rollers next week and also to keep an eye on things on the 2-ish hour drive down to M-Tech. Fingers crossed!
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1989 Peugeot 205 GTi - stolen! 1983 Mazda RX7 1968 Rover P6 - also stolen.
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Tepper
Part of things
Posts: 381
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The results are in: To say I'm happy is a bit of an understatement - as the printout shows, the car only managed 92 bhp before the tuning. The 1.5mm main jets were way too small, so the car was running very lean higher up in the rev range. These were drilled out to 1.8mm. As well as this, the needles were raised half a notch. After this, the ignition was sorted out with more advance earlier on to try to iron out a bit of a dip in the power curve. The tuning was done by B-8-D / Simon at M-Tech. Simon was great, not only did he transform the way the car drives but was also willing to share his knowledge as he did so. Many thanks Simon, every day's a school day! If you're thinking about a bike carb conversion, in my opinion this was time/money very well spent as it would've taken me ages to get anywhere near this level of tune without some help from a dyno and someone who knows their stuff. Would definitely recommend M-Tech / Simon, particularly for bike carbs. It's also nice to know the car's running a safe AFR... While I was down in Westbury I spoke to Matt at Motorsport Electronics to get some advice about getting the factory tachometer working. He gave me some diodes for free and explained how to wire them up. Unfortunately that didn't work when it was all wired up, so I had to go to plan B, again with Matt's advice. NODIZ is another thing I have been very impressed with - it has done exactly what it says on the tin and has not given me any grief at all. I don't know much about Megajolt as an alternative but I have been very happy with the NODIZ and the documentation/support available. I wasn't going to give up now, even with this lovely working environment: Can't beat a dark, rainy night for a spot of soldering What I did in the end was assemble the device described here. It uses a resistor, a transistor and the coil of a relay to simulate the coil output to the tacho and it all fits inside the original case. Clever stuff! The relay came out of a scrap Peugeot 106, complete with holder. Nice to keep things in the family I guess? 'Relay' installed and hey presto, we have a rev counter! Being a vehicle of French manufacture while I had the instrument cluster out, the first digit of the odometer has disappeared. OK then... Still, it feels so much better to drive now it's only done 76k I know it sounds like I've clocked it but this seriously just happened. Very weird. Anyway, time to go out for a quick run! I know it's got nothing on some of the stuff people are building on here but today has been the final point of a fair old bit of work and it feels pretty sweet.
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1989 Peugeot 205 GTi - stolen! 1983 Mazda RX7 1968 Rover P6 - also stolen.
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Tepper
Part of things
Posts: 381
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I'll just have to wait and see what happens after the dust settles in court. Curse word happens!
To answer your question, here's a fully non-scientific breakdown of the performance of the car at various stages:
1) Stock: good fun, but feeling a bit tired and I can't imagine the blown HG was doing it any favours. Idle was OK.
2) Head & cam: pretty disappointing, although I found out while stripping all the sensors that the ECU temperature sensor was completely broken, so I wonder how long that was affecting things. It wouldn't idle at all, generally ran like a bag of spanners until about 5,000 rpm when it shifted pretty well. To be honest at this point I was regretting messing with it.
3) With carbs & Nodiz ignition: perfect idle, but very flat performance. Things improved when I set the base ignition timing correctly but it was still pretty poor - I know now that the car was running very lean due to the main jets being too small.
4) Final incarnation: mucking farvellous. The rolling road setup was the final piece in the puzzle allowing all the mods to work together and was an essential part of this project - without that session the car would not have reached its' full potential. Given the amount of time it would've taken me to even get close to where it is now I'm glad I just put in the overtime at work instead to pay for it to be done professionally. Driveability is excellent, it's better behaved than it ever has been under my ownership and until you floor it you wouldn't know it was at this level of tune. Power delivery is great, there's a very minor mid-range flat spot but after that it revs beautifully all the way to the redline. Can't wait to get out on track now!
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1989 Peugeot 205 GTi - stolen! 1983 Mazda RX7 1968 Rover P6 - also stolen.
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