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My Project Saxo ( 7025 reads) |
Saturday, December 06, 2008 (05:52:45) |
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As were now being encouraged to blog our projects here goes...
A complete recap of my project thread.
Car started out like this over 4 1/2 years ago
First decision was to either go for the engine first or make the chassis capable of taking the VTS power. I had just sourced a VTS engine with only 56k on it, single plug ecu so was perfect for my car. Even with that temptation i decided the best way to go about things was to prepare the chassis for the new engine first.
I set about putting a VTS disk beam on the rear, but then found out it was roggered, so decided to investigate how to refurb it
Billies were added all round
New drop links and bushes all round
Then it would be rude not to install bigger brakes and braided hoses while i was at it!
That was stage one complete,
I then went to an RR day in November and she did me proud making 83bhp @ fly with 100k on the clock and just induction kit and de-cat!
So with the chassis now ready to take the engine over the winter months I decided my time was best spent in the garage totally rebuilding the engine, with a few extra goodies to be added 
So, I started collecting parts…
So now time to start on the engine – its under there, Honest!
Started work on the bottom end…
A box arrived in the mean time 
Then fitted the forged pistons….
The finished article
Bearings fitted,
Bottom end complete
Sump fitted
New water pump
The bottom end was now complete and the next task was to start work on the head.....
Stripped it completely and got the skimmed,
In the mean time the valves were lapped and new seals all over were fitted.
Head fitted to the block
Then some nice new cams (708’s) and followers turned up
Followers fitted
Exhaust cam and cam ladder fitted
With all the above now fitted the cambelt, new tensioner and idler were fitted
And the timing done on the cams before fitting the covers,
Next stage was the cam covers
And fitted these
With the head now nearing completion baring the inlet I decided to improve the exterior…
Firstly got some track wheels
And a little photo shoot with Willsy before he got his new wheels, brakes etc
I then was in a sporting injury which gave me some much needed time to work on the car
As I couldnt move around very much this time was spent sorting out the exterior again, this time de-listing it and took some more scenic pics
With the engine nearly complete it was time to turn my attention to the inlet side of things,
These turned up on the door step courtesy of GMC (kit no longer made)
So went about fitting these….
Matching the inlet manifold to the head (head port / size was not touched)
The red area being “dremeled”
With this complete the engine was really starting to take shape
TB’s put together and linkage made up,
Fitted to the engine
Now it was time to take my attention to the airbox…
Sealed
More bits and bobs cleaned up and fitted to the engine…
Trumpets and box were now fitted to the engine
So with the engine complete it was now time to get the old engine out and see what state the engine bay was in…
First task was to lift the 1.4 engine and box out
GTF!!!!!
My initial plans were to just clean up the bay and then drop the engine in,
However the engine bay had taken some obvious stick in the 100k it had covered and wasn’t in Brilliant condition….
So firstly decided to clean the whole bay up and treat the rusty areas!
At this point I thought the best idea was just to do the whole bay,
So picked up some 2 pack hardcore paint and thinners, hardener etc
Engine bay prepped for respray
Spraying tent….
Undercoat,
And how it turned out...
With the engine bay complete it was now time to start moving the engine into the engine bay
Started fitted a few bits and bobs…
Putting the loom and suspension back on….
Then the engine!!
Fitted the KMS
Big Brakes back on..
Throttle boddies
And Rad plumbed in with 82degree thermostat…
Now it was time to start building things back up around the engine,
Firstly the slam panel
And lights
Put in the VTS fuel pump…
And trial fitted the twin fans
Wiring in the second fan with its own power supply from the fuse box and relay
In the mean time made some brackets to secure the oil cooler and thermostat
Had this space to fit the oil cooler in…
But managed (just) to fit them in,
Then had some "fun" putting it the return fuel line,
Single line, GTF!!!
Go0o0o0o0ood morning Twin lines
Strut brace fitting? Nah…
So she was then left looking like this…
new styled BTB gmc 4-1 manifold
Finished the fuel lines up into the pump
Powerflex zorst rubbbers for the BTB / custom zorst
Style whorage wipers
BTB in process of being wrapped
Oil Cooler hose'd up 
Orange 90degree bend for my procomp
Pro comp cut and mounted into engine bay - no pics of it actualy mounted...
New dials
Old dial rapage
Dials fitted,
Custom first section zorst to join BTB mani and BTB centre and back box sections...
And the finished article
You wouldnt believe the amount of work that has gone in to make this custom 2.5inch first section up!!
Sprayed wiper arms to go with style whorage wipers (inspired by sax-p)
Sprayed ariel at the same time...
Catch tank ready to be mounted,
Cyclones cleaned up, sprayed black, and laquered (excuse spelling)
More engine bay work...
Pugsport Baffled Sump
First start up
A couple of pics from when me and Willsy went to get my tyres fitted....
106 + 8 wheels, 2 people, 4 boxes and 4 tyres :A:
Mapping @ GMC - made 139 @ the wheels!! 
Few final pics
First WM sax-p meet...
Nurburgring Prep:-
Some decent pads
My wubbbbbbaaaa to be abused round the ring.....
The mansion we stayed at
[SIZE="4"][SIZE="5"]Trax Pic's 2007....[/SIZE][/SIZE]
On the way down in convoy with the ssc boys,
Just about to go out on track with sax-p...
Out on track (pics from both sessions) - some 3 wheels action!! Lol
And one of my car on the stand
And won Best Ssc saxo & C2 on track :A:
Now the car was finished i started to iron out the few nigles expected with such an over haul of the car...
Raising the oil cooler to allow more airflow through it.
If you look closely you can acutaly see the top 4 row are the the only ones that have been getting a decent flow of air through them,
Its been raised 7cm, which should sit almost perfectly in the mouth of the vt* front bumper
First job - raise the brackets...
And give thema quick lick of paint
And all fitted back on
So went from this...
To this....
As i was just about to leave for another Sax-p meet we found the manifold had clearly taking a good beating from 2007's summer track days
We repaired it and its now looking all shiney again....
Then wrapped it again....
We noticed the near side top mount had bowed upwards from the track days
Nicely flatened
I then took the car up to my mate Matts to have the top mounts strengthened
Matt also welded up a part of the chassis that needed sorting - cheers again mate! Which i then primered and sprayed mango
Finaly sourced a mango fuel cap
I then had the car back to get it MOT'd...
Sorting out the horn, it had seized due to sitting around for 6months!
The standard System going back on
Standard vs BTB
Last few bits to be done before MOT time, found 1 of my arb plate bolts had snapped off, also found the other side was perfectly ok, but seized in so sorted that as well...
Bolt snapped
First one coming out
Other side
Dad working his magic
Both new bolts in
While the wheel was off got down to cleaning the Rear wheel arches,
Before:-
After:-
And painted in oil/waxy paint
Also sorted out the rear towing hook...
before:-
After:-
and New rear wiper blade
It was now ready to pass its MOT, so i wrapped it up for the winter untill i got back from uni @ christmas to MOT it!
Now..... I cant fit an 'off-the-shelf' strut brace because of the throttle boddies airbox as shown earlier.
So my mate Matt suggested making me a CUSTOM strut brace
So here's the pics
Brackets
Sprayed the brace Thursday night
And sorted the rest on saturday night untill 12:30 at night to get it ready for Sunday.... Lol
Masking
Home made tent again
The following day (Sunday) i went to a 106owners meet aka "Mini fcs"
Another great day out!
I then added some carbon and 106 door handles
I went to Llandow on the 4th April 2008 with SSC and co, Pic's tell it all really, she went really well - as quick as anyone there on the day
So was pleased over all
Then me, DannyGti and Dan all braved it in getting home and getting the car's ready for the Rolling road day the following day (5th April) that i had arranged for West Mids on sax-p. I got home at 8:00pm, managed a quick wash, emptied all of the cr*p out of the car, gave her a quick check over under the bonnet and finally came in from outside about 10:30. Grabbed something to eat and hit the pillow ready for an early start @ 6:30 to leave at 6:45.
The car went well in comparison to others again It was a great day out for us all (48 of us!)
Custom 170lb faulkner springs and group n top mounts fitted
24mm rear ARB
New pads and harnesses fitted!
My new harnesses (TRS, 4 point, 3inch shoulder straps, 2 inch wait straps with the fancy buckle) - p.s. there not my seats.
Catch tank work - I've always thought the catch tank hose (had to stretch it to fit) / fittings might be restricting the engine when breathing (mainly the fittings as they are a fraction of the size of the elbow which comes out of the rocker cover), also coupled with the fact the other breather is blocked (due to tbs)
So dad tapped out the tank,
And got the bigger fixings (old vs new)...
New hose to fit
Draining hose now fitted as well, which is now secured but i dont have any pictures of this unfortunately.
Group n lower mount pressed in
Mallory Park
Pictures
And a video
Here are the pictures from my PFC shoot...
I want to give a massive shout out to David who took the pictures and did the write up, i think you'll all agree he did an excellent job!!
Heres Davids website, and if you realistically believe you've got a chance of a feature i can put you in touch with him
www.davidcorfield.com/
Big shout out to Finning/CAT for use of the location as well
For those that havent seen the magazine, its the latest edition - just come out!
Top 25 @ FCS 2008
Here's just a couple of pics from Tricky (cheers pal)
I was pretty chuffed how it came out, also won £250 for being amazing on Wii bowling
Me and bullet having fun in the tunnel@ fcs 2008!
Nurburgring 2008
Managed 9 laps this time round without any problems at all, so was very happy all in all
Car cleaned before
Fancy custom ring sticker
Filled up... 45 litre tank, NEIN!! (red light had only just come on)
On the way over
One of the crew added a sticker..
At the mansion
Track pictures
Getting the arse end out
My 14th lap round the nurburgring (only lap that was timed all weekend)
Sam wrote on the track
About half of us enjoying Pinoccio's Pizza's
Having a play on the Autobarn on the way back
Here's Danny enjoying my car on the way to the nurburgring
Me and Sam watching close up
Again, had an amazing time - would recommend it to anyone!!!
Donnington Park 2008
Was a great day out, car went really well all day, definately need to get myself a bigger oil cooler rad though!
Pictures...
New R888's replacing the a048s
Raping a 172...
THat was the summer of 2008 just before i left to travel the world for a year... Shes now all covered up on the drive ready for the ring when i get back in the summer of 2009
Josh |
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You have done an amazing job there mate.
Must be thoroughly pleased. |
| Posted by suggy | Saturday, February 28, 2009 (01:13:25) |
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awesome job
what was the car origonaly before you put a VTS lump in |
| Posted by JT106 | Thursday, May 07, 2009 (23:03:38) |
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