Budget Forged MK2 Turbo Project

[Krish]

Sounds like a good plan. Are you going to the Bedford track?

[Danbob]

No we're going up to Curborough Sprint track, it was a bit cheaper than Bedford, Bedford is on the list of potential next venues though if this one goes well!


Fingers Crossed! Going to hopefully finish off the rear calipers over the weekend then crack on with the new engine and rustproofing the bay next week!

[Danbob]

Car goes up


Engine Comes Out




Just got to fit new water and oil pump and timing belt to the new engine now but the crank pulleys giving me some hassle! Managed to crack the nut off by jamming a screwdriver through the starter motor hole but now the pulley won't come off the crank, going to have to borrow a puller from work tomorrow hopefully!

[Danbob]

Theres been quite a bit of progress on the car, but I haven’t had any time to write it up!

Basically all the work on the engine is now done, - Water Pump – Oil Pump – Thermostat – Sump Clean – Water pipe clean - Hose From Hell - Hose From Hell on Earth - Water Temp sensors - Timing Belt Tensioner Pulley/idler - Timing Belt - Spark Plugs Etc.


I've fully underealed all of the underbody with Bilt Hamber hydrate 80, Cavity Wax and Underbody sealant. Very pleased with the lack of rust under there!

Engine is now reinstalled and fired up first time!! Very impressed considering it’s been sat in a garage for about 5 years.


Here’s some photo’s and video……….

Old Coolant from engine (Does not look nice!)


















TRIED ABOUT 6 TIMES AND CANNOT GET THESE PHOTO'S IN THE RIGHT ORDER, SO PLEASE USE YOUR IMAGINATION


First Startup

Just got to fix a clutch slave cylinder problem, then install shafts suspension brakes and exhaust, bleed brakes and then it’s MOT time!

Hopefully going to have it MOT’d before the 26/07 Trackday, but not going to have much time to work on it between now and then

[Danbob]

Clutch slave replaced and bled!
(Vacuum Cleaner and Pop bottle technique works very well!)

Shafts are in, Rear Suspension is all reinstalled, exhaust half way there,

Minor setback one front caliper bolt thread is stripped, but will have a replacement bracket soon

Fitted some replacement Ultra racing engine bay braces underneath as standard ones were rotten.

Still to do
Fit Backbox
Time ignition
Install rear brakes
Install gear linkages
Bleed brakes
Reinstall undertrays etc.
Drop the car on it's wheels

Need to have it MOT'd and ready to race by Wednesday! I know the list doesn't look long, but the car is putting up a fight and nearly every task brings unexpected challenges!

Can't wait to have it on the road!

[bobhatton]

I would turn your air flow meter round the right way, the black cover should be on top not on the side

[Danbob]

Ah right didn't know that, will do cheers

[Century Motorsport]

Really nice clean job your doing there - good to see!

As Bob said, rotate the AFM so it sits the correct way.

Good luck with the track day!

[Danbob]

SUCCESS!

Managed to get the car finished and MOT'd the day before the trackday,

Drove there no problems, car performed well on track, Won it's class

but then broke down on the way home and had to get towed

See my help thread in electrical for details of the breakdown.

[Danbob]

Problem seems to be solved with a different MAF and a decent bracket to keep it steady. gave it a wash, job done

Heres some pics

[craig]

Car looks great mate. Autopista spoiler really suits it

[Danbob]

Cheers
I didn't know that was what the spoiler was. Could tell it was aftermarket but I think it follows the original lines quite well, doesn't stand out too much, will definately keep it.

I'm really happy with the car now, first RWD, and Mid Engined Car I've owned and I love it.

Few little bad points, it leaks through the roof at the moment, but I'm going to try and keep it out of the rain anyway

Got some new leads, coil and Dizzy on the way now, just to make sure they're OK.

Then I'll have to save up some pennies before anything else happens!

[Danbob]

Got some photo's of the car on it's maiden track day.....
This was before it's maiden car wash so excuse the grinding dust!












Starting to really like the car now, pity the British weather isn't doing as well!

[Danbob]

Ran the car over the summer and really like it now! Took it to another sprint and a silverstone trackday, off the road now for some winter modifications.

Did the following to it while it was on the road:
Made my own Fuel cut defender:

Managed to get a HKS EVC from a mate and turned the boost up to 15PSI (makes a HUGE difference!)
Reinstalled Standard BOV
Magnecor HT leads, New Dizzy Cap, New Coil pack
Discovered I have front Bilstein Yellow struts


Fitted new front balljoints and new droplinks
CG Lock lap belt locking device
Sorted the exhaust out properly.

Going to try and get the car a bit more sorted for sprinting next year and tidy up the front end a bit over winter!

[Danbob]

Winter Work completed so far:

Ebay Bargain Aussie Performance Downpipe, Stripped:


Painted (DEI Silicone Paint):


Wrapped:



Front end Stripped



Very happy with how clean and rust free everything is underneath! (Touch Wood)


Bought a pair of Rear Yellow Bilsteins to match the fronts which still seem in good working order.

And a set of AW tracksport springs. TRD topmounts and PU Foam bumpstops.




Control arms and Tension rods ready for new bushes


Bushes burnt out


Shells Chiseled out (Pain in the ar$e, wish I'd pressed them out now)



Prepped


Etch Primered:


Painted:


Pressing in the new bushes (Superpro's, Caster adjustable)






Still to do before First Sprint in May:

Refit suspension
New Track Rod Ends
New Brake Discs (Grooved)
Mintex M1144 Pads
Hel Braided Lines
Front and Rear Poly ARB Bushes
Fit Downpipe
Fit Bigger Side Mount Intercooler
New Front Bumper, Rad Slam Panel, Under covers, Foglights
Fit Steering Wheel (300mm Momo Team)
Design and fabricate a cold Air Box
Emanage Blue and Remap at Tuning Developments

With all this done should achieve my brief of Low cost 300hp, tidy and clean summer sports car, which is comfortable on British roads but still reasonably competitive on track! Can't wait to have it back on the road!

[Gaz]

I'll be following this closely, it's pretty much what I'm aiming for with my Rev 2 Turbo!

[Danbob]

Been investigating the turbo fitted,

It has a turbo Technics Plaque



And a different compressor wheel to stock


So I am happy that it should provide a little more than standard CT26 and it will suffice for now.

Got a bargain 4" core intercooler


And a host of parts which the car has been missing from Julian at MR2SPAREZ for an excellent price

Car will now have all of its undercovers etc. and will be detango'd


Got a new front bumper also to smarten it up a bit!

[Danbob]

Cars been on the road again for a while now, haven't had a chance to update this:

Car performed well at its first Sprint at Blyton park (The day after I got it back on it's wheels for the first time)

Just need to sort out a few little niggles (Sure there is still a boost leak and exhaust leak somewhere) and the car will be all good, bigger plans for next winter are already underway!!

[craig]

Nice and clean, car looks spot on.

[Danbob]

Fixed the boost and exhaust leaks



Fixed Bucket seat and six point harness added - Had to radically modify the seat mounts to get the seat low enough for me to fit in the car with a helmet on!





Momo Team 300mm Steering Wheel


Since then the car did very well at its next sprint back at Curborough, then moved up a tyre size on the front to 205, and the car was performing perfectly back at Blyton Park again until - Head gasket failure

So this has brought forward some of my future engine plans!