31 replies to this topic

[Kam]

Bear with me on this this will be a slow build

 

After all the issues with photobucket I've deleted my pics, I was having other issues with them prior to them selling themselves out but I had enough

 

Using a new hosting site but its all new to me so bear with me...

 

Still got the mini but in true style I thought I would try another "big box in a little box" scenario - cramming a 3.0 V6 in a 205, lovely jubbly 

 

I've had fun with the mini and its still about but its time to have fun with something else, my ideal two car (reality) garage is a mini and a 205. I had a 1.9 white GTi about 16 years ago, unfortunately I had no garage so after quite a few break in attempts it was time to let it go and get something that no one would be bothered about - so I got a corsa

 

Went to Courtenays to enquire about an XE swap but seemed cheaper to just buy a calibra to start with so I did but the amount of problems I had with it was putting me off, then my 1.4 corsa sri started playing up so my love with vauxhall would come to an end

 

Picked up a beemer but really I wanted a 205 again...

 

So last year (2016) I picked up a non runner, originally a 1.6 but with a 1.9 thrown in but the most important thing was there - it was Alpine white 

 

 

 

 

Evidentially!

 

 

Got it trailered back, it was falling apart in places but I was buzzing

 

Plan was to get it MOT'd and enjoy it as I knew it, but with the mini sitting there I was wondering if I could put the B20 in? 205-tec-it 

 

Then decided mini has to stay as it is, too much blood sweat and proper tears have gone into it so with other things popping up (like a baby!) this 205 got left to gather more dust alongside its brother from another mother via a sister with a different mister, they are related 

 

 

Few weeks later I decide to tackle getting this on the road, 1.9 with big valves, Mi16 final drive on I think a 1.6 box, all sounds good, found a camera mount on the front bumper and this picture on a random search on the net

 

 

The last owner told me he bought it from someone who was setting it up for hillclimb etc, its running bilstein shocks, lowered about 30mm, the bonnet filter holes were all patched up when he got it so they obviously changed there mind, last owner thought he would try and get it running but gave up, no gears could be selected, would cut out straight after firing up, battery not holding charge, was a few bits but I was confident

 

Now don't get me wrong, I'm not making out here I am some master mechanic, my knowledge is still limited but confidence is a bit on the high side still after the mini, its been to europe with me so I must've done something right 

 

First things first, it starts buts dies, whip off the air filter/AFM and soon find whats wrong

 

 

 

Now I'm no genius but I'm guessing there is hole here letting in more air?

 

Bit of duct tape and fires up, all good on temp side - relief 

 

 

No gears, look in bay and main rod has popped off, ordered some new upgraded ones (with an internal clip) 

 

 

All gears work 

 

Take it for a little drive off road, ok yeah its quick but I think thats the short ratio box so definitely gotta be the 1.6 box

 

Time for a much needed clean 

 

 

 

 

 

 

 

 

 

 

 

 

Park it up and...yeah...it just sat there...

 

Cue few months later and I get more time to have another looksie to try and get this ready to use for the summer - then it hits...the dreaded 16v illness

 

Now I'm looking at Mi16's GTI6's, here we go

 

Either way I can see it happening so first up I grab some GTI6 calipers

 

 

Had to pick up some base hubs as my 1.6 ones with these would mean more positive camber I think, the base hubs have 10mm less offset I think but same driveshaft size as a 1.6. 1.9 are bigger shafts but correct offset with these

 

Got some custom Mi16/GTI6 front braided hoses at the correct size to stop rubbing

 

 

Interestingly I had NO brake fluid...very interesting test drive

 

 

Hmmph call that a packed bay!!! I pity you small people with all that room in the bay!!!!

 

 

So I've decided on a GTI6 lump...then...

 

 

I like 16V but sometimes 24 are needed!

 

Ok, so we haven't actually got a V6 here or know how to shoehorn it in but c'mon whats the worst that can happen...

 

Either way this bad boy lump has to be gone 

 

First up I get some lockable heavy duty castors and an old kitchen worktop

 

 

And start going to town on it 

 

 

Oh did I mention I love electrics! more so when more bodies have been involved in it!

 

 

Exhaust manny off, find a little crack...

 

 

 

Bad boy zhorst off

 

 

what the hell is this in the downpipe?

 

 

Top section seems clear but bottom gets blocked up???? 

 

Come to pappa

 

 

Hmmm run out of headroom here...load leveller might have come in handy

 

 

Bit of jiggery pokery and gearbox clears front bumper

 

Jiggery pokery later 

 

 

Gloves on bumper is a sign all is good, give a pat on the back 

 

 

So this where I am at the moment, looking at a V6 at the weekend, its from a 406 coupe, standard 194hp and around 196tq, my mini is currently untuned at 200hp 150tq so I'm guessing the same jekyll and hyde pleasure you but pain you drive

 

Before anyone asks, no I'm not entirely sure how it all goes in, no I don't know what management to use but I'm guessing factory and yes I want a fully packed bay

 

No rush on this one, I've got plenty here to keep me busy. Lets face it the 205 could not sit in the garage alongside a mini knowing it has bigger and better!

 

[Kam]

This is meant to be a slow build honest but I've already got 95% of the bits needed already 

 

Found someone who was looking to get rid of there conversion, he hadn't had a chance to install it himself but had heard the engine running from the guy he bought it from who was also another forum member

 

So I got

 

ML5T gearbox, cable linkage shifter which can go in place of mine and custom driveshafts

 

 

 

 

 

Modified standard front subframe

 

 

I might keep this one as a template and cut mine

 

It has the correct 406 mount holder on there to make things easier

 

 

Inlet with new gasket ready, I will clean the inlet and go all spicky and spammy 

 

 

One is a VR6 rad the other is just a standard vee dub one

 

 

Unlocked ECU

 

 

Random goody bits 

 

 

Custom slave clutch setup

 

 

And 'El Beasto

 

 

 

Custom top mount which allows standard one to fit

 

 

 

Started having a look around the exhaust manifolds

 

 

 

Its got a loom but I will get another made up

 

 

I reckon I can have this turn key within 2 weeks and first drive within 4, but I'm not gonna rush it. Lots of bodywork bits to tackle first!

 

All fun 

 

[Kam]

Not been doing much on the car today, just having a good look around whats what in the bay, what needs cleaning up etc

 

Main focus was getting the engine on my stand, I've only had my 1.6 and 2.0 on there so was a bit wary of just plonking a 3.0 on so after some chat with the guys over on 205forum it was time to offer it up

 

First up the lugs on the engine stand were too long and the bolts for the bellhousing were too short so I chopped them down a bit (the lugs not bolts!) I had to already chop them down a bit for the Honda clan so now found myself cutting them some more...

 

Making them shorter meant I had to take the clutch assembly off as the clearance wasn't there

 

Managed to get the engine on but I could see a major problem! 

 

 

 

Yes I know! Its not straight up but lop sided! Unacceptable, cue OCD...

 

My clarke stand has 4 spin positions but the cam covers were either one way or another so had to realign one of the lugs but the hard coolant pipe was in the way 

 

 

Couldn't remove this pipe as it had some kind of spring/tensioner behind it pulling it back on, strange never seen one or understand what its there for - must be a french thing 

 

Had to wiggle it out the way best I could then managed to get the spin plate on

 

 

Best I could get

 

 

Ok its not exactly straight up but my OCD was calm towards it...

 

I've also managed to source some 1.9 hubs (mine is a 1.6 with a 1.9 thrown in) I got GTI6 calipers here ready and waiting but the hubs were the main thing as the 3.0 run the same size shafts as 1.9, the shafts above I got with the deal are shortened 3.0 ones

 

Also I've got PAS, looking at the modified subframe I got compared with my original one I can't see how the PAS rack can fit? I need to drop my subframe so might offer up the new one and put the PAS rack loosley in place then drop the lump in to see if it'll go

 

I need PAS - I'm getting older 

[Kam]

Done a little more earlier today, I need to get my subframe off, I did get a modified subframe with the conversion purchase but I'm not that happy with some/most of it so I will be cutting my one up and use the other as a template

 

 

Sods law my jack plays up whilst trying to lift the body! I've had this racing low entry jack for a few years now (machine mart purchase I think) never let me down but when I bought it Burnard said bits and bobs were either missing or loose on his one!

 

 

Looks like whatever is meant to be there in the UJ has popped out so pikey'd it up with a couple of screws! 

 

 

Was having a 'mare trying to get the power steering union out of both the pump and steering rack so left them in for now 

 

Subframe off and all

 

 

I was trying to salvage as much of the PAS I got but these unions were starting to take the biscuit

 

 

I'm still in two minds with this PAS, I will try and make my one work otherwise I will go EPS

 

Rack is off the frame

 

 

Still having issues with the unions! so thought sod it, ripped into them, will worry about hoses another time!

 

 

 

 

Thought I'd offer up the old PAS pump to the engine and see whats what, little bit of shaving but mount holes line up

 

 

 

 

Obviously I don't know how this pump differs to the 3.0 one or how this engine fits in the bay or what clearance is left but it seems to stay within the lines

 

 

If there's no room I will EPS this, but its always nice to have a try and a little looksie 

 

I loosely bolted up my steering rack to the modified frame just to see how everything sits before I cut mine up. I won't be using the modified frame, really not happy with it, now don't get me wrong I'm no expert welder but if it don't look right to me it don't get used period

 

 

The underside will not put me on my MOT testers xmas card list thats for sure, looks like strengthening plates to me but again it may be functional but if it don't look right it can take all that away, just to confirm this is NOT work done by the guy I bought the conversion from, he already told me about this

 

 

 

 

So the modified subframe has my PAS rack on now so put it on my little height adjustable stool and the engine is still on the stand

 

 

Just wanted to quickly check PAS rack clearance so lifted the stool, it still has some height to go, you can see the mount holder on the middle right

 

 

Already the PAS part of the rack is a few mm from the exhaust and it still needs to be raised another 6" or so

 

 

The subframe is obviously not in its natural lateral position so when I next get a chance I will install the subframe and put the engine on the crane (minus gearbox for now) drop it down and see again before I decide if I can use the PAS or go EPS

 

[Kam]

Been doing a bit lately but not really much progress on the car 

 

On a plus note I've managed to source some 1.9 hubs 

 

 

Not easy to get hold of, my 1.6 ones are for the smaller driveshaft, the 1.9 has the bigger and same size shafts as the 3.0 ones

 

One thing (of two) that was bugging me was engine positioning, why I never bought this a long time ago I will never know but engine leveller purchased 

 

 

The other thing that was bugging me (big bug!) was the floor in the garage, its on a two step level not loads but enough to cause aggro...

 

Getting the engine crane moving took some effort but it wasn't ideal and that was with just the engine only no box, so large sheet of ply and some backing underneath 

 

 

 

So cue Kam madness    I remembered I bought a winch a few years back but it stayed in the box

 

 

Had some cement lying around 

 

 

I think you can tell where I'm going with this 

 

Instructions say only two M8 bolts needed in the ground, umm ok   

 

 

Gearbox on and winch seems to be working a ok hooked up to the crane 

 

 

Engine mount was torn off but still had the bottom part of the bush in place, read it can be a pain but drift punch on and started turning 

 

 

Molegrips to finish off

 

 

I LOVE my engine leveller 

 

 

Managed to get engine in close position, and marked out bodywork mods needed

 

Kambelt cover and side panel clash

 

 

Alternator clash

 

 

Will blow the dust off the grinder and sort this 

 

Once engine position is found subframe will then go back in for some more grinder time   

 

[The Matt]

YASSSS!  We had a 205 3.0 V6 on the Retro Run in 2013.  Quick car.  Like 150mph quick.  Fitted in nice too.  Modded slam panel was the only real thing.

The standard down pipes are like that, they've got a divider in them.  Should just be straight across, though.

 

It's as if you've got a list of standard faults for 205s and yours has them all.  The K&N kits do split like that too.  Not the best of materials for the AFM connector, no flex corrugations in it, so they get a bit fatigued and split.  Both of the ones I've had have done similar.  Might be that the AFM wasn't fitted with the correct support bracket that comes with the 57i kit?

 

Anyway, good to see you cracking on with another big-engine-in-a-small-car project.

 

V12 Fiat 500 next?

[Baldspeed Racing]

Fair play, always good seeing a 205 being worked on. Ive had a couple myself and last was a 1.9 on Weber 40's she had a really nice bark

[Kam]

Fair play, always good seeing a 205 being worked on. Ive had a couple myself and last was a 1.9 on Weber 40's she had a really nice bark

 

Cheers, had one years ago, I'm not too bothered about losing the original handling of this as its quite a heavy lump so will affect handling but like the mini it'll just be an enjoyable road car

[Kam]

YASSSS!  We had a 205 3.0 V6 on the Retro Run in 2013.  Quick car.  Like 150mph quick.  Fitted in nice too.  Modded slam panel was the only real thing.

The standard down pipes are like that, they've got a divider in them.  Should just be straight across, though.

 

It's as if you've got a list of standard faults for 205s and yours has them all.  The K&N kits do split like that too.  Not the best of materials for the AFM connector, no flex corrugations in it, so they get a bit fatigued and split.  Both of the ones I've had have done similar.  Might be that the AFM wasn't fitted with the correct support bracket that comes with the 57i kit?

 

Anyway, good to see you cracking on with another big-engine-in-a-small-car project.

 

V12 Fiat 500 next?

 

Would love a standard classic 500, I do like standard cars 

 

Yeah George has been really helpful over on 205. If I couldn't get the conversion as a whole I would've just got this road going with the 1.9 as I didn't want to be hunting for parts again from scratch

 

How's the XE going?

[The Matt]

 

YASSSS!  We had a 205 3.0 V6 on the Retro Run in 2013.  Quick car.  Like 150mph quick.  Fitted in nice too.  Modded slam panel was the only real thing.

The standard down pipes are like that, they've got a divider in them.  Should just be straight across, though.

 

It's as if you've got a list of standard faults for 205s and yours has them all.  The K&N kits do split like that too.  Not the best of materials for the AFM connector, no flex corrugations in it, so they get a bit fatigued and split.  Both of the ones I've had have done similar.  Might be that the AFM wasn't fitted with the correct support bracket that comes with the 57i kit?

 

Anyway, good to see you cracking on with another big-engine-in-a-small-car project.

 

V12 Fiat 500 next?

 

Would love a standard classic 500, I do like standard cars 

 

Yeah George has been really helpful over on 205. If I couldn't get the conversion as a whole I would've just got this road going with the 1.9 as I didn't want to be hunting for parts again from scratch

 

How's the XE going?

 

 

All good, but I need to boost my finances atm so have just had an offer on someone taking it off me.  Can't bring myself to sell it, though.  It's a car I've wanted since I was 17 (so for 23 years).

George is a really decent bloke mate. 

[Kam]

All good, but I need to boost my finances atm so have just had an offer on someone taking it off me.  Can't bring myself to sell it, though.  It's a car I've wanted since I was 17 (so for 23 years).
George is a really decent bloke mate.

Man this always happens to you

I think its because you take too long to finish them hence something pops up 

[Kam]

Had a small amount of time earlier so figured I'd try and get something done but the thought of going into a cold garage with cold tools wasn't exactly top of my list 

 

Took off the alternator and had my 1.9 one close by, interesting to see it was a bit smaller and lighter, not sure what amp difference it is, not that I'll need the extra for my cruise control etc 

 

 

 

Using the 1.9 one would mean a lot less work on the bodywork but a lot more work on making it fit...hmmm

 

Trimmed up some bodywork to clear the cam cover and dropped the lump in

 

 

 

 

 

Looks like it needs to be spaced up on the right hand mount

 

Got some room at the front, I say some...

 

 

Will chop out more of the cam side bodywork and have another looksie at the alternator 

 

Nearly ready for the MOT 

 

 

[domdee]

this thing will fly!

[GreaseMonkey]

 

 

Will chop out more of the Kam side bodywork and have another looksie at the alternator 

 

 

Small correction 

[Kam]

 

 

 

Will chop out more of the Kam side bodywork and have another looksie at the alternator 

 

 

Small correction 

 

 

Cheers Monks, gotta keep up with the grammar