Turbo Saxo build - Track And Street Grampian

[ThrushMotorsport]

http://img803.imageshack.us/img803/2756/tsg.png (http://trackandstreetgrampian.com/forum.php)


Hello guys, names cammy, thought id get some progress going, i dont think anyone on here knows me or what my previous cars have been, but ive had a few nice motors, but unfortunetly back with a saxo! (should be getting another car next month, so this will be my track car :y: )


For some of you who are into some turbo cars here is something i built at the start of the year, you can see my last turbo build over on seat-cupra net HERE (http://www.seatcupra.net/forums/showthread.php?t=343140)

I had bought this car for the pricely sum of £500, with a really fucked engine, pistons were gauged, all valves were bent.. so share the love.

http://img12.imageshack.us/img12/6799/cupra11.jpg

http://img846.imageshack.us/img846/2263/ohlook.jpg

http://img528.imageshack.us/img528/9317/engineout.jpg

http://img51.imageshack.us/img51/4097/engineinf.jpg

To;

http://img259.imageshack.us/img259/6150/049ss.jpg


http://img689.imageshack.us/img689/3339/55797935729445764501210.jpg



Anyways! Onwards with the saxo!

Turbo build ;) kinda gona keep this stealth so people wont know its turbo'd until it comes up against them, so most things that may be seeable will be painted black, hoping for about 225BHP atf atleast. which is perfectly gainable on this turbo running 8 PSI, im looking to run about 9-10 psi as this is what GMC has recomended me on this gasket they have supplied me.

Current spec;
Milltek Turbo Manifold
Garret GT17 Turbo
Milltek turbo downpipe
Megane 225 turbo injectors
GMC motorsport 1.9mm MLS head gasket
Mocal 10 row oil cooler setup
2.5" Turbo intercooler piping (painted black with black hoses)
Small front mount intercooler (painted black)
Baileys DV
Black vaccume piping
Boost gauge mounted on dash
Modified centre consol for oil pres, and water temp
BCR8ES Escort RS Turbo Spark plugs
Renault GT-5 turbo oil filter (slim 55mm oil filter to clear downpipe)
106 GTI top water hose (deletes the saxo VTS standard oil-water heat exchanger which is getting replaced by the mocal cooler!)
Water Temp gauge in centre console
Oil Pressure gauge in centre console

Running fully stripped
Evo 8 Recaro buckets to go in

Still to get;
Preadator ECU with built in map sensor module for boost.
Turbo oil feed from spoox
oil pressure switch t peice
Small bit of metal to weld onto sump for oil to drain out from turbo.
Timing/water pump kit
ITG Air filter
oil

then its play time ;) this shall be completed in july/august :)


----------------------------------------------------------------


Well.. im giving up on the idea of a posher car once again.. seen a saxo VTS tonight, liked it.. got it for a good price (850) sounds sexy as fook, its got uprated cams, its got a full exhaust system, to me.. it looks like a piper exhaust system and sounded the dogs nuts!

Think the plan with this one.. sell my parts for my Cupra build (as still got nearly a whole engine, and all my forged and hybrid parts! so thats a fair chunk of money there..)

It has a private plate too (L16 VTS) which looks aiigghht, cars done 64k and from inspection, no crash damage, and no rot on the chassis especially in the boot...


http://img14.imageshack.us/img14/4227/196rt.jpg



I was trying to buy this car a few years back! trying to hagle the guy who was selling it on pistonheads years and years ago, i loved the look of this car, unfortunetly, it sold to someone else :( so my colour scheme for track will be the following.


http://img840.imageshack.us/img840/1158/projectk.jpg



Mocal 13 Row oil cooler, and fittings.

http://img840.imageshack.us/img840/3467/004bim.jpg

Megane 225 turbo injectors (straight fit into the rail :) )

http://img692.imageshack.us/img692/3631/005ipqsk.jpg

1.9 MLS headgasket from GMC, and headbolts

http://img62.imageshack.us/img62/5565/006kvj.jpg


2.5" Intercooler piping, dump valve T peice etc, these pipes are being sprayed black as we speak :) want everything hiden so no-one can know it has a turbo strapped to it! lol

http://img528.imageshack.us/img528/255/007qz.jpg


standard vts Camshafts as the cams that are in it will mess with the boosting!

http://img221.imageshack.us/img221/1593/008pyz.jpg

Magnetic sump plug (this was a leftover from my cupra!, never used it, was gona use it when i whent for hybrid, but sold nearly everything lol)

http://img52.imageshack.us/img52/7579/009nsh.jpg

Intercooler, 2.5 inlet/outlet. (this was off my cupra as i wanted a massive front mount for that!)

http://img440.imageshack.us/img440/6091/010ju.jpg

How the intercooler piping coming out....

http://img33.imageshack.us/img33/9470/011bqx.jpg

Milltek downpipe

http://img715.imageshack.us/img715/8200/tdownpipe1.jpg

Milltek manifold :) - i do have a GT17 turbo aswell for this, will get pictures when it arrives.

http://img339.imageshack.us/img339/6513/tmanifold2.jpg

2 Pod centre consol - this will have oil preasure and water temp put into it.

http://img401.imageshack.us/img401/5381/0143g.jpg

Evo 8 Recaro's

http://img21.imageshack.us/img21/4752/54577139440060726773010.jpg

Dump valve and t peice.

http://img853.imageshack.us/img853/1217/001drn.jpg


REAL carbon fibre Airbag (where the glovebox usually is on a normal saxo) blanking plate, will use this when i can find a new fabricator to do my seats and will fit an omp wheel at the same time.. so this wont appear just yet.

http://img163.imageshack.us/img163/9650/002tkh.jpg

BCR8ES spark plugs from RSTurbo's - these are a grade cooler which will help with the turbo kit.

http://img607.imageshack.us/img607/1894/003lli.jpg

New fuel filter, still need to order up the blue clip that secures it that ALWAYS breaks when changing it.. will have to find one though :)

http://img109.imageshack.us/img109/1174/004gn.jpg

My 106 GTI top water hose, this will delete my standard o/e oil-water heat exchanger - i will be cutting this in half though somewhere to fit a 38mm dia water temp pipe

http://img713.imageshack.us/img713/5223/005fez.jpg


last but not least... my renault GT5 turbo oil filter, and my sandwich plate for the mocal.. just trial fitted it to see if it was correct they do fit, should help and mean i dont need a remote oil cooler for the build, because if i do.. not gona be happy forking out another £285 for a remote system! lol

http://img155.imageshack.us/img155/4641/006slv.jpg

[ThrushMotorsport]

Couple more photos for anyone whos interested..

changed the colour of my centre consol to black, isnt perfect.. but will do.

http://img696.imageshack.us/img696/1517/006utm.jpg


Fitted the gauges, started on the wiring allready, but too rainy to go do anything, and putting the gazeebo up will take a while! so tomorow will probly be likely..

http://img560.imageshack.us/img560/544/007my.jpg

My spal slimline fan (should give me enough clearance to fit the intercooler without cutting anything! (HERES HOPING!)

http://img717.imageshack.us/img717/5940/008wsf.jpg

Oil pressure selenoid, and water temp adaptor (1/8) and water temp sensor..

http://img841.imageshack.us/img841/668/009ocu.jpg


Tah-fucking-dah! this was a pain in the cunt to get done, the adaptor was too big for the pipe, but i got there!

http://img600.imageshack.us/img600/9143/010ng.jpg


More progress later on..


Just a few from today with me nd richy, theres 170 photo's in total, been hitting backroads for last 2 days, has been mental fun, this this weekend will be even better if we can get this weather again!

Really happy with the car, for what its cost me, its not that far off richys stage 2 cupra, as his words "in 1st and second, its pretty par, but afterwards, his just pulls that little more"

Really happy with it and im expecting it to have say.. 135 bhp or 140 atmost with the cams, so against a cupra that rolling roaded over 220 im fairly chuffed, and it handles awesome with the setup it has on it, definetly faster than my ibiza cupra anyways.. just dosent feel it due to lack of torque compared to cupra.

Turbo shall fix this though.


Made some new pals aswell on the our ventures.... say hello to natalie wood (this one had been rolling in cow shite), and spunks.

http://img225.imageshack.us/img225/2439/032ce.jpg

WROOD U LIKE WROOFIES?

http://img854.imageshack.us/img854/6642/033sx.jpg


http://img59.imageshack.us/img59/9079/084ow.jpg

http://img835.imageshack.us/img835/8245/082pn.jpg


http://img35.imageshack.us/img35/9581/153pc.jpg

http://img535.imageshack.us/img535/3649/154qx.jpg

http://img254.imageshack.us/img254/363/155sm.jpg

http://img818.imageshack.us/img818/6943/156ld.jpg

http://img703.imageshack.us/img703/1298/157tq.jpg




http://img191.imageshack.us/img191/742/140qr.jpg

http://img59.imageshack.us/img59/1341/118po.jpg


http://img9.imageshack.us/img9/7871/052uv.jpg


http://img607.imageshack.us/img607/4035/087gn.jpg


http://img708.imageshack.us/img708/3103/077os.jpg

Plenty of photos, 170 odd, but only a few, have uploaded a hundred or so to fb lol, takes ages.

[ThrushMotorsport]

weather is kinda decent right now... so made a start, will make a guide aswell on the forum somewhere for this too, incase someone wants to attempt it!

This is a little how-to on doing a single fan conversion.

The fan i bought...

http://www.txautosport.co.uk/12-slim-line-radiator-fan-154-p.asp

depending on the size of your radiator.. will be different sizes required.

lets begin..

Right.. bumper off just enough for access!

http://img560.imageshack.us/img560/8798/001roa.jpg

Now, on your fan unit there will be a JB (junction box) holding 2 relays, on my fan, there was 2 screws (1 each side) undo them, and take the caps off, you will see this.

http://img825.imageshack.us/img825/8002/002zud.jpg

http://img213.imageshack.us/img213/2631/003ref.jpg

These just lightly twist out, (remember to pull the relays off first! and mark where they were! there is numbers on the plugs and relay, but you wouldnt want to chance it incase, so i etched mine with a screwdriver. on the top of the plug, the relay, i knew what was the top as it had inprints of bosch.

http://img69.imageshack.us/img69/3460/004ifk.jpg

Next thing to do... Cut the wires going to your origonal fan, there should be 2 wires, 1 which is an earth, 1 which is a positive (dont cut it silly ammount, like right on the base of the fan unit! as you will only get yourself in to trouble if you cant get your fan to work atall!

http://img26.imageshack.us/img26/7020/005crh.jpg


Strip the 2 wires you just cut, generously.

http://img32.imageshack.us/img32/7640/006vih.jpg

Right... Now its time to mount your fan, and prepare it for being connected, these are held on by tie-wraps, you will have to tie it round the fins on the radiator, thats fine, dont be too hard on it though! as they are brittle, if you do go straight through the fin, it wouldnt really be a massive fault, as the fins are just there to help aid the flow of air to cool it.

http://img31.imageshack.us/img31/239/007zh.jpg


Next up... get your choch-block, i used one from my days of marine engineering, these are useful :) although afterwards i will be going out and buying a bigger junction box for ALL these wires to sit in, so it will be waterproof, or i will tape them up, either or works, On automotives if i remember correctly - black is a positive, not a negitive as if it were your house wiring, and blue is normally always a negitive.

http://img502.imageshack.us/img502/3742/008pe.jpg

Now that that is on... turn the car on, and wait for it to get to temp, remember if your car was cold, it will hit its max temp, open the thermostat, thus bringing the water temp down again which means a big wait... you then will have the fan come on at usually, mine came on like this... however, it was pulling the air, not pushing it.

http://img528.imageshack.us/img528/8765/009toj.jpg

To overcome this, you can remove the fan, and turn the fanblades the opposite way, OR you can reverse the polarity - if you do not know what this means... means switch the wires round! I however switched my blades round the opposite way...

http://img689.imageshack.us/img689/5927/010hfc.jpg

Finished product!

http://img72.imageshack.us/img72/163/011sxq.jpg


Enjoy, hope its useful to anyone..




Little more...

PLENTY of space for my intercooler, its sitting in there, will have to make brackets up for it to be where i want it, but will have to get some more 90 degree silicon bends first so i can get it poking into the engine bay so it will be a peice of cake when it comes to getting all bolted on, so fairly happy with that! :)

Also.. Gauges are in.. not wired them up completely, and the centre consol isnt finished either, in the light it shows up red underneath.. wont get rid of this.. also couldnt manage to get the cigarette lighter out in one peice.. so i will have to get another one lol

http://img193.imageshack.us/img193/1469/012sh.jpg

http://img846.imageshack.us/img846/884/013tbw.jpg


Enjoy!



Scince the last update, things that have changed arent massive as i have ran into some problems, however, ima tackle it again this weekend on the bits i fucked up on!

Its now got ;

BTB exhaust (2.5" system exclusively made by GMC motorsport for turbo and supercharged saxo's)

Removed oil-water heat exchanger, did place a oil cooler, but it pissed out as i accidently put it on wrong way!! so now filter is just straight onto the block.

1 bucket seat welded in on OMP frames, (still one more to go in)

3 Point harnesses in.

Gauges are now powering up, still to wire them up fully to read, although sending back a sender unit that was supplied for my extension for the oil switch stop! they sent the wrong one! hopefully have the right one by end of this week, as diying to get them working!

turbo manifold (needs a clean and i covered it in oil by accident...)

http://img507.imageshack.us/img507/6884/002zb.jpg


Water temp adaptor in, working fine.

http://img196.imageshack.us/img196/6726/003jxr.jpg

Oil-water heat exchanger removed...

http://img822.imageshack.us/img822/8949/004lvw.jpg


Fuck yo' axle stands, i cant actually get the car up on these ramps... i just jack it up and put them under as my axle stands are pish and are missing the pins to lock them... so these are so much easier lol

http://img209.imageshack.us/img209/8118/005dcj.jpg

The GT17 Turbo, shafts seem fine, it sounded a bit grindy when i first played with it, but the more i played with it, it stopped, so reckon it was just starting to seize with not being used/on for a while...

http://img607.imageshack.us/img607/5789/008jc.jpg

http://img228.imageshack.us/img228/2982/009xis.jpg


A sneak peak of whats in the box for the turbo ;) mani, downpipe, turbo, oil feed, gaskets for mani and turbo... still need a few more things in there...

http://img821.imageshack.us/img821/8206/010bte.jpg

My OMP subframes, this is the passanger one, still waiting to be stuck in car, but shall look awesome, feels so much nicer to drive with the buckets in! where's my cage?!

http://img593.imageshack.us/img593/3835/012uj.jpg

ENJOY!

[blackie_2k5]

looking good mate

was wondering if you had a thread up

[ThrushMotorsport]

Yeah, theres not really much left to buy to get this finished, wasnt sure to start a thread once its been finished or now..

However, im getting compensation for my motorbike being wiped out by an old' woman (the red ZX6R in the background of the cupra), so ive stopped buying so much parts for the saxo as im waiting to see if i am getting enough to buy an Audi TT or something with straight cash, then this thing will be off the road being built.

Really missing turbo action.. should really keep cars i buy longer than a few weeks/months lol..

[hamishj]

Thats Gunna be sweet! Will fly :y:

[The_Notorious_C_A_T]

Did you buy the car up here as most cars I see for sale are wanting silly money around our area!

Looking good though bud, might see it around if it's on the road.

[ThrushMotorsport]

Did you buy the car up here as most cars I see for sale are wanting silly money around our area!

Looking good though bud, might see it around if it's on the road.

Which one, the sax or cupra?

cupra i bought in westhill just outside aberdeen, origonally it had been bought from the dealer in manchester, made its way across to leeds and then came up here nd someone blew it up. :A: Got it for £500, gave me a nice project and some really hefty profit when i sold it on!

The saxo, i bought from someone in inverurie for the pricely sum of £800... no mot or tax, but.. my mot tester is fair but leniant, surprisingly the only thing that was actually wrong with it was one top mount has some play in it! and emissions obviously..

came with allot of decent goodies, including the private plate - although.. i dont care too much for a modded car when i buy it.. its my daily at the moment, untill i get another car.. then its a track beast that may come out on the weekends to embarress some big powered cars :y:

I see by your car(s) under your username, your not the laad with the white supercharged ST?

[ThrushMotorsport]

still waiting on some piping coming to make custom water feeds to turbo! but got a few things today..

inline oil feed filter:

http://img600.imageshack.us/img600/650/003wpe.jpg



New banjo;

http://img84.imageshack.us/img84/435/005ghj.jpg


Clear one is for oil drain, it can withstand some massive tempratures, and also 50 PSI of preasure that its not gona see!

Black one is for my water feed to the banjo's, will sort out something for the feed once i get my pipes :D

http://img256.imageshack.us/img256/6917/006dcdl.jpg

[blackie_2k5]

id reccomend going to a hose place and getting some stainless braided hoses made mate

gotta take some massive heat.... and little bits of vibration against anything will fuck them up

i had my old water pipes half braided into proper rubber oil/hydro/water pipe..it used to kink in places and and it nearly rubbed through in one or two places..go some new ones made up for £20 cash in hand ;)

just take the banjo down..plan the route of the pipe and get some decent measurements..and get them to make them up :)

[saxplee]

looking good :P

[ThrushMotorsport]

id reccomend going to a hose place and getting some stainless braided hoses made mate

gotta take some massive heat.... and little bits of vibration against anything will fuck them up

i had my old water pipes half braided into proper rubber oil/hydro/water pipe..it used to kink in places and and it nearly rubbed through in one or two places..go some new ones made up for £20 cash in hand ;)

just take the banjo down..plan the route of the pipe and get some decent measurements..and get them to make them up :)

I was thinking braided but both of these are very thick, and are tiny bit flexable, the route im thinking of taking is front my water temp adaptor (drill a hole in it, and weld on a 10mm peice of metal to it) this will be the feed to the water inlet on the turbo, then, from the other banjo, to the heater pipe off the thermo, same principle again, some pipe with a 10mm peice welded on the end of it

can get braided ones through my brothers company as he specialises in doing bearings and hoses for offshore, did speak to him about it and he said he can get me them made up - ill have a look into it, but for now, its mainly just getting it going (should be this month coming) then ill get better parts for it to withstand things better :)

Blackie, im looking for some turbo studs... im missing on off the top of my exhaust manifold flange, and cant find any in the UK, there all from china or australia, any idea's where to get? as banging my head to find these.

[gazza808]

Can get the studs from and motor factors (at least round here you can) or fastener place.

[blackie_2k5]

how long till its on the road?

[ThrushMotorsport]

Just got a nice lump of money tonight (birthday nd all that shit) so hi andy! Predator ecu and lc-1 wideband please!

Hopefully this month coming blackie, got money from someone pulling out infront of my zx6r coming so it's even more, although I want to spend most of it on a tt 225 as miss the engine that was in my cupra! :( shall phone andy this week coming and get it sorted! ;D

[blackie_2k5]

If you want it quick, probs best to call him quick mate :y:

[ThrushMotorsport]

Yeah have his number, will give him a phone :) this shall hopefully be finished completely (cage nd respray) long before knockhill in september I'd think, will see how my splashing on the cash goes as away to have a look at some cars today so hopefully can take this thing off the road and get it built up fully

See how it goes :)

[ThrushMotorsport]

Also just got a present from my dad.. A blackbox hd recorder for cars, just like go pro :) will use it when I'm down at crail on the 5th with the yellow cupra pictured in this thread, standing start he might leave me, slow rolling start (10-20 mph) were very even to 3rd gear, after that, he's got an edge, be interesting to see what standing start is like!

[ThrushMotorsport]

car hunting just whent well.. just bought an audi *facepalm*

[iSlayeR]

for the megane 225 injectors, do you have to change the connectors on the loom or do they fit ?