Vauxhall Astra Owner doing 1.4 Furio to VTS - Advice Needed

[bartonz20let]

Right, So slightly against my will I've agreed to do a build for my Girlfriend's brother, he in the army and is stationed in Greece so would like me to do the work while he's away. Told him to get a VTS and use that as a base but he won't have it and already has the furio although has nothing to spend his money on.

I have limited knowledge of the Saxo although my technical experiences are from modifying Vaxuhalls, currently run a 275hp/300lb MK4 Turbo which apart from the mapping I've done all the work myself so I have an idea of what end of the spanner to hold but have a few questions before I start ordering parts.

So the basic plan for the Furio is as follows;

Suspension/Brakes;

VTS Rear beam with VTS Rear calipers and braided hoses.

I'm assuming the rear beam is straight swap and I can use the original rear brake lines from the existing drums for the calipers?

Suspension setup were looking at is Bilstein B4's with Eibach Pro springs

If I use the VTS front struts will I need to make any further mods, wishbones/drop links etc?

Front calipers will be 206 GTi calipers.

Do these just bolt on, I know you need to grind the caliper to stop them fouling the front strut, how much grinding is required and will these need a 15" wheel?

Can I use the furio drive shafts with the VTS box?

Gona fit Greenstuff pads and EBC Turbo discs all round.

Engine;

Going to use the 1.6 16v from a VTS including box, loom and ECU and open cone induction kit.

Are all VTS engines the same or do they differ from MK1/2

He has ideas on a turbo kit at a later date so i'm gona try get the block ready before dropping it in.

whats the max power the internals can handle, i'm assuming he's gona need a re-hone, forged pistons, injectors etc?

I'm gona strip the block so if it needs new internals I may as well do them at the same time whilst fitting cams, head gasket and relapping the valves.

As for timing up once re built, is it a case of setting the cam/crank and letting the ECU take care of the ignition, my Astra uses a knock sensor is this the same?

Gona throw a 4-2-1 mani on but assume this will end up sold or in the bin if he does go turbo.

As for styling were gona go for some tasteful exterior mods, colour coding, front and rear lights, tinted windows but going more the standard/slightly modified look.

All the engine bits will get painted, hoses colour coded etc.

Thats all I need for now, (although I'm sure I'll need more help as i go on) I know some of you will be thinking click the fucking search button but I wana make sure I get clear answers for each question to reduce misunderstanding.

Really appreciate any help I get.

Here are a couple of pics of my Astra so you know I'm not a total moron or talking bollox, your help and advice is going to be used sensibly.

[RyanSaxo]

I'll answer some of the questions with what I know - but there are a lot of people on here with more knowledge.


Suspension/Brakes;

VTS Rear beam with VTS Rear calipers and braided hoses.

I'm assuming the rear beam is straight swap and I can use the original rear brake lines from the existing drums for the calipers? don't know

Suspension setup were looking at is Bilstein B4's with Eibach Pro springs
If going for Bilstein get the B8's or Group N setup - I personally have faulkner springs and really like it www.kamracing.co.uk do it as a kit now.

If I use the VTS front struts will I need to make any further mods, wishbones/drop links etc? Suspension/Brakes; not 100% sure but I thought the only difference in wishbones was with the 1.1 model. Not sure on the arb... It is a different rear arb on the vts from the vtr/furio though I think? Someone will clarify.

Front calipers will be 206 GTi calipers.

Do these just bolt on, I know you need to grind the caliper to stop them fouling the front strut, how much grinding is required and will these need a 15" wheel? There different between the 206 GTI180 and GTI138(?) basically, the difference is the diameter. 266mm ones fit under 14inch alloys 283mm (found on 306Gti6) fit under 15inch.

Can I use the furio drive shafts with the VTS box? don't know

Gona fit Greenstuff pads and EBC Turbo discs all round. personally I'd go with yellowstuff or mintex pads seem to be even more popular

Engine;

Going to use the 1.6 16v from a VTS including box, loom and ECU and open cone induction kit. standard vts airbox with cold air feed with uprated panel filter is much better than open cone

Are all VTS engines the same or do they differ from MK1/2 differ, clue is in the amount of "plugs" on the ecu. around year 2000 onwards they changed from a single plug to a 3 plug

He has ideas on a turbo kit at a later date so i'm gona try get the block ready before dropping it in.

whats the max power the internals can handle, i'm assuming he's gona need a re-hone, forged pistons, injectors etc? A big question - a lot of threads on it so have a search - it needs forged pistons/rods to cope with big power reliably

I'm gona strip the block so if it needs new internals I may as well do them at the same time whilst fitting cams, head gasket and relapping the valves.

As for timing up once re built, is it a case of setting the cam/crank and letting the ECU take care of the ignition, my Astra uses a knock sensor is this the same? don't know - there is a knock sensor I believe

Gona throw a 4-2-1 mani on but assume this will end up sold or in the bin if he does go turbo. if he turbo's it will end up in the bin yes

As for styling were gona go for some tasteful exterior mods, colour coding, front and rear lights, tinted windows but going more the standard/slightly modified look.

All the engine bits will get painted, hoses colour coded etc.

hope that helps a little bit. there are people with a lot more experience will give advice.


Consider putting the JP4 (similar engine in the C2 vts). It's explained here:
http://www.saxperience.com/forum/sho...s+engine+guide

How to Guide:
http://www.saxperience.com/forum/sho...s+engine+guide

[Mochachino]

Suspension setup were looking at is Bilstein B4's with Eibach Pro springs B4 are standard dampers. Get B8s as said or could get Apex kit. Also would reccomend faulkner springs.

If I use the VTS front struts will I need to make any further mods, wishbones/drop links etc? Why would you do this, a furio and VTS strut is the same, same wishbone etc.

Front calipers will be 206 GTi calipers.

Do these just bolt on, I know you need to grind the caliper to stop them fouling the front strut, how much grinding is required and will these need a 15" wheel? Straight fit, can fit under 14" wheels too irc. Not much grinding.

Can I use the furio drive shafts with the VTS box? Yes. But look out for if heyre tapered or non tapered, these differ between mk1 and mk2 and different fitment to the hub. Sports shafts fit perfect, non sports shafts fit but leak very very slightly from one side of the diff, drivers irc.

Gona fit Greenstuff pads and EBC Turbo discs all round. Why? Have you used greenstuff before on a small light car? Yellow stuff, Mintexx M1144 Ferodo DS2500 or the pagrid Blues etc.

Going to use the 1.6 16v from a VTS including box, loom and ECU and open cone induction kit. Its basics that an open filter is not the way to go. Heatsoak etc all back to basics stuff!

Are all VTS engines the same or do they differ from MK1/2 That bare engine is basically the same, the loom differs between mk1 and mk2 and some sensors differ between the mk1 and mk2.

whats the max power the internals can handle, i'm assuming he's gona need a re-hone, forged pistons, injectors etc? Some European guys have run 3/400bhp on standard bottom end. If he knows what hes doing then take his advice. Also alot of info on turbo builds on this forum. Not that clued up on them though.

I'm gona strip the block so if it needs new internals I may as well do them at the same time whilst fitting cams, head gasket and relapping the valves. ok

As for timing up once re built, is it a case of setting the cam/crank and letting the ECU take care of the ignition, my Astra uses a knock sensor is this the same? Saxo will sort it self out. Mk2 have knock sensor.

Gona throw a 4-2-1 mani on but assume this will end up sold or in the bin if he does go turbo. Yep.

As for styling were gona go for some tasteful exterior mods, colour coding, front and rear lights, tinted windows but going more the standard/slightly modified look. Oh right, good idea.

All the engine bits will get painted, hoses colour coded etc. Wicked Sick. wire tuck it if you want to make it something better than just a normal painted saxo engine bay