My supercharged VTS

[Andy_K]

Thought I’d start a new thread as the old one was getting quite long and was in no real order.

Old thread can be found here if you are interested: http://www.saxperience.com/forum/sho...d.php?t=117590

Anyway, I’ll shorten this thread into pictures and interesting bits only. The car is still a work in progress, and has been for several years now The project has been on hold for 12 months due to me buying my first house, meaning that money and time have been in short supply. However, the house is now nearly sorted, so progress should be starting again very soon


Contents
1. Full Spec list............................................ Page 1
2. The early days (2002-2007).................... Page 1
3. The donor car................................... ..... Page 1

[Andy_K]

The full spec list for the car is below. Items in black are things that I already have sat at home ready to be fitted. Red items are things that I still need to do/buy.
Engine
1.6 16v VTS bottom end (40k miles), rebored to take oversized pistons
Rebuilt bottom end with new bearings and seals throughout
ACL race spec bearings (mains, big end and thrust)
Wossner Low compression 79mm (0.5mm oversized) forged pistons
Forged Conrods (unknown make, possibly Pugsport)
ARP conrod bolts
Constella sump baffle
Brand new Rotrex C30/94 supercharger
Rotrex oil filter and oil tank
Brand New (0 miles) JP4 ported and polished head rebuilt with pugsport J4 double valve springs, J4 retainers and followers
1.0mm MLS headgasket
C2 VTS metal inlet manifold, plenum and fuel rail powder coated gloss black
GMC 55mm shaftless throttle body
GMC Charger bracket and auto tensioner
Newmans PH3 cams
Siemens 690cc injectors
alloy fuel rail
KMS standalone ecu
KMS wideband lambda controller and probe
KMS ICV controller
Cosworth 2 bar map sensor
MSD 8241 Coil Pack with Atspeed bracket
Magnecor KV85 Focus RS 8.5mm HT leads (part no. 45298)
AH Fabrications 1ltr swirl pot with AN-6 screw fittings
Full set of braided fuel lines with Earls fitments
Sytec 255lph auxiliary fuel pump and bracket
Sytec motorsport fuel filter
Weber 3.5 bar remote fuel pressure regulator
Mocal 13 row Oil cooler for charger
Mocal 13 row oil cooler for engine oil with Mocal oilstat
Mocal remote oilfilter and take off plate
K&N RF-1047 cone filter
Custom made Pace Front Mount Intercooler
Peugeot 205 Gti 'race spec' Alloy Radiator
Twin 9" slimline fans
Mocal oil catch tank
2.5" Alloy/Silicone boost pipes
3" Alloy supercharger inlet pipe
GMC/BTB 4-1 manifold (heatwrapped)
Full BTB stainless exhaust and decat box
Battery relocated to behind passenger seat in carbon look fibreglass box
Brand new Genuine Peugeot water pump
New cambelt and tensioners
Denso IKH24 Iridium spark plugs
Lightweight alloy underdrive crank/alternator pulleys from Colin Satchell
Piper Cams black anodised alloy vernier pulleys
New charger belt
82 degree thermostat
Silicone water hoses, including vtr radiator top hose to remove oe oil/water heat exchanger
Spec-R power steering fluid bottle
Streamline carbon fuse box/ecu/ brake fluid container/JP4 spark plug covers
Group A solid engine/gearbox mounts
Baker BM solid gearbox mount rear bush
Guage adaptor sandwich plate
Seam welded engine bay
Resprayed engine bay in rouge vittal
engine block painted gloss metallic black
Nitrous Oxide kit (may fit as I already have a full kit sat doing nothing)

Transmission and brakes

VTS MA gearbox rebuilt with new bearings and seals. Gearbox casing cleaned and painted gloss silver
Quaife LSD
Lightened flywheel (4.7kg's)
Helix 6 paddle clutch
Colin Satchell 'Satchshift' rose jointed gear shifter
WP Pro 6 piston callipers and 292mm front disks and braided hoses
Standard rear disks with Mintex pads
23mm master cylinder
Stainless steel braided hoses through out, running internally in the car
Wilwood adjustable bias valve
ABS system removed
Dave Mac flat hub uprated driveshafts

Suspension and Wheels

GAZ Coilover front suspension
2.5" id 300lbs springs
4" 40lbs helper springs and adaptor cups
Brand new wheel bearings
Struts shot blasted and powder coated gloss black
GAZ Adjustable Rear Dampers
Rebuilt rear beam with solid mounts
24mm rear antiroll bar
21mm Torsion Bars
Compbrake adjustable Top mounts
Rear torsion bar adjusted -60mm
OMP Upper front strut brace
OMP Lower front strut brace
Custom made upper and lower rear braces
Powerflex poly anti-roll bar inner mounts and front wishbone bushes
New standard wishbone inner mounts and track rod ends
New anti roll bar drop links
Welded in strut top strengthening plates
16" OZ Ultraleggeras in et16 powder coated in gloss black
195/40/16 Toyo TR-1R

Body work

ESP Designs Tourismo front splitter moulded into bumper
RGM bumper side vents
VTS front bumper wide mouthed with number plate recess cut out and meshed (for airflow to oil cooler/intercooler)
Bumper adapted to fit 106 Gti fog lamps
black TRS Towstrap
Small front number plate
Seat Leon Cupra R front splitter
Streamline Carbon Widemouth
Delocked doors with vts badges deleted
Heko Wind deflectors
Polycarbonate rear windows
Polycarbonate rear screen
ESP Designs Arbarth style sideskirts
SPA race wing mirrors
Side repeaters flushed and replaced by LEDs in wing mirror bases
Custom made bonnet with steel extension over headlights and with stamped louvres and lockable aerocatches
106 Bonnet Rams
Morrette twin headlamps with inner light removed for airflow to airfilter
6K HID kit
Smoked indicator lenses
Single Wiper conversion
Streamline Carbon carbon fibre non-sunroof roofskin
Flushed tailgate, with extended lip over rear lights
Cituning RS-R or Dimma rear spoiler (yet to decide but have both)
VT* rear bumper with 106 number plate recess moulded in and clio 197 diffuser modified to fit
Smoked Jewel rear lights
Streamline carbon carbonfibre B-pillar covers
Streamline Carbon carbonfibre door handle covers
Standard fuel filler cap flushed and cap relocated to drivers door shut
Full respray in Citroen Rouge Vittal with centre of bonnet and roof in gloss black with metal flake, morettes, grill and clio rear diffuser in gloss black

Interior
Semi stripped rear
Safety Devices Saxo cup cage
Flocked dashboard, vent surrounds, speedo surround, mirror trim covers (with tweeter pods)
Flocked 106 Ph2 door bins (with speaker pods) and handles
Flocked boot handle trim
Alloy door pulls
Audiosport guage pod smoothed into centre console, with cut out for KMS lambda display (painted Rouge Vittal)
Custom made guage pod in place of passenger airbag, also flocked
Streamline Carbon fibre front and rear doorcards
SPA Design dial binnicle with streamline carbon surround
Auto guage EL auxillary dials (AFR/Oil Pressure/Oil Temperature/Water Temperature/Volts/EGT
Cobra Evolution S bucket seats with alloy side mounts and Ghost Developments subframes
Sabelt 6 point 3" harnesses
Momo Steering Wheel and boss.
OMP adjustable steering wheel spacer
Citroen Sport Alloy pedals
OMP Alloy passenger footrest coated matt black
Black Carpet in front
OMP Helmet Hammock
Full plumbed in Lifeline Zero 2000 fire extinguisher system with engine bay and interior nozzles
MDF rear false floor
Respray interior in Rouge Vittal

I.C.E.

Pioneer DEH-7200SD Headunit with CD/MP3/USB/SD Card reader
MTX TXC6.1 6.5" front component speakers
JL Audio 12" sub in sealed box
JL Audio e2150 2 channel stereo amp with casing colour coded in Rouge Vittal
Jl Audio e1200 mono amp with casing colour coded in Rouge Vittal
Tweeters in custom made pods in mirror backing plates, flocked in black
Woofers in custom made pods blended into flocked 106 door pockets

**Please note - this is not a 'wish list'. This is what is actually going in the car when its built **

[Andy_K]

I originally bought the car in about 2002, totally standard with 16,000 miles on it and one previous owner. It started as a '99 V reg MK1 VTS in Rouge Vittal (Persian red), a limited edition colour. It looks similar to wicked red, but a bit lighter and has a slight pinky tinge to it.
As soon as I got it, I carried out a couple of small mods



A few more small mods crept onto the car over time, including the meshed front bumper, a full magnex exhaust and de-cat, tinted windows, front and rear light brows and also Seat Ibiza splitters on both the front and rear bumpers. The car was lowered by 60mm all round on G-max shocks and springs. I also fitted some 15" alloys as I’m not really a fan of VTS wheels.






The car was a little low on the 15's, and the wheels looked a little small for my liking. My next purchase was therefore a set of 16" Matrix Torques.






I then got some SPA race mirrors from Demon Tweeks. These were designed to fit a single seater race car, and so were a little fiddly to fit. I bought some universal M3 mirror base plates and smoothed them in after bolting the mirror legs to them.
Soon after, a new one-off bonnet followed. Its fully made from steel, and is extended and rolled over the lights and has two sets of louvers pressed in. I originally painted it matte black.

[Andy_K]

I then started on the bodywork. I’ve always liked bodykits. Not necessarily huge jap style monstrosities, but something a little more subtle to make a car stand out from standard.

I packed the car off to a bodyshop to have some work done. They fitted a front splitter, new rear bumper (custom made by myself to my own design), smooth boot spoiler and side skirts. They also colour coded the side strips and painted the bonnet. A custom exhaust was also fitted.

[Andy_K]

Got the car back from the body shop like this:





I then painted the wheels black, fitted a pair of fixed buckets and 4-point harnesses, removed the rear seats, Gti-6 283mm front discs and callipers and left it like that for a couple of years. Car was a daily drive at this time, but I soon got a second car to use for work to keep the saxo for weekends only.




In the mean time, I started collecting and making a few other bits and pieces ready for the next phase.

Got an OMP 6-point cage, made fibreglass front and rear door cards, fibreglass dashboard (complete with screen and hidden PS2) and new exhaust.









I was going for full install as well, which filled the rear of the car. Car was now off the read (2007) so that I could work on it. Pretty much everything was made/fitted/painted by me in my mum and dads garage. However, I then came across a bit of a bargain which changed the whole direction that the car was going.

[Andy_K]

I managed to buy a fully running supercharged vts for a pretty low price.











A power graph came with the car showing 189bhp at the fly when the conversion was originally done, although it was apparently mapped by GMC at a later date and showed 227bhp on their rollers.

The car was rough as it was a track car, but came with full Rotrex charger conversion and forged engine. Plan was to lift the engine straight out of this shell and into mine (after selling my standard vts engine to a mate), although this didn’t happen in the end. Upon closer inspection, I found a few niggly problems, which ended up with me stripping the engine down for a full inspection. The news wasn’t good, and I found damage to one of the pistons, and eventually ended up purchasing new pistons and fully rebuilding the engine.

The supercharged car was stripped down and all the spare parts sold off.

Video click











The direction in which my car was heading now changed as I didn’t see the point in having a car full of subs weighing several tons whilst having a nice engine. Therefore all the fibreglass panels and install came out.

[Dboyvts]

Happy new year Andy. Liking the new shorter project thread lol.. How's things coming along??

[Andy_K]

Happy new year to you too mate. Hope you had a good christmas.

Yeah thought its a bit easier to see whats going on in a short thread than 160 pages of the other one! Things are good at the minute. Hope your doing ok.

[blackie_2k5]

As above mate, good to get a new thread, look forward to updates now your all settled in

[Andy_K]

Heres all the parts that are ready and waiting for the rebuild:

Interior

[Andy_K]

[Andy_K]

Exterior

[Andy_K]

Engine Parts

[Andy_K]

[Andy_K]

Suspension/mechanical

[Andy_K]

I had the engine built over the space of about a year. I bought the JP4 head complete, so it was initially just the bottom end that needed building. I sent it to a local firm called Browns in Halifax for reboring, honing and the bottom end building.
Crank in, with the forged rods, ARP bolts and ACL bearings:



New crank oil seals, along with all other seals:




Wossner pistons fitted after block was re-bored by 0.5mm, new rings etc fitted:




I then gave the completed bottom end to Titch and Vinny at Northern Racing to fit the head, sump and all the other bits and pieces. They did a fantastic job and gave me a complete engine back, which is practically ready to refit into the car now, as soon as I buy a clutch place. Going for a Helix 6 paddle, together with a shaft strengthening sleeve from GMC for the MA gearbox input shaft.

This is how the engine stands at the minute:

















New manifold gasket fitted:


Little peek at the bottom of the valves, in all their shiney new-ness lol


Then back on with the mani, dipstick and charger. I also relaquered the oil cap so its nice and shiney (theres also a flake in the paint which now pops in the sunlight rather nicely), and fitted the new rocker cover, coil cover and thermostat bolts and washers:

[Andy_K]

Meanwhile, I sent the bare shell off to a bodyshop for painting and the carbon roof fitting. Mark1311 off here did all the work for me and he did a great job. We even smoothed over the standard fuel cap opening and cut a new one for a hidden cap in the drivers door shut.









All masked up:



Engine bay stonechipped:


Engine bay primed:



Outside primed and guide coated (for rubbing down):






Chassis legs plated over and a few holes welded up. Not going mad with smoothing the bay, but a few of the seams have been filled over, the strut top plates have been smoothed in and a few other bits and bobs. Most of the bolt holes on top of the inner wings are staying though as they will be re-used by the various fixtures and fittings:



Roof support bar is fitted ready for the carbon roof:


Interior in its first coat of primer


Carbon roof on









Still needs flatting and polishing, but the shine is unreal. Looks better in the flesh than on the phone pics. I'm really happy with the finish, and it can only improve with polishing.

[Andy_K]

Started fitting a few bits back on to the car now, like steering rack, brake servo and pedals, wish bones, lower strut brace and the linkages for the Satchshift:




And the fuel tank and rear beam:



And then for the first time in at least 4 years, wheels were fitted and the car actually stood on the floor:

[Andy_K]

That was several months ago. Since then, not much has changed due to other commitments. However, the car is now at my house ready for the full rebuild.















New windscreen fitted



Plan now is to refit everything to the shell and get it all up and running. Still a couple of bits to buy/make and a few of the body panels still need painting, but we'll get it all sorted as we go.

[Tannerman]

Awesome lovin this....n I love how the Saxo looks from behind when it hasn't gotta rear bumper on.if only it was legal I'd rock it.lol