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Something a little Different....
- Thread starter Dale!
- Start date
Awesome build. My brother know nige, as he is putting Saab 2lt into Mk3 astra.
Love the car mate
Love the car mate
scotty86d
Guest
Fantastic little car. It's a shame all the chav'd up ones ruin the reputations of potentially-as demonstrated here, very good cars!
![[B)]](/forums/styles/seatcupra/oldforumsmileys/shades.gif "Cool [B)]")
Had some free time this weekend so got cracking with monty...
First off was to carry on sorting the fuel system out.
Making the -8 hose from the swirl pot to bosche 044 pump..
Getting there now
New fuel goodies turn up
Free flow 90deg to replace "forge" 90deg (better flow)
Twin fuel filter bracket
Through body free flow vs old "forge" item
Getting there...
I Still have to make/attach lines from tank to "low flow" fuel filter and swirl pot to tank return.
As it stands the fuel system goes...
All hoses in PTFE braided lines with -6 fittings bar swirl pot feed to 044 pump which is -8
Standard Fuel tank
Walbro 255l Pump used as a Lift pump to fill swirl pot
Sytec low flow filter
2 litre swirl pot
Bosche 044 fuel pump
Sytec High flow filter
Aeroquip FPR
Injector dynamic 1000cc injectors
Then this parcel came
Inside
quick check to see if my cardboard mock worked.... The design has changed since design pictures. It uses a 70mm core as per design but now uses 80mm end tanks rather than 72mm the design had...
Worked well for me
I mounted the radiator and made brackets rather than good old cable ties but no pictures! Cut the slam panel out as i want it removable.
Mocked the intercooler fitment and welded the lower brackets. I'm yet to make the top hence the cable tie
Check fitment with bonnet shut (ignore the dirt he is very dirty )
And I removed the seats and all my old guage wiring inc wideband as this will all be replaced
Not bad for a Sundays work...
First off was to carry on sorting the fuel system out.
Making the -8 hose from the swirl pot to bosche 044 pump..
Getting there now
New fuel goodies turn up
Free flow 90deg to replace "forge" 90deg (better flow)
Twin fuel filter bracket
Through body free flow vs old "forge" item
Getting there...
I Still have to make/attach lines from tank to "low flow" fuel filter and swirl pot to tank return.
As it stands the fuel system goes...
All hoses in PTFE braided lines with -6 fittings bar swirl pot feed to 044 pump which is -8
Standard Fuel tank
Walbro 255l Pump used as a Lift pump to fill swirl pot
Sytec low flow filter
2 litre swirl pot
Bosche 044 fuel pump
Sytec High flow filter
Aeroquip FPR
Injector dynamic 1000cc injectors
Then this parcel came
Inside
quick check to see if my cardboard mock worked.... The design has changed since design pictures. It uses a 70mm core as per design but now uses 80mm end tanks rather than 72mm the design had...
Worked well for me
I mounted the radiator and made brackets rather than good old cable ties but no pictures! Cut the slam panel out as i want it removable.
Mocked the intercooler fitment and welded the lower brackets. I'm yet to make the top hence the cable tie
Check fitment with bonnet shut (ignore the dirt he is very dirty
)
And I removed the seats and all my old guage wiring inc wideband as this will all be replaced
Not bad for a Sundays work...
I thought I would share my other toy aswell.... Had him now coming up a year and in this time I've carried out the following...
TMS Stage 3 map
Pace FMIC
TMS Race Exhaust
Quaife ATB Diff
Whiteline RARB
Eibach Raceline Springs
Then time for a good bath...
Had him now coming up a year and in this time I've carried out the following...TMS Stage 3 map
Pace FMIC
TMS Race Exhaust
Quaife ATB Diff
Whiteline RARB
Eibach Raceline Springs
Then time for a good bath...
Had abit more time on him again today...
First off was the tack weld plates to make front panel removable
Top intercooler brackets tacked on
Mounted FPR and ran lines, haven't plumbed in fuel pressure sensor yet
Return from rail back to swirl pot
At present I'm going to use those XE cam's on standard marks, so first off was to put inlet back to standard marks and swap exhaust cam.
Strip down...
Exhaust cam removed..
Cam with pick up and sensor
Then I started routing my intercooler piping
With correct silicone joiners
Where the header tank is going
Then onto oil pressure sensor
Old vs new
Adapter for block, M14 x1.5 to -4 and -4 to -3 adapter then -3 hose to mount sensor on the bulk head
Then I seem to have hit a small problem..... placement for oil cooler so at present the location will be here and ducting and vent for cooler to help air flow, it will be changed to a 19row aswell....
Rough location
Using one of these
I will also be changing oil sandwich plate to 1/2 bsp with thermostat
First off was the tack weld plates to make front panel removable
Top intercooler brackets tacked on
Mounted FPR and ran lines, haven't plumbed in fuel pressure sensor yet
Return from rail back to swirl pot
At present I'm going to use those XE cam's on standard marks, so first off was to put inlet back to standard marks and swap exhaust cam.
Strip down...
Exhaust cam removed..
Cam with pick up and sensor
Then I started routing my intercooler piping
With correct silicone joiners
Where the header tank is going
Then onto oil pressure sensor
Old vs new
Adapter for block, M14 x1.5 to -4 and -4 to -3 adapter then -3 hose to mount sensor on the bulk head
Then I seem to have hit a small problem..... placement for oil cooler so at present the location will be here and ducting and vent for cooler to help air flow, it will be changed to a 19row aswell....
Rough location
Using one of these
I will also be changing oil sandwich plate to 1/2 bsp with thermostat
Update time again
Old oil temp vs new oil temp
Modified a coil pack bracket to take x20xev coil pack, currently have early head fitted on no threads on side for bracket
Few more goodies have turned up
New oil cooler 19row x 235mm vs old item 13row x 235mm
New hoses from Roose Motorsport, 2 way water pipe as I no longer use the 3rd connection for the inlet manifold, 10deg bend for intercooler pipe to trottle body and some other hose
Mocking oil cooler and cold feed to this
Currently using my old oil cooler lines to check for clearance....
All for brackets made top two go to front panel and bottom two go to battery tray
Then time to pull apart
For my reference the part number of the studs I used (BMW part number)
Studs fitted
Removed inlet
old 3 way pipe to be replaced
Next was to make adapter for the air temp sensor for the inlet, I used previous adapter which i cut the end off, drilled and tapped the m10 x 1.25 thread for air temp sensor....
Thats all for now
Old oil temp vs new oil temp
Modified a coil pack bracket to take x20xev coil pack, currently have early head fitted on no threads on side for bracket
Few more goodies have turned up
New oil cooler 19row x 235mm vs old item 13row x 235mm
New hoses from Roose Motorsport, 2 way water pipe as I no longer use the 3rd connection for the inlet manifold, 10deg bend for intercooler pipe to trottle body and some other hose
Mocking oil cooler and cold feed to this
Currently using my old oil cooler lines to check for clearance....
All for brackets made top two go to front panel and bottom two go to battery tray
Then time to pull apart
For my reference the part number of the studs I used (BMW part number)
Studs fitted
Removed inlet
old 3 way pipe to be replaced
Next was to make adapter for the air temp sensor for the inlet, I used previous adapter which i cut the end off, drilled and tapped the m10 x 1.25 thread for air temp sensor....
Thats all for now
Last edited:
man what do you do for a job, so jelous of both these cars bet that corsa goes like absolute stink
Cheers
Great stuff! Both really nice motors and the corsa's a beast!
Thanks, I can't wait to drive the corsa again
I work for BMW as a technician, work hard and play hard is the saying i believe.... It went well at 300hp so we will see soon...
Thankyou
Got my coolant adapters for the turbo
Old fittings
New Fittings
Thread is m14x1.5
Now onto the "Cooling issue/not issue" Some people don't run coolant feed to head but I would rather
Dewis Inlet with coolant feed marked out, you can see it has vent to header tank but nothing from 3 way pipe at the back of the engine
Standard Inlet
The Standard inlet manifold has a feed from the 3 way pipe with internal bore of roughly 25mm and the feed to the head has a width of 20mm.
First off was to make an adapter to go from the 3 way pipe, internal diameter of 26mm. We used a Barbed 1" adapter (external diameter of 25mm) which was braised onto a 1/2" barbed adapter (external diameter of 13mm) The reason this step was used will come clear soon...
Adapter that was made
Then to keep inside the 20mm hole in the head we used a 3/8 BSP parallel thread to 1/2" barbed fitting which uses an outside diameter of 17mm (thread end) the next size up was 21mm which would be to big for the port in the head.
Adapter with dowty washer
Drill and tap the inlet with 3/8 BSP thread
Fitted
Check fitment with inlet gasket
Adapter in
Trial fit inlet with joining hose
With joining hose fitted
From underneath the inlet
Now I know its still slightly more restrictive over the standard feed but some people arn't having issues without them, So IMO anything is better than nothing. There is still room to drill the adapters out internally aswell.
Prepping for paint
Old fittings
New Fittings
Thread is m14x1.5
Now onto the "Cooling issue/not issue" Some people don't run coolant feed to head but I would rather
Dewis Inlet with coolant feed marked out, you can see it has vent to header tank but nothing from 3 way pipe at the back of the engine
Standard Inlet
The Standard inlet manifold has a feed from the 3 way pipe with internal bore of roughly 25mm and the feed to the head has a width of 20mm.
First off was to make an adapter to go from the 3 way pipe, internal diameter of 26mm. We used a Barbed 1" adapter (external diameter of 25mm) which was braised onto a 1/2" barbed adapter (external diameter of 13mm) The reason this step was used will come clear soon...
Adapter that was made
Then to keep inside the 20mm hole in the head we used a 3/8 BSP parallel thread to 1/2" barbed fitting which uses an outside diameter of 17mm (thread end) the next size up was 21mm which would be to big for the port in the head.
Adapter with dowty washer
Drill and tap the inlet with 3/8 BSP thread
Fitted
Check fitment with inlet gasket
Adapter in
Trial fit inlet with joining hose
With joining hose fitted
From underneath the inlet
Now I know its still slightly more restrictive over the standard feed but some people arn't having issues without them, So IMO anything is better than nothing. There is still room to drill the adapters out internally aswell.
Prepping for paint
Have spent about £500 but that doesn't include swirl pot, pumps, filters, rail, injectors, FPR, half the braided hose as already had some and 10 or so adapters....
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