Megane Coupe Ph1 F7R Turbo - 197 Diffuser & VAG Box Content

[karpuz]

cleaned the camshaft carriers today!!! my god they were dirty!

before on the left after on the right...


happy enough with the results

got rid of most of the burnt on oil.

ordered a Head Gasket set today too so that should be in tomorrow, and im ordering the pistons tomorrow so my xmas deadline for the engine built up is looking promising, providing i dont make the mistake of taking the block to some cowboy machineist

had a delivery today...



got exited when i seen the size and shape of the package...



woohoo pistons are here!!!




cant bilieve how lite they are! 83mm diameter should see me up to nearly a 2.1 litre engine

courtesy of TSR perfformance, they specialize in VAG stuff but are a distributor for Wossner pistons, got them for £512 delivered where wossner themselves wanted £560

result

after xmas now the block is off for a rebore and hone, and ill go searching for a decent headgasket and it should be built up by january

whacked them on today.

2 new uniroyal rainsport 2's on the front, part worns on the back on my dinards that came off my scrapper all cleaned up and painted...



better late than never but gonna acompany them with some orange mirror covers and badges

Been playing with di-noc again...


And here's how it looks in place...


Looks much better with less Grey there now I'm sure youl all agree

Gonna do the drivers airbag when I get some more double sided sticky tape then to finish off the interior before fcs I have to dye the spare carpet I have and redo the headlining and parcel shelf. Will also be on some new wheels for fcs hopefully

inished stripping the block today crank looks good no scores or anything so bit of a result! cracked the plastic pump guard in the sump tho

!!! pished off about that!

anyway ill let the pictures do the talking...

sump off...


2 bottom ends off...


4 bottom ends off...


crank out...


pistons out

and the crank...


getting the crank mic'ed tomorrow in work to check it and taking that bloody heavy flywheel off!

engine should be built up next month when i get some cash together

my hands are also ripped to shreds too so im happy...

watch for an update tomorrow, hopeffully im going to get the block up to mine to blast it with a karcher ready to be taken to the machine shop

 

[karpuz]

well ive been fretting all winter about new wheels for the summer time and i just couldent decide what to do.

i didnt want to put my wolfrace ones back on because they were getting on my nerves and they needed 2 new tyres which i couldent be bothered to sort.

so i was on another site yesterday and seen some oz superleggeras for sale for £320 delivered with no tyres that were in ok condition and i thought bugger it ill buy them. as theyd been for sale for a while i thought id get them no problem and asked the guy if i could pay when i get paid on friday. as sods law would have it the day i enquired about them is the day he fecking sells them, so i missed out.

so anyway i decided to search the web for another set (i wasent very hopefull).

i ended up finding a set of 16's for £350 with good tyres (toyo tr1's, which i would have bought anyway) and in better condition than the ones previously.

i bought them anyway! lol



arriving next week

been busy today, ive mocked up the brembos on a spare F7R hub (has the same bolt spacing as the K4M hubs) heres what ive come up with...



i found spare 300mm disks in the scrap metal bin at work (result!!!) so i used them to mock up the disk on the hub, cut away the lower brake bolt hanger to get the caliper to sit correctly around the disk. by doing this i could see where i need to drill and tap the hub again, and what sort of shape brackets i need to fit the calipers securley.

now i just need to find some decent steel to make some brackets then see if it will be feasable to work them with the fiat coupe disks i have waiting to be used (these need the center bore machined out, which shouldent be a problem)

Then...

i got home to find a delivery waiting

they are very shabby behind the face but the face itself will come up nice with a good de-tarirng and polish. although i am tempted to go out and buy a dremmel now and refurb them

opinions?

anyway i put them against the car to have some sort of idea and they look far better than the old 17's i had! what do you think?



3 wheels have what look like nearly new toyo proxes tr1's which is great but one seems to have worn unevely so i may change it.

cant go wrong for £350 delivered

painted the block
should benice and undrstated in the bay now

 

[karpuz]

well i took her down daviedavies today as the mot is out today and it was going to fail so i made the tough decision to take it off road to start the engine work

im quite sad tbh but im trying to think of the bigger picture and getting on with things. i will be driving this badboy about in the mean time...

4X4 FTMFW!!!

anyway the car is tucked up ready for work on monday, progress will be slow to begin with but should start to pick up soon

im hoping to get it all up and running by xmas

here is her new home for the next few months...




bought an omex 600 standalone managment the other day for an absolute steal so thats something to keep me busy while i still collect a few bits for the engine.

t3 turbo off a sierra and some piper pulleys and its just gaskets and bearings to buy then along with a rebore before the engine is built up. if you see any turbos or pulleys that may do the job id appreciate a link

big thanks to daviedavie and let the project finaly begin

o i started today lol. as i decided to buy a ***** rather than a bloody car she wasent playing ball today

started by taking the back bumper off...


then proceded to take the backbox off and heat sheilds, but i couldent get the cat bolts off so i couldent get the whole thing off

then i went to take the rear axle off... still not playing ball

so the axle is half off now lol, just need to get at the bolts from inside the car!

am i right in saying i need to get in through the door cards to get at these?

anyway back down on wednesday no doubt... pics of some progress...




ingenious (pikey) axle stands to get the axle off

front bumper and inlet track off the car...


stored...


tucked away for some more abuse soon...





well shes fooked me off again today!

exhaust wouldent come off! took us 5 hours to get the rear axle and the cat off! what an absoluto ***** of a job!!!

anyway more pics from today

grinding the cat nuts off...




my ingenious solution to holding the engine forward

axle off ready to clean and paint, along with a new lick of paint on the calipers

had to take the rear seats out to gain acces to the bolts holding the axles on...


I love creme eggs

and my brake fluid catchers lol...


painting tomorrow

 

[karpuz]

done some more today, she was playing nice today too so it was a pleasure to work on her

i think i have paint poisoning now but meh, its all for a good cause

so we took the tank out...Hello!!!


gave it a clean

and the remaining exhaust heat sheilds and proceded to sand and paint everything with red oxide paint to prevent rust in the future, ready to paint with hammerite next week so its easy to clean.

Masking up...




primering...





then we done the rest of the underneath including the wheel arches

ignore the shocks im getting new ones

wheel arches before...

stupid tortion bars being in a stupid place made me bend my sill and now its gone rusty

how do you eat yours?


some pictures of me getting high...




and the result...

yes thats my head

and the car...



ready for painting black next week

also had a delivery today

= the plug and a load of wire to go with it

ight, lil update today, as jaff is currently sunning himself at a bbq.. (uncommited is what i call it

) as i wanted to do some work to mine, and his car has exploded everywhere in my garage, i had to do some so i had some bloody room to move

started to wire brush down all the bits that have come off and are, well, rusty as hell.







and after a lot of 'merde' and going thro 2 wire brush attachements on the drill...



hamerite them black next, after i have done all the other bits laying around

started hammeriting today! what a pain!

also primed the axle and other bits ready to go back on when theyre painted too.
we run out of hammerite, so theres a bit left to do, including a second coat!

rear sprayed gloss or satin black...


then the underneath hamerited




creme egg!!!




other bits...


and axle...
before


during...



after...


and the dust on my car

 

[karpuz]

well yesterday i went down to the car again to do a few bits and peices.
didnt get much done just finished doing the first coat underneath and gave the axle and other bits a coat

pics...

end result...




cant seem to find any pictures of the axle and stuff but its only a first coat on that anyway. as sods law would have it when getting the abs sensors out i got the broken one out no problem but the good one had to be butchered out

ghey!

anyway also had a delivery last week...

walbro fuel pump for a bargain, to provide enough jungle juice to the big boost

also dropped the block off to a reliable machineist yesterday for a rebore and hone

should have that back next week

also while i was up there i mocked daviedavies bumper up to my car to see if i like it, i do

lol so think ill be blending in my splitter but leaving the line not smoothing it out like he has and maybe chopping the grille out and ill be doing a couple of extra things because ill have intercoolerz!!!!

plus some big brakes that will need cooling ha!


aaannnnddd ive chopped the rover in for something more french and better on fuel because im dull like that

from this

to this

ive called it baby boost because its giving me a taste of things to come only in small doses

we had some fun changing the belts on it on sunday too

...



the mess...


missed catching the coolant haha...


and me trying to get some heatshrink to shrink without any form of heat haha...

well spent a good 12 hours sorting the car out yesterday! i came home and went straight to bed it was gruelling

story of the day...
second coat on the meg
play with the rear bumper
go out to fetch the fuel tank off the s**tter and get some spring compressors
get high in the car!
lower daviedavies coupe
put the rear axle back on my car
roll it out and wash the dust off it
go home lol

ill let the pictures do the talking...




creme egg!!!


wheel arch...


the mess...



the 2 fuel pumps that are going to give me a headache over the next few weeks...



car out for a wash...






we were both like this by now...

dont know why its upside down

then the finish...



needs another going over really, although the whole of the back has had 2 coats some bits must be pretty thin to let the red oxide through so a couple of touch ups when it comes to putting the fuel tank back in, when i decide which tank i have to use!

 

[karpuz]

done some more work today...

engine out, subframe off... thats pretty much it!
pics...




jaffa cake!!! because tesco dont sell cheap creame eggs anymore!!!


out with the old...



build the new ...

nice shiney honed bores

...


also got renault bearings, and a good head gasket along with the pistons and rods so this should be built soon

felt like this afterwards...


a whole lot o nothingness...


subframe and associated bits...


our romantic meal

rad needs to come out...


and how we left it...



ohh and the piece of exhaust that had me ryan, and daviedavie swearing for 4 hours a few weeks ago...


more stuff arriving in the post soon

spent a day down the garage with daviedavie again yesterday. managed to get a bit done. sprayed the middle of the car red oxide, painted various engine bits and removed the engine bay wiring loom along with some other stuff. theres still a bit more in the bay to do yet but hat will be done in good time

pics...
cam carriers


masking the cylinder head off...


jaffs turbo... powered by...

CREME EGG!!!


paining...



looks 10000 x better!

my delivery from the other day...


getting the sodding loom out!!!


makes me want to cry lookiing at this...


then the priming of the underside...

before...


durning...


after...



and i was once again a ginge

Today whilst daviedavie put the first coat of black under the car i procedded to build part of the engine. polished the crank, oil pump and rod bearing surffaces ready to be built then dropped the pistons in...

crank...


pistons and rods...


together in holy matrimony...


cleaning the block face up...



1 pot...


2 pots...


3 pots...


4 pots...

sexy!!!

powered by creme egg of course...


underside...


then a quick pic of the first coat of black underneath...


we also stripped the subframe and bits to sort out and clean/paint/powdercoat etc. no pics of this atm

theres also been a develpoment down the garage with pictures soon... we call it the fail wall! its there to remind us of the (no doubt) many failures we will encounter

it already has things from my car on there

 

[karpuz]

it of work done today, still arguing with renault for the correct bearings but ive managed to source the correct ones anyway. so wil build the bottom end up when i get them.

the rest is built now tho

had to take the pistons out again, cleaned the block thouroughly...



back in and gasket on



head on

also got a new attachment for my karcher that ive been meaning to try out and we had a chance today on my subframe, as demonstrated by daviedavie...

sandblasting attachment

subframe before...

during...


and the bit thats been done...


needless to say im very happy with it and the rest will be done when we get mroe sand

also made a little purchase today...

BAM! gt28rs ball bearing turbo done a few hundred miles from new at a bargain price

should spool up for me at about 3000rpm and good for 320 bhp

bottom end got built today and i started thinking about the wiring, not looking forward to that!

ecu plug


building the bottom end...




the correct bearings

oiled up...



torqued up..




waiting for my turbo to arrive and ive found some vernier pulleys i may buy

got some goodies the last few days...

turbo isnt as big as i wanted but it will do the job to get my target for now untill i get a better one next year and the pullies are second hand but a bargain so i couldent leave them

also had a development in the progress of the engine today that will be confirmed by the end of the month

wait and see

done a bit more on the car/engine the past 2 days

this includes:
modifying my fuel pump carrier to have a reg at the rail
build the basic engine
took both wings off
started my secret mod
made brackets for my bonnet strutts
tarted up the turbo and some other engine bits
gathered most of the engine bits ready to be prepped
made some enquiries into powdercoating

only a few pics...

secret mod...



cracking on!

 

[karpuz]

well ive been flat out all week doing various things. the secret mod is now as good as done, the engine has all but a few pieces sitting next to it ready to be rebuilt and run in in mine and daviedavies recent purchase...



the engine will be run in the week after FCS with no turbo on it so when the time comes to putting the engine in my car its a case of getting it mapped and off you go

this car is then set for scrap once its purpose has been served, so as usual pm me for any parts, theres not much left once weve finished with it but there could be something random that someone wants...


as for the enigne...


and all the bits minus the belts etc that are in a box under the table...


ive been waiting for the oil pump cradle to be fixed to finish building the bottom end, if you look top left of this picture you can see a mount for the pump has snapped off when i took it out. so i araldyted this together the other day and im now waiting for this to dry before putting it in...


this is the manifold ill be using, its a stainless one off a nissan 200sx which just needs the flange cut off and a new one machined and welded back on to fit to the F7R and it will suspend the turbo in an ideal place

ohh speaking of welding...

secret mod anyone?

well between FCS ive been slowly butchering things as usual

first heres the current state of affairs in garage a la davie...


to get the F7R out davie has used his noggin and the anti christ to great effect...


helps us be lazy and not push

so i got the engine out of the F7R ready to put my engine in for the run in milage

this is the mess we have to work in

while the F7R had the engine out i couldent help myself and i mocked up the turbo onto the manifold then mocked it up in the bay...


WINNING

cant wait to fit it into my car now

so far ive half stripped the F7R ready to use the parts on the turbo engine and started to build the turbo engine...




parts on the floor ready to be cleaned and fitted, not having dirty s**tty stuff all over my nice clean block and head

back down tomorrow to finish the build then wednesday or thursday ill put it in the car ready for a friday blast/boring run around

since the last update the engine has done about 800 miles, would have been well over 1000 had the car not let us down in derby by blowing a power steering pipe.


4 hours later it was back in the garage in ammanford ready for the engine to be taken out. the decision was made by the power steering pipe that the car will be scrapped and not salvaged.


now that the F7R is gone i can crack on with finishing my car as im begining to miss coupe ownership. on the to do list before the enigne goes in is...

send off running gear to be powdercoated so i can put the car on 4 wheels again
finish my clio 197 rear diffuser off, this requires more welding and some undersealing then cuttin the spare bumper and mounting it
paint the bay and under the wings.

while ill be doing these, amongst waiting for parts to arrive and paints to dry ill be working on the engine also. first thing to do is to butcher the manifold i have and get it to fit the F7R once ive done that i can mount the turbo and make the oil return also drill the sump or block. then i can buy an oil feed line too and mock that up so thats the main engine work left to do done.

the rest of the engine work includes changing the timing belt because i stupidly put the wrong cam seals in before first start up and the belt got contaminated

then general tarting up and making it look the part.

id also like to give a big thanks daviedavie and ryan (rtsportdti) for helping me and staying up untill stupid o clock in the morning to iron out some of the teething issues we had with the engine. things like the constant oil leak from the rear crank shaft seal(the one behind the gearbox and flywheel!) huge fuel leak from the fuel return and leaking exhaust manifolds. needless to say i would never have been able to do all this in time without their help

all in all i was very pleased with the engine. considering it was my first build and even though it went evrything other than smothly it still pulled as standard and went like a rocket once i had put a few miles on it held great oil pressure and started on the button every time

cant wait to get it into my car boosted and producing some good power figures

anyone who wants to read more about our days out in the car or see more pictures of the car in our week of madness you can see some in these 3 threads...
http://www.renaulton...est-drive-ever/
http://www.renaulton...drive-ever-pt2/
http://www.renaulton...drive-ever-pt3/

the doner car has now been scrapped and the engine is sitting in davies garage if anyones intrested in it?

if not im gonna ask davie nicley if i can butcher the block to see if i can get a meggy 225 box to fit somehow because im not happy with the thought of changing gearboxes every week. im convinced i can make it fit but time will tell.


not much more to update on but when i get some stuff powder coated things will start moving forward again then and things will be going back on the car, which will please me and davie immensley as its getting a bit packed in his garage now. when things start going back on its a good sign that were getting there! so watch this space!

ohh and i bought a forge dump valve

 

[karpuz]

so after waking him up we both went out the garage, cleaned up a bit,
it would seem we have an abundance of wheels...

moved the car forward a bit so i could work on the back and set to work.
the task is to get this...


onto the back of my car, not as easy as it first seemed!!!

up until now i have

taken the bumper off
married the diffuser up to the car
marked what needed removing
and removed the bits!

it started off that i was only going to cut the bottom of the wheel well off and weld a plate on the bottom. leaving enough room in the wheel well for a space saver or something. then me and davie noticed to get the dual exhaust exit to have the diffuser live up to its potential there would be quite a lot more modification to do it properly. my motto with this car since the day it went into davies garage is "if your going to do it, do it properly!"

so out came the grinder!

first i cut out the floor of the wheel well and due to the curve of the well and the fact it isnt central in the car i c**ked up and cut it squint, not to worry i chopped the rest out leaving about 8 inches at the back of the car about 5 inches deep. if you cant picture this it will come clear in a second...

with the boot floor practically gone it was quite upsetting seeing what id done to my car but it was too late to go back now.

so i gave my mate a ring, he brought his wleder down and set about welding the plates of 1.6mm steel i had cut to shape into the boot floor. today weve been cleaning up the majority of it because the welds werent great due to the ammount of underseal on the underneath of the car reacting during the welding process. there are still a few holes to be filled and then cleaned up and the slope of the wheel well is still there that needs to be cut off but its nearly there now, the car at least has a boot floor again

here are some pics to help you understand the shape and diffrence of my boot floor compared to a normall floor...

normall floor with wheel well...


my floor with small storage area...


this is a picture that gives you the idea of how much the wheel well sticks out from underneath the rear slam pannel...


this is too much for the rake of the diffuser to sit flush on the bumper!

so this is what mine now looks like...



looks cleaner imo

more pics of underneath...


note the lip on the circumfrance of the old wheel well is still there and needs to be ground off! but a nice space for some exhaust pipes and maybe a centre/back box to provide some proper exhaust

also like i mentioned before, i saved a few inches at the back of the car for a little storage space, nice little tool cubby hole and some tyre weld or similar, ideal size ...


more updates during the week, getting some seam sealer soon so i can seal it all up ready for paint, hopefully the diffuser will be mounted on a bumper next week then mounted on the car

so i took a handfull of stuff to a local powder coaters to see their handy work...



as you can see my misses still loves me by letting me put car parts all over her worktops

turned out very well, theyve also been primered in a zinc coating for an extra layer of protection so im well happy with them for the price and i will be taking the rest off tomorrow to be done too

ive also picked up a bit of 12mm stainless steel to make my manifold flange out of...



Top quality steel this is! cost me a fortune for what it is and had to have it special ordered from birmingham. the guys down at express metals, swansea were superb and managed to find me this and get it to me the day after i enquired about it so i was well happy

ive found a company that will cut the shape out for me, it was harder than i thought because no one wanted to touch it and it was looking increasinly like i was going to do it myself with a pillar drill every dinner time lol.

now its being machined by CNC machines so it should be of good quality

also my welder is coming up on the 1st or 2nd of august to finish off my boot, so that can be seam sealed fully and painted and finished awaiting the diffuser to be mounted which may end up in the bodyshop at this rate.

I couldent help myself when i brought the 300mm disks down to the garage either...

im also in the process of buying a mocal 13 row oil cooler with a thermostatic sandwich plate to keep my oil temps down and i will soon be searching for a load of silicon pipes. target is to have the bay painted and engine test fitted with the turbo by the time daveski and simon pop down in the middle of august, then we should really see some progress

i should have enough money to keep a steady flow of updates between now and then even with my apprenticeship end date looming and it looking increasingly likley that i wont be paid for 8 weeks and my last pay being substandard

either way im looking to partly strip and rebuild the engine again to put a turbo oil drain in and put some vernier pulleys on (+ a new fecking timing belt kit! damn oil leak!) before simon and dave come down so i have plenty of work left to do.

does anyone know anything about treating bolts so they look good and stay looking good rather than going rusty and/or dull. something like polarising but something i can do myself?

been busy with the spraying...

wings...


gets very dirty up there!




primered




finished...




taking evrything out of the bay...



taking things out of the scuttle...



more to come...

 

[karpuz]

http://www.cliosport.net/forum/show...-turbo-197-diffuser-amp-VAG-box-content/page2


Arkadaşlar devamı linkteki 2. sayfadan itibarendir. Çok fazla detay var. İlgilenenler kaçırmadan detayları incelesin derim. İDE kullanıcısı arkadaşlar bu yönde çalışmalar planlıyorlardı. Umarım fikir açısından iyi olur