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172 in a mk1, Superfatdan's very very long project....



So i've had this car for nearly 4 years. I bought it from a member on here, Brad Harding, back in sep 2008.

1993 K plate Clio 1.8 16v with a Hybrid 2.0 bottom end.

This project has taken a long time (and still isn't finished! lol) owing largely to the fact that I have two small children, a wife that will be ill for the rest of her life and two businesses. Basically, I don't get much time! But this car is my baby and I don't care if it takes another 4 years, as long as its done properly.

I first saw the car on here way before that and as soon as I did, I sent him a pm stating that i'd buy it as soon as he was going to sell it. Two years on, he pm'ed me and I jumped in my wifes car with my dad and was off to Leicester as fast as possible...

Now, whilst it was a nice looking car, I can honestly say I bought this thing with rose tinted glasses.

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SO I drove it round like that for about 6 months. I changed the headlights from the awful angel eyes back to the originals.

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Then one day whilst out with a mate, he uttered the fatal words.... ''IT doesn't feel as fast as your williams''

And he was right. I just put it down to (at the time) also owning a 320bhp M3 so the clio feeling naturally slower. But him saying it made me realise that something was a miss.

So I rang three different ''specialists'' in renaults about a throttle body conversion...

Now I'm a simple man with a simple outlook. I wanted someone to quote me, I drop car off, I go back after some time with a fist full of pound notes and I collect my newly built fire spitting bodied clio... But no. Not one of these ''specialists'' even bothered to quote me.

Oh well, their loss!

So it was decided (during some stupid piss up!) that me and my mechanicwould do the engine swap from a 172.

So I went and bought a ph1 172 from a member off here that had been written off (lightly!)

We then transferred the following bits into the mk1 shell...

172 engine, Gearbox, clutch, driveshafts, bottom arms, discs, calipers, radiator, alternator.... I basically wanted a 172 in a mk1 shell.

Whilst doing it, I hounded Jordan Fox and chris Whiteley (off here) as they had already done the conversion so massive massive respect to them. When I eventually meet them, the beers are on me! My mechanic hates renaults, I am a car valeter so in the grand scheme of things, we needed help! lol.

Eventually, after one evening a month over the period of a year, I ended up with my mk1 172...

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But things weren't right. The suspension was shot to s**t, the exhaust was bodged and tyres were horrific.

SO I went and got a custom exhaust built from the downpipe back, then ordered some FK konigsport suspension (williams fitment) and then did a deal with a guy on here for some TD Pro Races with nearly new PE2's in 195-50-15. Sorted.

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So I drove to work and back in it like that for about 6 months or so, covering about 1000 miles. There were a few niggles, but on the whole, it was good!
I figured out that the fuel pump wasn't up to the job, the suspension needed a pro to set it up properly and ideally It needed someone who knew 172's and mk1's to go over it.

Sadly, nobody was keen to help me so me and my track-day best mate decided that enough was enough, we'll do it ourselves!

My track day buddy is Sam, he's a lot younger than me, a lot cleverer than me and a lot more talented than me. And he's better looking... But he's a fcuking brilliant mate and has never given up on my car. He's come close a few times though..

Sam is the owner of this... http://www.cliosport.net/forum/show...rly-finished&p=8636150&viewfull=1#post8636150

While up at my mechanics one day picking a car up, I decided to have a look at the clio's underside as (stupidly!) even when buying it, I had never done it.

Well that day was a day i'll never forget...

It was rotten! There was rust everywhere. Despite being told that the car had new sills and rear wings, it had infact been bodged together with filler and mastik. I was mortified.

So after a long think, I decided to buy a 172 and break the clio, there was nothing else I could do.

But then, Whiteley from this very forum advertised his bare shell, complete with cage.
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So I was watching it on ebay, it got to the last 10 seconds and I stuck in a cheeky bid...

But i'm a prick and lost it by £20. FFs. :(

Down trodden and disheartened, I just put the clio to the back of my mind and got on with life. Even bought myself an Impreza to cheer myself up!

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Then, out of the blue, the new owner of Whiteley's shell had a change of heart! :D:D:D He wanted to sell me the shell as he had too much going on to carry on with it.

So, with no hesitations, me and sam jumped in the truck and drove the (very!!) long way to get my new shell.

So thats as it stands, I have a fully functioning clio mk1 with a 172 engine but a rotten shell, and a 95% rust free shell with no running gear.

Current spec of Rusty Mc Rustbodge:

172 engine with aircon and Power steering delete.
Clio williams subframe, ARB and steering rack (with ends looped to get rid of power steering)
172 brakes with DS2500's, Brembo HC's
Braided lines
Espace V6 Airbox with ITG race element
FK Konigsport suspension
Single box exhaust with 2.75" bore from front to back. 3" tailpipe.
Custom Renaulsport Seat, 3" OMP harnesses
Ktec/Vibratec engine mounts
RS matched inlets

And the lovely new shell that its all going in to this saturday/sunday.

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I have booked a track day for the 7th of june and have booked two days off work this week to get the grey car re-shelled...

Got my work cut out! lol.

So plans are...

This weekend: Paint engine bay gloss black, reshell car, scrap grey shell after stripping it for spares.

Do a track day with Burpspeed on the 7th of june.

Get interior of car painted gloss black, exterior will either be painted in original mk1 16v grey or wrapped in satin grey, i'm not sure yet.

Then, next winter I want to supercharge it, but thats a long way off yet.

Apologies for the essay, I will update with more pictures after this weekends work.

(providing my wifes home from hospital on friday!!)

Much love.
 
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Re: 172 in a mk1, Superfastdan's very very long project....

They were both about 830-840kg dry on R888/Slicks. I had Superleggeras on mine at one point and saved another 15kg
 
Re: 172 in a mk1, Superfastdan's very very long project....

cool project, hope you have better luck with this shell!
 
Re: 172 in a mk1, Superfastdan's very very long project....

Awesome project this, got to love the old school look of the mk1 now.
 
Re: 172 in a mk1, Superfastdan's very very long project....

awww was just about to say another k plate going strong lol.

is your new shell a phase 1? what year?

tbh after whipping mudguards off mine and getting the car up on axel stands ive found a hole or 2 that needs welding up, nothing bad though.

will be watching this!

also regarding fuel pump, did you upgrade it, if so, which did you get? im thinking of getting a bigger one but unsure if its simply a straight swap or if stuff has to be fabricated?
 
Re: 172 in a mk1, Superfastdan's very very long project....

The fuel pump was a walboro 255 l/h.

I had to remove the pump holder from the tank (you may have to drop the tank depending on the year of car) and dismantle the holder by drilling out rivets etc. I then put it all back together using cable ties as its the only thing I could find that wouldn't deteriorate in the tank.

I got the pump off ebay.
 
Re: 172 in a mk1, Superfastdan's very very long project....

awww was just about to say another k plate going strong lol.

is your new shell a phase 1? what year?

tbh after whipping mudguards off mine and getting the car up on axel stands ive found a hole or 2 that needs welding up, nothing bad though.

will be watching this!

also regarding fuel pump, did you upgrade it, if so, which did you get? im thinking of getting a bigger one but unsure if its simply a straight swap or if stuff has to be fabricated?

I put a walbro 255 in mine, IIRC I think I might have had to change the wiring plug over or something trivial like that (was a few years ago now so dont recall exactly), but certainly wasnt anything difficult to do.

Need to take it out in the next few weeks to swap it to my new shell anyway, so will take a picture if you like.
 
Re: 172 in a mk1, Superfastdan's very very long project....

sweet, would the carb need tuning if i got one of those or would it simply be the new pump would be able to keep up with the carbs demand for fuel instead of it struggling?

i know f**k all about engines btw, sorry if i sound like a r****d
 
Re: 172 in a mk1, Superfastdan's very very long project....

There should be a pressure regulator to ensure that the carb only ever sees the pressure it requires.

Its got 4 pipes coming out of it, one goes to the boost/vacuum in the inlet, one to the fuel pump, one back to the tank and one onto the carb.

Providing you dont fit a pump with such massively flow that the regulator is incapable of bleeding enough back off to the tank it should be no problem uprating the pump.

IMHO though ANY change to the fuel system, especially on a turbo car, should be followed by having your AFR's checked on a wideband or better still a rolling road with a wideband.
 
Re: 172 in a mk1, Superfastdan's very very long project....

Chris, the previous owner of the blue shell, weighed it at about 830kgs ish when it was F4r'd iirc. Don't quote me on that.

Spot on. From memory that was with Williams wheels/dunlop slicks, half a tank of juice and my (crash) helmet on the roof. I bet there's 50kg of cage in it though!

But i'm only having one chair, and i'll be using proper glass not polycarb, and i'm about twice the size (width) of him. Make of that what you will! lol.

Spot on too.
 
Re: 172 in a mk1, Superfastdan's very very long project....

Just spent an hour loading the car onto the truck.

The big re-shell starts tomorrow and I cannot WAIT! :D
 
Re: 172 in a mk1, Superfastdan's very very long project....

Up at my mates garage, RCK mechanics in soundwell. Literally 2 minutes from my place.

Ramp, roof, lights £20k's worth of snap-on and loads of space! Makes a change from my garage where i've got a 10mm spanner, some cable ties and a pair of mole grips.

Thats why i've got to do it as fast as possible. He's open 7 days a week and he's very kindly let me have the place for two days while he works outside on the floor with a trolley jack.
 
Re: 172 in a mk1, Superfastdan's very very long project....

Just me until 12pm, then sam in the afternoon and he's with me all day sunday.

Plan is...

Sat AM: Strip grey one down, go and weigh the shell in.

Sat PM: Paint the engine bay in the blue shell. Gloss black.

Sunday: Fit blue shell up and drive it home. (hopefully!)

Do my two track days and make a list of things that need doing.

Then, its going for a full repaint. Gloss black inside, standard grey on the outside, the orange wheels are staying but they'll be going silver.
 
Re: 172 in a mk1, Superfastdan's very very long project....

Fair play mate!!

Im working in the morning, and working on the race car in the afternoon but if i get back early enough il come lend a hand/get in the way - may have some time sunday,il let ya know x
 
Re: 172 in a mk1, Superfastdan's very very long project....

Just remember to lable every wire! Thats what will take the time
 
Re: 172 in a mk1, Superfastdan's very very long project....

Got your work cut out! Be good once its re shelled :)
 
Re: 172 in a mk1, Superfastdan's very very long project....

Today was a good day!! Grey one all stripped down, engine bay painted gloss black in the blue one, engine/subframe built up ready for nice dry paint tomorrow and we can start putting it all back together.

Ten hours well spent! Time for a curry....
 
Re: 172 in a mk1, Superfastdan's very very long project....

fair play dan, just seen your plans for today, and glad it went well,
hope all goes good for tomorrow too
 
Re: 172 in a mk1, Superfastdan's very very long project....

Thanks chaps.

Sadly (its a good thing really!) Sam has rubbished a fair bit of my previous conversion.

He has ripped out all the brake lines I made, my heater matrix pipes etc. He just threw loads of stuff in the bin and said ''Thats s**t, thats s**t get rid of that, you can't hasve that.....''

So I do have a lot more work to do but on the plus side, it will make the car a lot easier to work on and be a lot better designed.

It just means it will push me back a fair bit.

He is horrifically (sp) anal about building things. As you will all see when his 172/182 thing is finished.
 
Re: 172 in a mk1, Superfastdan's very very long project....

Projected finishing date reduced from 2027 to 2016, well done!
 
Re: 172 in a mk1, Superfastdan's very very long project....

Thanks chaps.
Sadly (its a good thing really!) Sam has rubbished a fair bit of my previous conversion.
He has ripped out all the brake lines I made, my heater matrix pipes etc. He just threw loads of stuff in the bin and said ''Thats s**t, thats s**t get rid of that, you can't hasve that.....''
So I do have a lot more work to do but on the plus side, it will make the car a lot easier to work on and be a lot better designed.
It just means it will push me back a fair bit.
He is horrifically (sp) anal about building things. As you will all see when his 172/182 thing is finished.

LIKE
 
Re: 172 in a mk1, Superfastdan's very very long project....

Sounds good Daniel, hope it goes well again today.
 
Re: 172 in a mk1, Superfastdan's very very long project....

Got got upto speed on this, awesome/well done/good luck with it. Hope today is as rewarding as yesterday
 
Re: 172 in a mk1, Superfastdan's very very long project....

I would liked to have seen your face as Sam ripped it apart lol.

Keep busy fat boy ;)
 
Re: 172 in a mk1, Superfastdan's very very long project....

Well, another busy day.

I got up and early to spend half an hour with the kids before abandoning them for a second day running. I left the house after seeing this...

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And I drove up to the garage to be greeted with this...

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Thats whats left of the old shell. Sadly I can't get rid of it just yet as there's a few little bits left to get off of it but I ran out of time this weekend.

I think we did pretty well in just two days! Please bear in mind that I am a glorified car valeter and Sam is a builder! lol.

I'm not one for pictures and write ups so this is terribly brief but I mainly wanted to do it for my own benefit so I can keep track of what i've done.

So anyway, Opened up the garage to be greeted with the newly painted engine bay.

This is where me and sam had our first disagreement because he wanted me to get it painted properly at a bodyshop. I wanted to just paint it with a brush and some hammerite. In the end we bought some etch primer, some gloss black and some scotch pads and rubbed it down a bit and painted ourselves.

TBH, I think the finish is outstanding considering this was in a filthy dirty workshop...

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I decided then to have a little tidy up seeing as its not my workshop and its not my toolbox so I wanted to make sure I hadn't lost anything as this little lot cost £15,000!!

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Next up it was time to unwrap and fit some new shiny stuff. I like new shiny stuff...

On went Ktec engine and gearbox mounts. I don't need a dogbone mount as I've got a solid welded one down there.

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Next up we dragged the engine and the terribly expensive bald goodyear engine stand over and lined it up...

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And lowered the car down onto it. With a bit of fiddling, swearing and trying our best not to scratch the new paint, we were in!

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It was at this point, we decided that we deserved a reward. 4 pieces of Miss millies chicken, large chips and some chicken gravy...

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Once we'd inhaled that little lot (literally took about 3 minutes) I decided to gather up some parts and get to work...

(i'm submitting this now because my laptops going funny. If it loses this I will go radio rentals)
 
Re: 172 in a mk1, Superfastdan's very very long project....

As per my text after the picture you sent, cracking work dude!

Thought id get rid of the solid dogbone, and get one back in with some powerflex bushes in - It needs a little bit of movement in x
 
Re: 172 in a mk1, Superfastdan's very very long project....

So, on we go. Sorry about that.

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Front coilovers fitted (I've had these about 2 years but they've done about 100 miles! lol)

FK Konigsports in williams fitment, Brembo discs, DS2500 pads, braided lines and 172 calipers:

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Fitted the rear shocks:

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Next up we had a mare with the exhaust, mainly due to the fact that the pikey cnuts at a custom exhaust place had beat the s**t out of my old grey shell to get the manifold to fit. I wasn't going to do that with the new shell so it took a lot of jiggery pokery to get the 172 manifold lined up with the custome exhaust without it fouling on any of the car or rear beam.

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And finally, this is what i've finished up with at the end of play today.

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So i've put all my mates garage back together, put the blue car back in my garage and the grey shell will be on my drive tomorrow so I can finishe stripping it.

It is however my wifes birthday tomorrow and I really need to go back to work on tuesday to earn some money so this will be on hold for the next fortnight I expect.

Still, I'm on target to get to the Burpspeed track day in it! *touches wood*

Cheers.
 
Re: 172 in a mk1, Superfastdan's very very long project....

I will defiantely be able to pop and help one wekend before Wales mate, just let me know when il il leave some time free
 
Re: 172 in a mk1, Superfastdan's very very long project....

Fair play Dan...quite impressed with the work so far! :approve:
 
Re: 172 in a mk1, Superfastdan's very very long project....

Certainly getting there now, fingers crossed for the burpspeed day.

I took the engine out of my blue mk1 today ready to go into the yellow shell but I have to start from scratch with the electrics as im swapping from an mtec v4 ecu to an autronic sm4 and the yellow car has a 172 dash and car loom and i'll be running a race technology dash 2, so in my case the mechanical bits are the quicker bits and its the wiring side of it that will slow me down.
 
Re: 172 in a mk1, Superfastdan's very very long project....

Quite impressed with the rate of progress mate nice one!
 


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