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MK1 F4R ITB - Ressurect PNX



  HBT 172 Cup
Thought as i am a member i should take advantage of the projects forum :D.

Im a little late with this one, this project has been going on for a while but today most of the work happened so ill just paste over what has happened.

So D Day arrives, i hadnt heard from the garage chap down the road so i was a little worried, i chased him up slightly later in the morning. But i was anxious because i had to literally role my car down the road to his garage which is probably 150m away and the car has been stood still for about 6 months, and the later i leave it the busier the road gets with traffic.

So i tied the exhaust up, freed the gearlinkage up which was smashed and destroyed and had wedged under the car and started . With a bit of a push i was off and made it fine, i had to sat truck my engine down the road, i got some rather funny looks lol! (pictures of that to follow, you will LOL).

Ok engine there and in the garage, off we go.

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Tools n s**t..

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It was f**king hard to line all the mounts up foxy 5th mount is a stiff c**t, and hard to line up the top mount with at the same time, but managed in the end with a bit of a push.

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Errrrrrrrrrrrrrr no doesnt fit, this engine seems to tilt upwards compared to the F7R i used to have, no idea why, but cause the bonnet to massively foul the airfilter.

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With the bonnet shut, the bonnet touches the air horns :(

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Mock up of the smaller setup im going to have to run (flat backplate with offset upwards by about 1cm to make the filter sit lower and some 45mm/60mm trumpets instead of the 90mm).

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Going to make the backplate tommorow.

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More pics later :D
 
  '92 172, Lotus Elise
Common as muck now! :D

how many are there now?

(Not in any order)
beanie
wayne (now in a mk1 ph3)
myself
foxy
whiteley
wilky19
adamanderton
patrick_g46
laine

dunno if andy's counts? :rasp:
 
  HBT 172 Cup
Its certainly testing my patience, spent another day up there. THe exhaust is the biggest arse ever to do, i wanted to make it a universal downpipe that would suit any Mk1 clio exhaust system, but wanted to keep my silenced williams decat to. For this to happen the downpipe has to go throught the smalle gap and drop very quickly to the right level, and it just isnt going to happen, so ive got to cut around 10-15cm out of my magnex centre section.

But currently its all tacked up, cant take the downpipe up cos neither of the flanges fit through the gap! Lower the subframe to fit/remove the downpipe, fun fun fun!

Ive finished making the flat backplate, and it looks like the clearance issue is sorted now, just need to find some smaller trumpets.
 
Its certainly testing my patience, spent another day up there. THe exhaust is the biggest arse ever to do, i wanted to make it a universal downpipe that would suit any Mk1 clio exhaust system, but wanted to keep my silenced williams decat to. For this to happen the downpipe has to go throught the smalle gap and drop very quickly to the right level, and it just isnt going to happen, so ive got to cut around 10-15cm out of my magnex centre section.

But currently its all tacked up, cant take the downpipe up cos neither of the flanges fit through the gap! Lower the subframe to fit/remove the downpipe, fun fun fun!

Ive finished making the flat backplate, and it looks like the clearance issue is sorted now, just need to find some smaller trumpets.
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Did you not start with a 172 Cat for the downpipe bit? A williams size cat should easily fit in there instead of my 'straight' section? Only took us a few hours in total to do the whole thing, fits any Mk1 exhaust system... Ive managed to get the downpipe out through the top once if the car is jacked high enough on stands too, does come out. Mine fits out through the bottom past the ARB oddly though!
 
  HBT 172 Cup
Yeah its sort of like yours unforuntaely it just doesnt seem to fit in, i have no idea maybe my cars some strange case, i'll make it fit though :)
 

wilky19

ClioSport Club Member
  Leon FR
i had the same problem there is a L bracket at the back of the subframe that holds the clutch cable, till i removed this it wouldn't fit. i then cabled tied the clutch cable back into the right place
 
f0xy, go in to business making up f4r-to-mk1 downpipes
please :eek:
LOl please, id buy one too
I would if every car/setup was the same, sadly it isnt :(

As you now know matteh using the 5th mount has allowed you to use the standard (ish) dogbone mount over the coops item, which you prefer. Whereas Ive got my downpipe setup with a coops mount so a copy of it would probably not fit...

Its the same with the solid subframe bush I have on mine, people were asking me to make them so they could remove the rubber one that usually falls apart - problem is out of the 3 subframes ive had the holes where the rubber usually is has been different sizes - so something that would me right on mine might not be on someone elses :(
 

Daniel

ClioSport Moderator
  Whichever has fuel
I cut the front off a ph2 cat and welded that to a mk1 centre pipe.
 
  '92 172, Lotus Elise
You forgot Geesus' ITB'd F4R too.
and Daniel :eek:

beanie
wayne (now in a mk1 ph3)
myself
foxy
whiteley
wilky19
adamanderton
patrick_g46
laine
geesus
Daniel

We've got enough to do our own meet!

Re: the downpipes, wish I could weld myself, then I could probably make one with a flexy joint that allowed the standard dogbone to be used!
 
I much prefer mine now that the 'doughnut' joint is bolted solid as tight as it will go with no springs. Flexi joint just before it meets the center section to allow movement and its all been fine!
 

Daniel

ClioSport Moderator
  Whichever has fuel
I'd love to find a garage with 15 ramps and get all our cars together. See what we've done differently. We could then develop the ultimate F4r'd mk1! lol.
 

wilky19

ClioSport Club Member
  Leon FR
I'd love to find a garage with 15 ramps and get all our cars together. See what we've done differently. We could then develop the ultimate F4r'd mk1! lol.
that would be an experience. the other day mine, f0xy's and Adams were all together. it was surprising how different the all were whilst being the same if you get what i mean. it was good to see everyone approach to the different problems.

Of that list, how many would start if you went outside and turned the key right now?
mine would, been using it everyday since i finished it. its my only transport.
 
  HBT 172 Cup
Lol at the above, ive come to the conclusion what im doing with the DP is s**t and its all for the sake of keeping the silenced decat (which i much preffered to the unsilenced version), but might just rip it out now.

Need to rig up the fuel pipes although that 80% done now, just the return line to do. Coolant pipes are a mess i cut the ones to the heater matrix when the engine was out the car and have subsequently chopped them both about 2cm too short, fail! so will need some niversal coolant pipe and joiners to save me there.

Ive completed the flat backplate which has presented other issued, it now fouls the alternator, so i have to lower the alternator and buy an even shorter belt (3rd one ive bought ffs!) and am swapping my 90mm airhorns for 45mm hopefully to sort all these clearance issues out.

SOmething thats still halting progress is the coil pack configuration, i need to know which pin is +12v, which fires coils 1&4 and which does 2&3, matteh has shown me what he thinks is sorrect but would like confirmation from someone else before i whip the soldering iron out.

More pics tonight as i will go and work on it once ive finished work :)
 
  HBT 172 Cup
No real update until Sunday when i hope to breath some sort of life into the engine.

Got my coil pack bracket and FPR bracket made all looking shiny, also having some 10mm DCOE spacers made because with a flat backplate the air filter latches foul the fuel rail pipes and would chafe it.

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Have taken my 16v sensor loom down to the car mocked it up and trimmed all unneccesary parts and excess wire out and am currently soldering and bundling it up ready.

some 16mm universal coolant pipe on order to fix the mistake i made of cutting the 172 heater matrix pipes too short aswell.

P. S Someone please confirm the coil pack wiring? :(
 
  HBT 172 Cup
More shiny bits spacers to help my air filter fit better, thanks Dangle. Also going back down the car tonight to finish off the water pipes, more pics to follow later.

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  '92 172, Lotus Elise
I'd love to find a garage with 15 ramps and get all our cars together. See what we've done differently. We could then develop the ultimate F4r'd mk1! lol.
Come on Matt, get organising ;)
Sorry to keep derailing your thread laine, but I'd love to do a meet

problem is, we're all going to have to travel as the midlands would be in the middle for all of us!
 
  HBT 172 Cup
OK did some more work today, the downpipe has now been welded up (although for some reason i forgot to take a pic of the finished article but its not very pretty anyway).

Crudeley tack'ed into place.

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First thing i did when i got to the car was fill the engine and box with fresh oil, joined up the fuel return hose, and replaced the coolant hoses that i cut to short to the heater matrix. I also butchered the lower rad hose but not 100% sure what im doing with that yet to get it hooked up still (mine will be different to everyone elses cos im using a low profile ITB rad that has hose locations in valver setup). SO i have to cut the bottom hose short and turn it back round on itself.

Anyway random pictures of no real interest..

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working down a side road lol, the car is absolutely covered in s**t and dust, its never looked so bad. All sorts of spiders webs everywhere lol!

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Replacement coolant hoses.

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Here is my downpipe clearance, note this is WITH the subframe dropped at the back, i had to undo the rear nuts a few more mm's before the flange would actually clear!

Matteh runs the R19 ARB, foxy runs a 172 ARB, and whitely runs valver i believe so i think im the only F4R'd with a williams ARB, which might explain why only im having problems although not 100% sure, but if i ever need to remove the engine ill jsut undo the manifold anyway, so droppng the ubframe wouldnt be a regular occurence.

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So i hooked up the bare essentials, the earth wires and positive wires to alternator and starter, (OMFG how much of an arse is that 13mm nut with the manifold on :/ ).

Whipped the plugs over and cranked it over, watched the oil pressure build up and peak to a very healthy 35psi. Popped the plugs back in and gave it its first crank.

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Does that sound healthy? almost sounds like its skipping a cylinder to me, but no idea really.

Will hookup the standlone wiring loom tommorow and try and breath some life into it! stay tuned.
 
  BMW M5 & E36
R19 and Williams ARB's are the same as far as I'm aware. That's what I'm running anyway, and it's identical to other 'Williams' ones I've seen. f0xy is running a Williams too, the hump in the middle of the 172 ARB would get in the way.
 


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