New project. Megane engined RS200 road car.

[Jamie86]

Thanks Jamie, I'm sorted now. I hate those guns btw, got chucked in the bin a long time ago!
Russ

Yet to find a better way with metal ties to actually get them tight? Share the knowledge!
Bin they are like 70quid haha

 

[Russ Rallye]

Been delayed by day to day stuff, work, family and garden shed building!
Sick of the garage being full of crap, lawn mowers etc so decided to build a new shed after being let down off a mate.
All the base and sides are done, just waiting on the cladding to finish it and put it up.

ap

Have got a few more bits stripped off the Clio though. Front bumper, crash bar and front panel along with the rads and headlights.

Having a bit of a crisis deciding what to do with the radiator and ac setup. I did want to keep the ac as it is a road car after all but the standard Clio rad is feeble when I've looked at it and I want a thicker core/alloy/megane rad (delete as appropriate!) so not sure if the ac rad can stay. Need to do some working out with that. Hopefully have the engine out this weekend.
Russ

 

[tomsteer]

Are you not starting a project thread for the shed build? It's the kind of thjbg I'd read!

Loving the Clio build too!

 

[Russ Rallye]

Lol probably not, wouldn't want the world to see my horrific joinery skills!
Russ

Are you not starting a project thread for the shed build? It's the kind of thjbg I'd read!

Loving the Clio build too!

 

[magic354]

Wow, looking great so far- following this with interest!

 

[Russ Rallye]

Shed is out of the way finally and cleared some space to get the car inside.

After much deliberation I've decide to bin the AC off for the time being. Ordered an updated alloy megane radiator + fan. Also ordered an AC delete bracket and pulley from Nick @ Pure Motorsport.
The ecu is unlocked and on its way back so I'm only short of a radiator top hose, some boost pipes, air filter and maybe a couple of vac hoses.
Russ

 

[Russ Rallye]

@tomsteer Sheds finished!

Need to get back onto the clio as I just haven't had time.
Some pics of the short shift mechanism fitted to the gearbox

The original part removed

Car itself still looks like this, just got the shafts to pull out then the engine can come out.
Russ

 

[Iain C]

cool poster.

 

[tomsteer]

@Russ Rallye That's one fine shed! I'm jealous of both the Clio and the Shed!?

 

[gambit]

Well done Russ, Dreaming to do a similar engine swap but with an rs265 engine and drivetrain , which chassis would be the easiest to engine swap rs200 Clio or meg 225? Presume drive shaft length would be different with the Clio chassis but the meg chassis should be more drop in?

 

[Russ Rallye]

Engine is out! Pulled both front struts/hubs out as well to change springs, links and some bushes.

Pulled the AC pipes out of the engine bay too. Need to get the exhaust off and manifold out tomorrow and get the meg engine attached to its gearbox ready to drop back in.
Russ

 

[NorthloopCup]

Engine is out! Pulled both front struts/hubs out as well to change springs, links and some bushes.

Pulled the AC pipes out of the engine bay too. Need to get the exhaust off and manifold out tomorrow and get the meg engine attached to its gearbox ready to drop back in.
Russ

What condition is the exhaust manifold in Russ?

 

[20vKarlos]

I rather like this thread

 

[Russ Rallye]

What condition is the exhaust manifold in Russ?

Not sure until I get it off mate, it's only done 59k though.
Russ

 

[NorthloopCup]

Not sure until I get it off mate, it's only done 59k though.
Russ

Text me and let me know mate as I'm after a standard one. Damaged flexis isn't an issue either way. :up:

 

[Russ Rallye]

Text me and let me know mate as I'm after a standard one. Damaged flexis isn't an issue either way. :up:

Leave it with me mate, that mount casting turned up btw, only just opened it this morning.
Russ

 

[NorthloopCup]

Leave it with me mate, that mount casting turned up btw, only just opened it this morning.
Russ

Yeah no rush mate. Just give me first dibs. Ah excellent!

 

[Russ Rallye]

This should be me updating to the engine is in but a hot bath with my name on it has won instead, I am getting old after all! Normal service will resume tomorrow.

Clio engine is out, ancillaries and mounts swapped to Megane engine. Some shiny bits added along the way, Pure Motorsport AC delete kit is on along with new belt and tensioner obviously.

Lightweight Single mass flywheel and R26.r clutch fitted with all new bolts and slave cylinder.

Gearbox on, mount on and all sensors connected.

Rest of the bits stripped out of the engine bay, manifold and AC pipes mainly. Also the oe fibre sound proofing/insulation has gone and some Nimbus put in its place. It came off the race car so excuse the dents!

In addition to this I had to swap the shifter mechanism for the Megane one as the gear pattern is different. Meant console etc out, heat sheilds off.

 

[Russ Rallye]

The 2 shifter units together with cables, straight swap.

All finished and back together, excuse the tatty Megane gear knob, need to order a new one.

That's it upto date, hopefully get it fitted tomorrow. New alloy R26 rad is here, boost pipes are on order along with the bits to refresh the front suspension, top mounts, wishbones, drop links and anti rotation links. Need some front discs and pads + an exhaust but it's financially ruining me, whatever anyone tells you, this is not a cheap conversion if you do it right and I could of spent far more as well!
Russ

 

[Austin-182]

A great read and view so far. I would love to be able to know how to do that type of work on a car.

 

[massivewangers]

Is the Meg box a viable swap onto the original 197/200 engine? Or is it a lot of grief?

Just curious given the problems with the standard boxes.

 

[Russ Rallye]

Is the Meg box a viable swap onto the original 197/200 engine? Or is it a lot of grief?

Just curious given the problems with the standard boxes.

Yeah it does fit with Megane shafts but the gearing will be terrible with an NA 197/200.
Russ

 

[massivewangers]

Yeah it does fit with Megane shafts but the gearing will be terrible with an NA 197/200.
Russ

Ah, that was going to be my next thought. Shame that.

 

[Russ Rallye]

Well the engine is in.

That was the easy but really! All mounts back on, just using standard rubber mountings to try and and keep it nice on the road. Fuel line connected, coolant lines to heater matrix done, shifter cables on, need a Clip for one however.
Clutch pipe is connected but not sure I'm massively happy with it as it's extremely tight on that side now with the megane gearbox.

Chucked the front lower cross member on to have a look at how the megane rad will fit as its a fair bit bigger, might need to make some brackets or drop the cross member down a bit.

Got all the wiring to do tonight and get the battery box etc back in. The wiring isn't particularly difficult but trying to get it looking oe and tidy is the bigger challenge hence why it's stripped down quite a bit.
Russ

 

[Russ Rallye]

er that's not meant to Happen!
Russ

 

[Russ Rallye]

Couldn't be bothered to do any wiring tonight so put my H&R springs on my front struts. As you can see above the drivers side spring has snapped in 2 places at the bottom.

Gave it a clean up and refitted new spring and new top mount and bearing.

Got them put back on the car so at least I can put the shafts back in tomorrow and hopefully the new bottom arms and links won't be far away.

Rest of the evening has been sober messing around with the little bits. Had a trial fit of the battery box so I know what's going on there. Modified the servo vacuum feed pipe.

Finally got the header tank fitted as well. There's no room for the standard 200 one with boost pipes in the way so most people either relocate it behind the battery box which leaves even less space for an air filter or others have said about a 172/182 one on the drivers side inner wing. It's extremely tight and ive had to trim and p1ss about to get it to fit with the standard engine mounting and also so the bonnet shuts. It's fine now just need to clean the tank up as it was just a spare one I had laying around.
Russ

 

[OssPoop]

er that's not meant to Happen!
Russ

Course it is, that's standard renault.

 

[RB5108]

Subscribed... Interesting read..

 

[Russ Rallye]

We're getting there, albeit slowly, I'm flat out at work and I've pulled something in my arm and it's really bugging me! Anyway!

Got all the wiring finished

And the battery/box back in

Had 2 goes at getting the rad and cooler mounted due it being a lot bigger than the oe Clio rad.
Take 1.

Didn't like it like that, as the bumper didn't fit and the alloy cross member didn't really fit either without being butchered so decided to trim the plastic slam panel back to get the rad higher and further back. Lower crossmember is modified too and brackets made up, real pain of a job and I'm not 100% happy with it so will come back to it once it's up and running.
Take 2.

Better, everything just about fits now. Got the cooler on and boost pipes fitted along with the air filter too. It's all a tight fit in there now.

Got all the suspension bits and driveshafts put back in. All
Brand new wishbones, arb drop links, anti rotation links and Megane driveshafts.

Got that put back together and put the standard discs back on for now until I get it up and running and they'll be changed for a 330mm kit with upgraded pads and lines which are sat here. Chucked the passenger side headlight back on as a token gesture really.

Engine and gearbox oil in, clutch fluid topped up and roughly bled until I get it too the workshop. Couldn't resist starting it to see if it would run, so I did and it does! Result, only for a few seconds but at least we're on the right track.

That's us up to date really. I need to sort an exhaust tomorrow and a new long driveshaft bearing retainer plate as they're different between the Clio/Megane. Will get the arch liners put back in later on. Only real issue is getting some coolant hose to pipe the expansion bottle up, hopefully sort that tomorrow too.
Russ

 

[RB5108]

Looking good Russ, I'm waiting on my pistons and rods but in the mean time I've borrowed a shot blast cab and cleaning all the parts up ready for paint.. Who unlocked your ecu?

 

[Russ Rallye]

Looking good Russ, I'm waiting on my pistons and rods but in the mean time I've borrowed a shot blast cab and cleaning all the parts up ready for paint.. Who unlocked your ecu?

Always thought about buying a little cabinet but never have, useful things.
Paul at Rs tuning did the ecu, sent him both the Clio and megane ones so the ecu is ready to go when it comes back. Think it was £95 ish
Russ

 

[elcie]

looking good, dacia sandero is meant to be the header tank to use, sits in that place better. did you need to trim the intercooler pipe much. you will love once its done, like you say its not cheap and if you done any less than you have done you would be cutting corners i like all the bits you have done.

 

[Russ Rallye]

If you've seen my other thread you'll probably know I've been out of action since new year with a broken leg.
Means I haven't done a great deal and it should of been finished ages ago.
Managed to finish the cooling system off this week and have roped my mate in to give me a hand next week to get a few jobs finished.
Got my new exhaust today anyway, good job the mrs was in otherwise I'd have struggled, the box is massive and I'm still on crutches!

The system it's self looks really good, 3" bore from down pipe back.

Welds etc are well finished.

Will hopefully have some updates next week and have a drive in it.
Russ

 

[paulrs4]

If you've seen my other thread you'll probably know I've been out of action since new year with a broken leg.
Means I haven't done a great deal and it should of been finished ages ago.
Managed to finish the cooling system off this week and have roped my mate in to give me a hand next week to get a few jobs finished.
Got my new exhaust today anyway, good job the mrs was in otherwise I'd have struggled, the box is massive and I'm still on crutches!

The system it's self looks really good, 3" bore from down pipe back.

Welds etc are well finished.

Will hopefully have some updates next week and have a drive in it.
Russ

Looking good matey.

 

[Russ Rallye]

Major news alert!
Fitted the R26 gearknob!

Once the big job was out of the way I started on the exhaust. Hardest part was probably getting the old one off the car.

Obviously needed cut between mid pipe and back box as it's once piece from the factory. Didn't realise the cat was part of the system as well.

Fitting was straight forward but was fiddly at the front as the one of the threaded holes in the down pipe didn't want to play ball. A new gasket was fitted up front too.

Back box on

And the rest of the system

Chucked the rear springs on while I was under there to match the fronts.

Few odds and ends to sort this week. It we're getting there.
Russ

 

[RichAwty]

Looking good, can't wait to see this when it's finished

 

[paulrs4]

Must be nearly finished by now Russ

 

[Russ Rallye]

Must be nearly finished by now Russ

Pretty much, still need to bleed the clutch and give it a once over on the ramp.
Russ

 

[Nigel-James]

Great thread. Can't wait for the next update.

 

[Russ Rallye]

Apologies for the lack of updates. It is all back together in one piece and running.

Doesn't run the best, I suspect there's a stock map on the Ecu even though it should have been mapped for a near identical spec to what I have. Everything looks ok on diag, map sensors reading, temp sensors reading and lambda switching. Code for decat present which shouldn't be there if it had the map on it that its supposed to. Nothing else sinister. Sounds good, exhaust isn't massively loud but it chatters like mad as I've no dump valve and it's all blanked off.


Anyway I've dropped it off with Chris @ Efi parts to be mapped so numbers when I have them.

That is assuming there's no issues!Hopefully be torque limited to 300/300 and I can start putting some miles on it.
Russ