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TwentyValver Project Thread
- Thread starter Mark One
- Start date
Renault Clio 16v
what size is your fmic
Renault Clio 16v
any pics fitted?
Renault Clio 16v
ah cool look forward to seeing the update
Hello Neck!
The N00B above me just gave me the link to this most excellent of build threads, very impressed, all looks wicked so far!
Have you sorted your clutch issues?
In the process of building up my mk2 project which was then abandoned, we had bought a vr6 clutch to use with the G60 flywheel as we had been assured by most that it would be strong enough for a 20V with ~280bhp and they are nice and cheap, under £80 from GSF if memory serves correctly
Keep it up mate, will keep an eye on this for progress!
The N00B above me just gave me the link to this most excellent of build threads, very impressed, all looks wicked so far!
Have you sorted your clutch issues?
In the process of building up my mk2 project which was then abandoned, we had bought a vr6 clutch to use with the G60 flywheel as we had been assured by most that it would be strong enough for a 20V with ~280bhp and they are nice and cheap, under £80 from GSF if memory serves correctly
Keep it up mate, will keep an eye on this for progress!
ValverInBits
Slight change of direction due to budget
I expected to have a little more cash to be finishing this project with :dapprove: It's got a bit silly now and i'm having to make cutbacks wherever I can. I won't be using the conrods I've got for this first build of the car. I literally can't afford to take the pistons out of the bores as then I'd need to replace the rings and re-hone. I plan to drop the compression later on anyway with some forged pistons as the AGU 20v compression is sadly very high at 9.5:1.
Also in the budget cut is clutch. I rang helix and they'd want £470 for a paddle clutch to do the job. Another company called CG motorsport do a cheaper one, but I still can't afford that really. So I'm going to run a VR6 clutch which are rumoured to handle the peak power of a K04 (audi TT turbo) ~280lbft/280bhp.
So the peak power the car can make is coming down, but I wouldn't say the new figures are going to be boring.
Driveshafts
GB engineering in nantwich are SLOW. I've now been promised free delivery on my custom shafts and he's said they will be with me by friday next week (18th)
Back to actual pictures and stuff.......
So, firstly, here's the gearbox, same colour as the engine. Nice and practical so I can see any oil spills. It's an 02J
Fitted the new oil pump (GSF) with pickup pipe (VW)
And fitted with plastic sump baffle:
My engine clearly came from a car that had a crash. There's evidence around the oil filter housing (now replaced) and on one of the OEM driveshafts. This is another place where it's had a knock. The crank alternator belt pulley. I looked into a VW replacement....but no....they are around £170
I just neatened it up delicately with a very thin grinding disk and sprayed a small amount of paint on. Took away the sharp edges and I think it can defo be used now.
I'm quite please that the donor car met it's death by crash really, it means that the engine was working when it was crashed.
Got the manifold back.
Built in 316 stainless by Jon Deeley.
[Plug]
Wolfy's Workshop NN13 5NU 07767743715
[/Plug]
The guy is ex pro-drive and made the exhausts and manifolds for the batmobile (tumbler or whatever) in the 2 new batman films
I'm really pleased with it. The engine flange was laser cut using a gasket, which makes them bigger than the actual ports on the head. So I have some porting to do, see further down.
Wanted to sort out the head with new valve stem seals and now also needed to port it so the valves had to come out.
Cams coming out
Rocker cover had a clean
Tried a couple of borrowed valve spring compressors but neither worked properly on this head so made by own :approve:
Had all the valves out in an hour (there are 20 ffs!)
Head went into the dishwasher
Came up nicely
This is my mum on the left catching me trying to sneak the head back out to the garage. She wasn't pleased :dapprove: lol
Tonight I pretty much finished porting one cylinder (to match the new exhaust manifold). I'm no expert (i'm a beginner h'actually), I'm just using a die-grinder to gradually bring out the port smoothly.
OEM size
Ported
That one is almost done i think.
Whilst i've been waiting for tools/part/etc, i've been strengthening the engine mounts.
VW bolted down these mounts in the OEM cars with 3 bolts, so I thought, for what it's worth I would too. I just used some bar to contruct a little setup on a plate and then weld it up.
Drivers side:
The top is the tapped with an M10 thread and it bolts down like this:
Passengers was done in a similar way and welded down to the car. (primered).
That should give the engine mounts extra support.
I think that's it. atm am porting the head out. Anyone know of a G60 Flywheel for sale let me know
Cheers,
Mark
I expected to have a little more cash to be finishing this project with :dapprove: It's got a bit silly now and i'm having to make cutbacks wherever I can. I won't be using the conrods I've got for this first build of the car. I literally can't afford to take the pistons out of the bores as then I'd need to replace the rings and re-hone. I plan to drop the compression later on anyway with some forged pistons as the AGU 20v compression is sadly very high at 9.5:1.
Also in the budget cut is clutch. I rang helix and they'd want £470 for a paddle clutch to do the job. Another company called CG motorsport do a cheaper one, but I still can't afford that really. So I'm going to run a VR6 clutch which are rumoured to handle the peak power of a K04 (audi TT turbo) ~280lbft/280bhp.
So the peak power the car can make is coming down, but I wouldn't say the new figures are going to be boring.
Driveshafts
GB engineering in nantwich are SLOW. I've now been promised free delivery on my custom shafts and he's said they will be with me by friday next week (18th)
Back to actual pictures and stuff.......
So, firstly, here's the gearbox, same colour as the engine. Nice and practical so I can see any oil spills. It's an 02J
Fitted the new oil pump (GSF) with pickup pipe (VW)
And fitted with plastic sump baffle:
My engine clearly came from a car that had a crash. There's evidence around the oil filter housing (now replaced) and on one of the OEM driveshafts. This is another place where it's had a knock. The crank alternator belt pulley. I looked into a VW replacement....but no....they are around £170
I just neatened it up delicately with a very thin grinding disk and sprayed a small amount of paint on. Took away the sharp edges and I think it can defo be used now.
I'm quite please that the donor car met it's death by crash really, it means that the engine was working when it was crashed.
Got the manifold back.
Built in 316 stainless by Jon Deeley.
[Plug]
Wolfy's Workshop NN13 5NU 07767743715
[/Plug]
The guy is ex pro-drive and made the exhausts and manifolds for the batmobile (tumbler or whatever) in the 2 new batman films
I'm really pleased with it. The engine flange was laser cut using a gasket, which makes them bigger than the actual ports on the head. So I have some porting to do, see further down.
Wanted to sort out the head with new valve stem seals and now also needed to port it so the valves had to come out.
Cams coming out
Rocker cover had a clean
Tried a couple of borrowed valve spring compressors but neither worked properly on this head so made by own :approve:
Had all the valves out in an hour (there are 20 ffs!)
Head went into the dishwasher
Came up nicely
This is my mum on the left catching me trying to sneak the head back out to the garage. She wasn't pleased :dapprove: lol
Tonight I pretty much finished porting one cylinder (to match the new exhaust manifold). I'm no expert (i'm a beginner h'actually
), I'm just using a die-grinder to gradually bring out the port smoothly.OEM size
Ported
That one is almost done i think.
Whilst i've been waiting for tools/part/etc, i've been strengthening the engine mounts.
VW bolted down these mounts in the OEM cars with 3 bolts, so I thought, for what it's worth I would too. I just used some bar to contruct a little setup on a plate and then weld it up.
Drivers side:
The top is the tapped with an M10 thread and it bolts down like this:
Passengers was done in a similar way and welded down to the car. (primered).
That should give the engine mounts extra support.
I think that's it. atm am porting the head out. Anyone know of a G60 Flywheel for sale let me know
Cheers,
Mark
ValverInBits
also, if anyone has any tips for head porting (even though i've already started) let me know. I think I'll leave the inlets if they match the manifold ok.
Also, massive thanks to ben who got me an air compressor for free last week! really pleased with it, even though it's small, it's free
Also, massive thanks to ben who got me an air compressor for free last week! really pleased with it, even though it's small, it's free
ValverInBits
if you need some cash i need a GT28RS
LoL, not now I've had a manifold made thanks mate
Mainly a tow truck
I love looking at other people project threads, this looks great. Just gutted i will have to wait for more to come. (hoping it was complete)
Carl
Carl
ValverInBits
So bit of progress then,
Head porting was finished. Anyone doing this should note that it's much much easier if you keep the tungsten grinding bit oiled at all times. Then it doesen't clog.
Matches the manifold well now.
Spent ages lapping in the valves with coarse and fine grinding paste and then using my home-made valve spring compressor to refit them with brand new (and expensive!) collets (cotter pins, whatever) and new valve stem seals.
Used pliers and a large jar of oil to gently try and pull as much oil as possible into the hydro-tappets before refit into original locations
Refited cams, and cam chain tensioner and torqued down the cam bearing caps. Then removed the pulley off the cams and changed the cam oil seals.
Then replaced the rocker cover. I originally thought that an RB rocker cover would be nice with the white car.....but I tried it with a rattle can of something close to RB and hated it :dead: http://i202.photobucket.com/albums/aa79/Point8/TwentyValver/originalrockercolour.jpg
In the end went for primer, then laquer. Dub
Yes, that's a genuine Bentley oil filler cap.
....cheers if your reading
Refitted the head to the engine using new headbolts. All torqued up properly. Manifold and throttle body also in primer+laquer.
Now I'm trying to source a G60 flywheel before it can go back in the car If you know of any for sale, please please please let me know. (golf MK2 or corrado.)
Head porting was finished. Anyone doing this should note that it's much much easier if you keep the tungsten grinding bit oiled at all times. Then it doesen't clog.
Matches the manifold well now.
Spent ages lapping in the valves with coarse and fine grinding paste and then using my home-made valve spring compressor to refit them with brand new (and expensive!) collets (cotter pins, whatever) and new valve stem seals.
Used pliers and a large jar of oil to gently try and pull as much oil as possible into the hydro-tappets before refit into original locations
Refited cams, and cam chain tensioner and torqued down the cam bearing caps. Then removed the pulley off the cams and changed the cam oil seals.
Then replaced the rocker cover. I originally thought that an RB rocker cover would be nice with the white car.....but I tried it with a rattle can of something close to RB and hated it :dead: http://i202.photobucket.com/albums/aa79/Point8/TwentyValver/originalrockercolour.jpg
In the end went for primer, then laquer. Dub
Yes, that's a genuine Bentley oil filler cap.
....cheers if your reading
Refitted the head to the engine using new headbolts. All torqued up properly. Manifold and throttle body also in primer+laquer.
Now I'm trying to source a G60 flywheel before it can go back in the car
If you know of any for sale, please please please let me know. (golf MK2 or corrado.)
ValverInBits
Cheers Dude, God I hope he has one.
ValverInBits
Everyone loves a picture of a fat turbo.
Also spent a little bit of the afternoon making a custom turbo actuator bracket using 2 bits of 3mm plate.
It's been sprayed and the paint is drying, here it is before spraying. Before you ask, the original actuator bracket above won't work with the compressor housing at that angle.
Cheers,
Mark
Also spent a little bit of the afternoon making a custom turbo actuator bracket using 2 bits of 3mm plate.
It's been sprayed and the paint is drying, here it is before spraying. Before you ask, the original actuator bracket above won't work with the compressor housing at that angle.
Cheers,
Mark
Renault Clio 16v
better side of the inlet for boost pipework tbh!
ValverInBits
ta :approve:
She should be reet.
It sit's lower than the standard F7P. Rain catcher has to go though. as for the inlet manifold, as said it's so much easier to route boost piping if it picks up on that side. The AGU 20v engine code is the only one that picks up from the left afaik, so that was lucky.
ITB'd MK1
boost pipes will be a pain on the ancilliaries trust me
trust me
ValverInBits
boost pipes will be a pain on the ancilliaries
one of my main worries is the drivers headlight
Course he is... look at the size of the turbo!!! Its gonna be Bonkers!!
You’ll have to put a good heat shield between the turbo and the coilpacks, your turbo must almost be touching the bulkhead.
Turbo pipe work won’t be that bad... but you may have to trim the headlight cover.
