Archive for 2015

Coming Soon

Posted: 31st December 2015 by asteriskr in Rally Shop
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Website refresh and new progress coming from a new garage workshop in 2016…

Rally Shop

Old Parts Reacquainted

Posted: 18th December 2015 by asteriskr in K16 PUG
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Remember these?

Parts

Parts

Parts

Now back in my garage so that they can eventually be bolted to the engine, which now looks like this (well kind of as the clutch is now off and a few more bits):

Parts

Should have the Maxi transported back home and in the garage workshop of our new house by mid January. Updates and progress on this build coming in 2016.

Dilemma

Posted: 14th October 2015 by asteriskr in K16 PUG
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Bit of progress in that I did a deal with Bic last month and once Sandy tracks them down should have the exhaust manifold and flywheel on the way up North.

I’ve partially stripped down the EW and put a load of surplus bits for sale on eBay. Just need to split it from the box but have been waiting for time to properly clean it first as I hate selling dirty kit and it needs a good degrease. I have got as far as fitting the Hockly engine mount back on.

Ultimately this is progress but I can’t work on the car until I have a home workshop again and that is somewhat distant as a prospect for a variety of reasons. Working on that front.

In terms of next steps I have been stuck in a dilemma over what to do with all the TU stuff I have. Off the top of my head:

  • JP4 with 708s and lightened flywheel with clutch comes with Omex 600 and loom – had a bottom end rebuild before I bought it and has a ported head. Graphed at about 165bhp.
  • Dan Thorne’s inlet setup which is a long Satchell inlet mani with 42mm Jenveys and carbon trumpets
  • Fuel Lab pressure regulator
  • As new Nissens Rad
  • Dan Clayton’s old Quaifed BE box and all shafts, hubs and mounts
  • My bespoke hydraulic handbrake setup that works off the normal lever
  • Some Streamline Carbon bits
  • Anodised Satchell alternator pulleys and polished alternator
  • Possibly some other stuff…

I had been thinking of getting another Rallye and putting all this in but realistically this is years off and means diverting money from the Maxi. So I am thinking of selling all these on and if I fancy another 106 then buying one someone has already done up. I suspect that urge will continue to diminish as I’d prefer a faster Estate than another hot hatch. Need to work out market values but reckon that should cover most of a Sadev box, but…

  1. The engine has never run in the time I’ve had it so is a bit of an unknown quantity. Might need to get it running first.
  2. It would be a mission to get these bits out of the car to sell them until I have a home workshop.

Based on that happening the next challenge is conversion back to EW. I carefully removed the engine mount Hockly fabbed up as it needed to come out to tub the front arches. Then I needed to mount the TU and BE box to move house back in 2013 so I made a TU mount. That needs chopping out and the EW mount welding back in. Simples eh?

Er no. I’ll need to hire the ST-75 casing back from SWR Motorsport to be able to get the position right which may be more problematic as the original EW bell housing might have been custom.

Then SWR have advised that the ST-82 is the better box for the intended application as a tuned EW exceeds the rated torque on the previous box. That box has a different mounting point to the ST-75 so I’ll need to fab up a new gearbox mount. I’ll need to sell or trade in all the spare ST-75 parts (several boxes of).

Then new inlet manifold and bodies – thinking 48mm Jenveys as before. DTA s60 management and loom. That’s just the work in engine bay…

Then there’s tubbing the rear arches, fitting new seat rails, full respray, new front arches and bumper off the proper maxi moulds (there is a difference with the current Dimma based ones) to properly centre the wheels in the arches. List goes on.

The Maxi

Posted: 8th October 2015 by asteriskr in K16 PUG
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It’s been a mad month, my Father sold his place in Norfolk and that meant the Maxi was homeless. A local family friend agreed to provide sheltered accommodation up here so the car has now come back up the Northwest. It feels like progress even if I’ve done nothing…

K16 PUG

New Heart

Posted: 4th August 2015 by asteriskr in K16 PUG
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Might need to change a few things back to how they were meant to be…

Engine

I bought basically most mechanical and electrical parts off the front of the GTI 180 donor car. Engine with both manifolds, box, all ancillaries, loom, Ecu, etc. Not had a chance to really look at it all yet.

In terms of management I am planning on a DTA S60 which will do switchable maps, full sequential/CoilOnPlug and cam control as well as anything esle I’m likely to need. The advice from Sandy Brown is that on a well written map on an atmo engine, there’s little point in having multiple maps – his view is that it’s a gimmick without any meaningful control over cylinder filling.

The South West’s expert engine builder also tells me that the variable cam phasing on the RFK engine is little more than an emissions device really, so cam control isn’t even that important over 1500 RPM. I had been thinking about the S80, but Sandy advises that all it really offers over the S60 is fully sequential twin injectors and four wheel traction control, neither of which are likely to be of any use for this build.