Posts Tagged ‘K16 PUG’


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…


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…


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.

K16 PUG Update

Posted: 11th July 2015 by asteriskr in K16 PUG
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Christ it’s a long time since I updated on this car. Well it’s still in hibernation, I’ve seen it about four times in 18 months. Our house sale is finally going through after 24 months on the market and I am looking for opportunities to work back in the North West. Beginning of last month I went down to see Bic and picked up a few bits related to the car.

Interior 3/4 door cards now paired up. They’re still a bit dirty and have some gaffer tape residue on them. They also seem to be special lightweight ones and thinner than those to be had through the Streamline Carbon shop which gives them more flexibility to fit to the shell:

K16 PUG Parts

Fitted – interior needs a clean and a respray 😉

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Also picked up few other bits, which you’ll have all seen before like carbon foglight/air intake surrounds for the front bumper. These hub caps however are custom for the Image wheels:

K16 PUG Parts

Trial fitted

K16 PUG Parts

K16 PUG Parts

Love the lines on this car…

K16 PUG Parts

Not much else to report. I’m looking at 180 GTIs as donors for a new engine and I’ll put an EW back in once I get a workshop up and running with the car in it. I am toying with another 106 for a road car too as long as we have the space for one on the drive, plenty of nice bits to bolt on…

Satchell Engineering Work

Posted: 8th February 2014 by asteriskr in K16 PUG
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I’ve clocked up some mileage in the last few days, Durham to North Norfolk, then to Northampton and then back up to Formby last night and will be heading back to Durham Tuesday. It’s the first time I’ve seen the car since it went into storage. I needed to take off this rear quarter interior panel so that if the matching half can’t be found, a new one can be made up from it. It was covered in Gatebil debris.


Dave Vanstone finished welding a few bits and getting them powder coated, before Christmas but I’d sent them to be with the car so this trip was the first time I’d seen them. This was a repair to the oil cooler that had been damaged. I’ll get it pressure tested before refitting just to be sure there is no hidden damage:


This was the original catch tank, but the threads were knackered so it needed a weld-on fitting too. Dad’s looking at putting it into his Alfa Romeo 2000…


I picked up a spare sump and Dave welded on a fitting to it as the return for the oil catch tank and arranged powder coating.




Sandy gave some input on internal baffling…