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Old 23-02-2008, 09:03 PM   #1
Dj_mini
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my 205 take two

Im new to the forum but iv meet a few members at the events that iv been to so you know my current car iv been out quite a bit in the car now and i hope im finaly at the end of my engine troubles

But after meeting colin satchell and seeing one of his prepared cars in action i decided that a new shell / suspension set up would be a good idea as my current shell was a steep learning curve for me so it isnt as good as id like. so for the past couple of months colin has been working away doing his bit including rear turrets, tb's removed, rj bottom arms, wide track, rj track rod ends, rj top mounts, strengthend subframe and rj gear leaver ready for me to start the shell prep im hoping for sub 750kg's this time
ill let the pics to the talking:
Cheers Dan

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Old 23-02-2008, 09:11 PM   #2
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Nice car, and I love the Shaftesbury roads. I saw a yellow 205 Rallye in Stourpaine on Fri.
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Old 24-02-2008, 05:16 AM   #3
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Going to be a beast!
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Old 24-02-2008, 08:01 AM   #4
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Fair play - Loved the car when I seen it at Combe this year. Is it going to be at Combe in april if finished by then?
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Old 24-02-2008, 08:39 AM   #5
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That looks very promising Dan, I saw it up at Colin's about a month ago, he's doing mine at the moment, and if it comes out anywhere near as mint as your white one I'll be really happy! The level you finished it to was fantastic when I saw it up at Combe.
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Old 24-02-2008, 09:36 AM   #6
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Nice white 205 and great picture by Mr Jizz
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Old 24-02-2008, 10:12 AM   #7
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i thought the name sounded familiar when colin said who's it was.
i like it
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Old 24-02-2008, 05:13 PM   #8
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Thanks for all the coments.
Im still going to be using the current car this year as progress on the new shell is going to be slow as im spanering on a mates 1400 tarmac rally car this season and due me and gem buying are first house this year so i am skint and busy but will be worth it in the end
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Old 24-02-2008, 06:16 PM   #9
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Looks like its gonna be a good'un
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Old 18-03-2008, 08:52 PM   #10
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Bit of an update:
Iv seam welded the floor pan (im not great at welding thin material)


Then put the hole saw in to the rear


But i was looking at it and still thought there was more to come out so iv cut all the rear area out completely now! Then the roof inerskin came out as looked heavy and the lower boot pannel then the area that was left got the hole saw put to it

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Old 19-03-2008, 06:27 AM   #11
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Looking good Dan!
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Old 19-03-2008, 09:42 AM   #12
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Cheesy! Looks very nice!
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Old 29-01-2009, 06:02 PM   #13
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A little bit of news.

Lightweight slipper piston (30% lighter than an Mi16 Omega!):


Custom made con-rod to suit:


Custom JRE profile cam, double springs and solid lifter:


Lightened, precision bored/honed and surface ground block:


The spec as it stands:
Iron block 87mm bore x 92mm stroke (2188cc)
Forged steel crank
Robson custom spec con rods
CP custom spec lightweight slipper pistons
Wet sump lubrication
XU7J4 head ported by SB and Mark Shillaber
JRE custom cam profiles
Cat cam adjustable cam pulleys
Piper double springs/retainers
Solid lifters
SB custom inlet design made by Colin Satchell
Jenvey TH bodies and DJ custom panel filtered air box
Custom 4-2-1 exhaust manifold to JRE spec
Custom two box exhaust system
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Old 29-01-2009, 08:20 PM   #14
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is the move to an iron block purely because of the larger capacity?
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Old 30-01-2009, 04:37 AM   #15
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Mostly, you get more for the same money.
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Old 30-01-2009, 07:00 PM   #16
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looking good, i like these builds
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Old 30-01-2009, 07:08 PM   #17
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i love 205's good luck with it
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Old 30-01-2009, 07:34 PM   #18
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Cheers sandy i wonderd where this thread had gone.
Id best get on with updates:

The shell is now sprayed,






Custom manifold / exhaust to jre / sandy's spec




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Old 30-01-2009, 07:36 PM   #19
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Awsome - Glad to see its got a lick of paint now. good choice on sticking with the white to!
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Old 30-01-2009, 07:37 PM   #20
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New fly wheel


Iv finished the s40 loom now:
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Old 30-01-2009, 07:46 PM   #21
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This is in danger of being my favourite 205........ Espen's is top of the list currently!
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Old 30-01-2009, 08:58 PM   #22
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hats off to ya fella.... gonna be a bit more than your average 205 track toy....
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Old 30-01-2009, 10:04 PM   #23
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Quote:
Originally Posted by indigorallye View Post
This is in danger of being my favourite 205........ Espen's is top of the list currently!
Link to espans 205 please


Love the above build as quoted on SSC!
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Old 31-01-2009, 02:20 AM   #24
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That flywheel is insane. Whats the weight of it?
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Old 31-01-2009, 09:13 AM   #25
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wheres the flywheel from?
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Old 01-02-2009, 09:36 AM   #26
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That flywheel is nuts
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Old 01-02-2009, 10:27 AM   #27
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Espen's 205 on 'Drivers'
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Old 04-02-2009, 07:55 PM   #28
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The fly wheel is from lynx enginering its a billet steel one.

Had a day off work tuesday due to the snow so made the most of it and got on and made my pedal box.

So i revved up my new welder and a few hours latter and jobs a gooden just needs a lick of paint:

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Old 07-02-2009, 04:19 PM   #29
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Nice one

Keep the photos coming!
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Old 27-02-2009, 06:21 PM   #30
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Well after an absolute epic (as usual) over the final stages of preparation, I finally got the engine on the dyno yesterday. We don't dyno XUs very often so it took a while to make all the necessary connections and once we got it running the oil pressure seemed a bit on the high side. I had no choice but to drop the sump to look at the relief valve, which wasn't easy, being very well stuck on with my faithful Loctite! The pump was a brand new genuine one, but there was a lip on the relief valve piston which seemed to be the issue, so it was dressed a bit and re-assembled. That only left us enough time to do an hour and a bit of running in yesterday.
This morning I started by checking everything was in order, including a final check of the cam timing. With it up and running I mapped progressively through the load and speed ranges building up towards the more stressful areas of the map. It was clear early on that the mid range would be good; before trimming the ignition it was already making 180lbft at 5000rpm!
Mapping over 6000rpm is a very noisy and stressful business on any engine, but a fresh one that I've built myself is especially worrying. Before long we were seeing peak torque of 204lbft (corrected DIN) at 6500rpm, which at over 93lbft/litre is very pleasing, not exactly a spike either with over 180lbft from 5000-8000rpm. It took some careful trimming of the AFR to see best power, which peaked at 281bhp (corrected DIN) at 7500rpm. It was still wanting the same fuel at 8000rpm, but power was slightly lower at 277bhp, so it'll probably peak higher with some miles on it, John designed the cams to work up to 9k, should the extra range be wanted, but in the interest of longevity, 8k seems a prudent limit and we didn't go higher than that, because it barely has 3 hours running on it yet.
This build has been a long and intense process which started last July. I don't build many engines and it's a big deal for me everytime! Above all I have to thank Dan for his faith and patience. I also must gush a bit to give credit to the essential people who've helped:
Colin Satchell for the fabrication and generally being married to me without the benefits
John Read for the brilliance of his technical input and crucial experience, I'm very lucky to have his help, he has as much ownership of this as I do!
Mark Shillaber, Neil Shilling, Pete Willis and the others who have helped.
Alvin Powell for the final throes and the suppliers.

Here's the graph of the dyno results, I've put a trace of Dan's last engine (from the rolling road mapping) to give it some scale.

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Old 27-02-2009, 06:25 PM   #31
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Awesome, Nice work as per usual Sandy
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Old 27-02-2009, 07:10 PM   #32
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Bloody hell Sandy, nice work! Dj_mini you must be well pleased! The 205 looks pretty dam good to
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Old 27-02-2009, 07:13 PM   #33
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Cheers Dunc!

Some pics from the last couple days:
About to go on the dyno...


On the dyno.....




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Old 27-02-2009, 09:35 PM   #34
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Top effort sandy i know the past few days havnt been easy for you!
I must say thanks to sandy as he goes way above the average engine builder much appreciated mate
Cant wait to get it in the car now!
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Old 28-02-2009, 05:39 AM   #35
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Holy cr@p!

Must be so nerve wracking to have the engine revving its nuts off right next to you, when youve just finished putting it together!

Good work everyone
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Old 28-02-2009, 05:51 AM   #36
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Thanks Dan, I'm pretty keen to see it in too, but equally very nervous about it!

It's terrifying Matt, I've dyno'd quite alot of engines now (other peoples mostly), but taking it up to 8k and holding it there is scary. On the first 8k run as soon as we took it to WOT the silencer blew off the sleeve joint and until I realised what had happened, feared the worst! But what you'd happily do to an engine on the road is quite different in the cell, especially when you think about what's gone into it!
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Old 28-02-2009, 03:29 PM   #37
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Thats some excellant results!!!
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Old 01-03-2009, 07:39 PM   #38
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Wow, great results I was tempted to pop in to see it on the dyno on Friday but didnt want to add any stress!

I bet she sounds a bit mean, its hard to imagine how well it will go, but with double the power of mine, id say pretty damn well
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Old 01-03-2009, 07:42 PM   #39
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Rite iv been pottering around in the garage today so iv taken some pics of my progress:

Int nearly together when pushing the rubber on the screen i broke one connection for the heated screen but iv managed to get a small drop of solder and it seems to hav held so i hope its goin to still work


Iv also got a bit more of the front end done.
Iv made up the strut brace and a new cradle to hold the rad so can remove it easly
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Old 01-03-2009, 07:53 PM   #40
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Old 01-03-2009, 08:00 PM   #41
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That's wicked
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Old 02-03-2009, 05:58 AM   #42
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Very thoughtful Leo, I wouldn't have minded, would have been nice to see you!

Looking spanking Dan, as I expected!
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Old 02-03-2009, 07:11 AM   #43
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- Awesome!
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Old 02-03-2009, 05:07 PM   #44
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coming on great

you sold the old shell??
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Old 02-03-2009, 05:23 PM   #45
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oo lala!
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Old 02-03-2009, 06:53 PM   #46
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Is it a common mod to replace the rear torsion bar setup with turreted coilovers?

what are the bennefits of this setup?

the whole build is awesome!! it has really inspired a few great ideas for my wee AX.
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Old 02-03-2009, 07:20 PM   #47
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andy baker of ab motorsport doest rate turreting, standard beam with 306 trailing arms (slight toe in, more neg camber) running proflex or AST are far better in his opinion. and jesus his car seems to handle places like epynt pritty damn well!
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Old 03-03-2009, 02:54 PM   #48
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The problem is, the standard damper location means the dampers operate at approximately 2/5ths of the wheel movement. You can reduce the severity of the issue by using very high quality/expensive dampers, but converting to vertical coilovers (done correctly) is a properly engineered solution that shows a massive improvement in handling even with modestly priced dampers. You also get the facility to fine tune the spring rates cheaply by increments not possible with torsion bars.
I've driven alot of fast road and competition Peugeots and Colin's Peugeot chassis is head and shoulders better than any of the others I've tried, the strongest traits being the linearity of the responses and the friendliness on the limit. It has changed my idea of how a FWD car should handle, it's that much better. The most surprising bit is the ride quality, impressive for a road car, let alone a competition one. This may read like a slightly enthusiastic over-reaction, but that's because Peugeots with an uprated standard set up don't drive anything like as well; not because someone has told me that, but because I know from using them.
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Old 03-03-2009, 06:05 PM   #49
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Very interesting. I wonder why pug/citroen moved away from having the rear beam set up like this in the 104/visa? My dads 104 rear beam looks very similar to my AX but it has upright coilovers.

are there any real advantages to the torsion bar setup? or was it just to increase rear boot space?
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Old 03-03-2009, 06:09 PM   #50
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it was a cheaper option for the manufacturer. same with the torsion bars on the newest civic type-r as aposed to the better handling independant suspension running one before it.
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