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Old 12-08-2011, 08:00 PM   #1
jackie
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cherry red s1 rallye 16v thottlebodied build

hi im jack from belfast . ive been registered for a while now but only got round to buying a rallye a few months ago

tbh i dont know an awful lot about the spec so any input would be great cheers

anyways this is what i know of

4branch
full peugoet sport exhaust
fully polybushed
quick shift

the noise off this wee 1.3 is unreal

anyways heres the pics












pic of my 2 cars lol


Last edited by jackie; 26-10-2011 at 07:11 PM. Reason: change title
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Old 12-08-2011, 08:04 PM   #2
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here's abit of background on the build im doing

its started off a year ago with a wrote off gti






that cat is for clearways asap lol



the tasty bits lol




random



more pics



















Last edited by jackie; 12-08-2011 at 08:04 PM. Reason: Automerged Doublepost
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Old 12-08-2011, 08:07 PM   #3
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dead easy to do, fire it up then find and disconnect the immob unit while the car is running, jab done



1 unlocked ecu

the boy elvis was nagging me about the 1/2 tank of petrol in the car, couldnt be arsed lying under the car so we just cut the floor away above the tank to gain access to the fuel lines lol





also whipped the rear axle out



trailed the whole front off her (got black eye in the process)


just for the craic



stopped arsing about and removed the abs and pas pumps,
sorted out the loom removed gear linkages etc



all thats left is to remove shafts the trail the donkey out

mite do it 2morro if i can be arsed

engine out was abit of a hanlin' on my todd with no crane but got it out in the end








Last edited by jackie; 12-08-2011 at 08:07 PM. Reason: Automerged Doublepost
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Old 12-08-2011, 08:10 PM   #4
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tonite me and the boy elvis stripped and degreased the engine

behold











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Old 12-08-2011, 08:12 PM   #5
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ok slaggs because i has a black eye its impossible for me to go out tonight (belfasts stuck-up bouncers)

so instead i when up the shed to fanny about for a while





engine has scrubed up well imo

anyways i began to strip it down for the rebuild





head of [TEXT SPEAK] buck!!!!





now off with the sump




trailed the oil pump off her then the took the pistons out
inspected the crank etc all in good condition thank feck










bores look ok but ill probs have them honed




how she sits atm



next update will be end of the month payday lol
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Old 12-08-2011, 08:16 PM   #6
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update

i cant buy any bits untill im paid to i cracked on with the boring tedious job of sorting out the loom :rodent:

behold



1st thing to do was cut the main connection to the car off [TEXT SPEAK]





now to (buzz) continuity test every wire on the loom to determine its pupose and where it goes... fun



once i find out what each does and where it feeds to the car loom i tag it




jab done

plug n play mutafucker

cant do anything more with the wiring until i get the rallye

laterz

elvis lives



all of that happened last year the i picked up my s1

and began the build proper

got the finger out and removed the 1.3 tonight









next ive to splice the 2 looms together

and get the vts engine built up n bucked in

Last edited by jackie; 12-08-2011 at 08:16 PM. Reason: Automerged Doublepost
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Old 12-08-2011, 08:18 PM   #7
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went up to splice the looms up today but i forgot to lift my multimeter out of work rage.
so just when about tagging up the rallye loom and stripping the engine




loom stripped off the engine



head removed








domed pistons nice





inlet valve is fuckin huge lol



headset and bearings arived today


done some more work on the loom before the big fight

the goal to make these 3 looms into 1 working 1


joining up the wires i tagged earlier then heat shrinking them



loom all built up and con checked really comming together now


just need to remove all the tags and tidy it all up so it looks like a factory job

went up to the shed and finnished the loom tonight really happy with it

heres some pics



some wires still need routed around the engine bay so ive left them dissconnected until the engine is put in




main connector to the car. plug n play now lol







ok next job on the list is to tidy up the engine bay
it could do with a patch under the ecu tray other than that it just needs a lick of paint

the boy elvis getting the ball rollin



"will work for sex"

Last edited by jackie; 12-08-2011 at 08:18 PM. Reason: Automerged Doublepost
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Old 12-08-2011, 08:23 PM   #8
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new piston rings arrived today




just need the pistons pocketted then reasembely can begin

106 gti ecu case with DTA S40 inside saves having to build another loom






plug n play bitches :P

big thanks to martin [mef off this site]

my clio 182 injectors arrived today



ok thats you's up-to-date lol

speaking to colin stachel about some gsxr tb goodness

then i can re-assemble

Last edited by jackie; 12-08-2011 at 08:23 PM. Reason: Automerged Doublepost
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Old 12-08-2011, 09:50 PM   #9
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looks like you've made some good process

you got any plans for power wise?
Handling mods?
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oooo that looks good
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Old 13-08-2011, 12:58 AM   #10
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Coming along nicely mate, Seen your thread on RMS. This cars going to be alot of fun when its finished.
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Old 18-08-2011, 05:28 PM   #11
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my gxsr 1000 throttlebodies arrived today:thumb:

along with my webber 3.5bar fpr









all these are being sent off to colin satchell to get modified to fit my gti head
also sending my pistons to be pocketted turnaround time is about 6weeks

so untill then this thread will probs be abit quiet

shitty iphone pics
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Old 19-08-2011, 04:06 PM   #12
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had a busy day today posting shit and other guff

but i managed to get my block painted






next to the list is the gearbox

need new seals cleaned up and then painted silver i think tho im open to suggestions lol
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Old 19-08-2011, 07:51 PM   #13
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Good work, how long have you being doing this for? What type of power are you looking for?
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Old 19-08-2011, 08:02 PM   #14
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Quote:
Originally Posted by GazM View Post
Good work, how long have you being doing this for? What type of power are you looking for?
comming up to a year soon

id be happy with 165-170bhp
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Old 22-08-2011, 10:10 PM   #15
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got my finger out and cleaned up the gearbox today

special gearbox cleaner

















jab done

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Old 23-08-2011, 09:58 PM   #16
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doing feck all tonite so went up to the shed to fanny about

behold lol

got some new diff seals






just like a new one lol

took the notion to start painting guff again

here's the crank seal carriers (forgot to lift the new seals out of work ffs)





there was loads of paint left in the tin sooooo








dung out the gti clutch and flywheel

boggin hi



10min soak in sillict bang

like new


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Old 24-08-2011, 10:36 PM   #17
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more shiney bits arrived today :up:

uprated gear selector rods



old yokes





new 1s fitted





GMC motorsport quick shift




fitted




my racey gearknob hasnt came yet ..rage!!! will look ticket




more pics when the racey gearknob comes
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Old 30-08-2011, 11:27 PM   #18
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few more shiney lightweight yokes

crank pulley and alternator pulley



cheers cacks


racey jp4 rover covers and powder coated sump



cheers john


genuine pug/cit timming belt kit

cheers ebay lol




where im at now is

waiting on my throttlebodies and pistons coming back, then ive to send my head away to be ported & polished the throttlebodies are being ported to match the heads

once that all comes back i'll have everything i need to get the engine in the car and running


almost forgot

racey gearknob pics


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Old 07-09-2011, 07:35 PM   #19
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just a quick pic of all the shite i have lying about my room waiting to go on the rallye lol





once i have all the parts back ill take another pic of it all before its reassembled head/block/throttlebodies etc
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Old 26-10-2011, 07:07 PM   #20
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well i haven't updated this in a while



got my block and crank back today honed&polished

excuse the shitty pics's flat out with other stuff today, better pics later or 2marra






few pics of the polished crank





had planed to have the crank in the block today but didnt get the time


had some free time today so got some of the more tedious jobs about the block done


cleaning out all the treads in the block so i am lol


very important to clean and lubricate the mains bolts and threads to make sure you get the correct torque onto the main bearings.

piston oil jets feed and threads. again its very important to clean the old loctite out of and replace with new. you don not want 1 of these coming loose








yes every fucking thread in the block cleaned :L


its doing my head in waiting on parts
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Old 03-11-2011, 10:54 PM   #21
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Now this is a proper good read
keep it up mate
also i dont quite understand what your doing with the looms?
are you not just gonna use the whole gti loom and just feed each wire into the dta ecu?
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Old 03-11-2011, 11:29 PM   #22
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cheers dude the dta is housed in the gti ecu casing and pre-wired to the original pin-outs (cheers mef)

another small update


well today i done a big brake conversion on my daily hack lol took the brakes of the rallye and stuck them on the derv







dandable stopping oul yock now lol






anyways on to the more serious stuff set about putting the crank back in the block

started by cleaning all the bearing carriers and mating surfaces with 1200 grit to make them nice and clean






then fitted the oil jets, loctite and torqued







then test fitted bearings






happy with that it was time to fit the for real and set the crank in


lube lol







put the caps on and torque up the bolts. making sure the bolts were lubed at under the head and on the threads




final torque is measured by angle of rotation




job done.. just to check the end float which should be between .07-0.35



0.25 :thumb:


just waiting on my pistons and head comming back now

new powerflex lower engine mount came today



fitted


Last edited by jackie; 03-11-2011 at 11:29 PM. Reason: Automerged Doublepost
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Old 11-11-2011, 08:43 PM   #23
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santa came earlier and left off this







supersprint 4-2-1 lovelyness:P
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Old 16-10-2012, 07:03 PM   #24
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yeah so i haven't posted in a while been very busy

anyways

update





still needs a thottle linkage sorted and mapped
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Old 22-10-2012, 03:47 PM   #25
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Good build
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Old 17-06-2013, 11:04 PM   #26
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right well havent updated or posted on here for ages been busy with other things so the rallye took a back seat

making a push to hopefuly get it on the road in the next few months

sorted out


throttle linkage
fuel lines
coolant leak
oil leak from oil cooler unions

car needs

axle
mapped
door latch

then it should pass mot

heres a vid from earlier

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