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Old 14-08-2006, 08:53 PM   #1
Gus
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Gus - Member Info and Car Blog

Welcome to my Rallye blog, now open for comments, so post away but please keep spam to a minimum

Name: Angus Ross

Location: Inverurie, Aberdeenshire

Age: 24

Forum Name: Gus

Car: S2 106 Rallye

Colour: Indigo Blue

Modifications:

Engine:
  • JP4 (16v) rebuilt bottom end, pistons reworked by Sandy Brown
  • QEP 'Big Valve' 8v head
  • 646 CatCam, cam timing by Garry Muir
  • CatCam adjustable pulley
  • GSXR1000 42mm throttle bodies Colin & Sandy manifold with short trumpets
  • ITG air filter
  • Vauxhall Cream 224cc injectors & 3bar FPR (max 78% duty)
  • Supersprint 4-2-1 exhaust manifold, heat wrapped primaries
  • Pegueot Sport exhaust
  • Emerald K3 ECU
  • Group-N gearbox and lower engine mounts
  • Strengthened upper engine mount
  • Magnacore KV85 ignition leads
  • Oil catch tank
  • Mapped by Russ Paton at Wallace Performance Aberdeen
  • 140bhp @7000rpm
  • 115lbft @5600rpm

Transmission:
  • Rebuilt S2 (20CD15) gearbox
  • Rose jointed gearlinkage
  • Quaife LSD
  • Helix clutch
  • TTV billet flywheel

Suspension/Chassis:
  • Wishbone Powerflex bushes
  • Rear Beam Powerflex bushes
  • Group-N wishbone supports
  • XSi 20mm Front ARB, 24mm rear ARB
  • Top mounts in PAS position
  • Faulkner 180lb 240mm springs
  • PSF 21mm torsion bars
  • Bilstein B6 front dampers, B8 rears
  • Lowered 20mm at front, and at rear
  • Sparco strutbrace
  • 185/55/14 Goodyear Eagle F1 GSD2's

Brakes:
  • 266mm 307HDi calipers
  • Ferodo DS2500 Front brake pads
  • Tar-ox front discs
  • Ferodo DS2000 Rear brake pads
  • Mintex OE Rear Discs
  • Motul RBF 660 brake fluid
  • Master cylinder brace

Interior:
  • Sparco 323 steering wheel
  • Stack gauges, AFR, oil pressure, water temp
  • Stereo removed, replaced with mp3 amplifier

OE Replaced Parts:
Too much to list!

When you acquired your rallye: March 2005

Previous cars owned: Fiat Bravo

Hobbies: Cars, Motorsport, Music, BMX



Had been looking for the ‘right’ Rallye for about 4 months back in 2005, then this one popped up only 20 miles from me. So it was bought that week and had a little rest as I went about my ‘de-chaving’ jobs. The previous owner had one of those mechano spoiler’s on the boot but thankfully she took that off before selling, along with the Lexarse lights, it did leave 4 nasty holes it the boot tho . I removed all the excess stereo cables, and gave it a damn good clean, along with the usuals of sparkplugs, oil etc.

Before long money was being spent First up was the GAZ suspension kit (4 dampers and 2 springs) which improved the feel and handling of the car greatly, as the dampers were well worn. Second on the list of RR approved Mods was the K & N replacement element filter. The alloys didn’t last long as they weren’t part of my mission for a sleeper S2, so they were proptly swapped for some freshly resprayed steelies, wrapped in Eagle F1’s.

I’m not going to go through everything I’ve done to date, but I’ll put up pictures instead. I’ll keep this thread updated as I go along


Just home,



Just Lowered,







Busy cleaning,



Steelies are go,




New wax and Polish,





Gearlinkage (TimmyB special),





New exhaust system,





Random shots,





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Old 14-08-2006, 09:17 PM   #2
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Little video at the SIDC day at Alford this year, cheers Slik (I see what you mean by the auto focus clicking )

http://www.youtube.com/watch?v=MdjFF1mEKAs
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Old 23-08-2006, 08:26 PM   #3
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Fire extingusher in (well been in a month now but never mind ), curtasy of Dave P and Lidl. Simply two alloy plates. Drilled and tapped a hole in the top of each of them to bolt the plastic cage onto, then drilled holes the bottom so it could be bolted to the car. I used one of the bumper bolts, and threaded another hole that had them white plastic things in it. Hey presto une Fire Extinguisher in La Rallye



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Old 25-08-2006, 08:57 PM   #4
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Toot Toot!

(Phone pic )



Big up Pri racing
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Old 23-09-2006, 05:19 PM   #5
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New ICV fitted as the old one decided it didn't want to play game anymore , also got a new fuel filter to fit.
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Old 10-10-2006, 09:42 PM   #6
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Quick update, been doing some winter preperation jobs and some pointless but 'make me happy' jobs too. I've replaced the brake servo vaccuum hose with a silicone one as the existing one looked a little suspect. Ordered new handbrake cables, a dipstick and a timing belt pulley cover from Peugeot today. My timing belt cover has one of the mounts broken and I don't want it moving about and rubbing on the pulley. Handbrake cables are more of a proactive measure than anything, as mine are looking a old and rusty about the calipers, and my dipstick is on its last legs too.

Also my new PIAA bulbs from 106parts should come in sometime this week so that'll be another box ticked
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Old 31-10-2006, 09:33 PM   #7
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The Rallye has been sitting since last Wednesday now, feel a bit sorry for it, been away in Sheffield at the weekend and been busy with uni work at the start of the week so not been doing much with it. Also while I've been away mice have eaten thier way through my nice new silicon hose for the brake servo but set a trap last night and got one of them, set another three tonight too Checked all the other hoses (inc brake lines) and wires but everything was fine, they must have a taste for silicon! Just put back on the standard hose for a while untill I kill some more mice.

Been working on a oil catch tank too, got one off of ebay for the grand sum of 99p! It was from a Renault 5 Turbo. Have cut and glued (bodge I know but if it works well I'll get some proper hoses made up) some rubber hose as where I want the tank placed there isn't alot of room for the hoses to bend, pictures soon.

Haven't noticed much of an improvement in changing the fuel filter but at least I know the one thats there is a good un , but the PIAA bulbs I got are brilliant!
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Old 08-11-2006, 03:06 PM   #8
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Renault 5 Turbo oil seperator, like I said above, the hoses are a bit of a bodge!



Also fitted two new handbrake cables, and taken off the exhaust tunnel heat shields as the studs just snapped off when taking off the nuts, oh well .
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Old 15-12-2006, 05:19 PM   #9
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Fitted the new alternator today and went for a little tootle about some local roads. Also getting some plans underway for the post winter re-build/restoration
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Old 18-02-2007, 06:58 PM   #10
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Quick update before Topgear comes on, heres my beam I'm using to rebuild my one with. Got powerflex bushes and Goodridge hoses to go on at the same time. Also thinking of getter a propper bias valve and getting rid of the trouble some S2 compensator

Anyway, before stripping and painting,

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Old 21-02-2007, 08:20 PM   #11
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... and after stripping, de-rusting and primed I used a thickish mix of car primer under the grey rattle can stuff





Also gathered all the new bits from Peugeot,
  • Inner and outer bearing seals
  • Bearings for both sides
  • New 'big washers'
  • Main fixing bolts and nuts
  • ARB end plates

Coming together nicely
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Old 06-03-2007, 04:42 PM   #12
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Well so far taking off the beam has been like opening a can of worms

It turns out the beam really was buggered, so was the rear brakelines and to make matters worse someone has welded one of the torsion bars on Its upwards from here tho...
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Old 11-03-2007, 07:03 PM   #13
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Been at the rear end for the past two days now, nearly finished Got the stuck torsion bar out thanks to Sandy's guide and some Irn Bru! Also managed to clean up the end of the torsion bar that was welded in

All the rear brakelines needed replacing, including the ones from the master clyinder, so replaced them. Now need new calipers because the bleed nipples are fubar'd (drilled out the old ones after they snapped, re-threaded the holes, but its seeping fluid through the thread) so not taking any chances on them.

On a positive note we've raised the back end up, so it now sits 5mm higher at the back then at the front, rather that 15mm lower No photos yet as I didn't have time.

Will be back on the road this week
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Old 14-03-2007, 10:31 PM   #14
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All fitted up and running smoothly, I'm quite happy with the ride height, if anything maybe a little high, I'll see how it settles.





Was going to paint the trailing arms but ran out of enthusiasm to do it

Also my car seems to suffer from rust in the wheel arches so after treating it and re-sealing it I made up some splash guards to keep the crap out, will probably just put them in when the weather is not so good,
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Old 27-03-2007, 04:55 PM   #15
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Been busy underneath the car, treating every bit of rust. Still looks a mess tho (random bits of fresh underseal everwhere ) but untill I get my own garage space it'll have to do
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Old 02-04-2007, 09:07 PM   #16
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Just an update after this weekend. If you haven't already read in the events forum I have take part in the Scottish leg of Le JoG Rallye 2007, this was a charity run from end to end avoiding motorways and dual carriage ways. I covered 780miles from leaving my house on Saturday 31st March and returning on Monday 2nd April, whilst covering some of Scotlands most scenic and challenging roads.

More information can be found in the latter pages in this thread.

Big thanks to Tom for organising it, and to everyone I met during the journey, events like this is what being in a car club is all about.

Quick Random Selection, more photos are here









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Old 09-05-2007, 11:05 PM   #17
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And I'm back for more blogging. Binned the R5 Turbo oil catch tank because the bodged hoses looked crap! So some ebay searching found me a nice black alloy tank for 30



Its one of those ones that can be mounted either upright or on its side. The main reason I put the R5 tank in in the first place was the lack of room in the engine bay with the standard airbox, however this tank fits neatly into the little space behind the ECU, beside the drivers side strut. Also thanks to Peugeot being clever, there are two square holes already there for them fancy slip in bolts (the ones that have the square heads, for fixing the standard airbox onto the slam pannel on the S2) A quick look around a scrappy gave me a bracket that fixed in this place (from an single point injection AX) and the two bolts, for free

Like this...



I couldn't use the bracket off the AX so I made one up out of alloy, and it now looks like this



Quite pleased with it, its quite well hidden there. Just waiting for some black silicon hose to come in the post and job done
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Old 09-06-2007, 06:08 PM   #18
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Boo Yaa!

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Old 29-07-2007, 06:36 PM   #19
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I felt a bit tired of the standard steering wheel, decided that I didn't want to feel like I was driving a bus anymore! Went for a Sparco 323, as you can see below, 330mm all black with suede. Feels great, a big improvement over the standard item. It sits slightly closer to you which is what I wanted, but not so far you can't reach the stalk's when your hands are on the wheel. I didn't put the 'Sparco' horn badge on as it stood out too much, and the horn isn't wired in, just covers the hole Went for an OMP boss from 106parts, and the wheel was from RallyNuts.

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Old 01-09-2007, 11:18 PM   #20
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I've been planning this since the start of the year, but my rear beam was more knackered than I though so this had to wait a while. Anyway, despite my trying, I've always felt left down by the state of the engine bay (not that is was a mess in the first place), i knew there was some bad bits of rust, and poor paint work. So engine out, passenger wing off and grinder out!

The full thread can be found here

Stripped down,



Attacking the worst of the rust,



Repainted,





Its taken about a month of work to get it to this stage, but we done alot of prep work cause its the kinda job you want done right first time! but today I pretty much put everything back into the bay, suspension wiring etc. Tomorrow I'm preping the slam pannel for paint, painting the engine block and getting the pannels to line up better than they did before, and picking up the gearbox from getting rebuilt on Monday night, on the final straight now
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Old 12-09-2007, 11:43 PM   #21
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The second Major rebuild this year is finally finished, and just in time for Anniversarallye

Spent Thursday and Friday last week building everything back up, and the weekend running in the gearbox, having put the engine in on Monday (which is alot easier to do with the slam pannel off!)

Basically
  • Entire engine bay cleaned or rust
  • Strutbrace, Rocker cover, ECU and Battery tray powder coated
  • Suspension cleaned and painted, satin black
  • Peugeot Sport Group N top mounts fitted
  • Engine block painted
  • Gearbox rebuilt
  • Rear of bonnet slightly raised
  • Pannel gaps corrected
  • Wiring loom re-wrapped
  • New water pump and belt tensioner fitted
  • Manifold primaries heatwrapped

Full thead can be viewed here.





Rams have been repainted satin black, the red was too 'in your face' for my liking,






Next on the list I think will be some lovely parts from QEP ... some time next year!
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Old 15-10-2007, 07:31 PM   #22
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Well this weekend passed I attended my first car show with the Rallye, Anniversarallye The car performed faultlessly on the 1000+mile trip and hooning it around the track, looks like all that time and money has payed off in getting a my Rallye in a nice reliable state I'd just like to say thanks again to everyone I met new and old faces, you really brightened up my up-till-then depressing week, cheers guys



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Old 12-12-2007, 10:21 PM   #23
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Been a bit quiet recently, so bit of an update...

After seriously considering selling up and moving on to something else, I even typed up a for sale thead but, I can't do it! Its such great fun to drive and work on theres no way any other car could compare, especially when you see so many ex Rallye owners returning. I didn't want to be one and end up buying another Rallye in a few years time and doing exactly the same again!! Also I quickly added up how much I've spent in the past 4 years!!

So, I'm never selling her, I know thats quite a statment to make, but I'm sticking to it

Right back to the car, it split a CV joint the inner one of the drivers side shaft. At this time of year its a pain working outside in Scotland, so just shipped her up to the garage and got a new OE replacement from Peugeot, should be back home tomorrow. Also got a new battery (from Peugeot) to say sorry for nearly selling it

Can't wait till next year now! Plans are being made...
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Old 15-02-2008, 06:43 PM   #24
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Word yo!

Doing even more refurbishment work, all in time for Rallye Du Retour.

This time
  • New Headgasket
  • 266mm brakes

Whilst I'm doing the gasket I'm putting in new headbolts, thermostat, temp sensor and fan switch. Got a new 266mm setup from Peugeot, with Ferodo DS2500 pads and Nitrac 8 Groove discs, also I'm putting in new brake lines and using my front Goodridge brake flexies.

Parts so far,


Carriers are in the garage after being painted, and discs will be with me at the end of the month
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Old 20-02-2008, 09:38 PM   #25
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Well, just finished doing the headgasket tonight, only hickups were Peugeot ordering the wrong gasket, and having to replace a water hose Will roll her out of the garage to a shake down tomorrow

I also got new exhaust manifold gaskets, and doubled them up (so the peaks of the gasket are facing the head and manifold faces) as my Raceland never sealed 100% with one gasket, seems to be fine now.

Thanks to Sandy for the correct head gasket part number.

Fubar'd gasket



Mandatory head picture,



Correct gasket (No. 0209W8) ready to go,

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Old 02-04-2008, 06:39 PM   #26
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Right then, a month later than I'd planned to be finished and I have my 266 brake setup on.

List of things that went wrong,
  • I ordered the wrong offset discs.
  • Peugeot could only get the 'square ended' calipers
  • My Goodridge hose' were the wrong fitment.

The first two weren't so major, but I'd only noticed last Friday that the caliper and hose weren't compatible (both had concave seats) so I had to order up custom ones from Rally Design. As far as I understood it all Peugeot calipers had the same fitting? ( M10*1 convex seat). Never mind tho, got there in the end

Old,



New,



I went for Nitrac 8 groove discs from MSW (34.5mm offset), and Ferodo DS2500 pads. The calipers and carriers were new from Peugeot,

Carrier - 44 0496 / 44 0497 - 36.77 each
Caliper - 44 1067 / 44 1068 - 28.98 each

I also ran in new brake lines at the front, firstly because I had to cut off the old fittings to get the old flex's off, and secondly because I have already put new lines into the rear.

First impressions of the bigger calipers on the standard master cylinder were not good, huge amounts of travel and poor braking performance, and it didn't get much better after bleeding the system twice. The travel was so great it would it the floor under heavy braking. Thankfully I had a 23mm master cylinder on hand, this massively improved things. The travel is now back near where it was with the 247's and the feel is excellent, really responsive and progressive. I don't understand how people find using the larger MC 'on and off' but I guess its down to personal opinion and type of caliper, mine certainly needed the bigger MC.

Further write-up when I get back from Europe On another note, I'm now happy with my upgrades to the suspension and braking, engine next I think
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Old 27-04-2008, 06:03 PM   #27
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Relocation, Relocation, Relocation!

Been meaning to do this for a while now, but I've moved my catch tank lower down beside the battery. I was getting problems with the gunk collecting in the hoses and running back down into the head. The hoses are now considerably lower now and should improve things. The tank is on a bracket that bolts onto the battery tray studs. You can also see the much simpler AX air intake pipes are.

Also fitted one of the new driveshafts, which was totally problem free, wicked

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Old 02-05-2008, 09:35 PM   #28
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Back in action!

Well tonight the old faithful Rallye turned a wheel since coming back from europe. I think it was a well deserved rest! Finally got the handbrake repair kit so I could get the seal I needed. If you've read my Peugeot rant you'll remember that the 'repair kit' for the rear cylinder doesn't actually include all the seals you need to 'repair' a caliper. If you are going to rebuild them properly, you'll need the 'Repair Kit' and the 'Handbrake Repair Kit' Peugeot logic....

Anyway, the offending seal,



One rebuilt cylinder. Those eagle eyed of you will notice my caliper bodies have steel inserts for the bleed nipple and brake pipe, which mean I shouldn't have any problems with snapped bleed nipples or seized unions. These calipers were reconditioned ones that I put on when doing the rear beam, and I didn't fancy getting another reconditioned caliper incase they didn't have the inserts in the body, which is why I got the repair kit(s)

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Old 08-05-2008, 09:57 PM   #29
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Today I solved another of the European caused rattles (no thanks to Belgium), this time it was the ARB drop links. I must be showing my 'Rallye ownership age' now, this is the second time I've had to replace them! I've also added a drain plug onto my oil catch tank. Since moving it beside the battery it is now a total ball ache to remove, so I've threaded in an alloy socket cap bolt and an O'ring to seal it. Now I can drain the gloop into a cup with little hassle

No pictures, I'm sure everyone knows what a bolt and drop links looks like!
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Old 05-06-2008, 11:38 PM   #30
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Clutch Cables and Driveshafts

Finally got my passengers side driveshaft, only 1 month late from Peugeot No problems with fitting, only that is was raining and I had to clear a space in the garage!



I've been meaning to do the clutch cable since i changed the clutch (2 years ago!) and I wanted to ditch the self adjuster mechanism, its crap.

It seemed like a nightmare of a job as you can't really see what is going on. After much confusion at my local parts supplier and I ended up with a cable from a Saxo (First Line part number FKC1319). The main problem is that it seems my Rallye has a different pedal box to what I expected, for what ever reason the S1 cable I ordered has a different bulkhead fitting (a large white oval end, where as mine requires the small round end) I can only presume theres been a cock up at some stage as I appear to have a pedal box from a PAS car!

Never mind got there in the end

Correct Cable - Old Cable - Wrong Cable
The two little plastic bits beside the old cable are the remains of the clip that fix it to the pedal box, I smashed it off (screw driver and hammer method!) to help taking the old one out.


This is the clip that holds the end of the cable on to the pedal, it simply levers off if you use a screw driver up the inside of it.


I made this spacer as the cable was a bit too long and left very little thread for adjustment without it.


The new cable has massively improved things, the pedal is alot lighter and by ditching the self adjuster I've lost the 1.5 inch of free play in the pedal, top job
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Old 16-07-2008, 07:59 PM   #31
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I'm long overdue an update!

Right then, since my last update I've had the car stripped out, been on two trackdays, and put the interior all back in again. I have now been at Croft and Knockhill, both excelent. My preference being Knockhill as the hills make it alot more fun, and it didn't rain Great to meet Kev, Tommy and Crossie.

Croft,



Knockhill,



I've now fitted my powder coated steelies, and a sunstrip, exciting stuff I'm sure you'll agree! Non the less I've taken photos anyway



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Old 26-07-2008, 06:27 PM   #32
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Its throttle body time! I picked up a set of GSXR 1000 K1's, the biggest benefit is that the bore size is as near as perfect for a N/A TU engine, and that they are very neat units. Bodies from 2001 - 2003 (K1, K2 and K3 series) are all the same. The bodies are basically four individual throttle bodies bolted together, so you could alter the spacing between them to suit various cars/manifolds.

This certainly isn't going to be a quick project, its another 2 weeks minimum untill the Emerald arrives, and then however long its takes for Colin to send them back with inlet manifold and trumpet fitted. I'm certainly in no rush to get it done anyway, then once I have everything I'll start building the new loom, and get it up to my local friendly mapper.

Keeping Sandy and Colin busy!



The only down point of the GSXR TB's is the second butterfly/choke. This needs to be removed as it will not be used.



Second butterfly's removed and ready to be posted!



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Old 03-08-2008, 06:09 PM   #33
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Gear change has been pretty dire recently in comparison to when the rose joints were new. So replaced the rose joints, and fitted protection boots which will keep the grease in, and the crud out.

Old shafted linkage,



All three built up with new joints,



Happy to say its even better than when they were new, I think I've landed with better quality rose joints too, top job
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Old 16-08-2008, 03:27 PM   #34
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Replaced the all the steering related gubbins today, rod ends, steering arms and centre bush thingy The rubber boots on both the old rod ends were shot. The mess they were in with rust, it made the job alot easier replacing everything. Just need to get the tracking done now



Crusty,


Still waiting on my Emerald
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Old 09-09-2008, 08:48 PM   #35
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Back to the throttle bodies, finished the flying loom and the relay unit. Still alot to do, I need to do make up a mounting plate for everything (when the Emerald comes in, which I'm reliabily told should be this week), finish the loom, fit the bodies, get it set up, sounds alot easier than it will be! Colin has finished the 8v bodies and my set is currently waiting on a custom filter from ITG to get around clearance issues with the scuttle pannel, I don't want to cut it because I'm awkward

Loom,
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Old 15-09-2008, 09:31 PM   #36
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Just got an email from Colin, bodies are finished


Thanks to Colin for the picture.

Wiring loom is now 're-organised', the pile of bits at the bottom of the picture is being removed, the other pile being put back in the car for the gauge sensors etc. Also my Emerald came in last week, now have it mounted on a bit of alloy plate along with the relay and fuses. Need to get some connectors and heat shrink so I can finished the wiring at the ECU end and it will be ready to mount in the car.



Bare,
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Old 21-09-2008, 07:24 PM   #37
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Argh, wires!!



The TB's and ITG filter,





All fitted up. There wasn't any major problems with getting them on, a few brackets on the fuel rail needed removing and one of the engine mount studs needed replaced with a bolt to allow clearance.



Tight like a tiger! I've had to ditch the strut brace to get clearance, but I should be able to modify it to allow it to fit.



How I left it this afternoon, (I'm just back in from wiring the TPS so the wiring is now 100% finished )



Need some fuel hose to connect up the fuel rail, put the battery back in and its ready to turn the key, happy days! Will be next weekend untill I get back on to it, as I'm off on a team building do dar with the rest of the 5th year Engineers this week.
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Old 13-10-2008, 06:56 PM   #38
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Right an update on this TB malarky!

I had the car mapped last week and found that the injectors were at max duty through the mid range, totally my fault as I over looked the injectors and hoped they would be big enough Anyway, after speaking to Sandy I now have some Vauxhall Cream/Beige ones in which are rated at 224cc, much higher than the 150cc on the standard S2 brown jobbies. It is also booked in to get properly mapped on the 29th, so untill then its having a little holiday. Had a little drive about when I first got it back, the power delivery is so smooth, and the noise is imense!

Sold my old Sparco strut brace as it didn't fit with the bodies in place, I now have a OMP one that comes further forward than the Sparco, and painted it stain black.

Next update on the 30th with RR graphs
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Old 29-10-2008, 10:57 PM   #39
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Well, I'm just back from my local rolling road getting it all properly mapped. Firstly, big thanks to Dave P for coming over with the right software, as I'd forgotten to take mine with me and to Russ for being patient and explaining everything.

Slightly mixed feelings about it, but I think its because I was basing what I'd expect to gain on a (potentially) duff RR graph from 2 years ago (which gave my car with 117bhp @ 6500rpm and 100ft.lb at 4500rpm, with only back box!) After a lengthy discussion with the mapper theres nothing he feels is wrong with the engine, but he did expect slightly better gains from standard (103bhp @ 6200rpm, 97lbs/ft @ 3500rpm), and to be honest so did I! But on a standard cam I wasn't exactly sure what would be possible, or what to expect. We came to the conclusion that its maybe not getting enough air at the top end, which is my fault for not wanting to cut the scuttle .

Anyway heres the graph (110bhp @ 6250rpm and 98lb.ft @ 5046rpm),



I'm all for thinking the power run from 2 years ago is a bit high, as surely theres little chance it could have made 15bhp over standard with only a back box! Anyway, figures aside it pulls so much better than it did prior to the bodies, and thats not just a placebo from the noise. Which also makes me think the old power run graph was wrong.

Anyway I don't want to get tied up in figures, it drives superbly and the noise is amazing

Also a picture of the finished product, with my new strut brace,

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Old 30-11-2008, 03:39 PM   #40
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I've been making further progress with the TB's, mainly in getting more air into them. I've re-routed the fuel lines so they do not go round the front of the trumpets. I shortened the original hard line fuel hose by removing the plastic connectors by heating up the fuel line, cutting it, re-heating the hose again and the plastic connectors can be fitted again by pushing them in. Thanks to Tommy and Bowya for the tips.



I have also cut enough out of the scuttle to allow me to remove the filter, I can now properly balance the bodies by using a Gunson Carbalancer, which should fit nicely over the trumpet mouths. This cut out should also allow more air to circulate about the trumpets.

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Old 04-01-2009, 02:28 PM   #41
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Now with Stack AFR gauge I went for the stack as imo the gauges that go with the Innovate Wideband displays look abit naff, whereas this one blends in to the rest of the dash nicely.



Now I can keep a close eye on the air-fuel ratio, and I can do a little live mapping (which is bloody hard if your driving and mapping at the same time!) I've fitted it in one of the central heater vents (as you can see) so there wasn't any need to fit a naff gauge pod anywhere, its sitting off centre so I can see it easier.
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Old 17-01-2009, 12:31 PM   #42
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Last weekend I shifted my oil catch tank, again! Its now mounted on a bracket off of the coil pack mounting. The reason I moved it again is because with the tank on its side there was alot of gunk coming out of the filter, now with it upright its stopped it completely Its also alot easier to remove to empty it.



In bad news however, my exhaust has a rather large crack in it at the front of the first 'silencer' So I've whipped it off so I can get it welded.



Feel free to comment, but please keep spam to a minimum
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Old 17-01-2009, 04:49 PM   #43
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Shame about the exhaust, but otherwise looking fabulous Gus!
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Old 23-01-2009, 09:05 PM   #44
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Right then, I've had the exhaust welded/patched, the guy's done an ace job of it. Got it back on the car tonight.





Still in perfect condition after 3 years,




I've also given it a full service before spring, my usual Silkolene Pro S 5W-40 oil, oil filter and Motul RBF660 brake fluid. I done the spark plugs and coolant before winter, so they'll still be fine.
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Old 31-01-2009, 04:37 PM   #45
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That is a brilliant job on the exhaust Gus
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Old 19-02-2009, 10:16 PM   #46
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just read from start to finish, really informatively written, ace blog
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Old 19-02-2009, 11:26 PM   #47
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An absolute stunner of a rallye, the finish is amazing!

Any sound clips of the engine n bodies?
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Old 19-02-2009, 11:40 PM   #48
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Cheers guys. No clips on it running properly on the TB's I'm afraid, but its awesome, I will get as soon as I can (but don't hold your breath!)
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Old 04-03-2009, 11:25 AM   #49
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Your finish is impeccable, Somewhat better than my currently half-hearted engine bay clear-up..

I'll hopefully get my engine done in the next year or so along with a spruce up of the bay. So hard to keep everything rust free with all the salt about and with the S2 sitting outside.
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Old 18-03-2009, 06:04 PM   #50
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fair doos gus, stunnin mate. if i had a rallye id want it simular spec. hows the emerald mapping coming along? ive looked into them as my mate has his mk2 escort with a red top in runnin the management.
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