Travis Bickles VTR8 project, updated with pics.

[TRAVIS BICKLE]

Bad times! Really annoying, the new clutch is too small for the flywheel. I need to use the dturbo clutch to go with the dturbo gearbox. Gonna have to change the flywheel for a GTi6 jobbie.
With a bit of luck I should have one for the end of the week thanks to a lad from the GTi6 and rallye forums.
At least I'll have time to get some heat shields made now.

[TRAVIS BICKLE]

Well I've been beavering away at the interior wiring while waiting for the flywheel to turn up. I took out the heater box to remove the rest of the weighty sound proofing crap and just about worked out what all the plugs are for, got the steering column back in and routed the main dash loom where it needs to be, I've found that the 406 stalk plugs fit straight into the xsara stalks so that's a bonus and got the transponder mounted on the barrel.

Just got to bolt all the earths up plug everything in, then once the engine is somewhere near I can test all the electrics. The 406 didn't have a sunroof as it had climate control so I'll use a now redundant rear window feed to power that, I've taken the motors out of the 406 heater box as I'll try and make use of them for some kind of electronic boost control.

[TRAVIS BICKLE]

I thought a trial fit was in order as I didn't know how it was all going to sit once it was in, I had my old tubby engine and whipped the head off, all looked okay in there. I remember it was down on compression on number one, the gasket wasn't brilliant so I can only assume it was down to that.

I had noticed there was a huge amount of crank end float and when I stripped the bottom end I found a thrust washer sat in the sump!!! The crank is okay lucky for me, but this is my spare engine so its not a worry.
With the block stripped I put the sump back on and lifted the empty engine into place, then the gearbox on and finally the complete head with turbo went on.

Its tight but it all fits great, I'm well impressed! Even the exhaust is almost perfect. I put the steering rack and subframe on and all is good, no problems.
I am a happy bunny!

[steve_earwig]

I knew I'd forgotten something... Does the thrust washer have any wear marks on it or do you reckon it was a manufacturing cock-up?

Sounding good anyway Which gearbox are you using? What's the deal with the flywheel?

[TRAVIS BICKLE]

Well one half was okay, the other one was mangled. I have no idea how its happened? Maybe when I took the gearbox and clutch off with the giggling. But then again it must have been running for it to get mangled? Its a mystery I've never seen that happen before.
I've had to change the flywheel as I can't use the 406 box (too big) and the 406 clutch is 235mm and the dturbo clutch is 215mm so the clutch cover holes are in the wrong place. The box I'm using is from an HDI which is a little longer in the gears than the dturbo box.

The gti6 flywheel has turned up today so the engine should be in and maybe running at the weekend yippee!!

[TRAVIS BICKLE]

Finished work early today so whipped the lower engine mount bracket off, cleaned it all up and removed the old rubber flip flop that lived in there.

Took the bracket down to my local fabricator chap and after a brew and some chin scratching he's going to make a nice solid alloy bush that will be pressed in, with the hole being 15mm off centre to enable the engine to lean back so that the turbo heatsheild no longer touches the bulkhead.

Sure ill get more engine noise and vibration with a solid mount but the other end of the fork still has a rubber bush in. But this is not a maybach so does not have to be quiet and refined. Just good enough for trackdays and to and from work. I doubt I'll hear any extra noise anyway as its bare inside anyway lol!

[TRAVIS BICKLE]

Well I picked up an intercooler from the scrap yard the other day, from a Saab 9-3 aero. Its as wide as the radiator Not as high as the old one but much deeper and the bars are much larger so it will flow muuuuuuch better than the restrictive small piped old one. it should fit behind the bumper low down so ther is no danger of any heat soak that the oem one suffers being sandwiched between the water rad and the air con condenser.
Can't remember who's it was but they have a decent intercooler somer colder plugs, decent exhaust and a VAG V6 fuel pressure regulator, and that made over 200bhp at 1bar so things are looking good.

[TRAVIS BICKLE]

Made no progress at all this weekend due to family problems. Will update when I've sorted things out.

[steve_earwig]

That's fairy nuff dude, it's not really the weather for it now....

Sounds like this little car could end up a bit of a firecracker

[TRAVIS BICKLE]

It should be nippy I hope. Its the only thing that's been keeping me going lately and I've not even been able to get in the garage. New problems this weekend include my teenage daughter causing grief on top of all the stress. I need a holiday.

[TRAVIS BICKLE]

Well, progress resumed this weekend, not a great deal but progress all the same. I swapped over the flywheel and fitted the new clutch and finally the gearbox could be mated to the engine.
I'm still waiting for the lad I bought the gearbox from to send me the clutch cable release arm that was missing from the box though.
I'm still also waiting for the custom billet alloy bottom mount. Which I was promised last week, I'm told it will be ready to pick up today.
Other parts that are still missing are the O/S driveshaft, cambelt kit and some more exhaust tubing and rear silencer. But things are moving once again so that's good news.

[Welly]

Good man, hope to see some more soon

[TRAVIS BICKLE]

I have been struck down with flu now, I had booked holiday all next week to get stuck in, but for the last two days full on man flu has erupted. Need a quick recovery to get cracked on.

[lozz]

I have been struck down with flu now, I had booked holiday all next week to get stuck in, but for the last two days full on man flu has erupted. Need a quick recovery to get cracked on.

Sorry to hear your ill mate,

sod the car keep warm,
been out in this weather for a few hours enough was enough had to come home and camp infront of fire,
its Feckin freezing,
ithink were all going to get the Back lash of scotlands winds, mixed with ice & snow not good,

[steve_earwig]

That's a bastard Loadsa fluids, vitamins and if you do have a tinker with the car stay warm. Unless you want to find out what Christmas dinner is like in hospital...