small update, not really done any thing with the car...
painted the rear calipers red and gave it a nice due service.

i did how ever notice the car was down on power, a few chats with Nigel on the phone and he helped me track it down to a boost leak!

after a quick pipe swap, all good!

Now its a case of getting it ready for spa.

the list has started again

4 wheel alignment
another serivce
plug change
weld my bucket seat frame
change brake fluid to DOT 5
change the coolant
change the gearbox oil
change the fuel filter
2 New front tyres

also, i still need to align a few body panels as im still not 100% happy with the way i fitted a few panels to the car!

so, 26 days and counting till Spa...

well, started on my bucket seat with the help of a new work mate!!!









should have the seat in and fitted for the sprint track tomorrow

Now once we stripped the runners down and cut the metal plates to fit

We tacked them in place

Also heated and bent the metal so we could mount the harness onto the seat base

A quick welded nut on there and we are nearly ready to go

We welded it all up and where ready to mount it


Then it was finished ready for the bolts for the seat!


Looks lovely in the car!!

Well, nothing has been done really.

Ive now unsersealed the car including the oil cooler pipes!

tracking has been done also!

just keep finding im chseing my tail with this car.

Today is the day i finish every thing off ready for Flea to do his thing after Pappa Nigel told me off for having a slow car and letting the Team down!

so, todays work will consist of the following..

New thermostat + Sensor
SIP
silicone pipes
coolant change
boost leak test
HIDs fitted
LED number plate bulbs


im already booked into Dr Flea for him to see how far he can take my coupe!

ready the tuning guide, im got a complete stage 2 coupe!
but yet its dire slow as all the forum members have seen compared to McMike's car & Begbies car.

i will upload the video on the thread so every one else can see the difference between a 250bhp sprinty VS McMikes rapid LE and Begbies monster only running 0.4Bar BOOST!!!!

Marco getting spanked!

done a bit more work on the FMIC yesturday.

my bent one was causing flat spots and making it go alot slower than it was.
so i changed it to an EVO FMIC.


We made new holes and put better bolt in so it fitted nice and snug to the cross member.



Very happy with the results!

Also chucked on some brand new hors while i was there

time for an update..

long short of it all... Went to flea, expecting a decent result BUT no.. the car went sour on me.

216bhp sour.

so i left him with a nice list of things to do and check..

turns out it was the turbo actuator.
It was well and truly shagged, when i tested it on a midivac it could just about hold 0.3 (5psi) before opening the waste gate.. JOY you could easily open it with one finger pushing the actuator arm!!

Well, firstly a massive thanks to RMJ, Nismo & Mario (well.. Mario " helped " ) off this forum!!

RJM had an actuator, he was near Nismo, Nismo and Mario brought me the actuator today!
Lovely!

with it fitted, the car is feeling great!! Gave Mario a surprise on the way home!
it feels like it use to be, nice quick and responsive, it holds boost and does not start dropping off till near redline!
im a very happy boy again!!

i also found a leaky fuel pressure regulator...

So i had to change it to a nice sand and aqua blasted unit I done ages ago

while removing it, found the inlet doughnuts had split so i now need to change them asap before it goes to flea as i have a feeling its letting out pressure or taking in hot air.

i have my last set of these in my garage so im going to have to change these this week as i cant risk nothing with the mapping booked.

Also fitted a Gizzmo boost controller so i can manage boost a lot better than the PRV.


Nigel, you where right... AGAIN.. i don't think i can live with out now

you will get bored of being right...one day.

also changed the fuel filter a few days ago and ive changed the fuel in the car to 99 octane to keep the detonation in line.

Roll on thursday

Well... an update.

what i fort was a leaky FPR was in fact split inlet doughnuts.

Hoping to manage to go back to Flea at some point to get the map tweaked..

things that have been changed since last update..

Lower brace fitted/tweaked
Gearbox oil changed again
Inlet doughnuts changed
got the rear brakes working again
Sand/aqua blasted inlet plenium


Things needed before track day..

New front pads
Brake fluid changes (some dot 4 was still in the system.)
rear tyre change
N/S/R Wheel bearing
Oil & Filter change
Map tweak.

ALLLL RIGHTY THEN...

the car is nearly ready for its first track day (excludng the sprint tracks )

Bucket seat in
rear wheel bearing done
rear tyres changed

tonight i will only need to change the oil and brake fluid along with my front pads!

what wounders will the car stress me out with tongith i wounder?

p.s Thanks Joe for getting me a wheel bearing in such short notice

.

The car decided it wanted attention...
It decide to have a sticky throttle..

After a quick chat with Joe (CC) he pointed me in the right direction..

So I removed the throtle body, cleaned and greased the butterfly inside when I noticed a *MINOR* restriction in the throttle body it's self...

A great big bloody chunk of metal blocking the lower part of the butterfly..

So while I cleaned it.....

I decided to port it... A bit...




The results... Quite simple really...

My sticky throttle is gone, my throttle body is VERY cleaned and I aqua blasted it too so now it looks mint!!

As for power ect, weirdly... My idle is smoother? Throttle response seems to be better and the car feels really nice to drive!

I no there not many gains but it's some thing extra to add to the spec list

.

So the car is out of storage as spa is coming up.

its also booked it to see flea shortly.
Things that needed addressing when we where there last was

intercooler pipe work length.. it was a "tad" on the long side.
so i had some new pipe work made up and it looks the nuts and shortened the pipe work by at least 50%!!!


This could be the solution to the pipe work issue that some people get!

ive also made the exhaust system 2.5" from down pipe all the way back.
Makes it sound a a lot nicer and has given it a bit of noise that i feel she was lacking!!!


im in the process of heat wrapping all the down pipe again upto the de-cat pipe to help reduce heat soak.

some how ive managed to go from nothing needed on the coupe to a LONG list of crap.

How does this happen????
Any way, this should keep me busy till spa...

Fun times.

Just so people can see, I remove this much pipe work from my FMIC set up!!

well.. its been a long bloody road.

where to start..

well, from the top maybe??

engine 1, the original engine that came with the car failed.
lost compression on cyc 1.


plus low oil pressure..
it lasted 3 years and tbh i was happy with that.

after a long hard decision, i decided to scrap the car..

but being a weak minded fool, i got talked into making her live again, Just in time for spa 2012.

So, we went for it.
in the mean time i looked at teh car and made a lsit of every thing that i needed to change (besides the engine)
this was already a scrap to afford but if i did it once, i wouldnt need to do it again..

So we sent the car to Joe at FCSS for a repalcement engine, belt, RSR Turbo, New rad, 3.8 bar FPR, new plugs, fuel filter, new bearings and the list went on..

then a flea mapp once it was all done.

so before spa, i get the call from Joe, sort out a day to go see flea.. All is well.

The car makes 316bhp & 302ftlb @ 1.4bar.

RESULT!!!!

the car was the best it had EVER been.

so i was a happy bunny!!!!!

then... the shit storm hit.. at mac 10.

Driveing to work.. i noticed a puff of blue smok come out.. then i wanted to see if i was going insane or this really happened.. so a shot forward and lifted and it did it again..

so straight onto the hard shoulder..
checked the oil..
topped it up to full, it was only 3/4 on the dip stick.

drove to work..
checked the oil again..
EMPTY.
No boost
low oil pressure down to 1bar ect

whipped the sip off, the turbo was McHammered.

GUTTED.

that night, i got the turbo off and found the exhaust side was like a di*k in a bucket.



Now.. at this point, i wanted to set fire to it and say there was a fuel leak.

after speaking to Joe.. and talkign more he managed to talk me round AGAIN to not breaking or burning the car...
so, we came to a deal that i borrow a turbo from him and see if if i got lucky..

Well.. i didnt.
The turbo had caused some damage which reulted in the another dead engine.
and work related abuse.


So.. i sent the car back upto FCSS for further investigation..

which confirmed it.. its buggered.

So.. a month goes past.. still nto done any thing.
We had failed in the "Get Marco to spa plan"

Which if im honest, ive never been so touched by this forum.

I had every one possible wanting to help, i had offers for engines, labour help and 2 people on here who even went too far with the help..
to name a few Joe (FCSS), Proccy, Mario, Sedicivalve, Nismo, Nigel, Joe78, Porkypaul and im sure theres more.

you guys, i can not thank enough for every thing

any way, back to the project.

We decided this car needs a Full re-con engine.
i could not afford a barbz engine and really wanted to have a go on my own..

this build has pushed me to points i never wanted to EVER go.

Begbie.. i weridly know how you feel.. Nick_D you just lazy

so, i got a donar 20vt engine from Nismo

got it back to my work..
stripped it

cleaned it all

then realised theres a lot of parts..


after finding out some info on the engine (Thanks JBT ) the engine had an over heating issue so i decided to scrap the head and got another one from Joe


so, now i decided to do a fully lightened and balanced engine.

so the Crank, Rods, pistons, flywheel, clutch, aux pulley & crank pulley went to an engineering shop to be lightened and balanced along with the head
Head ws having new new stem seals fitted and cleaned along with a skim.

i have port matched the inlet and exhaust to the gasket.


Also, ordered new bolts, gaskets ect..


Also, i did a tidy deal with Nigel and purchased some CP gapless rings.. Giggady..


So, a few adys into the engineering work.. i get a phone call thati REALLY didnt want.
The crank is FU*KED.
GREAT.
Thats all i need.

So a chat to proky paul and a drive to tourette household..
i have a new crank.
But as Lady luck wanted to give me a swift kick in the nuts..
the crank paul gave me has defected bearings..
Minor set back..
look liked they had been crushed in transit.. But no dramas..
he got me another one
Thanks again Paul!!!!
p.s spot the damaged ebarings


So, after that, i gt the call, pick up my parts.. readyto build..

so i spray the block..and we start..

then stop straight after we check the bores.

YEP.

you guessed it, lady luck gives me a harder kick in the nuts.
Cyc 3 is fubared.


So, call to Joe, and i get a new block the next day.
after the weekend

so, we check that, PERFECT!
lets start the build.. after i spray it..
again


So we give the bores a light hone and test fit the rings!

*MOIST*

So, now we start fitting the crank..

bearings in.


Crank nearly in..

and its in.


Now rings where fitted and the psitons start going in!!


Then i fu*ked some thing up.

i Aqua blasted the oil pump and stupidly filled it with grit.

IDIOT.

So, Joe sent me another
(could of cleaned it for me )

only joking!!

so after a a few hours cleaning the strainer, that went on

then the sump


then the head went on



Now, after we put a fewotehr bits on here, its going to Joe for fitting.
Along with a fully re-con RSR turbo
New clutch.. again..
new belt
New phase sensor
new Water pump
and all the otehr crap that goes with it.

with a little bit of luck... i hope to be at the AGM with the car..

more to come later

Well, the engien is finished.
Its on the pallet awaiting collection to go to FCSS!

the turbo was sent to CR that should be with Joe soon!

ive also ordered new power flex ARB bushed for the front.. may as well while the engien is out!

Also, while im there... new mocal oil cooler and some thing to make the car EVEN more different!!!

the next update should be an interesting one!!!

Everyone, please refer to the discussion thread for comments

Well, every thing is at FCSS!

Turbo has been fully rebuilt so I have a complete chain!
No weak links!!

And got the best call today from Joe, the eninge is on the stand and work has started!!!

Well, the cats out of the bag

the new item getting fitted to my car is...

drum roll please....




i know people are already using these, its nothing new but i hope this will change a possible 300 to 350bhp coupe to a complete animal and should be able to give other cars some stick!!

i would love to go head to head with a coupe with similar power around a track to see how much difference these will make!!

one thing i know, JBT's at spa changed my life!!
i can not wait!!!!

also, these are getting fitted to!!




so.. if you want me, im sitting in a dark room eating rice and beans as i cant afford food at the moment

Well..

its Done.

picked it up from Joes (FCSS) a week ago today and im happy to report every thing is going ok so far!

500 miles completed with out any boost.
today i willl make the change over to a 10/60 oil and start the boost loading process!

after a qucik chat with Flea yesturday (thanks again for the call) i know my fueling should be ok for upto a bar of boost.

not that i want to go that far... although its bloody tempting.

after a 100 miles of applying boost, im going to take it to Flea to work his magic on it.

Every thing is good with the car.

one thing thats hard to get use to is the clutch.
im using a CG 6 paddle...
god its a pain in the arse, but as the miles tick over, its getting a lot better.

ive also noticed my boost is coming in VERY early..

it starts reasching positive boost a 2k!!
which is nice! Feels REALLY responsive and wants to jsut fly off the handle!

now the handeling..
the Quaife has changed the car.
Turn in is just a treat, it really does handle like its on rails.
ive not been able to push her very much as of yet, but i will, and share my forts with you all!!!

I really can not thank Joe enough for the work he has put into my car.
he has spent the time to check every thing out and send me packing with a smile.
not only has he stored the car for me while i built the engine, he also reparied the bonnet cable which snapped on him and sorted a few rattles a squeeks out that bugged me.
Also, he popped a 1 bar actuator on there...
Joe's words..
"may as well put a new actuator on there as every thing is new"
Brilliant

He really has gone to extreams with me and my car.
His after care is great to!
getting texts at 11pm to make sure the car was ok and no leaks or any thing, plus inviting me back to his place for a health check before the mapping!

Thats a nice service to have!

so, overall, its been 7 months, 2 engines, 2 turbos, 7 gallons of tea and coffee (that was just Joe) a fu*k load of stress and money i havent got..

But she is back now.

and i love it

and ive got this forum to thank for that.

With out this place my car would not be alive and kicking now.
(Granted i would have more money in the bank)

Last night i treated the girl to a new set of brake discs i planned to fit before Spa.. well, thre was no point

So, my boost contoller is set to 0.5bar and im goingto enjoy it

So, happy days!
i hope.....

p.s when i have some time to detail the engine again, i will put a photo up...
Proccy.. keep your eyes out for the next update

People, please use the discussion threads else I will start locking all threads relating to projects, which is a bit unfair on the people doing projects and contributing to the area.

Well I promised an update...

Well, she hold boost very nicely!
It's more adictive then popping bubble wrap!!

Any way, the afr gauge is fitted, it's not brilliant but it's the only thing I have to make sure all is well!!
And looks good too!


Now a pic of the engine bay...

Firstly a massive thanks to Nismo for doing this..
He is brilliant at this stuff!!




Welcome to my purple headed monster
Giggady.....

Proccy... Thanks for the inspiration!!! Lol

well...

after a chat with Dr Flea..

im booked in for a map tweak on the 30th of November.

fingers crossed... AGAIN..

So... After a bit*h fit with this paddle clutch, I decided to try to find what was causing so much vibration out of the blue.

So th hunt was on...

Then I found it...
Drivers side lower engine mount was not looking healthy...
Managed to get a spare...

And got to work today.
What a pain in the arse.

But.... Worth it..
This is the old mount..



It should look like this...


Get a paddle clutch they said..... Handles the power they said....


But it has sorted the car up no end...
Vibrations have gone away, little annoying squeak has gone, I'm happy now
Just wish this went when it was at Joes as its a horrible thing to replace.

Now roll on Friday

minor update..

managed to find some time to make a 3" decat system!

so now its 3" from the turbo all the way back to he milteck system!

really happy the tone on idle has not changed too much, its atouch deeper but all round great sound..

but when hit comes on boost the sound is just spot on..
it added what i wanted on full throttle.
gutted i could not enjoy it more..

but there's always tomorrow

Well, as people are aware, ive had it mapped

its GOOD!!

im over the moon with the car at the moment..

some things need to be address as a matter of urgency.

1. Rear subframe bushes
2. Rear antiroll bar needs fitting

after a chat with countycrusing about my momment on the M4 where i span out under heavy braking, it needs attension at the rear end.
No car coupe should be that dangerous.

if im honest, its been on my list for a whiile..
so now i think i better pull my finger out as yesturdays spin could of been a lot worse.

not worth thinking about if im honest.

Well, that's another years ticket on the coupe!

My coupe Passed its MOT with out too many issues!

1. Handbrake cables need changing
2. N/S/R caliper handbrake not realising properly on the caliper.
Either a sticky cable or caliper!

Either way easy fix!

So another year happy motoring!

well, the decision has been made on my coupe.
im putting it back to standard.

Every thing that makes it none standard is going.

over the next week or so it will make its final trip to my unit where i will dry store it and stip it back and re-build it to standard spec