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Bravo 20vt Project (getting pic heavy)- On Track! #947099
07/12/2009 14:28
07/12/2009 14:28

N
ninja
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ninja
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For the last 3 years ive been running my bravo HLX (on and off) as a second car for show purposes. i bought the car 5 years ago and put a lot of effect into cosmeticaly modifying the car. I was lucky enough to be in a position to be able to afford a 20vt coupe without selling my pride and joy smile but i always wanted to do a 20vt conversion and ive always wanted a track orientated car. So thanks to this forum and a few of its members (your assistance and advise will continue to be required troughout the duration smile ) ive combined the 2 elemements and started my project.

The Base:

Fiat Bravo HLX 1.8 1996 ink black

click to enlarge click to enlarge click to enlarge click to enlarge

Mods:

abarth front bumper/ Laguna splitter
abarth skirts
custom p&a rear bumper
custom cat-back powerflow exhaust twin 5" tips
Fiat coupe 20vt alloys
-35mm pi springs
etech alloy spoiler
smoked side repeaters
colour coded delocked merea handles
merea poly headlights
prof tinted windows
tinted tail lights
custom rear brake light (glows 'abarth')
philips vision plus bulbs
lightbrows
full varad undercar neons
k&n 57i induction kit
chrome bonnet lifters
corbeau carrera bucket seats
corbeau sub frames
footwell neons
custom switches in centre column for all neons
abarth car mats


I aquired a 20vt as a donor vehicle earlier this year, the previous owner had already started breaking, but most the neccessary parts were still attached smile

click to enlarge

The Plan:

20vt conversion including:
rear subframe including rear disc conversion
front subframe, wishbones, hubs
suspension,
running gear (drive shafts etc),
front brakes,
steering rack,
engine,
ecu,
fuel pump,

As mention the car will be track orientated, so i'm looking for a good balance of handling, braking, and power.

modified parts collected so far smile

(i'll update this bit as and when)

Power:
ported inlet manifold
3.8 bar FPR
port matched exhuast manifold
GT2560 turbo
FMIC
Greddy EBC
3in downpipe with 5 stud v-band
2.5in decat
custom midpipe
NGK 7 plugs
SIP
Apexi filter

Handling:
solid rear bushes
Polybushed wishbones
seam welded subframe
FK coilovers (20vt) with camber adj mod
HEL braided brake lines
Whiteline 24mm ARB
Front strut brace
Nigels lower brace
20vt brembos

Other:
VDO oil temp
VDO oil pressure
VDO volt meter
AFR
intake temp sensor

still to source:

DBA/3G disc
EBC yellow pads
adjustable fan controller

Possibly a roll cage!!

The project will be an ongoing one, with the suspension and brakes components first, then the engine will be re-built to spec at some point early next year before fitment. Wish me luck laugh

Ninja

Re: Bravo 20vt Project [Re: ] #947215
07/12/2009 17:47
07/12/2009 17:47

N
ninja
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ninja
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i actually started the project a few weeks ago, progress so far:

the coupe has been stripped, and the shell has been scrapped.

bravo front subframe, wishbones, struts, hubs and calipers were removed.

with the access under the car the coupe track rods have been swapped onto bravo steering rack, (cores are the same bar a gear linkage mounting so i cant swap rack just yet but the rack core and transmition tunnel will be swap with engine)

click to enlarge

coupe subframe was stripped, welded, then fitted with polybush wishbones, then the assembly was fitted,

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coupe hubs and standard struts fitted for now,( top mounts fitted directly and suprisingly the 1.8 drive shafts still fit despite the coupe wishbones being marginally wider smile )

click to enlarge

brembos painted and fitted, abs sensors plug straight in, and bravo flexipipes fit straight on (for now).

click to enlarge

coupe 20vt wheels are required for brembo clearance, and the wider track is just about ok with the hlx wings, but i think i will fit wider arches at a later date.

click to enlarge click to enlarge

unfortunately i snapped one of the manifold studs removing the downpipe, but it went back together with just 2 smile (sounds a bit rough tho rolleyes ). other than that and having the clean the a few threads with a tap everything went pretty smoothly, most parts were a straight swap.

the car is still actualy mobile under its own power which is good, but is declared as sorn so i wont actually be driving it.

few pics added, and the garage is a mess i know tongue


Ninja

Last edited by ninja; 07/12/2009 20:07.
Re: Bravo 20vt Project [Re: ] #952240
16/12/2009 13:16
16/12/2009 13:16

N
ninja
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ninja
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N



Update....

Few hours to spare yesterday so i decided to swap the fuel pump reservior. I was imformed the coupe pump would not fit the bravo reservior, but the whole assembly would be a straight swap, so...

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on comparison, they look indentical, all fittings are the same, plugs are the same, although the wiring in the bravo reservior (brown one) look alot more robust than the coupe wire confused

click to enlarge

short time later later, fitted,

click to enlarge

turn the key and.... the pump didnt prime grr

i tried unpluging the fitted pump, and plug the old pump back in and it primed fine so i know its not a wiring issue. unfortunately i ran out of time so will look at it again this weekend.


Also, 24mm rear ARB has been ordered, so rear subframe will get its overhaul just after christmas smile

Ninja

Re: Bravo 20vt Project [Re: ] #961125
04/01/2010 23:19
04/01/2010 23:19

N
ninja
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ninja
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well i think i know why the pump didnt prime shocked

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must have been sat for sometime without anything in the tank . .

luckily i kept my original pump when i had my walbro fitted, so the reservior is now re-assembled with a working pump and ready to be fitted smile expect its too cold atm lol

click to enlarge click to enlarge

Ninja

Re: Bravo 20vt Project [Re: ] #967481
16/01/2010 15:12
16/01/2010 15:12

N
ninja
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ninja
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new assembly was tested and fitted this afternoon, fired up first turn off the key smile

all i'm waiting for now is confirmation of rear solid subframe bushes and i can start rebuilding the subframe smile

Ninja

Re: Bravo 20vt Project [Re: ] #980458
07/02/2010 22:47
07/02/2010 22:47

N
ninja
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ninja
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just a quick update,

progress, has been a bit slow over the christmas period, a few little cosmetic enchancements have been fitted,

including
triple A pillar pods
20vt wheels are being prepped for a respray in black
also test fitted the strut brace with the coupe struts, with succeess smile

still waiting for the bushes to build the subframe.

on a slightly different note, my 16vt has had a centre console refurb, a coolant flush, and its first actual run since october last year smile brakes were a little rough and it needed a jump start, but other than that it was a smooth ride. i almost forgot how comfy the standard seat actually are, there like armchairs lol

Ninja


Re: Bravo 20vt Project [Re: ] #1048809
07/06/2010 08:21
07/06/2010 08:21

N
ninja
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ninja
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N



ok time for an update, and a to take a bit of a break . . . rolleyes


well i finally got everything i need for the rear subframe rebiuld, this includes

ARB
Solid bushes
FK coilovers
Braided lines
Rear disc conversion from a HGT
Radial repair kit

and........ i leave the country for 3 months lol, i'm due to return in august, and will be looking forward to gettin stuck in smash

until then..........

Nijna

Re: Bravo 20vt Project [Re: ] #1097326
06/09/2010 18:02
06/09/2010 18:02

N
ninja
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ninja
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N



well i'm back, not had chance to get into the garage yet so ive been doing a bit of prep/spray work

ive taken the apart the intake assembly,

click to enlarge click to enlarge
click to enlarge

degreased and cleaned

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Paitned

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and re-assembled

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intake manifold is ported, 3.8 bar fpr. and red injectors.

cam cover has been sprayed blue, exhaust manifold is black and so is the heat shield.

hopefully i'll be in the garage by the end of the week.

Ninja

Re: Bravo 20vt Project [Re: ] #1107193
26/09/2010 13:46
26/09/2010 13:46

N
ninja
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ninja
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N



right, finally got some progress

got in the garage (a nice new one too smile ) and managed to remove the rear subframe.

firstly took down the fuel tank and exhaust from cat back. split the brake hoses and heat sheilds/covers, this let us remove the subframe as a whole assembly smile

click to enlarge click to enlarge click to enlarge click to enlarge

first job for monday is too strip the frame, then swap the bushes, fit the ARB, fit the disc conversion, swap the struts, and the springs. some new brake pipes and the whole thing should go back up it one peice too smile

made a start on the engine build, block has been cleaned (came up very well smile ) but goona give it lick of paint anyway cool )

click to enlarge click to enlarge click to enlarge

Ninja

Re: Bravo 20vt Project [Re: ] #1110320
02/10/2010 22:17
02/10/2010 22:17

N
ninja
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ninja
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N



well frame was stripped, cleaned (including some surface corrosion, which is weight saving at its strictest smile )

solid bushes fitted

24mm ARB fitted (with original brackets and a spacer for now)

caliper brackets/dust sheilds cleaned, sprayed and fitted

FK rear shocks, springs and height adjusters fitted

subframe re-fitted

bravo hubs and ABS sensors fitted

Coupe calipers

disc and pads (ive used old discs and pads cause the car will still be stood around until the engine is bilt and fitted, and i dont want the new stuff to start rusting!)

Hel brakelines

new brake lines from compensator

new handbrake cable

click to enlarge click to enlarge click to enlarge click to enlarge

Ninja

Re: Bravo 20vt Project [Re: ] #1114808
12/10/2010 17:09
12/10/2010 17:09

N
ninja
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ninja
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N



nearly there suspension and brake wise smile

Standard front struts removed.

click to enlarge

FK top bearing were cleaned and regreased, top mounts had a coat of colour

click to enlarge click to enlarge

Then fitted, together with HEL braided lines and a new brembo spring kit

click to enlarge click to enlarge

only thing is the coupe braided lines look a little too long for the bravo, the connection bracket must ne in a different place!?

next is a new set of rear brake lines for the compensator, then its on with the engine smile

Ninja

Re: Bravo 20vt Project [Re: ] #1118341
21/10/2010 12:54
21/10/2010 12:54

N
ninja
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ninja
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N



the car is back on the ground and rolling again under its own power again smile

the blocks had its first coat of paint, and ive picked my new hybrid GT28r up too evil

pics to follow....

Ninja

Re: Bravo 20vt Project [Re: ] #1118517
21/10/2010 18:54
21/10/2010 18:54

N
ninja
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ninja
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and here she is laugh

click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge

Specs
GT28r w/hybird compressor wheel (8/8 blades too smile )
(comp)ind 48.3 exd 69.6 trim 48 A/R.60 / (turbine) whl dia 53.0 trim 62 A/R.64

i wish i had taken some before pictures, because the guy did a fantasic job, complete strip and rebuild.

cant wait to test her smile

Ninja

Re: Bravo 20vt Project [Re: ] #1136563
26/11/2010 20:40
26/11/2010 20:40

N
ninja
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ninja
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N



time for an update, and quite a big one too woohoo

managed to strip down the donor engine, wiring loom off, cylinder head came off, gearbox off, clutch + flywheel out, sump off

click to enlarge click to enlarge

everything has had a good clean too smile

Cylinder head has been stripped down ready to be sent off for acid dip, polishing, and skimming.

click to enlarge click to enlarge click to enlarge

short shift fitted

new block has been sprayed, along with a few other things

top engine mouunt, oil breather tank, thermostat, ancilery bracket, and a few brackets/hose ends

and a small amount of test assembly has been done, cant goo too far though until the pistons are fitted, which arrived today smile

click to enlarge click to enlarge click to enlarge click to enlarge

Can you see a colour theme here? laugh

hopefully my new pistons will be fitted in the block very soon, and then as haynes always says 'refit is reversal of removal'

...and these little beuties arrived too smile

click to enlarge

It all feels like its coming together laugh

Ninja

Re: Bravo 20vt Project [Re: ] #1142791
11/12/2010 00:09
11/12/2010 00:09

N
ninja
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ninja
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having some time off work ive been busy on the project

Head has come back with reground valve seats + new stem seals fitted

click to enlarge

head gasket + seal set, and head bolts came with it smile

Head has been sprayed black

click to enlarge click to enlarge

lifters has been sqeezed, cleaned and refitted

click to enlarge

cams have been cleaned up, ready for refit

sump has been cleaned and sprayed, also black

click to enlarge click to enlarge

cleaned up a few other little bits and peices, brackets

tried the gauges in situ love

click to enlarge

now all i'm waiting for is a nice christmas present off JBT, in the way of a freshly rebuilt and balanced bottom end, lightened flywheel and new clutch smile

The cars been looking a little bit sorry for itself in the cold weather, but will soon have a new lease of life, or should i say 'heart' laugh

click to enlarge

Ninja

Re: Bravo 20vt Project [Re: ] #1150559
01/01/2011 19:50
01/01/2011 19:50

J
johnnybravoturbo
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johnnybravoturbo
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J



Quote:
now all i'm waiting for is a nice christmas present off JBT, in the way of a freshly rebuilt and balanced bottom end, lightened flywheel and new clutch smile


Christmas present from Jbtclause would imply its free. wink


Update

Engine fully stripped.,

the following shall be done by 2nd week in Feb
6 paddle clutch
Hone bores
Skim block(slightly oxidised over 4 and 5 piston)
Skim,lighten and balance flywheel
Replace big ends
Fit the best of the 100 pistons i have been given laugh
Supply and fit new rings
Check oil pump
Replace crank seal
Replace rear main seal
Replace under piston jets
Balance crank pistons and rods
Match big end caps to rods

A few days away from measuring the wear on the crank,bores and mains.But fingers crossed.

Looking forward to seeing this on the various track events towards the summer Rich. love

Also in that head set Rich its difficult to tell from the pictures but ENSURE that its the metal 3 piece gasket and not the fibrous type that a lot of kits nowadays are supplied with.
The fibre type don't last 10 minutes whereas the stock metal one is a very substantial gasket and its near impossible to blow it.The engine will melt first.

Re: Bravo 20vt Project [Re: ] #1151874
05/01/2011 10:56
05/01/2011 10:56

N
ninja
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ninja
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Originally Posted By: johnnybravoturbo
Jbtclause
xmas

Originally Posted By: johnnybravoturbo
Also in that head set Rich its difficult to tell from the pictures but ENSURE that its the metal 3 piece gasket and not the fibrous type that a lot of kits nowadays are supplied with.
The fibre type don't last 10 minutes whereas the stock metal one is a very substantial gasket and its near impossible to blow it.The engine will melt first.


I will double check but i'm 99% sure it is (at least its what i asked for following our conversation at donny)

Ninja

Re: Bravo 20vt Project [Re: ] #1219540
25/05/2011 22:41
25/05/2011 22:41

N
ninja
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ninja
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time a looooooooong overdue update on this, and well the reason it hasnt been updated is that nothing has productively happened frown

Just before i sent the bottom end to be rebuilt, it was identified that one of the pistons was actually cracked, no wonder the engine was smoking, not a good start!

... then after recieving a replacement set i find out that they new pistons are out of tolerance with the old bores (too small), so not getting any better.

In the mean time i aquired another bottom end with pistons fitted, only too find out that it too had a cracked piston in it grr

so unltimatey ive got 2 engine blocks, 2 cranks, 2 sets of rods and no pistons and i'm back where i was 5 months ago.

I dont really want to go mix and matching the remaining pistons, too much hassle. There is nothing wrong with the blocks, or the cranks, so I could buy larger forged items and get the bolck bored to suit. If i had the despoable cash, but i dont.

In order to move forward i bit the bullet and bought a running engine, with good compression and no smoke smile

Ive ordered i virgin ECU from our friend leighton, so i dont have to mess around with immob and keys, and barrels.

So hopefully with that in light it wont be long until i have a car i can actually drive and have some fun in woohoo driving

The car has also had some cosmetic enhancements while all this engine malarky was going on too. (pics too follow smile )

Ninja

Re: Bravo 20vt Project [Re: ] #1225092
09/06/2011 00:38
09/06/2011 00:38

N
ninja
Unregistered
ninja
Unregistered
N



quick update

click to enlarge click to enlarge click to enlarge click to enlarge


new engine is out the the car ready to be stripped down, a bit of a clean, and then fitted with the uprated part smile

and here is how the new arches look smile

click to enlarge click to enlarge


Ninja

Re: Bravo 20vt Project [Re: ] #1225940
11/06/2011 13:40
11/06/2011 13:40

N
ninja
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ninja
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the ball is well and truely rolling again smile

engine was stripped down to just the block and head this morning (no need to seperate these)

it will get a bit of a scrub over the next week, and hopefully re-assembly with the uprated parts next weekend smile

Ninja

Re: Bravo 20vt Project [Re: ] #1284797
29/10/2011 23:27
29/10/2011 23:27

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ninja
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ninja
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Ok, time for a very big update smile

click to enlarge click to enlarge click to enlarge click to enlarge

click to enlarge click to enlarge

With the engine stripped i gave the block a lick of paint and cleaned up the head.

click to enlarge click to enlarge click to enlarge

The upper mount was changed

click to enlarge

the water pump was changed

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new cambelt kit was fitted including pulley and adjuster

click to enlarge

new thermostat was fitted (although i believe its one from
a stilo, cause its got an extra output!? still fits though smile )

click to enlarge click to enlarge

New oil filter fitted

click to enlarge

started fitting the components and sensors on the engine

click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge

Fitted a JBT modified lower pulley (with a bit of help from JBT, thank)

click to enlarge

Started fitting oil breather, breather hoses and new silicon water hoses

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auxillary bracket fitted.

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Water rail went on

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Swapped the cam cover, and fitted new gasket.

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Intake assembly fitted (please see earlier post for parts list)

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More fitted around the back

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Ported manifold went on (early manifold so i modified it to seperate the 5th brach)

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click to enlarge

Started collecting spiders already smile

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Nice assortment of new hose clips

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wiring loom was laid out, cleaned, checked, and re-wrapped

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Oil cooler pipes and PS pipes were cleaned up and coated in protective paint

click to enlarge

Spark plugs were changed (for NGK 7's)

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Intake pipe and DV fitted

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Alternator and PS pump in, new auxilery belt and pulley and oil cooler bracket on.

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Cambelt cover was modified for the larger pulley and fitted.

click to enlarge click to enlarge

Mated up a test version of a 5-stud to 3in adaptor developed with MIJ

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Had to take the turbo apart because the actuator bracket was not in the right place!?

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turbo fitted onto manifold (with gaskets)

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flywheel on

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6 Paddle clutch on

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realised i forgot to put the backing plate on at this point so had to take them off again lol

re-fitted, then the gearbox went on. At this point we made a short shift too, although i think i went a little too far lol (its short!!)

click to enlarge

wiring loom went on, or as much of it as i could at this point smile

click to enlarge click to enlarge click to enlarge

the engine was ready to go in now smile smile smile smile


Re: Bravo 20vt Project [Re: ] #1284818
30/10/2011 01:27
30/10/2011 01:27

N
ninja
Unregistered
ninja
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N



time to bring the car in, she had not been started for a while, so the jump start was a painful...

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1.8 engine out (not many photos of this but you dont need to see this bit anyway smile )

click to enlarge click to enlarge click to enlarge

I failed at the ABS swap, unfortunately the plug on the bravo ancillary loom was completely different, and i can live without splicing the loom smile

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With the engine out, this gave me chance to clean up the bay and make a few modifications that would be very difficult with the engine in place.

Bravo 1.8 brake master cyclinder and reservoir are a single unit, i was advised it would foul the coupe intake manifold so needed to be changed.

click to enlarge ]

the coupe reservoir fit in the same place as it would on a HGT and luckily the mountings were already there on the HLX laugh although the wiring had to be lengthened somewhat.

the cylinder however, fit, fitment wise, but the piston was much bigger than the 1.8 bravo unit, this meant the brakes would be permanently on. To get around this we had to modify (shorten) the push rod at the back of the peddle to allow the correct and full peedle movement.

click to enlarge click to enlarge click to enlarge

The brake servo vacuum pipe was swapped for the coupe one

click to enlarge

Breather thingy was fitted behind the PS reservoir

click to enlarge

Bravo transmission tunnel had to come down due to the difference in gear selectors (bravo = rod/coupe = flexible) the tunnel fitment was the same, so i opted for the coupe tunnel, as the gearstick fitment differed, but i had to swap the handbrake for the bravo one as they sit in slighly different places in the centre console (handbrake bolt pattern was the same on both tunnels)

We had to removed a bracket on the steering rack (used for the selector rods so no longer need) this made the steering rack core exactly the same as the coupe one)

Throttle cable was removed

Heater matrix hoses were swapped

we also bled the brake fluid through the master cylinder before the engine went in.

The engine was then put in place!!! woohoo

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Clearance between the turbo and the radiator support looked ample.

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Oil cooler was positioned perfectly

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Drive shafts were fitted (fitted perfectly as i already had coupe hubs, wishbones etc)

Wiring loom was fed through the bulkhead, and fitted in the footwell. (fitting was perfect, ecu sat in the same place, wiring was the same route, relays and fuses were the same fitment also. Only had to remove glove box for access to fit everything)

click to enlarge click to enlarge

Scuttle panel went back on, and a few clips and cable supports in place, and header tank hoses connected.

click to enlarge click to enlarge click to enlarge


Radiator support bar was removed and checked, (looked like it had seen better days but removal of the surface corrosion showed it was fine, so added some corrosion protective paint and refitted) i did have to modify this for extra clearance of the oil cooler pipes.

click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge


Gear selector cables were connected, and slave cycinder was connected and bled.

click to enlarge

A couple loose plugs connected (engine to ancillary loom, earths fitted, battery connections swapped, lamba sensor and just made sure everything was in secure place)

Throttle cable fitted through bulkhead, and onto peddle (alot of adjustment required to raise peddle)

Battery tray fitted

click to enlarge

fuse box fitted to the front of the battery tray (bravo item)

Coupe EBV fitted to the fuse tray smile

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MAF to turbo intake hose fitted

had a bit of an issue with the water hose/DV hose/battery tray and DV blank rubbing, so a trim, a and a turn later and clearance is achieved smile

click to enlarge click to enlarge click to enlarge

MAF fitted and (temporary) air filter. Although im comtemplating an SIP.

click to enlarge click to enlarge

Left it there for today smile



Now i have a few outstanding issues.

1. the connector at the top of the left strut. The coupe plug is 3 pin male, and the bravo plug is 2 pin female!? I have know idea what this plug is at the point but i believe its the light etc on that side

click to enlarge

2. The 3rd plug by the battery tray, the coupe plug is 4 pin female, and the bravo plug is 2 pin male!? again i have no idea what this plug is.

click to enlarge


3. Radiator choice!? the coupe rad wont fit due to the top mounting being different, the bravo rad will fit obviously, but the hoses are different. Luckily i have managed to get hold of some HGT hoses that should match the bravo rad to the HGT/coupe water rail (although this makes my rather expensive silcon hoses redundant :grrr: )

I also have no idea whether the 1.8 radiator will hold up the cooling a 2.0 turbo engine

(cant find a good second hand HGT rad for love nor money either)

Lastly, the coupe power steering reseviour is down behind the headlight, whereas the bravo reseviour is on the bulkhead.

now, the coupe PS pipes run 2 pipes from pump at front of engine to rack at back of engine (1 feed to rack, 1 return),

the bravo had the PS pump on the back of the engine, so the return goes from the rack straight up to the reservoir, this means the coupes return feed is redundant, but the bravo feed is not long enough, so i am going to modify the coupes return to feed the pump at the front of the engine (make sense confused )

Still need to fit EBC, feed of for boost gauge, oil temp, oil pressure and fit downpipe/decat/exhaust, but the end is in sight laugh

Regards
ninja

( ive not spelled checked any of this so no comments please :P)

Re: Bravo 20vt Project (getting pic heavy) [Re: ] #1285065
30/10/2011 17:19
30/10/2011 17:19

N
ninja
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ninja
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today i have fitted the EBC soleniod

click to enlarge click to enlarge click to enlarge click to enlarge

piped in the boost gauge/controller feed, and setup an access through the bulkhead for oil gauge feeds

radiator was put in place, and the hoses were offered up.

click to enlarge click to enlarge click to enlarge

Intercooler fitment and pipework, PS fluid feed and exhaust still left to do.

Ninja

Re: Bravo 20vt Project (getting pic heavy) [Re: ] #1287824
09/11/2011 13:21
09/11/2011 13:21

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ninja
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Well after an interesting weekend.....

I have decided to go with the SIP, not just for the fact that it positions the air filter in a better place, but it also gives me more room to route the intercooler pipework etc.

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Unfortunately, i have ran into clearance issues with the radiator fan hitting the turbo frown hopefully nothing a dremel wont solve.

Also, the bravo rad does not have a feed for the turbo, so this will need to be created.

I believe i have finally got my head around the plug situation smile now i just need to do something about it before i forget... and as a bonus, 2 of the empty pins are for the oil pressure/temp which means i have easy feeds for the gauges laugh

@AP1 - i have not, there was not problem with it when i removed the engine, so did not feel the need. I had a good mouch around while the cam cover was off, and everything looked fine up top.

Ninja


Re: Bravo 20vt Project (getting pic heavy) [Re: ] #1291005
21/11/2011 20:52
21/11/2011 20:52

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ninja
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ninja
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right, gave up on the bravo rad and fan, so went with the coupe rad and fan, this is tight!

click to enlarge

newly developed, MIJ 5-stud to 3in adaptor, and full 3in downpipe, down to std cat/de-cat smile (oil pipes do need to be pryed forward a bit, and i need to get under the car to fit properly)

click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge

intercooler fitted, and pipework routed

click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge

had to double up on the silcone to fit the turbo properly

variator relay have has to be extracted from the coupe loom (cause the 1.8 bravo hasnt got one), and i found a spare relay clip down by the battery, so that sorts that plug.

The code wires match the coupe plug (albeit a 2 pin male plug into a 4 pin female plug, but hey)

getting close now laugh

Ninja

Re: Bravo 20vt Project (getting pic heavy)- ITS ALIVE! [Re: ] #1294429
04/12/2011 19:02
04/12/2011 19:02

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ninja
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ninja
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AT LAST, ITS ALIVE!!

After finishing off the last remainig bits;
swapping the coupe charcoal canister
fitting the variator relay
connected up the DP, decat and rear section
putting some oil and water in

it was time to connect the battery and turn it over for the first time since the rebuild

put the key in, we have ignition, turn the key and........... nothing

fuel pump wasnt priming!!??

after a call to leighton, turns out the ECU had no chip in the ECU he sent me lol blush

chip installed try again, fuel pump priming and try again.....nothing!??

link it up to ECU scan which has the feature to test a few realys (handy feature in this case) they had power, but still nothing!?

bridged the starter (there must be an electrical issue somewhere) and it turned over and fired up woohoo

First Start

sounded a bit rough (but thats to be expeted at this stage)

found a slight oil leak, and registered a fault with injector 3

fixed the oil leak and dis/re-connected the injector (which seemed to work?), second time lucky!?,

Second Start


sounds better but upon increasing the revs we had a single loud bang each time!!??

turned out the power steering pump was not seated correctly and was jumping in the housing

that sorted, third times a charm!?...

Third Start


this time sounds much better now the lifters have some oil, very impressed with the sound of the engine, turbo, exhaust

Exhaust


also seems very level smooth on a std chip considering the changes ive made (injectors, FPR, turbo, DP etc)

few last thing to sort in the way of EBC, gauges etc and get her down to leighton for a map laugh

Public thank you to leighton and JBT for answering my ramdom calls smile and all the help from various people on this forum.

Massive thanks to NB Autos (my father and brother) for the help, work, garage space and for putting up with during this somewhat drawn out project smile

Last edited by ninja; 04/12/2011 23:10.
Re: Bravo 20vt Project (getting pic heavy)- ITS ALIVE! [Re: ] #1305847
13/01/2012 09:43
13/01/2012 09:43

N
ninja
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ninja
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Not too much progress over the christmas period, but a few niggly bit sorted

VDO gauges installed
EBC/charge temp/AFR installed
Strut brace installed
Power steering plumbed in

and a few presents smile

new helmet
jerry cans

but most importantly, i collected a trailor and ordered a tow bar laugh this means i can get it to fleas for mapping woohoo

i think im going to have to make up a new radiator support bar to move the rad forward slightly, only about 20cm or so but it all helps smile

Ninja

Re: Bravo 20vt Project (getting pic heavy)- ITS ALIVE! [Re: ] #1313328
03/02/2012 12:19
03/02/2012 12:19

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ninja
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ninja
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Well i modified the rad support, and added extra intercooler support brackets while i was at it.

also modified some of the intercooler pipework to get the bumper back on without trimming.

I actually had the car booked in for mapping today, but the car has developed a perculiar fault (as per my technical issues thread). After spending all day last sat checking everything i could think of, and even a visit from JBT (in what is now an awesome coupe) on a cold saturday night (now thats what i call service beer ) unfortunately we did not come to a conclusion, so it has had to be postponed cry

Further investigation is required, and hopefully it will be something simple and she will be booked back in soon...

Ninja

Re: Bravo 20vt Project (getting pic heavy)- ITS ALIVE! [Re: ] #1314888
08/02/2012 15:46
08/02/2012 15:46

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johnnybravoturbo
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johnnybravoturbo
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laugh great stuff.Well done Rich.

Re: Bravo 20vt Project (getting pic heavy)- ITS ALIVE! [Re: ] #1315111
09/02/2012 09:07
09/02/2012 09:07

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ninja
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ninja
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cheers john, and thanks again

problem solved - bad earth

so back on track (or i will be soon smile )

ninja

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