Project Stealth

[Grim Reaper]

by fitting the engine you would think that the hard part is over...WRONG lmao

you and me alike on wiring dude, i hate wires

[Carneyste]

The car is finally running. The problem was I had earthed a wire that needed to be connected back to a sensor lmao. Im now in the process of rebuilding the dash. Eveything works now apart from the electric windows for some reason . Heres a quick vid of it running. It has no exhaust apart from the precat and still needs a couple of sensors plugged in but you get the idea. It cuts out because it blew a boost pipe. I had wondered where that spare jubilee clip was ment to go lmao

[Grim Reaper]

I had wondered where that spare jubilee clip was ment to go

its always the way lmao lmao lmao

nice one on getting it going

[Carneyste]

its always the way lmao lmao lmao

nice one on getting it going

cheers mate

Hopefully I should have it sorted and driveable by the weekend to give it a good shake down to see if/where any problems lie. Judging by the pile of spare bolts I have there will be some lmao

[Grim Reaper]

lmao

[Carneyste]

I keep forgetting to update this. No more pictures as everything Ive done has ended up with me being filthy and I dont want to cover my phone.

The dash is now back in and sorted. The electric windows now work and Ive sourced the sensor that should be above the airbox. The shafts are in and tightened and a few other bits are done.

All that is left now before I can drive it is to fit a new track rod end as the old one was broken when I got over excited with my specialist track rod end removal tool (a big hammer lmao), bleed the clutch, align the gears and put some box oil in.

Ideally at some point I will need to put an exhaust on it and do something with the heaters but those are minor sticking points

Il get some proper photos up on monday once its all tidied up a bit but one is rather excited to take it for a blast

[Carneyste]

cheers mate. Aye thats me, couldnt have SteveC on here so settled for carneyste instead lol. Did you get suspicios when you saw distinct similarities between this and a project on there lmao?

[Carneyste]

Right, I got the track rod end on so, bled the clutch, whacked some box oil in and took the car down to the bottom of the road and back. I pulled up on the drive, had a look under the car and the long shaft wasnt in properly so all my box oil was pissing back out lmao. So off with the wheel again, put the shaft in the box properly this time and away I went again but this time down to the roundabout.

All seemed well until it came on boost and just started back-firing and going no where. Looking at the boost gauge the needle was going nuts but the turbo was still making the same noise so it was leeking bost from somewhere. All the boost hoses were tight so the only possible place was the dump valve. I took it off and had a look and sure enough the spring and diaphragm were both ****ed so as soon as it came on boost it was pushing it open and forcing all the air out. A quick bit of bodgery involving whacking a contact lense holder in the hole and I was out again and this time it works properly. It must be said its a fair bit quicker then what it was .

The list of jobs is now down to get my new front tyres fitted, fit an exhaust and make the indicators work then its job done

[Carneyste]

Right, another update. Every time the car got hot as soon as it came on boost it was misfire central and there was literally no power. Luckily enough it only appears to be a faulty coil pack so thats swapped over and it seems OK from what Ive driven it. Everything is now working, the only thing that doesnt fully work is the adjuster to control where the air blows on the heaters. I got so sick of the cables I realised I was going to smash the heater box/the whole car so gave up. I can get it to blow on the windscreen and my face which was all I used anyway so not too bothered there. Now for some pics

How the interior stands. All back in, just needs a wesh


Engine before;


Engine now






And this is my new exhaust. its 75mm so not quite 3" but close enough for my liking. This is how it was when I picked it up;


And after 10 mins with some metal polish on a buffer it was looking like this


Really all that needs done is the exhaust fitted then its road legal again. At some point I will be getting the rocker cover powdercoated again and look at getting some black silicone hoses. Once thats done its performance time. As its a daily driver I have no intention of doing anything more than a bigger front mount, some VXR injectors and a decent ramap to see it up to 270-280bhp ish.

[Grim Reaper]

[Carneyste]

Bit of a boring update but I decided to give the car a wash today because it was filthy and needed a little bit of love. Its still got the odd wheels on but I really cant be arsed to fit the 5 stud rears or refurb the other 2 turbo wheels so its staying that way for now lmao





And as everyone knows, the reason for doing an engine conversion isnt because you go from a 98bhp 1.6 to a 240bhp 2.0 turbo, its so you can have one of these stickers lmao (and in doing so give the finger to the people who said "buy a GSi instead, it will be cheaper". This way was cheaper and I still have the car Ive spent lots of time and effort on and have the satisfaction of doing it myself )

[stiloboy]

Looks great fella. front looking good

[Carneyste]

Looks great fella. front looking good

cheers mate. Hopefully when I get a cheeky front mount behind there it should look a bit better. The back and sides will continue to look **** until I get round to putting the other half of the turbo rear splitter back on and the turbo wheels on the back

[Carneyste]

Right, the rest of my exhaust turned up today so I set about fitting it. All was going very well until it came to bolting the cat back to the decat and there was a 3/4 inch gap between them . It would appear that the decat section is too short. Ive bodged it together for now by pulling the catback forward a bit but its not ideal. Im also pissed off at how quiet it is. Its literally the same as a standard one. There is a silencer in the decat, a centre box and a back box so the centre box and decat silencer are getting chopped out ASAP to get some proper noise back. Hopefully then it will pop and bang again. Anyway, the bit that set out to annoy me today;




I also came in pissed last night and thought it would be a good idea to spend 200 quid on an intercooler on ebay . Should make it quicker tho

[Carneyste]

Bet you were gutted when it dindnt sound any louder

it was always going to be quieter cos it didnt have any exhaust on but i didnt realise it was gonna be pretty much standard noise wise . I dont want it stupidly loud but a bit of volume with a couple of pops and bangs now and again would be nice

[Carneyste]

well, the henger has broken again . Ever time it boosts it spools up and then there is no but at all (but the turbo is still spinning) so I must have a leak somewhere. My finger is pointed at a dodgey actuator.

And the other even more irritating one is the little sleve off the top of my gear cable keeps coming loose so the cable bends rather than pushing so I cant get 2nd 4th or reverse . Dare say a new cable is in order

So all in those 2 little problems have put paid to my york mission tomorrow so the 1/4 mile can wait for a few months now

[Carneyste]

OK, got the boost sorted. It turns out when Id clamped the precat on it was in the way of the actuator rod so it couldnt move to keep the boost in. Ive also got a new gear cable fitted so all good there

And another suspect package turned up today;


Turns out it was my front mount


Im now waiting on the hoses coming and its getting put on. It seems to be a pretty good fit behing the bumper too which is excellent saying as I guestimated what size i needed

[Carneyste]

Well, saying as my intercooler turned up yesterday I thought I better crack on and get it fitted.

So this is said intercooler


So it was off with the bumper and crash bar and I realised instantly my plan wasnt going to work unless the aircon fan went the journey too. I found some interesting leaves underneath it too lmao


Then off I went for some wizzardry mount fabricating. I worked out to miss the bumper the mounts had to be about 3.5 inches long so I cut them to 4" and drilled the holes 3.5" apart. Said mounts;


And then I bolted it to the crash bar. Not a bad size me thinks


And thats it with the front bumper on. It needed a bit of a trim to get it under but all is well. Its pretty straight too


So now Im waiting for my boost pipes to turn up and I can get it properly plumbed in. While Im waiting its back off so I can spray it black as I think it looks out of place in silver.

Oh, and all the interior is back in. Now it has enough power to drag the back seats around I thought I might as well put them back in and save my head being battered. To refit them and clean the interior for the 1st time since the conversion took 6 hours so that gives an idea of how dirty it was. God knows how I had a footprint on the head lining either lmao

[Grim Reaper]

friggin awesome update youre inspiring me to pull my thumb out

God knows how I had a footprint on the head lining either

hmmm lmao

[Carneyste]

friggin awesome update youre inspiring me to pull my thumb out


hmmm lmao

Cheers matey . get some work done - it should be a nice day tomorrow to crack on

As for the footprint it matched my size 13 work boot so I really do have no idea how it got there as there has definately been no dodgey business happening in them lmao

[Gaz86]

was that the £200 intercooler? I had one on mine, was just over £100 delivered brand new, nice intercooler for chinese cheapness.

[Carneyste]

was that the £200 intercooler? I had one on mine, was just over £100 delivered brand new, nice intercooler for chinese cheapness.

nah mate, it was even cheaper still. 57 quid jobby. Even if it only lasts 6 moths you cant grumble really. With the hoses and tube it stands me just shy of 90 quid. Slightly better priced than the pace one for 600 quid lmao

[Carneyste]

Well, if youre gonna fail one you might aswel do it properly lmao. 21 faults they picked up



Nearside headlamp not working on dipped beam

offside headlamp not in good working order or adversely affecting beam image

direction indicators not working

rear fog lamp switch faulty

offside rear fog lamp not working

offside front tyre tread depth below requirements of 1.6mm

anti-lock braking system warning lamp indicates ABS fault

nearside front brake pipe excessively corroded

(both front to rear) brake pipe excessively corroded

nearside inner rear brake pipe excessively corroded

offside inner rear brake pipe excessively corroded

nearside front suspension arm has excessive play in a ball joint

offside front suspension arm has excessive play in a ball joint

offside track rod end ball joint has excessive play

nearside steering arm has relative movement at its fixings

offside front brake hose leaking

brake pedal creeps down while the pedal is held under pressure

nearside rear brake binding

nearside rear parking brake recording little or no effort

offisde rear parking brake recording little or no effort

parking brake efficiency below requirements


And thats it haha. The ones done in red Ive already sorted. Im getting 2 new wishbones with bushes for 50 quid which will sort the bottom ball joints out. I can get a track rod end and steering arm for £20 so thats not too bad. The rest is off to the garage cos I hate brake lines so have no intention of changing them and cant be arsed to fanny on with the drums. On the upside with only a precat it passed a genuine legitimate emissions test.

[corsaXEV_chris]

now thats some list...

good progress, u got the boost pipes yet??

[Grim Reaper]

Bloody hell