EsCosRacer

another resto thread

needed a small track car for the somewhat tinyish french track thats just around the corner from me. so after a while i saw a R5 GTE 1.7 n/a former swiss cup car which seemed to have all the right bits. went to look at it and took it home

getting it track ready :
day came where i wanted to go to a trackday. sparco seat and harness put in, engine fully serviced, cambelt changed and a 4pot / 285mm discs (hi-spec, rainbird supplied) fitted in the front, along with Dunlop D3 slicks on 15" ronal wheels

result:
apart from changing master brake cylinder along with the rear brake proprtioning valve the night before, everything went great very happy i was with the handling of the car which has all the original cup bits on and the brakes

but the lack of power on the straight.......

conclusion:
so out i went and bought the ugliest, shit looking car ever made in automotive history:

















a volvo 480 1.7 turbo
(not mine but the same)
i know....slate me

so now i took the engine out of the volvo, which happens to be a renault engine and will fit it in the R5....

result should be around 250hp with another turbo and some additional tweeks

will go take pics now and do some work.....

EsCosRacer

this is a LOW BUDGET build....or wants to be

got the car for 1k pounds...so still cheapish

EsCosRacer

here the pics :

engine donor , my god its soooo ugly



the engine




the volvo engine loom and electrics


original ecu plug in the renault, been abandoned in favour of the cup ecu


original cup exhaust by devil


rear


the magic of hi-spec, 4pots with ferodo pads and 285 discs



cup engine 1.7 n/a 8v


original cup ecu






done tearing stuff out of the volvo, now time to get cracking on the R5

EsCosRacer

ok....turbo is now bought, after talking to stavros i had some little clues on what to get...thanks m8

GT28RS and bought a cheap downpipe that i can modify to suit my needs

big injectors and fuel pump coming from bosch-man

intercooler from pro-alloy





sorry...only pic of the turbo that was there, but its the internals that count .....

EsCosRacer

ok...now for anyone interested in the mapping side of things here......

theres 2 ECU's ... one if for fuel only, the other for ignition and boost:

the so called Bosch EZ210K Ignition / Boost ecu




the bosch jetronic ecu for fuel



now i spent quite some time with several tools to figure thisone out....

FUELING :
long story short, for the fuel ecu theres a smart guy called ragnar who wrote a little program that lets you nicely edit fuel map etc

only thing is : u need windows 98 and the revlimit setting doesnt work.
i looked at the ecu data of several LH 2.2 Jetronic equiped vehicles and revlimit differs on almost all of them

heres the software, free and legal for everyone
http://www.tfd.chalmers.se/~burenius/LH22edit10.zip

IGNITION ECU:
well now this is a real bitch 1st of all bosch is hiding the revlimit and boostlimit in there but a bit garbled up i'd say...
I think i might have figured it out now with a little help from a german pal, someone is currently testing the first chip in which we think boost and revlimit should be raised a good 10%.
There is mods for this ecu but mostly they are hardware mods that i, as a former chiptuner, dont like. if its in the software then thats where it needs to be changed

I will keep this post updated and if it works everyone interested can have it This LH-Jetronic is so old, i cant see reasoning to make money with it still....

michael

EsCosRacer

thanks m8, means a lot to me

thanks for pointing me in the right direction several times

EsCosRacer

volvo engine has gone in and today started to modify a few bits n bobs:

inlet now has a AN6 boss welded onto in to allow me to have vac for the brake servo

started to modify the stainless nissan downpipe i got off ebay to fit the R5

fitted the proalloy intercooler (damn...they made the drawing wrong, now my subrame looks like a swiss cheese )

intercooler pipes and air inlet pipe (to go to MAF and filter) started to take shape

fitted a 70mm throttlebody instead of the 60mm that came as std

tomorrow is aeroquip day get to fit the intercooler and all the bling bits that came from summitracing





sorry, only phone piccies this time

EsCosRacer

now that intercooler....what a mess the installation is just to get that part straight : pro alloys "direct fit" involved me getting the welder out, drilling various holes and using a ally profile to make it sit sturdy where it needs to be

done and dusted though.....but now....guess what....the oil filter doesnt fit no more so the relocation kit is already ordered.....

tomorrow i start making up the exhaust in 2.5 inch V4A...i know, why not V2A....thats what my metal guy had laying around....

fuel system will also be attacked tomorrow, lets see how far i get.....

didnt have a cam with me but will take pics tomorrow


THE CAR NOW OFFICIALLY HAS A NAME : LITTLE SHIT

EsCosRacer

any time, any day my friend i would be flattered by your presence

EsCosRacer

ok....todays updates.....

oil filter story since the intercooler was fitted was a no go....so i ordered a relocation kit that will solve the clearance issues.

i started to make up the exhaust downpipe and all the way back to the rear axle. now im waiting for the silencer to arrive and then it will be finished off.

also in the pics you can see the swiss cheese of a front subframe and the washer i had to tack into place to fit the intercooler

also it got apparent that the heatshield will not be sufficient and needs 10cm added to it...

while i wait for the back box i'll tackle the fuel system tomorrow

oh...the last pic....i passionately HATE VOLVOS....so i had to grind their shit off the intake

heres the pics :

EsCosRacer

i just tacked it in place with the mig welder cause its easy, the rest will be done with tig welder so gaps will be closed as if it was a bend

AND :

those stainless bends in 2.5" cost a fucking fortune, so not keen on cutting up a dozen, rather do it the dodgy way on the little cunt

EsCosRacer

ok....some more work accomplished :

i started off welding on the heat shield behind the turbo. it needed 10cm added to it to pretect the bulkhead and the brakelines running across it sufficiently. i also have a heat protective cloth/foil ordered that is selfadhesive, resistand to 2000deg fahrenheit and will be glued onto the shield.

then i attacked the fuel system.... put the fuel tank in on rubber mounts, then the surge tank and added the prepump to fill the surge tank.

after that i realized that for the bosch-man supplied 044 pump i was missing the right adapters....must have ordered the wrong thing from summitracing

anyhow, all is in place now apart from the 044 and i think it looks good....getting closer n closer to completion

the exhaust is put on hold, i ordered 2 mufflers because of our strict noise limits and will be putting those in as soon as they arrive. also i had 8 triangle flanges watercut from V2A so that everything is easy to take off

piccies :

EsCosRacer

the 044 fits on it ?? dont have a holder for that yet.....

EsCosRacer

its a love / hate relationship

a bit like chip and bosch-man

EsCosRacer

small update:

sorted the ignition today. new rotor cap, new rotor finger as well as all the plug leads. found out there were NGK plugs in it so left them where they were cause i think they are

anyways had lots to do at work today so couldnt really do a lot hope the bits from the US arrive soon (they not on strike like u lot )
so i can continue on wiring (yes, ryan, u will have to move ur lazy ass for once ) the exhaust and the DASH

EsCosRacer

exhaust is completed..... made out of V4A, not the ordinary stainless

also i welded a bung on the inlet so that i can connect the brake servo, volvo didnt have one...

the remote oil filter mount has arrived a work of art that is really and was cheap as chips on ebay

EsCosRacer

more updates:

- the exhaust now fully tig welded, looks a treat i think
- fitted a 16row oil cooler to the bottom of the crossmember
- made even more of a swiss cheese out of the bumper than its already been
- still got clearance issues with the remote oil filter, so now i ordered bajo fittings to go on the adapter....we'll see if that works
- needed to cut a hole in my newly enlarged heat shield turbo wants to dump oil back into the sump, missed to leave room for that fitting / hose
- aim dash still not here, gave em shit yesterday so should have it within 3 days now hopefully

EsCosRacer

naaa...i love the R5 otherwise i'd have scrapped it already. it has a french character and has an attitude aswell

and its far from waisted money