Lee_R21Turbo

iTrader: (1)

Hopefully this project might interest some people on here as its a little different.....

Background to it is - I like Renault 21 Turbos (no harsh comments please lol) - I also have alot of respect & awe for the Cosworth scene as well. Got a lot of mates with them etc. So I thought - instead of struggling like fuck to get a genuine reliable 300bhp out of the Renault 8v Turbo engine - lets do it properly & fit a 400-450bhp Cosworth Engine...and make it RWD...so here it goes....

Proper fabrication started today on her .....

My modified sump (from a MK2 cosworth) came last week so I was able to get cracking!!

Started off by chopping out the subframe which was causing me issues....



Dont worry.....the subframe will be getting redesigned properly & strengthened again.

Then with that out the way I was able to get the engine in its proper position all central so that I could start getting jiggy with fabbing up the engine mounts....

How the engine currently lines up & fits around everything...

Back of head - about 1cm from steering assembly..


Sump & Anti Roll Bar...When I get the sump big winged I might get this altered a little more to give more clearance - not 100% sure how much the engine will move/shift under acceleration yet so just to be sure.....



I'm using a kit thats designed for Pinto lumps in MK1/2 Escorts but obviously can be adapted for other uses like mine - the tube that is supposed to attach between the engine & the chassis mount I got with the kit was too short by approx 2cm so I improvised & used some 2" box section instead..

Chassis mounts tacked in place...



Box section roughly shaped for the mount..




Mount all measured up & tacked in place on one side...



I took my time for the first time ever so I've only got this far so far today unfortunately....but its coming along really well & I'm happy with my progress - the real test will be when I come to do do all the proper welding as to how neat I can do it lol....

How I left it tonight...



More tomorrow hopefully......comments....suggestions or anything else welcomed!!

Rab

Nice one!

Love seeing other cars Cossie'd! I'm still dreaming about building a cossie Capri.

ESCYSCOTT

iTrader: (1)

lot of work gonna go into that mate!!

Wouldn't it be easier though if you mounted then engine onto a std cradle and make that fit to the chassis?

Lee_R21Turbo

iTrader: (1)

Scott.....not as much as you probably think tbh matey!! I decided against doing what you've just suggested (I did think about it) because the Renault wishbones bolt to the subframe etc etc so it would mean buggering about with the suspension too!!

Shorty

iTrader: (1)

Looking alot different to when i last seen it, and that was only a couple of weeks ago!

Fair play mate, gonna be cool.

Richie.

iTrader: (5)

Nice project

What exhaust manifold are you going to use ???

That engine mounting arm looks like it will be in the way especially if you use a standard 2wd one.

Good idea on the mounts though, thats what i'm using for the Ka so i can keep standard Ka wishbones/subframe at the front.

May be make a bolt in brace for the front subframe like the SportKa uses. Means you would be able to drop the sump of in need be.

Daveysaff

iTrader: (9)

Gonna be sweet
I've still got bits of running gear left if you're still after anything? Beam, prop etc

longdog

iTrader: (1)

Going to be keeping an eye on this.

Lee_R21Turbo

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Rich....I did wonder about the exhaust manifold/engine mount clearance to be honest - I'm picking one up at Central Day off RsNissan so will be able to try it then - if it catches it slightly then I might notch it out - failing that if its too close then I'll fit a 4x4 jobbie - I'm only after 400-450bhp anyway so should be cool.

As much as a bolt on brace jobbie sounds tempting...I think I'm gonna go down the welding route because I'll be removing the subframe as some point 2 change the bushes so if I need to remove the sump at anytime it should be easy really just to lower the subframe on its bolts.

Lee_R21Turbo

iTrader: (1)

What about diff mate??

Richie.

iTrader: (5)

Got a 4x4 manifold with a small crack in it if you need to borrow one. Let me know and i'll take it to Central Day


Far enough on the subframe The SportKa brace one is an addition over the standard Ka. A Ł88 piece of steel from Ford

Lee_R21Turbo

iTrader: (1)

Nice one mate.....whack it in your car anyway if you dont mind...that way I've got both to experiment with if need be.

Yeh....subframe was the trickiest part of this build so far - I just prefer overkill
rather than 'your not sure' type of approach! lol. Have you have to remove the centre section of your subframe in the Ka too??

Karl 3dr

iTrader: (9)

Very cool looking project, cant remember seeing this done before??
Good luck with it!!

Lee_R21Turbo

iTrader: (1)

sapph1 - AFAIK this will be the first ever Cosworth powered Renault 21 Turbo in the world lol.

....and to be honest its not really a whole lot of work to pull it off.....well so far anyway! LOL!

Richie.

iTrader: (5)

Agree with the overkill approach


No the front wishbones bolt into seperate subframes on each side. The brace is added to the Sportka/StreetKa as they have a wider track and bigger tyres than the the standard Ka.

Lee_R21Turbo

iTrader: (1)

Fair enough.....what holds the front together in standard cars then inbetween the chassis??? Anything???

Richie.

iTrader: (5)

On standard/SportKa the steering rack is bolted to a double skinned crossmember that runs across the shell between the chassi rails. But as thats been cut out to fit the engine/gearbox the plan is to use the Ford brace as a extra even though the cage will be linked into the bulkhead above the gearbox.

Cross member there


And gone


The brace bolts between the two 'black' subframe assemblies.

Twins

iTrader: (18)

Great project ,will keep an eye on this

Chip

iTrader: (3)

Cool project Lee, love it

Daveysaff

iTrader: (9)

Mine went, but I may know someone selling a complete 7.5" rear end (diff, shafts beam arm etc) for not much money. I'll let you know later on

Lee_R21Turbo

iTrader: (1)

Rich....interesting that mate cheers

Daveysaff....only need the diff matey...let me know.

MAD EVO 4

A different project at last to watch

MARCOSWORTH

iTrader: (24)

Cool Lee,i'll show this to a mate who recently bought a red R21 Turbo

chris85uk1

This is gonna be cool car, gonna suprise a few people!!!
Good work, nice to see people doing different things

JonnyBravo

Nice work Lee, certainly got a fair bit done yesterday

MrCapriScort

Sounds very interesting

jonnyrsturbo

should be differant at the least

but why a 21

a few of me mate have 21's!

Lee_R21Turbo

iTrader: (1)

Cheers for the comments guys......

Right.....onto todays updates - had a really good day actually again - things working out very well indeed.

Here are the pics from today.....

Starting passenger side engine mount...




Both mounts tacked up & ready to be welded...


I then removed the bushes before welding

Now the nerve racking bit......doing a whole load of welding, trying to get it strong & look half decent...the metal is 2 and 3mm thick so I did a few practice lines to get the settings right....


I'll be honest here & say that I have never called myself a decent welder so this was going to be interesting to say the least - I was more concerned with proper penetration to make them as strong as possible as I dont want the engine suddenly falling out of the car! lol I think I did reasonably well to be truthful - the welds between the 2mm box section and the 3mm plate where the hardest I must admit - I might grind the ugly welds down & re-weld before I get them powdercoated black.

....and here's how they turned out





Good penetration....


Re-fitted the bushes...



Finished articles


Re-attached to the engine to make sure they hadnt moved whilst welding which they hadnt..


Then I welded as much of the chassis mounts as I could with the engine still in place



Re-attached the mounts again - tightened everything up properly this time...then checked clearances with the engine now supported by its new mountings...

Around the anti-roll bar - loads of clearance



I am very impressed with how little movement there is....and as in little I mean nothing...I cant rock it at all - mounts seem to be VERY strong...

Next onto bracing the cut subframe...

Using another spare subframe I measured up & cut a length of 8cm x 4cm box section..


Then c clamped it in place & tacked it..





Basically thats all I got done today - still I'm very pleased with what I have achieved so far and everything is going according to plan.

Next time I'm down I will fab up the gearbox mountings.

Clearance is excellent towards the front of the engine too - it sits further back than the standard engine so I've got 10cm between the front pulley & the front crossmember - lots of room for a decent sized rad & intercooler etc.

Ignore the fact that its bent - its going to get replaced...seems that alot of people seem to think that towing using the crossmember is a wise idea!! LOL

Lee_R21Turbo

iTrader: (1)

Because I've had them for the past 9 years & know them like the back of my hand......plus I like to be different! lol - No-ones going to expect this at all!!

What are your mates names?

JonnyBravo

Another good days work mate.

Have you got a timescale ?

Lee_R21Turbo

iTrader: (1)

Well to be honest matey....timescale wise probably a couple of months before it will move under its own steam - well hopefully anyway!!!

focuschivvy

JonnyBravo

Best if its not rushed thats what I keep telling myself anyway LOL

Charlie Chalk

iTrader: (1)

Cool, About time there was a thread

Keep at it

Lambchop

iTrader: (1)

nice one lee! i'll look forward to my next spin in this car seeing as the last was erm "eventful" lol

Dan

Cool project mate, keep up the good work!

Ryan

why is the engine out of the clio?

Lee_R21Turbo

iTrader: (1)

Ryan - I was bored one day!!!

Naah...the clutch went at Donington in February...the easiest way to change the clutch is by dropping the whole lot out the bottom. Gearbox is currently away getting a gripper diff fitted. Getting a paddle clutch for it because standard ones arent much cop anyway,they overheat too much, and I'm planning ahead for when the throttle bodies go on!! Also got a load of other goodies waiting to be fitted as well.

Dan

That little clio will fly then! Was awesome at Bedford in Feb Lee!

Red16

nice work Lee will be keeping an eye on this one