Flame Red Clio DCi 172 Rep - 1.9DCi conversion - 27/03/15 (Exhaust time!) - Corsa Sport - for Vauxhall and Opel Corsa B, Corsa C and Corsa D

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Corsa Sport » Message Board » General Chat » Projects and Builds » Flame Red Clio DCi 172 Rep - 1.9DCi conversion - 27/03/15 (Exhaust time!)

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Generation

Member

Registered: 7th Jul 09
Location: Essex
User status: Offline

22nd Sep 14 at 19:59

Good progress mate! Saw it at trax; and plate was upside down lol

AlexW

Member

Registered: 25th Oct 08
Location: Essex
User status: Offline

25th Sep 14 at 19:51

quote:
Originally posted by djgritt
Nice.

Should go well with the 1.9 in place!

I bloody hope so, its a lot of work!

quote:
Originally posted by kedowan
That sounds like its going to be awesome!

Cheers dude!

quote:
Originally posted by Simon_16v
About time!

Tell me about it! Finally got time to do it!

quote:
Originally posted by Edges 58
Reading the title I thought you had sold or selling te dci.. Thinking id love to buy it.. Then realise you're changing to a bigger dci engine haha. Looks great btw!

Haha, I'd never sell it, only break it, It'd hurt to see somebody else have it, plus its not worth enough complete.

quote:
Originally posted by Generation
Good progress mate! Saw it at trax; and plate was upside down lol

Cheers dude. Yeah that'll be one of many mates fucking with the plates lol.

Further update...

Last weekend I started getting the engine out of the Laguna..

Huge lump coming out

Drove the Clio home from work Monday evening, started work on it circa 5.30.

Lots of mess later

Soon after

Amazingly for me, the first time I've had the engine out.

Then by the time it was dark (7.30 ish) I had the 1.9 sat in place, although this pic is from Tuesday morning.

Fucked about with it a little, Top drivers side mount will work with a bit of messing about...

Now I've decided to source a Megane 1.9 DCi 6speed box, Ive got the Laguna 6speed box, but its a huge PK6 box which is the same used in the Clio V6 & Trafic Vans, so its fooking massive, and bloody heavy. The Megane box should be a much better option. Found one, just gotta collect it!

Hopefully get it mounted up properly soon, then its...
Custom Driveshafts (172 outer, 6sp inners)
Custom boost pipes (hard pipe as much as poss)
Complete Custom exhaust (3inch, no boxes)
ECU/Wiring pissing about
In-tank fuel pump/fuel lines
Hydraulic Clutch conversion
Gear cable conversion
Custom A/C & Alternator brackets
Custom coolant pipes.

Plus lots lots more.

It will get done, ideally before Xmas as I hate not having a car of my own to drive (I can share with other people luckily)

Common question has been about power and torque, This engine in the Laguna was circa 120bhp and 220lbft. Although with the breathing mods I should gain about 10 on each of those figures (as per my 1.5 did), and then with further mods, BMW injectors, Fuel pump, hybrid turbo (its already VNT) and a major remap, it should be circa 250bhp and 350+ LBFT, I'd like as much as poss, but that is figures I 100% know I can get without issue.

More progress soon!

taylorboosh

Member

Registered: 3rd Apr 07
User status: Offline

25th Sep 14 at 20:10

That will be so cool

AlexW

Member

Registered: 25th Oct 08
Location: Essex
User status: Offline

25th Sep 14 at 20:52

I'm glad you approve!

--ToM--

Member

Registered: 23rd Nov 07
Location: Wirral
User status: Offline

25th Sep 14 at 21:05

Mega cool can't beat a performance diesel power and economy

--ToM--

Member

Registered: 23rd Nov 07
Location: Wirral
User status: Offline

25th Sep 14 at 21:12

quote:
Originally posted by Steve
172's are two a penny, and pence to buy.

Just get a 172 instead of fucking around with engine conversions, more hassle than its worth

Made me giggle this , "more hassle than it's worth" says the bloke who's permenantly fucking round with a rusty old defender that'll be lucky to see a puddle never mind mud.

Crack on with it mate looks a great project hats off for doing something g different and getting stuck in

Jamie-C

Member

Registered: 3rd Jun 08
Location: Ballycastle
User status: Offline

25th Sep 14 at 21:34

Will this ever see the road again?

pow

Premium Member

Registered: 11th Sep 06
Location: Hazlemere, Buckinghamshire
User status: Offline

26th Sep 14 at 09:27

Looks awesome!

AlexW

Member

Registered: 25th Oct 08
Location: Essex
User status: Offline

8th Oct 14 at 17:51

quote:
Originally posted by Jamie-C
Will this ever see the road again?

Yeah, I have more interst in finishing this than the Corsa.

quote:
Originally posted by pow
Looks awesome!

Cheers dude.

So I have some bits to update, not a huge amount of pictures however.

I decided the PK6 Laguna box was too big, and was going to cause too many issues, so fucked that off for a Megane ND0 box, still 6speed, and still hydro clutch. Cut a small box peice out of the chassis leg and it bolts up to the factory clio mounts no issue.

Pic is from before I cut chassis leg, but close enough.

Chucked things back together, to get an idea of weight, and ground clearance.

Not a lot of ground clearance is the answer.

Had lots of bits turn up this week, inc nimbus heat shield, mocal oil cooler (Binning standard oil-to-water cooler), and figured out lots more bits.

Now I'm packed out for a couple of weeks, so probably no progress on this until the 18th/19th as its having all the welding done that weekend.

Its looking good though.

AndyCorsaSport

Member

Registered: 12th Feb 06
Location: Horsforth, West Yorkshire
User status: Offline

9th Oct 14 at 11:23

Looking good that. The 120bhp model? Or 150bhp (think they did one?)? Should go well, especially if mapped! You find a megane box ok? I weighed one in a few month back. Got £13 for it. Had it forsale for £50 for ages and nobody wanted it so weighed it in

AlexW

Member

Registered: 25th Oct 08
Location: Essex
User status: Offline

9th Oct 14 at 11:31

quote:
Originally posted by AndyCorsaSport
Looking good that. The 120bhp model? Or 150bhp (think they did one?)? Should go well, especially if mapped! You find a megane box ok? I weighed one in a few month back. Got £13 for it. Had it forsale for £50 for ages and nobody wanted it so weighed it in

Cheers! They only did 120/130bhp in 1.9 (in a car anyway), 150 would be either 2.2 of similar age or the later 2.0 16v Dci.

Mine is 120, and would remap to about 170 as it is (already sorted hybrid turbo), but new injectors, and different Bosch fuel pump will push that too about 230 easily, but I'm aiming for 250/270hp with 350+ lbft.

Typical, tbh I found this box on my doorstep for not a lot, inc shifter etc.

Bought more bits today, which is all I've seemed to do so far!

pow

Premium Member

Registered: 11th Sep 06
Location: Hazlemere, Buckinghamshire
User status: Offline

15th Oct 14 at 16:41

Update plz

AlexW

Member

Registered: 25th Oct 08
Location: Essex
User status: Offline

15th Oct 14 at 21:06

quote:
Originally posted by pow
Update plz

I don't have much to update yet....

Just one pic where I mocked some stuff up yesterday. Will have proper progress this weekend as its going to my mates workshop so we can weld up the chassis leg, make the front and rear engine mounts and do fuck loads of other stuff.

Not a lot of room for my new bigger boost pipes (obviously, old stuff fitted at the mo), airfilter pipework needs air flow meter, and then a reducing 90 plus a straight etc for onto turbo.

I've been a bit busy with other stuff though

[Edited on 15-10-2014 by AlexW]

AlexW

Member

Registered: 25th Oct 08
Location: Essex
User status: Offline

19th Oct 14 at 18:49

Update timeee.

So, got the car down my mates workshop this weekend...

Got engine out, changed inlet and exhaust manifolds.

Everybody loves welding photos

Chassis leg done

Threw the engine back in

Half of the front gearbox mount made

Moar welding

Other half made

Done

Then we did the rear mount

And got it home

So much still todo...

Bulkhead heatshield
Gearstick/cables
Clutch pedal conversion
Driveshafts
Fuel pipes
Fuel filter mounting
Engine wiring
ECU stuff

Probably more.

Slowly getting there though.

pow

Premium Member

Registered: 11th Sep 06
Location: Hazlemere, Buckinghamshire
User status: Offline

13th Nov 14 at 20:23

Hows it going?

AlexW

Member

Registered: 25th Oct 08
Location: Essex
User status: Offline

13th Nov 14 at 20:42

quote:
Originally posted by pow
Hows it going?

lol... Okay, I'll update.

Got my hands on a Clio DCi 100 pedal box, which is hydraulic clutch as standard, so bolts straight up and makes the hydraulic conversion so much easier.

Painted up the Chassis leg, looks factory

Mounted up the fuel filter, mocked up the air filter/induction kit and boost pipes, plus sorted all the coolant pipes. I've still got to sort the fuel feed pipe.

Then its been messing with this lot!

Believe it or not, I'm getting somewhere here.

I did sort the induction too, I was going to fuck about with full silicone right down to the turbo, but this works so much better.

Wiring should all be finished tomorrow, I've basically got 5 wires to connect, and then the ECU stuff, which is about 10 wires once I have the correct ECU Pinout, then I'll be able to start it.

Then its Custom driveshafts and completely custom exhaust. Both expensive things, which is a struggle for me as I'm currently unemployed and my own self employment is pretty quiet atm

More soon hopefully.

pow

Premium Member

Registered: 11th Sep 06
Location: Hazlemere, Buckinghamshire
User status: Offline

13th Nov 14 at 20:56

Glad you understood me

- Fucking good show mate, looks great.

gavin18787

Premium Member

Registered: 22nd Feb 05
Location: Basildon, Essex
User status: Offline

14th Nov 14 at 09:45

amazing work

Loving the clio driveway

Drives supercharged Tec with torque

AlexW

Member

Registered: 25th Oct 08
Location: Essex
User status: Offline

18th Nov 14 at 17:42

quote:
Originally posted by pow
Glad you understood me - Fucking good show mate, looks great.

Haha, Cheers dude.

quote:
Originally posted by gavin18787
amazing work

Loving the clio driveway

Dunno about "amazing", but meh lol.

Its back to full capacity too again this week.

Little bit to update on the DCi today...

Wiring is all located correctly now, just some tiding, and then corrugated plastic stuff.

Mocked boost pipes up etc, Roughly how it'll look with the addition of coolant pipes and rad obviously.