My Td04 Xud9 205

[Boosted-Dturbo]

Hi, not long ago I bought myself a 1.6 205 Gti with plans to make it into a Xud track car

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[attachment=16333]I drove it about as a 1.6 Gti to use up some of the mot and tax but got bored of it fairly quickly although it was good fun.

Whilst trolling eBay and gumtree I found a cheap omp cage so got in contact with the guy and headed through to collect it.
My tip would be don't go to collect a 6 point cage in a impreza, bad idea lol.

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[td_dan]

Same cage as mine im afther the front bars and door bars to

[Boosted-Dturbo]

[attachment=16336]I didn't pay anything near the asking price for it and sold the absolutely perfect interior out it

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[attachment=16337]Then got these. Mega lightweight which is the direction I'm heading

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[attachment=16338]Next I got the old engine out as I sold it.
Just in time as I got 4 points for speeding in it that week.
Iv had a clean license since my teens lol.

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[attachment=16339]I found a good engine from a written off 306.
Unfortunately it had a lucas pump but atleast it had a good t2 on it for my 306 workhorse which currently runs a kkk. I had a td04 lying about but it's less than ideal for many reasons but I'm happy to use it until it goes then It'l be plug and play with a td04l.
I got an td04 adapter plate and the turbo is clocked.

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[attachment=16340]I got a xantia inlet and got to work on it.
I work for a company that restored classic cars so have access to handy machines

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[attachment=16344]Engine going in

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[attachment=16345]One of many strength plates

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[attachment=16346]I shot blasted most of the bay while the engine was out, acid etch primed it then it was coated with 3m spray sealant before getting sprayed. It looks a funny colour under the infrared lamp. I have plans for the upper inner arches so iv just painted enough so that the engine could go in

[Boosted-Dturbo]

[attachment=16347]When I was running it back and forward to work it handled like a dog despite having a gmax on the front with bilstein shocks on the rear. We stuck gauges on it and found it had positive camber on the osf and negative on the nsf so I bought camber plates to correct it

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[attachment=16348]I managed to get a set of compomotives which ill have to drop off to the powdercoaters soon. I'm not keen on black wheels plus they need a freshen up

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[attachment=16349]When I first fitted the engine and connected the gear linkages I found a internal problem with the gear box which had come on the engine from the written off 306 so got a spare 1.6 gti box and fitted new clutch arm bushes etc. Iv used them on the xud's before and it's a crazy ratio but should be fine for knockhill. Also it's now a push clutch instead of the heavy pull type. I took a dw8 flywheel into Engine Resource and got it lightened then buttoned everything up

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[attachment=16353]I found I had a clearance issue with a the gear linkage and turbo. I couldn't find anything online regrading anyone with the same issue so want sure if it was to do with the dodgy variant of td04 I'm using?
I ended up modifying everything for the greater good lol.
The linkages are now fully rose jointed start to finish with bronze bushes on my DIY quickshift and gear stick . The gear feel very positive to say the least and they now clear the turbo

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[attachment=16356]The linkages are all fitted and setup but I'll need to take pics.
I got a 205 derv loom from the scrappys and stated to sort it out with amalgamating tape and p-clip in.

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[attachment=16357]I'm planning on making my own screamer pipe soon. Not exactly the normal setup but should sound good.
I'm going to make a divorced downpipe and use the wastegate side as the screamer pipe

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[attachment=16359]Can anyone tell me anything about this turbo? If it's really bad, I'll just get another to replace it. Iv had it lying about for years.

[Boosted-Dturbo]

[attachment=16360]I bought a stainless td04 downpipe and cut it close to the flange as it needs to instantly turn into a 90 bend.
I ordered a tight 90 today which I'll weld onto the modified downpipe flange

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Same cage as mine im afther the front bars and door bars to

Hi Dan, if I ever add sections into my cage I'll just get the joining hardware off eBay and get the correct seamless pipe from a blacksmith. The door bars would be easy to do. I'm looking for a good non sunroof roof to fit and once that's done I'm adding another roof cross in

[juz22]

nice 205, brings back memories of my 1.6.

[Boosted-Dturbo]

nice 205, brings back memories of my 1.6.

That looks a clean one. Mines has it's faults lol

[Tom]

Looks like your doing a great job! Good project

[Boosted-Dturbo]

Looks like your doing a great job! Good project

Hi Tom, I followed the Build of your 205 and seen it on eBay. Can't believe it's not sold yet. I know how much cash mines stands me so far and that makes your a bargain

[ally406]

I'm a regular at Knockhill, I look forward to seeing this going round Where abouts are you?

[Boosted-Dturbo]

I'm a regular at Knockhill, I look forward to seeing this going round Where abouts are you?

Excellent, what will you be running? I'm located in Brechin.
My friends and I have been building track cars to use this year plus one of them is doing the xr2 challenge at the moment. I can't wait

[ally406]

Orange Clio 182, I was hoping to get it into SLS this year but mortgage, bills, paying for food etc got in the way. Will come over and have a chat if I see you there.

[Boosted-Dturbo]

Hi, been a whole since I posted with any actual progress.
I bought a couple of subaru Justys and iv been out having crazy off road fun for atleast a couple of months so the 205 has sat in my driveway lol.

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The last pic shows the 205 with a new complete front panel. It's been spray sealed so it lasts as long as possible.

I made up a downpipe which bolts onto the td04 and heat wrapped it.

[Niall]

Hi mate,
Project looks fantastic. Ive moved it to the correct section for you

[Boosted-Dturbo]

I got some silicone pipe and a alloy header tank. The plan is to get a coolant swirl pot, the largest alloy radiator I can fit in, Evans waterless coolant and a few other bits. I have to small radiators off a motocross bike which I am fitting behind the bumper with ducts. One of them is for cooling the turbo and the other is for a outlet on the cylinder head which would normally be for the heater matrix.

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Today I bought Brembo four pot calipers with new discs and caliper rebuild kits. Also I bought another td04 turbo as the one I used which I had lying about is a pain for running boost pipes.
I week or so ago I got a Nitrous oxide kit which was originally a wet kit but obviously I needed dry so just removed the fuel solenoid and iv ordered a dry nozzle. I'm not too sure what jets to order, think I'll buy a load and work my way up incrementally.

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The way it sits, it will fire up off the key and drive.
I fitted a good condition replacement derv loom. The fuel lines now run through the bulkhead and inside to a alloy fuel tank.

[rocker8742]

Looks like a great project will have to keep an eye on it

[Paul_13]

Are you getting new wheels to accommodate those brakes?
Won't fit under 1.9 wheels

[Boosted-Dturbo]

Are you getting new wheels to accommodate those brakes?
Won't fit under 1.9 wheels

Hi, yeah I got a set of 16" Compomotives but I'll need to drop them off to get powdercoated soon. Not too sure what colour to go for tho

[Boosted-Dturbo]

I got the Compomotives sent away to the powder coater earlier in the week and hopefully get them back tomorrow. I ended up getting them done golf as I liked the look of it when I bought it so we'll see what it looks like soon.

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I got my turbo, brembo 4 pots, and intercooler delivered so I'll get started tomorrow morning.
Iv ordered a alloy radiator 650mm wide with a massive 56mm core.
When I checked up on Evans waterless coolant I found the price pretty crazy!
They also want you to flush your old coolant system with their own stuff which costs about the same as the coolant.

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I got my turbo, brembo 4 pots, and intercooler delivered so I'll get started tomorrow morning.
Iv ordered a alloy radiator 650mm wide with a massive 56mm core.
When I checked up on Evans waterless coolant I found the price pretty crazy!
They also want you to flush your old coolant system with their own stuff which costs about the same as the coolant.

[Boosted-Dturbo]

After moving house etc I finally got back to working on the 205.
I mot'd and taxed it today then maxed out the Lucas pump.
It's pretty dam impressive for not having a built Bosch pump.
I'll have to fit the Polycarb window kit and coilovers.
I went to fit the brembo's but Iv either got the wrong discs or hubs, I'll have to look into it.

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