I started out with a lot of tubes. The 2 to 1 collectors were crafted by the pipe shop, they also supplied 12 x 90 degree bends and 2 meters of straight pipe. I cut he collectors to their minimal length and fitted them to the engine flange with some masking tape. After that i started working on the 4 to 1 collector which turned out pretty nice. With the new tig welder i began my first tig welding job; welding the collectors to the engine.

The tubes were fitted to the engine using some masking (and other various types of) tape.

Great progress during the weekend, welded up the entire manifold, unfortunately i did not have the camera available, so i can just show the final results. After cutting the nose cone i made the tiny pipe beteen the collector and the turbo flange.

02/03/2004: Got the manifold back, i could not reach the inside of the collector with the torch, had it welded at the pipe shop.

I welded the pipe, which was mated to the flange and collector, in place.

16/03/2004: The last week few weeks have been really busy, i've welded the clutch pulling handle, flattened the back of the manifold and grinded the rough edges from the ports. Assembled the rest of the engine and fitted the flywheel, clutch (pressureplate) and gearbox. The engine is ready to be fitted to the car. After pulling out the 'make-things-fit-engine' i cleaned out the entire motor area you also get a nice view of my uprated suspension (i used to have the 1.6 gti type).

16/03/2004 - 21:36: Fitted the engine tonight, it looks sweet !!!

25/03/2004: Engine has been in for a while now, but no start yet, its getting close though. I've cut the downpipe flange to shape and picked up the 60 mm id pipes. Unfortunately im out of gas for the welder (good excuse) so the downpipe will have to wait for a while. Great progress on the engine loom going to the dash, its done and verified. The peugeot s16 coils came in today, with a little persuasion they will be mounted.

18/04/2004: My v3 came in friday, yes!! did a lot of soldering the last few days. Decided to fit the v3 in the case that used to house my oem ecu. After some remodeling it fitted very nicely, [picture of todays work].

Back again, sorted out the [connector pinout], and did some work on my [config.txt], [tables.txt] and [my_make]

26/04/2004: Lots of wbo2 circuit testing / debugging the last week, some pics of the results [pic#1] [pic#2] [pic#3]

07/05/2004: Finally the gas has arrived. Put it to use and welded most of the downpipe: [pic#1] [pic#2]

11/05/2004: It runs!! *happy face* pictures of the (almost) finished engine: [pic#1] [pic#2] [pic#3]

12/05/2004: Proof, two movies of the engine doing some humming [movie#1 starting] [movie#2 run]

18/05/2004: Welded a nut to the downpipe for the wbo2 sensor [pic#1] [pic#2]

23/05/2004: Tonight the car will be ready for a short testdrive, this is what it looks like now: [pic#1] [pic#2]

30/05/2004: Drove a few km today, made a [logfile] of the drive.

31/05/2004: some pictures showing the DR = 22 flyback [#1] [#2] and [a movie of me driving the car back into the garage] (the interesting stuff happened before that (check the logs above :) )

01/06/2004: measurement day, i build a test rig to measure the injector opening time with scope. To do so i connected a 0.1 Ohm current measuring resistor in series with the injector and (with scope) measured voltage across it. Made a few screenshots: [a low voltage (11.7v) table setup without fuel pressure] and [a test in car with 3 bar fuel pressure and 13.8v battery voltage]. The resulting injector opeing time proved to be 1.36 mS for my highZ injectors. [A complete injector pulse with flyback voltage can be found here]

10/06/2004: Results of last weeks work: [changed coolant container to a compact volvo item], and fitted a [later type valve cover] (i has cut-outs for the cop coils).

29/06/2004: Another test drive, this time some nicer movies. I fitted an other iat sensor (open-cage-type) and connected the turbo watercooling. Movies: [#1] and [#2] also a [datalog of the drive] [Picture of the engine in its current state]

03/07/2004: As expected, the standard air filter hoses could not deal with the boost pressure, after fixing a split hose for the third time, i decided it was time to upgrade to some boost resistant hoses with thin walled steel pipe in between. Result of a few days work can be seen here: [engine] [engine inlet closeup]

05/07/2004: Drove around with the new pipes today, the logfile of the drive can be found here: [log05072004]

06/07/2004: [Another logfile], took the car for another spin :)

29/09/2004: The car spend some time on the dyno today with impressive results: [263.3Hp @ 6821 rpm / 336 Nm @ 4825 rpm]; more proof: a [video of the dyo run] and [a datalog of the dynorun]

31/01/2005: The saga continues! I'm sourcing a bigger turbocharger Holset HX-40 is on the list, does anyone have flowmaps of this turbo?

07/09/2006 Actually, the saga has been discontinued, engine has left the car, and the body has left for some paintwork ..

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