Adam's Fabia vRS Mk1 - 2.0 litre GTB powered

[Southy]

Great work, what injectors have you gone for? There is a NPS cam for sale in the classified for 300 from a very famous seller! Might be worth a punt?

I'm going for DSSR 130% that way I have room overhead for future power upgrades.

I had thought about buying the cam from Steve but I dunno if I would trust him....

[Southy]

Finally got the engine finishing touches done this morning at work and then got it back home ready for this weekend to start dropping it back into the car.

She flys!!

[Southy]

So this Sunday just gone I set about making a start to drop the engine back into the car. I refitted the newly balanced and modified clutch and flywheel setup along with the last remaining parts to the engine ready to drop her back in.

After a bit of faffing about and adjusting the lifting position of the strap and with the aid of a trolly jack the engine was finally dropped back into the car.

At this point the cylinder head was given its final torque down stage and then set about connecting everything back up.

By 6ish the light was fading fast so was called a day. I still require to bolt the injectors down and fit the roller rocker system and setup the injector backlash.

[coskev]

Nice

The little bit of green you can see now of block looks spot on!

[Southy]

Cheers Kev, doesn't look too OTT at all now it is all back together. Can't wait to get the car up and running once again and back driving it. I have missed it so much.

[MartM]

How much power does the 2L make with a 2260 at 2.5 bar?

[Southy]

How much power does the 2L make with a 2260 at 2.5 bar?

Not sure just yet as it isn't up and running and mapped just yet. I think it will be around 280-290bhp myself however

[Stuart27183]

Great work and great enthusiasm for the build! Look forwar to your review of the 2ltr good luck with the mapping etc

[Southy]

For those not on Facebook and haven't seen the car was up and running yesterday afternoon. Had a slight teething issue however in the form of an oil leak from the oil filter housing where it mates to the block itself, turned out I had torqued the 3 bolts up which was easily accessible but the 4th down the bottom and through/behind the coolant pipes I had only left nipped   

 

I managed to sort the leak out this morning and load up the new base map and went for a little test drive, heading out soon to but some miles on the clock so we can get the car run in and start mapping it proper  :clap:

 

Video of the first start up here

http://vid264.photobucket.com/albums/ii200/south001/Engine%20Build/20160326_160146_zpsn4zqywvv.mp4

 

And a video of the car running on and off the clutch to listen to the noise of the SMF

http://vid264.photobucket.com/albums/ii200/south001/Engine%20Build/20160327_093727_zpsuaxt4wt7.mp4

[alex_e3]

Fantastic news! Flywheel sounds very quiet.

Can't wait to see the results!

Sent from my D5503 using Tapatalk

[Southy]

Update time, car is running in nicely with around 400miles on the engine now so ahe is starting to be opened up a little more now.

Wasn't without issues however, between 2-2.5k on sustained light throttle there was a lot of a bluey/white smoke coming out of the back. Initial fear was the car burning oil as it seemed to be mainly noticed in 3rd gear down slight hills. However, after altering the fueling the issue has gone away.

[kellaway86]

I bet you had some hand In mouth moments seeing possible blue smoke! Can't wait to see how much power this engine will make!

[Southy]

I bet you had some hand In mouth moments seeing possible blue smoke! Can't wait to see how much power this engine will make!

I was dreading it and fearing the worst and maybe have to pull the engine once again and re-ring it and glaze bust the bores so was majorly relieved to see it clear up once John had altered the fueling.

Been trying to sort out some logs but my VCDS lite refuses to connect and can't communicate with my ECM so I'm at a loss.

[fergy]

How you finding ur mpg with injectors in ,I've just fitted my 130% last weekend but only running a base file until I fit some stronger headbolts

[Southy]

Can't say I have noticed a major difference really. I put about £30 worth of BP ultimatr in it the other week and it's done about 250/300miles on it but I'm not pushing it that hard just yet due to running the engine in still. I am also running a base map of 1.3bar. Hopefully be upping that soon now more and more miles rack up.

Edited 6 April, 2016 by Southy

[coskev]

How you finding ur mpg with injectors in ,I've just fitted my 130% last weekend but only running a base file until I fit some stronger headbolts

Mine when it was on the first couple of maps and really smokey was doing 300 miles to £50 using it daily.

Now seeing around 400 miles to £50 on the much cleaner map

[Southy]

Major update time. Been a very busy boy lately, car has now done around 1500miles so it has had an oil change, I had issues with my VCDS cable so wasn't able to carry out any logs until John kindly sent me his spare, however I can't run any logs as the car if currently off the road once again.

I have stripped the front and rear suspension off to send the tired looking coilover springs to the powdercoaters to tidy them up for the show season. I have also stripped off the wishbones and rear beam and the RARB also also sent them to be powdercoated also

I then had to remove the bushes from the rear beam using a drill, hammer and chisel anda blow torch

The replacement bushes for the rear beam along with some shifter link bushes

The nice pile of parts to be taken to the powdercoaters

Some of you may notice the part on the left in the above pic. I decided to make myself a custom crash bar from 1" box section.

First of all take one majorly butchered standard crash bar.

Then bolt it onto a piece of dexium to act as a jig.

Then take an angle grinder to the front cross member and remove it from the legs.

Then cut the legs down to the desired height

The work then started on the framework.

A sample fit to see what it looks like

I then decided to add cross members for extra support

And all welded up

This weekend I set about cleaning the coilovers and the neglected wheels.

Edited 15 May, 2016 by Southy

[Southy]

And the wheels

The wheels have come up a hundred times better but very badly require a machine polish now followed by some Platinum wheels

How the car currently sits

Edited 15 May, 2016 by Southy

[Stewpotz]

very nice crash bar, how long did it take to make?

 

Fancy taking measurements

[Southy]

very nice crash bar, how long did it take to make?

Fancy taking measurements

Took me about a day and half to make it in the end took a bit of time and effort to measure and get it all right.

Its 1m wide and 10cm high. Its 1inch box section with 2.5mm thick wall. The cross sections were started an inch in from the ends and equally split between the 4 parts

[ThomasItis]

Epic built! Are you a vehicle technician? 

[Southy]

Epic built! Are you a vehicle technician?

Thank you very much. I'm not no, I am a CNC machine operator by trade but have been messing about with cars and trucks from a young age so I'm pretty handy with a spanner

[Titanium_Man]

Still my favourite build thread  :clap:

 

Very interesting work with the replacement Crash-bar. You've made it look and sound so simple, which is obviously credit to you, sir 

[Southy]

Thanks very much Jars, tbh it was fairly simple to make, just faffing about to cut the material to the correct size and angles.

Further progress update.

I made a start on polishing the wheels up, I have also touched up a few stone chips, most of them seem to be on the rear wheels. However I haven't fully finished the wheels due to running out of time and needing the car mobile again so will be removing them and finishing them off soon.

Cheeky pic part way through the machine polish.

I had a go at one of the spokes before I touched up the stone chips to see how it came up.

Before

After

On friday afternoon I went and collected my parts from the powdercoaters.

Then late into friday night I spent a while applying Platinum Wheels to my coilovers, springs, and the RARB aswell as building back up the coilovers ready for refitting.

Then on saturday I set about refitting my freshly powdercoated parts. Started off with the rear beam and fitted the powerflex beam bushes first of all.

Didn't get many pics inbetween the torrential downpours we had but managed a few final pics once back together

[R1chard]

Top work, looks excellent