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Last weekend I fitted the oil filter re-location flange and had a first look at the new clutch release bearing. I need to change the bearing, since the clutch is meant for 50 mm OD bearing and the stock is 45 mm. I tested it with the old one, but it will cause problems since the clutch “nails” are too short for it, i.e. the clutch bearing could get stuck.

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I also managed to continue the oil sump. It is almost ready, I just need to test fit it to the engine with the dry sump pump to ensure the proper lining of the pump. Then I need to TIG weld the rest of the seams of the sump from the inside also. Then I’ll make the suction points for the scavenge and cut out the excessive parts off the dry sump pump fitting plate.

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I’ll try to work out the summary next, I think I did overthink it too much...

-Wales

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Coming along very well Wales - Oil pan looks great!  Is the welding still being done with your mig?  

Just occurred to me that the shift fork might also need some beefing up as the new clutch likely has a much higher clamping force and may stress it some more.  I've seen and heard the shift fork arm cracking - but shouldn't be too hard to reinforce.

Rabin

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On 4/24/2019 at 9:02 PM, Bean said:

Coming along very well Wales - Oil pan looks great!  Is the welding still being done with your mig?  

Just occurred to me that the shift fork might also need some beefing up as the new clutch likely has a much higher clamping force and may stress it some more.  I've seen and heard the shift fork arm cracking - but shouldn't be too hard to reinforce.

Rabin

I welded the rest of the outside seams and all of the inside seams of the oilpan with a TIG to ensure the sealing. I only welded the outside of the flange with a MIG on the oil pan.

Any idea of the stock clutch release load? As for the TTV one they say it is 275 kg for the 50 mm release bearing.

-Wales

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I intended to make this summary to conclude all of the future plans also, but they are pretty much open at the moment, so I’ll just add the things I have done so far and the parts I have already acquired.

 

Engine:

Head serviced, port imperfections removed, flow benched, otherwise stock

Engine head gasket: Elring MLS

Engine head bolts: ARP head stud kit

Pistons: Forged Wösnerr Low-Compression (8:1)

Connecting rods: Forged H-Profile PEC

Connecting rod bolts: ARP 2000

Connecting rod bearings: King Racing

Main bearings: King std

Thrust bearings: Glyco std

Gaskets: Elring

TTV Racing Billet auxiliary pulley

PACE CD2000 Dry sump oil pump

DIY oil sump with support for dry-sump oil pump

DIY oil filter relocation flange

DIY bracket for auxiliary devices

 

Fuel and ignition system:

Fuel tank: JAZ 45 l (12gal) safety tank with fuel level sensor and safety foam

Fuel pump: 2 x Bosch “044”

Fuel lines: Stainless steel AN8 Hardlines with Teflon/Stainless AN8 braided hoses

Fuel line fitting: Aeroflow AN8 “Full-Flow”

Injectors: Bosch EV14 1100cc

Ignition: Stock Coil-on-plug

O2: PLX DM-6 with Bosch LSU 4.9 sensor

ECU: Megasquirt II with full sequential mod

 

Body:

Excessive rust repairs in the rear half of the car

Fuel tank lid welded shut

Sunroof welded shut

 

Drivetrain:

DIY clutch bellhousing with crankshaft position sensor insert

TTV Racing Custom lightened flywheel

TTV Racing Clutch cover

TTV Racing Paddle clutch disc

Propeller shaft housing sand blasted and painted

 

Chassis:

Rear subframe, rear trailing arms and suspension support sand blasted and painted

 

Some of the upcoming things:

3,5” Downpipe

3” Exhaust

DIY Exhaust manifold

DIY Intake manifold

Rollcage

Carbon fiber hood

Adjustable coil-over suspension

Big brake kit

Running on E85

Cooling system upgrade

 

Some of the planned things:

Garrett GTX3076R Gen2

505 Super production styled body kit

 

-Wales

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22 hours ago, Wales said:

Any idea of the stock clutch release load? As for the TTV one they say it is 275 kg for the 50 mm release bearing.

I think it's 5250 N or 535 kg with the pull type clutch, best stock 215mm clutch for a BE gearbox ; you can go up to 228mm but then the flywheel is a bit tricky.

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This is the BA10/5 clutch fork that would need to cope with the 275 KG load of the pressure plate.  Any chance you have stock BA10/5 pressure plate specs?

I checked SPEC clutches to see if they listed pressure plate force, but nothing listed / found.

Rabin

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Yes, thanks for clarifying it Rabin.

 

SRDT, are you sure that 535kg is the release load, since half a ton sound a bit high for stock clutch? I know that pull type can handle the torque better but it shouldn't add the release load too much?

 

Oilpan is almost finished:

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Dont mind the condition of the body too much, since it is going under work after I have finished the oilpan and the engine mounts.. Like I mentioned in the 2018 post the rear of the car has already been trated excluding the differential and the drive shafts:

IMG_20190428_153315.thumb.jpg.193c6b1ec14485b8c1525198913ae090.jpgIMG_20190428_153354.thumb.jpg.4e5a454bb985f30cdd08b651f729a219.jpg

Oh yea, and there are threaded bars instead of the rear suspension, for finding the proper ride height.. I'll add more pictures from the rear of the car after I have cleaned it a bit, so dusty right now..

IMG_20190428_153803.thumb.jpg.daf1f5475ffc0cd1190a3467550c0686.jpg

 

-Wales

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It may be 535kg on the disc and not on the bearing, I'm not sure how Peugeot is measuring this.

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On 4/29/2019 at 8:42 PM, SRDT said:

I think it's 5250 N or 535 kg with the pull type clutch, best stock 215mm clutch for a BE gearbox ; you can go up to 228mm but then the flywheel is a bit tricky.

Flywheel and clutch on my turbo is 235mm. Is the older ones 215 like the NA-cars? 

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