I made my Mk2 much lighter by removing my chassis.
General Full Shell Restore & Rebuild! Mk1 - Mk2!!
- Thread starter 601176005
- Start date
Currently reading:
General Full Shell Restore & Rebuild! Mk1 - Mk2!!
Well, you had a good try at taking the NSF corner off as well, but I think that was taking the weight saving thing too far Ucof
Will post pictures on here also from now on..
Update!
Here is my replacement heater box, yes that is an old injector cooling fan. :lol:
And fitting my central locking unit..
Didn't want to drill into the chassis so cable ties only :lol:
Fitted the last window
Then i stripped the oil pump down and checked it over, there were a few sharpe edges on it so i smoothed them out just to aid flow
Heres a pile of old crap being sent for some shot blasting action :lol:
and this is how it returned..
hung up and ZINC primered and painted
Paint
Used the red i used to paint the car on these bits!
While i waited for them to dry
Fitted the anti roll valve thingy
Cover
Je fini
Next up front brakes Mintex extreme baby!
Fitted discs, they are cover in primer as i didnt want the center parts where the wheel bolts rusting and looking manky!
Fitted up Calliper carriers with 6mm spacers.
Pads in
Calipers on
Other side
Sorted!
Next i sorted the rear handbrake pully
Next i did the gearchange rods
Rose joints!
Threadlock
Fitted heatshrink to the rod for a bit of colour :lol:
Otherside
Tada!
Fitted some olives to my fuel lines so the hoses won't come off
My next trick is to port the inlet
Rough!!
Making a start
My 'Tool'
Tada!
Now its smoooooth!
But whats the point when still using the 2p size butterfly!
Well...
RS Turbo throttle body, not to big but certainly bigger than standard!!
Ported that to!
Can't wait to try it!!
Next up i used a tipo 1.4 N/A (Same engine as Uno 1.4) camshaft but it had no drive for the dizzy.... This came has about 1mm higher lift btw.
So i marked it up against my original Turbo one, it dont matter if the marks are slightly wrong as you can adjust the dizzy
Using a dremal to cut the marks....this took AGES!!! But i want to remove a very small amount of material at a time for a perfect fit.
Getting there!
Done
BIG update soon
Update!
Here is my replacement heater box, yes that is an old injector cooling fan. :lol:
And fitting my central locking unit..
Didn't want to drill into the chassis so cable ties only :lol:
Fitted the last window
Then i stripped the oil pump down and checked it over, there were a few sharpe edges on it so i smoothed them out just to aid flow
Heres a pile of old crap being sent for some shot blasting action :lol:
and this is how it returned..
hung up and ZINC primered and painted
Paint
Used the red i used to paint the car on these bits!
While i waited for them to dry
Fitted the anti roll valve thingy
Cover
Je fini
Next up front brakes Mintex extreme baby!
Fitted discs, they are cover in primer as i didnt want the center parts where the wheel bolts rusting and looking manky!
Fitted up Calliper carriers with 6mm spacers.
Pads in
Calipers on
Other side
Sorted!
Next i sorted the rear handbrake pully
Next i did the gearchange rods
Rose joints!
Threadlock
Fitted heatshrink to the rod for a bit of colour :lol:
Otherside
Tada!
Fitted some olives to my fuel lines so the hoses won't come off
My next trick is to port the inlet
Rough!!
Making a start
My 'Tool'
Tada!
Now its smoooooth!
But whats the point when still using the 2p size butterfly!
Well...
RS Turbo throttle body, not to big but certainly bigger than standard!!
Ported that to!
Can't wait to try it!!
Next up i used a tipo 1.4 N/A (Same engine as Uno 1.4) camshaft but it had no drive for the dizzy.... This came has about 1mm higher lift btw.
So i marked it up against my original Turbo one, it dont matter if the marks are slightly wrong as you can adjust the dizzy
Using a dremal to cut the marks....this took AGES!!! But i want to remove a very small amount of material at a time for a perfect fit.
Getting there!
Done
BIG update soon
nice gearlinks!! Ant!:idea:
Lots of great pics there - hope no-one's on dial-up
Fuel pump, brakes, gear linkages, suspension all look fantastic - great attention to detail. I really like how you don't refit anything that's rusty or unfinished.
You are going to have to take me through the finer points of the HVAC engineering, though - the Heating, Ventilation, and Air Conditioning... I don't quite see how an injector cooling fan by itself is going to cut it...!
I've never seen the plenum chamber ported out or the throttle body upgraded before... I don't think the Tipo N/A cam is a good idea. Two reasons, first you'd be better off with a 70's FIAT cam, such as an X1/9 cam, for power... and secondly, this engine is turbocharged. The cam timing is designed to be assymmetric for turbocharged engines, to avoid very-damaging compressor surge/stall under certain conditions. That's why the standard cam timing for the Turbo has such odd figures; inlet valve opens at TDC, for example, and not before. 0/40 30/10. I'm sure if the standard cam (9/31 39/1) was better, FIAT would have used it.
Presumably you're going to have an upgraded turbo on there (that is why you've ported out the plenum and enlarged the throttle?)
Anyway, keep up the good work
-Alex
Fuel pump, brakes, gear linkages, suspension all look fantastic - great attention to detail. I really like how you don't refit anything that's rusty or unfinished.
You are going to have to take me through the finer points of the HVAC engineering, though - the Heating, Ventilation, and Air Conditioning... I don't quite see how an injector cooling fan by itself is going to cut it...!
I've never seen the plenum chamber ported out or the throttle body upgraded before... I don't think the Tipo N/A cam is a good idea. Two reasons, first you'd be better off with a 70's FIAT cam, such as an X1/9 cam, for power... and secondly, this engine is turbocharged. The cam timing is designed to be assymmetric for turbocharged engines, to avoid very-damaging compressor surge/stall under certain conditions. That's why the standard cam timing for the Turbo has such odd figures; inlet valve opens at TDC, for example, and not before. 0/40 30/10. I'm sure if the standard cam (9/31 39/1) was better, FIAT would have used it.
Presumably you're going to have an upgraded turbo on there (that is why you've ported out the plenum and enlarged the throttle?)
Anyway, keep up the good work
-Alex
You are going to have to take me through the finer points of the HVAC engineering, though - the Heating, Ventilation, and Air Conditioning... I don't quite see how an injector cooling fan by itself is going to cut it...!
I've never seen the plenum chamber ported out or the throttle body upgraded before... I don't think the Tipo N/A cam is a good idea. Two reasons, first you'd be better off with a 70's FIAT cam, such as an X1/9 cam, for power... and secondly, this engine is turbocharged. The cam timing is designed to be assymmetric for turbocharged engines, to avoid very-damaging compressor surge/stall under certain conditions. That's why the standard cam timing for the Turbo has such odd figures; inlet valve opens at TDC, for example, and not before. 0/40 30/10. I'm sure if the standard cam (9/31 39/1) was better, FIAT would have used it.
Presumably you're going to have an upgraded turbo on there (that is why you've ported out the plenum and enlarged the throttle?)
Anyway, keep up the good work
-Alex
Hi Alex!
Well the injector cooling fan is mearly to clear the screen when it mists up, unfortunately its heating capacity is fairly limited! :lol:
In a few months i may be switching to stanalone management which is why i have changed the throttle body and done a little porting.
One of my good friends has a very powerful Nova with the 2.0 Turbo engine,
and he made most of his gains by doing the small things such as removing resistance through the inlet system etc etc. I figured as the engine was apart i may aswell do it, and also have a look and see how small the standard butterfly is!
Also inside the inlet the finish is very rough and poor, i don't no if that's its design but it looks very much like poor casting! I will leave porting the head to a professional as i figured this is the important bit! I am using a T28 Turbo
As for the cam, it is a bit of a experiment really, i am 100% sure weather to use it yet....
Sounds good! T28 eh... I guess that's on the Mk2 manifold?
Maybe the throttle body is small to improve the low-end torque, or maybe because it doesn't have to be any bigger? Either way, with the bigger turbo and custom engine management, I'm sure you'll wring out quite a bit more power. Looking forward to the dyno plots...
I'm sure this is all going to be rather more satisfying than the pimped-out Panda - that WAS you, right?
Yeah, I think the standard heater would do a better job of demisting the windscreen, I suppose the heater was too heavy for you?
-Alex
Maybe the throttle body is small to improve the low-end torque, or maybe because it doesn't have to be any bigger? Either way, with the bigger turbo and custom engine management, I'm sure you'll wring out quite a bit more power. Looking forward to the dyno plots...
I'm sure this is all going to be rather more satisfying than the pimped-out Panda - that WAS you, right?
Yeah, I think the standard heater would do a better job of demisting the windscreen, I suppose the heater was too heavy for you?
-Alex
Last edited:
Sounds good! T28 eh... I guess that's on the Mk2 manifold?
Maybe the throttle body is small to improve the low-end torque, or maybe because it doesn't have to be any bigger? Either way, with the bigger turbo and custom engine management, I'm sure you'll wring out quite a bit more power. Looking forward to the dyno plots...
I'm sure this is all going to be rather more satisfying than the pimped-out Panda - that WAS you, right?
Yeah, I think the standard heater would do a better job of demisting the windscreen, I suppose the heater was too heavy for you?
-Alex
Yes but not just any manifold a hand built stainless steel manifold, looks like this.
And yes weight is what makes this car quick, so the less the better.
PImped out Panda
you mean this?http://www.turbocollective.net/phpBB3/viewtopic.php?f=24&t=754
As for not needing to be any bigger i am not sure, after all throttle body size is how they restrict performance of some race cars is it not? We shall see!
No I didn't mean your speaker-filled Uno, I thought you were the guy that had the green Pimp My Ride Panda, so I have mixed you up with him, sorry I was probably reading HIS Uno thread on that other forum when I thought I was reading yours. You'll just HAVE to explain that username some time and then maybe I'll stop mixing you up
That pipe fabrication and welding is beautiful and should really do justice to the turbo.
Still, all that pipework must weigh as much as a heater ...but less than a subwoofer
How are the electrics going - all worked out?
-Alex
I was probably reading HIS Uno thread on that other forum when I thought I was reading yours. You'll just HAVE to explain that username some time and then maybe I'll stop mixing you up That pipe fabrication and welding is beautiful and should really do justice to the turbo.
Still, all that pipework must weigh as much as a heater
...but less than a subwoofer How are the electrics going - all worked out?
-Alex
Last edited:
Hello again!
Ready for an update, nearly there now!
First of the gearbox
Finnally got my engine back!
New pistons/rings
Reground crank
New mains and bigs
Lighted flywheel
ARP Bolts
Also got the head back, new bronze guides 2 new valves, ported polished, 3 angle seats. Polished combustion chambers.
Just on the side, i was going to use a cable clutch, but as they are pretty **** i figured i would use a hydrolic box instead.
I figured i would give the block a paint while i was doing a few other bits.
Finished
Time to fit the head.
Refitting oil pump
New oil seal for camshaft.
New crank oil seals
New water pump and housing
Cam reshimmed
Block ready for sump fitting
Sump on
Fitting other bits
Rebuilding halfshaft with new bearing
Fitting manifolds.. this took 4 hours what a complete bastard!
Turbo on!!
Ran into a small issue with the water feeds to, the feed from the block was to close so i had to blank it off...
Turbo stay was also no good so i had to remake it..
Nearly there!
New cylinder
Gearbox finished
Fitting lighted/balanced flywheel
Clutch
New mounts
Ready to go in!
And...
..
..
..
..
..
IT'S IN!!
Turbo was so close i had to remake the heastsheild on the bulkhead for it to fit!
Fitted my linkages
Everything was so tight i decided to make a heatseild to protect everything
Fitted with the actuator..
To have a break i fitted the sideskirts and arches lol, just stuck on as i didn't want to drill holes :lol:
So now it was all nearly there i sent the car away to have the exaughst made for it, from the turbo all the way to the scorpian backbox!!
Bye bye!
then a few days later..
It cost 200 and is the tits!
Anyway after that i fitted the inlet
Also sorted the injectors, i will use the standard ones for now until its ran in... but i changed all the hoses for new ones and had the injectors cleaned
Next i cleaed up the cam cover
Painted the bits
Fitted it up
Inlet fitted
Leaver for throttle sorted perfect fit and works spot on!
Braided oil feed
I had a spare Mk1 seat passanger side it was in good nick as i assume they get less use so i removed the cover and fitted it to my drivers seat
Fitted to car
Oh last pic of the clearence between the turbo/selectors! it is at most 7mm! :shock:
See you next time!
More soon
Ready for an update, nearly there now!
First of the gearbox
Finnally got my engine back!
New pistons/rings
Reground crank
New mains and bigs
Lighted flywheel
ARP Bolts
Also got the head back, new bronze guides 2 new valves, ported polished, 3 angle seats. Polished combustion chambers.
Just on the side, i was going to use a cable clutch, but as they are pretty **** i figured i would use a hydrolic box instead.
I figured i would give the block a paint while i was doing a few other bits.
Finished
Time to fit the head.
Refitting oil pump
New oil seal for camshaft.
New crank oil seals
New water pump and housing
Cam reshimmed
Block ready for sump fitting
Sump on
Fitting other bits
Rebuilding halfshaft with new bearing
Fitting manifolds.. this took 4 hours what a complete bastard!
Turbo on!!
Ran into a small issue with the water feeds to, the feed from the block was to close so i had to blank it off...
Turbo stay was also no good so i had to remake it..
Nearly there!
New cylinder
Gearbox finished
Fitting lighted/balanced flywheel
Clutch
New mounts
Ready to go in!
And...
..
..
..
..
..
IT'S IN!!
Turbo was so close i had to remake the heastsheild on the bulkhead for it to fit!
Fitted my linkages
Everything was so tight i decided to make a heatseild to protect everything
Fitted with the actuator..
To have a break i fitted the sideskirts and arches lol, just stuck on as i didn't want to drill holes :lol:
So now it was all nearly there i sent the car away to have the exaughst made for it, from the turbo all the way to the scorpian backbox!!
Bye bye!
then a few days later..
It cost 200 and is the tits!
Anyway after that i fitted the inlet
Also sorted the injectors, i will use the standard ones for now until its ran in... but i changed all the hoses for new ones and had the injectors cleaned
Next i cleaed up the cam cover
Painted the bits
Fitted it up
Inlet fitted
Leaver for throttle sorted perfect fit and works spot on!
Braided oil feed
I had a spare Mk1 seat passanger side it was in good nick as i assume they get less use so i removed the cover and fitted it to my drivers seat
Fitted to car
Oh last pic of the clearence between the turbo/selectors! it is at most 7mm!
:shock:
See you next time!
More soon
Bandwidth fail fixed!
Don't take too long in getting back to us.
I love reading the post and the photos are amazing.
I love reading the post and the photos are amazing.
/jealous
Wish I had a Turbo I could pull to bits, clean up, then put back together
Wish I had a Turbo I could pull to bits, clean up, then put back together
Your project is looking fantastic!
The detail is brilliant. Nothing is original, it's all so much BETTER than original, even if the parts are standard, the paint really lifts it.
I still like those Alfa Romeo wheels, I really think this looks totally different to any other Mk2 Uno Turbo I've ever seen - for a start it has a Mk1 engine! And no heater!
Oooooh the WEIGHT of that heatshield, I'm surprised :nono:
Only joking
What a great idea with the seat cover transplant, I should keep an eye out for an earlier-style Mk1 passenger seat, then I can 'restore' my driver's seat and ditch the covers. Dunno why I'd never thought of that before - mind you, it is really hard to get the early (FIAT logo) seats in good condition (driver or passenger!)
Not long now till she's a runner? Take care, I never want to see anything bad happen to this
-Alex
The detail is brilliant. Nothing is original, it's all so much BETTER than original, even if the parts are standard, the paint really lifts it.
I still like those Alfa Romeo wheels, I really think this looks totally different to any other Mk2 Uno Turbo I've ever seen - for a start it has a Mk1 engine! And no heater!
Oooooh the WEIGHT of that heatshield, I'm surprised :nono:
Only joking
What a great idea with the seat cover transplant, I should keep an eye out for an earlier-style Mk1 passenger seat, then I can 'restore' my driver's seat and ditch the covers. Dunno why I'd never thought of that before - mind you, it is really hard to get the early (FIAT logo) seats in good condition (driver or passenger!)
Not long now till she's a runner? Take care, I never want to see anything bad happen to this
-Alex
Your project is looking fantastic!
The detail is brilliant. Nothing is original, it's all so much BETTER than original, even if the parts are standard, the paint really lifts it.
I still like those Alfa Romeo wheels, I really think this looks totally different to any other Mk2 Uno Turbo I've ever seen - for a start it has a Mk1 engine! And no heater!
Oooooh the WEIGHT of that heatshield, I'm surprised :nono:
Only joking
What a great idea with the seat cover transplant, I should keep an eye out for an earlier-style Mk1 passenger seat, then I can 'restore' my driver's seat and ditch the covers. Dunno why I'd never thought of that before - mind you, it is really hard to get the early (FIAT logo) seats in good condition (driver or passenger!)
Not long now till she's a runner? Take care, I never want to see anything bad happen to this
-Alex
Hi again Alex!
Thanks for your kind comments, makes it all worth while...
The seat transplant is very easy!, the only problem is the bolster on the bottom seems to ware out and look uneven. I assume thats because most people rub on it when getting in/out. However if you buy some thin foam you can rebuild this edge!
Still not sure about the Alfa wheels, they weight so damm much.
Oh and hopefully she may be a runner this weekend!
Looking very good and a great thread with some real content
What's the plan for the car? Do you do this for a living or is the car for personal use? What happed the the GTV V6?
What's the plan for the car? Do you do this for a living or is the car for personal use? What happed the the GTV V6?
Looking very good and a great thread with some real content
What's the plan for the car? Do you do this for a living or is the car for personal use? What happed the the GTV V6?
Big update people!
GTV i sold a few months ago, great car but not quite what i was after.
For those interested it is now all finished!
Final update people!
First of i changed my dump valve as i didn't like it...:lol:
Then fitted a fire extinguisher....you never know... :?
I didn't have enough room to fit my air filter in the engine bay so i moved the battery to the boot.
Then i fitted my new steering wheel, :lol: £7 of eBay! Took the covers of my doorcards.
I was going to have no grill but it looked a bit ****, so i made one up.
And now for the big moment it is finally complete!!
Finished!
Final update people!
First of i changed my dump valve as i didn't like it...:lol:
Then fitted a fire extinguisher....you never know... :?
I didn't have enough room to fit my air filter in the engine bay so i moved the battery to the boot.
Then i fitted my new steering wheel, :lol: £7 of eBay! Took the covers of my doorcards.
I was going to have no grill but it looked a bit ****, so i made one up.
And now for the big moment it is finally complete!!
Finished!
That's really nice...
Quite a racer-look going on with those door cards and general lack of interior luxuries... I bet it's LOUD
That photo in the carpark is classy - I can just imagine it heading up a sign WARNING - BEWARE OF SPEEDING VEHICLES...
I like the photo with it lined up between your boy-racer friends' rides (though the composition of the photo could be better) Well presumably they're your friends - the Uno doesn't look out of place at all next to the Subaru Impreza, since you have really brought the Uno up to scratch. Well done.
I didn't quite spot the difference with the dump valve - I wonder if those first two photos are both the same.
I'm looking forward to hearing how it works out on the road If Dunc still has his super-Uno-Turbo (I can never remember if he does or not), you should arrange a race!
-Alex
Quite a racer-look going on with those door cards and general lack of interior luxuries... I bet it's LOUD
That photo in the carpark is classy - I can just imagine it heading up a sign WARNING - BEWARE OF SPEEDING VEHICLES...
I like the photo with it lined up between your boy-racer friends' rides (though the composition of the photo could be better)
Well presumably they're your friends - the Uno doesn't look out of place at all next to the Subaru Impreza, since you have really brought the Uno up to scratch. Well done.I didn't quite spot the difference with the dump valve - I wonder if those first two photos are both the same.
I'm looking forward to hearing how it works out on the road
If Dunc still has his super-Uno-Turbo (I can never remember if he does or not), you should arrange a race!-Alex
Last edited:
Looking good. I think Dunc broke his super UT, I don't think it ever got on the road in the end.
