Lancia Delta HF Turbo, Part 2...

Considering i own it (again!), i thought i'd start a new topic with the work i've done on it so far-

Windscreen/scuttle repair-

10/05/08-
So its the Saturday before Dakota racewars and its time for some engine bay spring cleaning! Plenty of plumbing to sort out, but first of all bonnet off, rad out and intercooler off-



Crankcase breather was looking a bit sorry for itself, the rubber gasket that i'd made a while back obviously didn't agree with the oil-



Made up new card gasket and all was sorted.

Then it was time to stop those nasty octane lowering oil vapours from getting into the inlet manifold-



and the small tail the other end soldered up-



The large tail here went to the inlet just after the filter, which was removed and vented down to the ground. Eventually i'll pick up a cheap catchcan to keep things clean(ish).

Then it was time to link out the water heating supply to the throttle body, as its not like we live in iceland or anything!



Then last but not least, get rid of the overboost solenoid and fit a manual boost controller bleed valve-



Turns out it didn't do much as either the wastegate mechanicals have jammed or the actuator is shot. Will find out pretty soon next time............
Guy

So here's what i've got to improve on, just over 11 seconds 1/8 mile-



Here was my race against Dave in his Scooby. As you can see both being motorsport legends we got off the line pretty damn quick (ok so that was my fastest reaction of the day and probably Dave's slowest!!!). As you can see i almost had him!!! *coughs*



Guy

This post has been edited by Infectus-Guy on Aug 27 2010, 12:50 PM

21/05/08-
A little peak at the what work is going into my secret power-hiking mod -

Broken studs, these were VERY hard and a pain in the arse to drill-









Even with it perfectly setup on an adjustable angle plate it was very hard going, blunted at least one carbide drill!





Helicoiling-





Bit of VHT paint, it'll look nice for about 5 minutes anyway!!!





More coming soon.......

No more secrets, hopefully everyone at the last race wars will remember how slow my HFT was because here's what i'm up to!

24/05/08-
OK its saturday and i'm worried i spend more time with cars than people............. oh well that can wait! :haha:

Old T2 and manifold off, clean the block-







Enter F.O. great big Garett T3. I'm thinking this might not be such a good idea, which only makes me press-on.

Little snick out of the front cross member to accommodate compressor section-





Dress rehearsal with intercooler and rad in place, i think it's gonna work!


Guy

This post has been edited by Infectus-Guy on Oct 4 2010, 09:00 AM

25/05/08-
Front cross member has seen some action in its time, apparently one of the previous owners wanted a close up look at a kingsbridge post office or something! My Dad and I had cut it right out straightened it a few years ago but i left the welds. As i was there with the grinder i flatted them back and took off a load of surface rust. A bit of "beige" (pink?!?) primer and we were good again-





Also had to cut a relief out of the back of the cross member for the compressor outlet to intercooler hose-



A broken manifold stud needed sorting but to get a drill in there i had to cut down and resharpen a stubby 8mm drill bit ready for helicoiling-





Some of the threaded stud holes actually go into the oilways of the head. Best stuff to make sure they don't leak is a bit of PTFE plumbing tape round the thread-



During the dress rehearsal i noticed that the compressor housing thrust plate was just touching the gearbox bell housing so just a quick skim with the grinder sorted it out. This could have been a total show stopper, though saying that grinder would have met turbo and bellhousing until it damn well fit!!!



Tomorrows job is to bolt it all together, make up an oil return pipe then start making up an adaptor to get it onto the exhaust.
Guy

i reckon this project will be finished soon then guy

No sir, being maintenance i'm in work this week. Not that it will stop me getting it finished! Will be running tomorrow but with no exhaust, need to do some downpipe adapting but getting it running will be half the war won.

27/05/08-
Spend today and yesterday overcoming a few more little niggly hurdles, nothing massive but enough to slow me down.

Dress rehearsal over, time for the real thing! First job is to bolt the turbo and manifold together. No gasket just the machined surfaces but they're very pitted with age. Heres a nice trick, just to give a little extra seal spray some silver paint on the mating surfaces. The soft aluminium particles in the metallic spray form a micro gasket and help keep things sealed. Time will tell if it is enough to do the trick-



All bolted in and you can see how close that actuator rod is to where the bellhousing flange meets the block!





Solid pipe that feeds the top rad hose was pointing right at the actuator so i had to cut it back a bit to give the hose a chance to squeeze round it-



Had to remake an oil return flage and weld the original T2 solid pipe to it. Wasted a couple hours but its right next to the impeller section of the turbo (bloody hot!) and being solid pipe at least it won't melt!
All fabrication is finished now though and tomorrows job is to plumb it all back up, fire it up, give it an oil change then go out for a quick (and possibly quite noisy!) spin round the block.
Guy

Thanks chaps, its all down to brute force, ignorance and a fair amount of swearing. Oh and a LOT of late nights which is really taking its toll on me, but the end is close!

28/05/08-
No pics today, forgot the camera! But it was just a case of bolting stuff back together. Got it all plumbed up, and turned it over with the low tension wires to the coil off. Oil pressure came after about 15 seconds of cranking so i was happy, but with the fuel still going through (should have pulled a pump wire really) it wetted the plugs and wouldn't fire. Just as well probably, i don't think the neighbours would have been pleased to hear the exhaust note straight from the turbo!
Tomorrow it will run and i will have vids....
Guy

Nail - head! OH MY GOD!!!

Traced the wiring diagram and found i'd put the low tension coil wires back on in the most logical but unfortunately wrong way. I can't tell you how excited i was to take it out on its shakedown, it has literally been YEARS since i've had anything to tune & testdrive. Reminds me of many years ago when i used to tune my Capri and get loads of performance gains out of very little money. I'm happy as a dog with two dicks at the moment, made me feel like i was in my teens again! It may even be boosting a little higher than it should be so i've not been able to properly pin it yet. One other thing that needs sorting is one of the rad pipes, its routed a bit funny and may be restricting the flow a bit. I'll make up some mongrel of a creation to sort that out, but for the moment - very happy boy. Vids soon!
Guy

Nope, the injectors and MAP sensor will keep up with 1.1 bar of boost so i'm sticking with that, or maybe 1 bar just to be on the safe side. I could get integrale throttlebody, injector, inlet and MAP sensors and safely run 1.2+ bar but i don't think the engine is quite up to it. Not that it's an unhealthy engine mind you, but as you say it'd need at least a copper head gasket.
I'm gonna have to find that chap with the pink 2.0 8v Nova at the next Streetwars, the gauntlet is well and truely thrown down!!!
Guy

At first a few clouds of exhaust brown dust from the old bit of exhaust pipe that i used! Now that's cleared out those it runs really clean, no excessive smoke at all which is a nice surprise. This is one naughty little car and is going to be surprising/embarrasing a lot of cars which far outvalue it. Look at it this way - £300 for the car, £150 worth of turbo/manifold, bit of free exhaust and some free intake pipe.Just odds and sods, just how a ratracer should be, very cheap! ........oh and a lot of time, headscratching, a pinch of stress and a dab of effort went in too!!!
Guy

01/06/08-
OK here are the last pics for the turbo conversion.
Modified turbo oil return pipe-





A very tight fit!





Support bracket for air filter, not particularly graceful but that bit of alloy angle is strong as hell and does the job nicely-

As it's now had the main important bits done to the engine, i thought it deserved a bit of a spruce up on the outside. Got myself some 8v Integrale alloys off ebay for £100 which my brother (Cheif Chimp) kindly picked up for me on his travels. They're the same width (wider won't fit) but at 15" are bigger than the original 14"s and although have a lower profile tyre they do have a slightly larger rolling diameter. They need a refurbish but i'll sort that out next time the tyres need doing, for now though i'm dead chuffed with them and think they fill the arches perfectly (fronts rub a little every now and then but i'll go for lower profile tyres next).





Guy

08/12/08-

Here's a bit of remedial work i needed to do on my HF Turbo for the MOT. The outer CV joint had gone which was in danger of flicking 'moly grease onto the brake disc - not good! It just happens that the CV joint is knocking and i wanted to replace it, problem is i had 10 working days (for the free MOT retest) to get hold of one and fit it while i was doing the CV boot. Infact as my missus needed the car 2 days after i had to do it in one day; the challenge is set! So changing the CV joint was not an option and neither was removing the driveshaft to change a boot only to have to remove it again in a months time. Bodge time! I'd heard about this trick several years ago and have been dying to try it. Basically it involves changing the CV boot without taking the driveshaft off, and here's how:-

Hack the old one off and give the area a wipe with a rag-


Instead of spending out on an expensive OEM boot, CosSi gave me a generic "stretch boot" which i slit down with the mould flashline with a shart knife-


Wrap it round the driveshaft then bit at a time, superglue......yes SUPERGLUE it back up again-


Superglue actually melts rubber so it basically welds itself back together-


Couple of zip ties and we're sorted-


I've heard of this method lasting for years, i only need mine to last months but we'll see how i get on!
Guy

Thats good to know Guy. You never know when it may be useful. I normally find the clip comes off the hub thus resulting in grease every where

Put it this way....I can't ever remember buying new gators to replace them..

As long as everything is nice and clean when you glue them and you don't go straight out and do a forest stage rally I think you could almost call it a perminent fix.
Dave

Nothing big to report, other than rubbing off Choppers matt black paint with cellulose thinners and lots of rags! Big plans for the brakes though! I was planning on slapping some Integrale brake calipers and disks on, until i found out that the mounting holes wouldn't line up. I would need to make adaptor brackets which kind of defeats the object of an easy bolt-on upgrade, and not being one to do things the easy way i have a plan!!!

The stock 4-pot Brembo brakes on my integrale evo are ok but have never been that good under pressure coz although sharp, they suffer from brake fade at high temperatures. Because of this it has always been my plan to upgrade to Porsche calipers or something similar, one day making my Brembos an obsolete shelf item. So the plan is to fit them to the HF Turbo now and then put them back on the Evo when it see's the road again (at which point the HFT will have its stock brakes back). Then when I upgrade the Evo brakes, the HFT can have the Brembo's back again.
I was thinking about saving the Brembos for the V8 Capri, but i'll only end up having brake fade problems and need to upgrade.

Anyway those Brembos are going to be perfect for the HF, and with bigger (than standard HFT) Integrale disks they should perform pretty damn well.
Guy

Capri sport just use Fiat coupe turbo calipers for their conversions because they work well and the pads are cheap. They sell all the brackets and stuff for them to fit the Capri.

Ahh they're making a kit for the brembo's now eh? I've got the old GTR260 kit which uses the Granada calipers and S2 RST vented discs. They're better than the originals i suppose but still not that great!
Guy

19/02/09-

Due to a badly tracking cambelt, i've taken the car off to do a bit of engine work. As well as the cambelt i'm also going to be fitting fresh camshaft seals and gaskets. First things first though and thats to have a damn good clean up!

Cam boxes off-


Although it doesn't look like it, i gave the crank pulley area a good clean up (you should have seen it before!)


Blasted the pulleys and gave them a lick of paint-

Nice to see the Delta getting some love, it's such a great little rat-rod! Saw it at college last week all the matt black seemed to be off, just needs a blow over in some Nero Metallic get that lovely metal flake shining again! If you need anymore paint just let me know

You the man!

Gem, it's gonna be in pieces 2 times between when this is done and the track day! Once to fit bigger throttle body with (maybe) high lift inlet cam and then again for the brake upgrade. Oh i'm going to america for 2 weeks between now and trackday too, damn i love a chase!
Guy

25/02/09-

Just spanked 150 notes on these beauties, almost as much as i bough the car for!



I'll probably fit them when i've got the head off. I'm going to be fitting a performance headgasket and N/A inlet cam, christ knows when i'm going to be able to get it done though!
So the plan before coombe is-

-Remove head
-fit N/A inlet cam
-re-shim lifters
-refit head with new gasket
-make brake adaptors
-buy and fit integrale master cylinder, brake biaser and discs
-go to america for 2 weeks!!!

This is going to be hard work.
Guy

Nice new shiny bits

Does the delta gain torque by fitting the N/A in let cam? I know with the vauxhall turbo equivalent of my engine clain gains of upto 30lbs/ft of torque.

I signed upto combe hoping it would enjoyable. Now it's becoming a mission to get everything sorted

21/02/09-

Remade the crankcase breather out of stainless-


Freshly painted pulleys on-


Grinding the valve shims to size-


Got the engine all back in and running, but allas MORE oil leaks. Infact it leaks even more, but now from different places. Will sort that in a couple of weeks when the head comes off.
Guy