Sorry I have not been on here in a little while, if I could sum up the past few months building the TF Turbo in one word it would be PROBLEMS!!, and lot of them, there is a reason there are not many TF Turbos around.
I will list just some of them
• Faulty PRT unit (Now replaced)
• Oil pipe blew off and covered everything (that was fun to clean up)
• Coolant leaks everywhere
• Exhaust leaks everywhere
• Stripped bolt on rear track rod
• Alternator not charging the battery
• Boost leaks
• Top end of the engine rattle.
• Etc. Etc. Etc
I have been able to overcome allot of the problems above, and continue to do so but it does take allot of time and patience. I do however have a problem that you guys might be able to help with, the car now starts runs and drives perfectly, it boosts nicely and really is really quick, however once the engine has been running for about 20min and the oil is warm I get a rattle from the top end of the engine, it sound like hydraulic tappets but I have replaced all 16 of them with brand new ones. Its does not affect performance but obviously should not happen.
Anyway enough moaning let get down to what I have been doing.
I was told that you could use the existing fuel rail, leave the regulator in and just add another regulator in line on the return, but I could not get the fuel pressure to adjust high enough so I removed the old regulator, drilled and tapped the hole and converted the rail to accept AN fittings, this allowed me to increase the pressure to the required level, happy days!
Old fuel rail with FPR.
Modified with 3/8th fittings (used a hydraulic hose line to test it), then I used a 3/8th to AN adapter, and adapted the Fuel filter fittings to AN as well.
Exhaust down mainly made from stainless, I cut and tacked it together then my friend (Thanks John) Tig welded it for me.
I then made a new center section to join this to my existing CAT and TT MK7
The Alternator system needed a tweaked quite a bit. Using a custom belt and relocated the tensioner and support arm, I manged to get the it to fit but
the electrical connector was different, after quite a bit of messing about I came to the conclusion that it must be faulty so bought a used one online for £11
delivered!!!!!, I love how cheap the parts are for these cars, this one fitted and worked straight away
Next up PRT system, replaced my faulty eBay PRT unit with a brand new one, only £25 should of done this in the first place instead of being tight.
I needed to have an oil temperature gauge, I don’t like pillar gauges as there just not my thing or dash pod gauges so to avoid have yet another gauge,
I have Modified a boost gauge to fit into the existing hazard warning switch and painted it in gloss black to match. Happy with the result looks fairly OEM.
I did an epic job of fitting my Air Fuel Gauge, turns out using a high speed drill to cut a circular hole, not such a good idea!!
I have also relocated and replaced the hazard warning switch with a “Savage Hazard Switch” I am happy with this setup and it works really well.
I then had to take my roll bars out in order to remove the center console and fit the new one that I had to buy, this time I used a jigsaw with a metal
bit, and the fit is perfect (Pic coming soon)
I have fitted plazma dials and have on back order the plazma heater surrounds (will post a pic as soon as they get here)
All the piping is now in for the air filter and the engine cover is fitted again. (I will be ducting some air up to this in the future)
New coolant bottle fitted as the old one had seen better days
Washer Water jets up graded to Citron Xara Mist ones (This is well worth doing and is a 5 minute job and they are a direct replacement)
A few nice and shiny stainless bits fitted.
I think that's about it for the minute, there are still lots of little jobs to do but I do have a working driving TF Turbo.
It would be nice to have the mechanics 100% complete this year but I fear the top end of the engine is toast and will need a rebuild. (Well if it had worked first time I wouldn’t of learned half as much)
Next year I will be focusing on the outside of the car and getting the styling how I like it.
I will keep you guys updated as I progress.