My City E, Now Running Turbo Short Motor And Box
Turbo Mini Forums

Thanks for the advice Retired. I will read that thread and decide what to do. Binning them and getting high grade replacements would be safest, so I'll probably do that

On 12th Nov, 2009 Paul S said:

I think Gary OS has taken over my role as the forum smart arse

Well after having a crap day working on the engine build yesterday I decided to work on bodywork today.
I need to do front floors, inner sills, outer sills and doorsteps on both sides. It was the best fun I've had in a long while (what a sad life I lead :() I started on the drivers side. I got the outer sill and door steps tacked in and cut the inner sill out. Heres a few pics:








Oh, and I have a Benross head, a 2wd RS IC, an Innovate XD-16 gauge kit and a few bits from Avonbar arriving this week. Motivation is now high again :)

On 12th Nov, 2009 Paul S said:

I think Gary OS has taken over my role as the forum smart arse

Well my angle grinder shat itself today so I didn't make as much progress as I would have liked. I got the inner sill done. Just the front floor and seam welding everything left to do on the driver side. I'll get nothing else done this week though as I won't be able to afford a new grinder until Friday

On 12th Nov, 2009 Paul S said:

I think Gary OS has taken over my role as the forum smart arse

Good work there dood looks good going to be some cracker when its all done I can feal some serious mini hooning coming on :)

This week was better than xmas when I was a nipper. Look at all the money I spent!


A big thank you to Steve at Benross. This 12G295 is stunning. And it's red so it's good for 200HP





Boost gauge and breather filter


Avonbar turbo oil pump

Edited by GaryOS on 9th Aug, 2008.

On 12th Nov, 2009 Paul S said:

I think Gary OS has taken over my role as the forum smart arse

K&N universal cone filter


2WD RS Cosworth intercooler


Rebuilt carb


XD16 gauge kit


Le Mans dump valve with neotech (whatever the hell that is) digphram. I hate trying to spell that word

On 12th Nov, 2009 Paul S said:

I think Gary OS has taken over my role as the forum smart arse

Paul and myself made some good progress today. We got the cam timed in aswell as a few other bits



And to keep moral going, we threw the head and sexy filter housing on.


We also decided how to mount the turbo. Never mind exhaust gasses, water pressure is the key to forced induction. With this setup and the right intercooler it will be good for 250BHP easy.

On 12th Nov, 2009 Paul S said:

I think Gary OS has taken over my role as the forum smart arse

looking good

just a quicky, as youll prob get to this bit soon

the 'turbo' oil pump are 1275 based, and you might need to mod to get it to fit the 998 block

besides that, its looking cracking

"Turbo's make torque, and torque makes fun"

"did you know you can toast potato waffles?"

how come you never went for a 1275cc head in the first place?
looking good tho!

you mean oilpump and block..
looking cool man
in those pics up there ^^ is that grease round the bores to stop crap ingress?

On 17th Aug, 2008 hario said:
you mean oilpump and block..
looking cool man
in those pics up there ^^ is that grease round the bores to stop crap ingress?

Edited by GaryOS on 17th Aug, 2008.

On 12th Nov, 2009 Paul S said:

I think Gary OS has taken over my role as the forum smart arse

With the crap weather I only managed to get some little jobs done. I painted my ther 2 wellers, sorted out some towing eyes and cut my bonnet for the intercooler


Oh, and I went to check out a garage. Its in my granny's which is going to be rented out. If the new tennants don't need the garage then I get to use it. Its only 10 minutes from my house and is abut 5 meters by 4 meters. It would make a massive difference to the amount of work I can get done. Fingers crossed I get it

I booked 3 days off work this week so should make some good progress

On 12th Nov, 2009 Paul S said:

I think Gary OS has taken over my role as the forum smart arse

how tricks mate glad to see another small bore turbo from ireland

ive just finished my 998 turbo with a sw5 cam but havnt had it on the road yet thats my next job this week...

anyway this is wot the guys at swiftune said about their cam.

<The SW5 has worked in Turbo/supercharged engines very well, it's very low duration and short duration helps with the exhaust pulses to spin the turbo at lower revs. This was a trick we learned from our association with Mountune and the Cossy engines in the past.

The cam has also improved with the new SW5-07 profile and steel blank.>

That mini is determined to Kill me!!!!

We've made some progress with the build recently. The head will be bolted on during the week and we will start to make the manifolds.

I made the maifold flanges on the head side during the week. Now I have to make a fuel pump blanker, HIF44 to manifold flange, turbo to manifold flange, turbo to downpipe flange and plenum inlet flange. I'll have a busy few days ahead!

We had a 1.8T VAG in work which needed an engine. I took the oil feed and return from the engine and it seems that it will work with a little effort. Was a bit of a fluke really

We also ran into some trouble with the primary gear bush. I had trouble finding a floating one for a small bore. Then I noticed that Swiftune done one. It is listed as a 998 floating bush on the website but it wasn't a simple fit. It turns out that its a bush designed to fit a 1275 primary to a 998 crank. So it was way too big external diameter. We turned it down in Paul's lathe to make it work.

I also replaced all brake lines and pipes aswell as shoes and cylinders. And I made a start on the passenger side sills and floor

I also got a bosch fuel pump ( part number 0 580 464 070 ) and an electric fan. I got ARP rod bolts and thanks to the advise of people on here I managed to track down ARP centre main bolts.

It's my last week in work this week so I have a full week off before I go back to college to make good progress.

On 12th Nov, 2009 Paul S said:

I think Gary OS has taken over my role as the forum smart arse

4 lates now made. Fuel pump blanker/oil return, plenum inlet, carb side of inlet manifold and turbo to exhaust manifold. I just have the turbo to front pipe one left which is by far the most complicated to make.
I also managed to get some stainless bolts for the turbo mounting.



I'll have some pics of us making a start on the exhaust manifold tomorrow.

On 12th Nov, 2009 Paul S said:

I think Gary OS has taken over my role as the forum smart arse

Turbo positioned. As you can probably guess, I decided not to try for an equal length manifold




Awwwwww, my first ever TIG. All I've ever done before is MIG and even then I'm just a monkey that picked up a welder and tried to stick things together. I've no qualifications. Now I'll turn my nose up at MIG and I'll want to TIG everything . I absolutely love the control of TIG so I'll be practicing alot once the car is done




I've this week off work so I have 9 days to make massive progress on the shell and engine (hopefully).

On 12th Nov, 2009 Paul S said:

I think Gary OS has taken over my role as the forum smart arse

what turbo is that? looks to have a sort of KKK type mounting flange..

James, it's a Garrett GT1544S. It's used on alot of small VAG TDIs like the polo/lupo 3 cylinder yokes. It's got super low ARs and its very small. It looks like it will suite my application well. It doesn't seem up to making big power but it should spool very quickly which is exactly what I want from this long stroker.
It is a strange mounting flange. I've never seen anything similar on a Garrett. Here's some info on the turbo
http://www.turbobygarrett.com/turbobygarre...44_454083_2.htm

One problem with using a turbo this small is the size of the pipework. Its a 36mm outlet pipe on the induction side of the turbo We will be making some reducers to go into the cossie IC to keep pipework lookng neat though

On 12th Nov, 2009 Paul S said:

I think Gary OS has taken over my role as the forum smart arse

The manifold has now been mocked up and tacked together. Next step is to get is welded up and cleaned with the grinder. Then we'll start on the inlet manifold.
I also have the driver side of the shell completely welded up and ground back. Just the floor left to cut/weld on the passenger side then reassembly will start.








Plugged up bypass take-off. Will a 12.9 bolt be strong enough?

Edited by GaryOS on 16th Sep, 2008.

On 12th Nov, 2009 Paul S said:

I think Gary OS has taken over my role as the forum smart arse

super job!

interested to see the inlet mani. this is giving me ideas!

Myself and Paul made some more progress on the engine. We made a sandwich plate to go behind the oil filter housing. It will be used for turbo oil supply. The turbo oil supply and return should get sorted next week.



Had a good day on the shell today. I got to sit in the mini for the first time in about 5 months. It doesn't have a pedal box but it was awesome!

Edited by GaryOS on 27th Sep, 2008.

On 12th Nov, 2009 Paul S said:

I think Gary OS has taken over my role as the forum smart arse

are you certain that the oil is filtered at that point?
actually, thinking about yes of course it is

looking good!

"Turbo's make torque, and torque makes fun"

"did you know you can toast potato waffles?"