Latest Update: 09/10/08 

 

 

 

 

 

 

 

 

 

 

 

va Sprint Car

PPP106

 

 

 

 


 
Welcome to the car section:
Last update on - 17/02/08
Engineered By Design compete in Sprints, and Hill Climbs (when time allows!). The cars are designed, fully prepared and built by ourselves.
Peugeot 106 Series 1 8 Valve - competition Engine Build - the "PPP-106 "
Full Car  Full Car
Click Here or On the Photo above to go to the PPP-106 Mini site
Current Specifications (Before we started this little project!)

Car: 106 Rallye S1
Colour: Red
Modifications:
All round Avo Adjustable struts + 35mm Eibach lowering springs
Weight removal mainly carpets and sound deadening(25kg)
Chipped ECU (10bhp Apparently)
Gas flowed cylinder head by GainSpeed with matched inlet manifold.
Fully rebuilt head using new springs and retainers.
K&N 57i Induction kit.
Corbeau Revolution Seats (wideboy edition).
Carbon Fibre bonnet. (2.4kg instead of 12.6kg for original)
OMP steering wheel.
13" 205 Rallye wheels with 175/50R13 Bridgestone RE720s buffed to 2mm for dry weather
13" 205 Rallye wheels with 175/50R13 Bridgestone RE720s unbuffed for wet weather and travelling to/from circuits
DTM wing mirrors (so I can walk around the car in the garage!)
Magnecor Competition spark leads
Poly sport bushes
Lots of stickers (because I was bored over the winter and they were cheap!)
Blaupunkt E-Freestyler Satellite Navigation.
 
Engine Build Specifications

The PPP106- Has taken much thought & Design work, include pages of calculations, hours of simulation & testing. The , initial design intent was to produce an over-square high & free-revving engine. After lengthy discussions, (most of which took place down the pub... hmmmm) The final decision was taken to develop a 76mm Bore & 77mm Stroke system. Combining the TU2J2 1296cc Engine & The TU3 1360cc Engine. - Achieving a total swept volume of 1397cc

Full Standard Engine
Standard engine
 
The Bottom End:

Pistons: Wossner 76mm forged slipper pistons.
Lightened and balanced crank and flywheel ( crank > 1.145kg lighter, flywheel 400g lighter) The balancing of the system was quite complicated due to the radical modifications of the Crankshaft. Each individual component was first balanced in isolation, then in as a whole including the group "N" Clutch Cover.
The Crankshaft has been highly polished to minimise "oil-cling" during running (thus reducing moment of inertia).
Lightened and balanced Forged Wossner 76mm slipper pistons and lightened & stress relieved con-rods.   
 
The ebd "Stage 4" Head
 EBD Fully gasflowed head - This is what we would refer to as a Stage 4 head, (which roughly translates as we stopped short of the platinium plating! - just!) The list of head work includes but not limited to:
  • Modified valve guides (to suit opened out ports)
  • Reprofiled Combustion chamber
  • Chamber Matched to Pistons
  • Head Skimmed - In combinatino with above modifications to attain 11.5:1 Compression ratio
  • Bronze Cam Thrust Plate
  • Inlet Ports have been "re-pitched" to even the inlet tract length between cylinders & open the flowpath up
  • Inlet Ports matched to custom designed inlet manifold to suit R6 Throtle Bodies
  • Valve seats re-cut.
  • All modificiations are designed around the production of a very High Volumetric Effieciency Head.
 
Other components:
   

Head matched with High performance CATCams special profile,
New Spring Retainers,
Uprated Valve Springs - (single)
One Piece 214N Austenitic Stainless Steel valves, - Wasted away as part of Head modifcations.
Overall the system uses 8 Injectors, 4 in the original positions, and 4 upstream in the form of a Yamaha R6 throttle body conversion using EBD custom inlet manifold,
Raceland Exhaust Manifold - modified so it actually fits the head!
Exhaust Manifold has been fitted with custom designed Insulation Jacket using 12mm Thick fibreglass wadding. The reason for this two fold, it is designed to reduce under-bonnet temperatures, thus maintaining a cool inlet Charge. It also protects the carbon fibre bonnet from the elevated temperatures produced from the application of the PPP-106.

Engine Management: controlled by Emerald M3DK - Mapped using 8 injectors
Button control for stalk controls (removing all stalks)
OMP 129AE Roll Cage - Ready for fitting
Carbon fibre front splitter
Carbon fibre rear diffuser
Varley Red Top battery
Coil over conversion

 

This covers the general build specification of the PPP-106 - Cherry Red Series 1 8V Peugeot 106 Rallye, to see a full Blog of the engine build have a look at the: PPP-106 mini site...

 
The Fiesta CVH-1400
 

Fezza   Hot Manifold

This project started as a daily drive, we thought it would make a pretty fun project car to put on the Track, people were really suprised to have a 5-door fiesta come past them! - The Picture on teh right is of the wrapped exhaust manifold after a heavy run!

See Below for specifications:

 
The Engine
 
 
  • 1.4 Litre CVH 8 Valve!! 
  • 101 Bhp @ 6000 RPM (at the Wheels) max 6700 RPM  (circa 120Bhp @ the fly wheel)
  • 2 x Twin Choke Weber DCOE 40 carburettors
  • Custom modified inlet manifold
  • Custom modified Ashley Exhaust Manifold & system
  • Custom made exhaust adaptor plate
 
Bottom End:
 
  • Lightened, Balanced and Cross Drilled Crank Shaft (standard Cast Iron)
  • Lightened and Balanced Con Rods modified with fully floating small ends (standard Cast Iron)
  • Standard Ford Pistons lightened and balanced and modified to accept circlips
  • Custom made gudgeon pins
  • Lightened and balanced flywheel
 
Top End:
 
  • Custom modified Head – chamber and ports
  • Kent Camshaft – Long duration and high lift
  • Anti-pump hydraulic followers
  • Lightened valve spring caps
  • Double valve springs
  • Modified Rockers
  • Modified Valves - (Standard Size)
 
Suspension; Front:
 
  • XR2i Antiroll bar
  • Custom modified Lower arms for adjustable camber
  • Adjustable ride and rate coil over struts
  • Lower and Upper adjustable strut brace
             
Suspension; Rear:
 
  • Rear Antiroll bar
  • Adjustable ride and rate coil over struts
  • Strut brace
               
Brakes:
 
  • Front XR2i vented discs and callipers
  • Rear standard drums
  • Goodridge steel braided brake hoses front and rear
  • Face it, Brakes only slow you down!
 
Wheels & Tyres:
 
  • TSW 15” Alloy wheels
  • Front tyres 195/55/15 Goodyear Eagles
  • Rear tyres 195/55/15 Yokohama A539
 
The Nova: YAJ-1400
 
YAJ-1400 - Nova GTE @ Bromley Pagent 1     Nova @ Lydden    YAJ-1400 - Nova GTE @ Bromley Pagent 2  
The Engine:
    • 1.4 Litre OHC 8 Valve
    • 73 Bhp @ 6000 RPM (at the Wheels)max 6700 RPM  (circa 100Bhp @ the fly wheel) - a lot more to come!
    • 2 x Twin Choke Weber DCOM 40 carburettors - modified to be tunable!
    • Magnex Exhaust system
    • Janspeed Exhaust Manifold
    • Custom modified inlet manifold
    • Custom made Inlet adaptor plate
    • TAS Competition engine mounts
    • Kent Cams Camshaft Belt

Bottom End:

    • Lightened, Balanced and Cross Drilled Crank Shaft (standard Cast Iron)
    • Lightened and balanced flywheel
    • Pinned Ring gear

Top End:

  • Blydenstien B+ modified Head – chamber and ports
  • Kent Camshaft NV062 – Long duration and high lift
  • Vernier adjustable pulley
  • Anti-pump hydraulic followers
  • Modified valves – standard size
 
Gear Box:
 
    • F13 – Close Ratio Low Final Drive
    • Quick-shift Gear linkage

     
Suspension:

Poly Race Bushes all round

Front:

  • OMP Strut Brace
  • Custom Strengthened Lower arms for adjustable camber
  • Bilstein Sprintline Shock Absorbers
  • 250lb rate springs

Rear:

  • Poly Race Bushes
  • Bilstein Sprintline Shock Absorbers
  • 200lb Springs

 
Brakes:
    • Astra GTE ATE 10.1” (254mm) Front vented discs and callipers
    • Rear standard drums
    • Goodridge steel braided brake hoses front and rear
 
This little thing sounds pretty rough on tick-over due to the low mass of the Crank shaft and Flywheel. But as can be heard, when the revs build up it really does sing!