309 Goodwood turbo conversion for free!!

hiya all as some of you allready know if been planning to swap by twin weber carbed 1.9 8v gti engine in my 1993 309 goodwood gti for a turbo'd engine

first of all was to set a budget for the converison so it didnt run away and end up costing a fortune

i took into account my wage, my outgoings and the fact i im forking out a sh!t load on the marriage of the century, so decided my budget was £0, nothing, nada, nil, zip, sweet fa (you get the point)


first things first was to find a suitable engine, i didnt take long to get in touch with a lad who was willing to swap me his 406 2.0l turbo engine with 70,000 miles, unlocked ecu and all ancilliries (the 150bhp version) for my twin weber carb setup

so he got these




and i got this (took the turbo and exhaust manifold off to have a good look at the turbo)



so next was to get the old engine out but to do so i needed an engine crane, but of course theres no money in the conversion pot so i sold my old head, block, afm and induction kit to pay for it

i got a 1000kg clarke strong arm for £150 and i sold the bits for (wait for it) £150

one of the carbs gone which was a peice of p!ss





then came the start of im sure a million problems im gunna come across on this conversion, first off the two bolts on the exhaust flange were rounded so out came the 'long' screwdriver and the 'big' hammer it come off after some good swings but i managed to saught of punch a bolt sticking out of the rocker cover and rip half the skin off my middle finger

then the sodding nearside wishbone was having none of it so i gave it a good soak in wd40 then after a 6ft iron bar and a 18st weight (me) bouncing on it for nearly 6 hours it finally came loose so i cracked on with getting the old engine out which didnt take that long in the end

i went for dropping the engine out underneath, the way i did it was to lie it on its back and shuffle it out the front underneath the bumper (which sounds easier than it was) but after a bit fannying around


hey presto!!!



picture of the engine plus my new crane


plenty off room in that arch now theres no weight on the front end




next thing to do will be to strip the engine bay back more, brake servo and master cylinder to come out, expansion tank, radiator, headlights, grille, fans, and any other things i find lurking, treat any rusty metal, prime it and get it sprayed back to original colour

i'll be swapping the brake servo for a smaller diesel version for clearance on the turbo and replacing all the brake lines

once thats done i shall update this thread with more snaps hopefully wont be to long

love the photos mate, i love 309s had one for 9yrs until garage fire, may be ill get another one in the future.

great project m8 cant wait to see get going

309 4x4

Making good progress mate

progress aint to bad ive only had three days on it and that was dodging in and out of the rain

i did look into the 4x4 but apparently the only one that'll fit (with alot of work) is the 405 4x4 system which is a load sh!t

ill be upgrading the brakes to either gti 6 or 307 hdi's, getting rid of the big exhaust for a standard one and im sticking a boost gauge were the oil pressure dial is now on the dash

then in the future ill be 'tweaking' the engine, tt manifold with a better turbo, emerald management, bigger cam, more boost naturally and a lsd to get the power to the floor

so it'll be well over 220bhp and 240ish lbs of torque


these wont come out of my '0'0 budget though obviously (mind you, you never know)

Plans sound awsome

Getting the power down will always be the issue in any FWD car

well i'll have 3 set of gti-6 front brakes for sale in the new year if i'm able to take em off

wow sounds like a lot of work... good luck with it and hope it all goes well...

_Mike_ wrote:Plans sound awsome

Getting the power down will always be the issue in any FWD car

especially in this because it only weighs 950kg so that'll be 235bhp per ton or a shade under 5 secs 0 - 60

gunge wrote:well i'll have 3 set of gti-6 front brakes for sale in the new year if i'm able to take em off

dont suppose you need anything of simular value keep my budget on track

If you can get the power down that well i think you will have one very fast little car

Is the 309 lighter than the 205?

no but theres not much in it

but it handles alot better

moz_goodwood_309 wrote:

gunge wrote:well i'll have 3 set of gti-6 front brakes for sale in the new year if i'm able to take em off

dont suppose you need anything of simular value keep my budget on track

sparco rev seat centre
30mm rear bars
5lt black paint
avo rear adjustables

?????????????????????????

Moz.. your forgetting that Si has basically every pug part somewhere

He is well and truly your 'One Stop Pug Shop'

i have accumilated alot of parts over the years

what sort of paint you after? ive got a mate who can get it pretty cheap

he wants pink flip paint for his rallye

high gloss black 2 pack with the hardner thinners my supliers dont sell it any more

any particular make? i take it its for one of your motors?

Paint is getting harder and harder to get nowadays

_Mike_ wrote:Paint is getting harder and harder to get nowadays

not if u know someone whos a sprayer.!

racermike wrote:

_Mike_ wrote:Paint is getting harder and harder to get nowadays

not if u know someone whos a sprayer.!

still hard to get 2 pack, though i have found a guy on ebay

going to be a mental car when its done. simon you can get 2pack paint from a place in johnstown well my mate got some from there for a his missus dads rover, also einsley harris in penrhiwllan near my house im sure he can get 2pack paints still

yeah i tried county motor factors in johnstown but there very expensive alway have been, but they used to do good colour match rattle cans