Uno - Uno Turbo - Build Thread!

Introduction

Hi there guys

Note been here for a while, but back in the Uno fold!

So, here is what i brought, a Uno 60 with a Punto GT engine conversion.

I wasn't really looking for an Uno again, however this was absoultey mint! Never seen a welder, been waxoled religiously, was just too good to pass up...

Anyway, here are a few of pics of from the previous owner.

Pre conversion

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and a pic of the engine and conversion, nice low mile 33k engine and box from a crashed GT.

33k miles

Few pics showing how clean the chassis leg's were!

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And a few of the conversion parts

Turbo Loom

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Turbo rack and brake servo

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GT Brakes and Turbo Hubs

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New valve guides and stem seals

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And a few of the pics of how i brought it..

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When i brought it, it had a few issues i wanted to sort, firstly a really unstable idle, and a few bits that i wanted to re-do to my spec. Firstly the fuel system...

This was how it come

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Firstly, i got a Metal Mk2 Uno Turbo fuel rail rather than the plastic GT one.

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So, cut off the fittings and TIG welded some AN6 Fittings on

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I also changed out all the lines to 8mm nylon front to back

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Next i needed to make up a mount for the FPR

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Next up made up the lines and fitted

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At the fuel tank end i replaced the original turbo tank with a baffled tank. The days of an undertank fuel pump are gone what with the invent of high flowing in-tank pumps

Old tank

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Old vs new pump

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And fitted

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Next up was sorting a pet hate of mine, bad wiring...

Stuff like this

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A few before and afters:

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and after

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Drivers side

Before

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After

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Next up was the engine loom, i wanted to clean up the engine bay, move the ECU and relays into the car and make it look clearner

Here was the loom before

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Making a template of the original loom

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Mid making

All new wires

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And done, lovely MIL spec connectors

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ECU, Relays, Fuses, and Bar sensor moved into the car.

This was the location when i brought the car.

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And after, tucked under the dash.

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Sorted a few other bits such as this massive leak..

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And cut and welded smooth

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Also fitted central locking

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Next up was sorting the lack of any kind of ducting on the intercooler and oil cooler, seen the difference a well ducted design could make on my Supra so figured i would fabricate some up.

Before, you can see the gaps all around where the air would escape

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TIG'd up some ducts from aluminium

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Oil cooler

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New ducts and stainless hardware

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Much better, now the cooler will do something!

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Next up i wanted to make an AFM mount as it was just floating about, so...

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Picks up on original mounts

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Also made up a cable mount

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Also TIG'd up some new boost pipes to replace the original mishmash, also changed the filter to a stock air filter housing

Before

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Making the new pipes up

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ICV Spout

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Swage the ends

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Fitted and done

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Last job was fitting a light grill i got from italy along with Mk2 Sideskirts

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Next a nice simple thing, getting rid of my old knob as it was a bit blue for me..

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Nice little carbon number to replace it

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Next up was to put a proper Turbo boot on, this is the one that come with the car, looked great but prefered the turbo look

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Weight of the stock metal boot

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Weight of the new fibreglass turbo boot

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And fitted

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Much better!

Next up was fitting my new boost controller, using the original clock location

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Perfect fit!

I still wanted the original digital dash boost gauge to work, so i used the original MAP from the Uno Turbo ECu with a 5V step down power source mounted to the back of the clocks

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Cut down

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And fitted

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Next thing to replace was the original black carpet with a red turbo item

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Stripped out and cleaned the floor and protected

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Above you can see the original sills, the previous owner regularly waxoyld it and you can tell... no rust!

Now thats a carpet!

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While fitting the carpet i decided to add the turbo door and rear cards along with electric windows.

This is how the cards were before...

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First up was putting relays in each door, made up a little aluminium mount

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All fitted and wired up

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Turbo door cards, electric motors and rear cards fitted

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And also fit my new clutch slave as the old one started leaking.. new braided stainless line too...

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First the Speedo stopped working! Looks like the original Sharp optical sensor had started to break down

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So replaced with a modern sensor, was very tricky!

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Next up was a wheel change, got some Strada 14" Speedlines

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This is how they come back

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Next up was to change the rad, i want a 50/50 split with the intercooler. I looked at a few options but in the end went with a 4 core 60mm thick Civic radiator.
So, here goes...

Stock rad

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As the radiator was rotated 90 degrees i needed to split the radiator flow path, so gap cut

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Plate slid into the gap

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Welded up

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Temp switch bung welded in

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Mount added to top to connect to slam pannel

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Bottom rad hose fits perfect

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Top rad hose needs some work

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Made a custom top alloy rad hose and added an outlet to the top of the rad

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As the rad was moved right to the passenger side i needed some very small trimming and wanted to push all the air through the rad

Trimmed up

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TIG welded in place

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ground back

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Primered

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and painted

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Radiator wiring done, all contained so a direct plug in connection

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And all completed!

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Here you can see the area left for the intercooler

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Last mod was a little anti social...

Welded a T into the downpipe

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Welded in

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and fitted

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And done

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First up was changing the rear bumper to a nice Mk2 one..

Then i had to take a look at the brakes, they were pulling to one side and really needed a stomp to get them to work...

Soon found out why! Pad's were welded in place with rust!

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Stripped the brakes off cleaner re-painted and new pads

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Much better

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Then i fabricated a new clutch pot as the old ones look nasty

Old

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New with AN4 Lines

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Next up i wanted to improve the OE airbox as the pipe sizes are tiny and i will eventually be doubling the power

So fabricated this alloy case and s2000 paper filter with ducted inlet from behind the light. This way i get lots of cool fresh air and it allows the engine to breath

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Here you can see the large 3" inlet pipe to the sealed airbox, little perspex window is to make sure nothing gets trapped in the box, 4 bolts allow quick removal and changing of the filter. This

all fits in the stock battery tray so no mods to the shell needed.

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So with the new airbox in place i now had to find somewhere to fit a battrey. Didn't want it miles away in the boot and no way was i mounting it inside the car. A few years ago a cell went down in

an old car i had and started pumping acid into the cabin of the car... not a great experience...

So here is where the batt was, where the air filter now lives..

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Then i thought, there is some space below the battery tray!

So...

Here is the replacment

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New mount i made

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New location

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painted and foam to protect the batt

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In place

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And new leads fitted!

The leads are all stock Jaguar parts for the battery and required no mods, i also get the benifit of a fuse which the Uno never had. The only change was crimping new terminals onto the Uno starter

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Looks OE too

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So next up i wanted to make a bonnet lifter rather than using the stay all the time

Simple plate that slides into the reinforced section of bonnet to spread the load

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Then a mount bolts onto that

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Here you can see the parts

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The long part bolts in the original airbox mount holes so no holes need to be drilled

The ram is from a Mk4 Golf Bonnet

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Another small mod was finishing the rad setup, i had made a temp top hose out of alloy

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Howver my new AN20 fittings arrived so i welded threaded bungs onto the rad and thermostat and made the new hose

Big!

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With the theme of AN fittings i also wanted to make a catch can

So made this tank, here is the inside showing the deflection plates and twin filters

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Fitting welded to the original breather

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Bolts where to the OE air box went so no holes (theme starting here lol)
You can see the drain at the base

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Made the lines

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Next on the list is the header tank, hate the big plastic OE one shown here

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So been trying to learn some CAD, made these 2 files over a few evenings

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Sent them off to a chap with a 5Axis CNC Machine

And these come back

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Fabricated a tank and welded it all up with AN fittings

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Last item which is still a work in process is the inlet manifold

Currently my car has the stock Mk2/PGT type

Here is an old pic:

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So, i wanted the better looking Mk1 Manifold but they have a really old odd fuel injector setup, also no spot for a ICV and just need modernising in gerneral

So a stock old Mk1 Manifold

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Here you can see the old style angled injector mounts

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First job was to smooth them out and remove the old mounts

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Both sides done

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Next i tackled the throttle itself. It has no location for a Punto GT TPS and with my future power goals i decided to go for a 57mm (i think) Coupe 20V Turbo throttle body

So, cut off the original

Here you can see the coupe size vs stock!

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Needs a bit more taking off the stock manifold

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Machined some more out

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Then welded the new coupe TB flange and also new injector bungs for modern style injectors

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Started mocking up the rail also, needed some more work to get it bang level but needed to get the holes in place first

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Next up was the throttle cable, needed a new mount for it and i also wanted to suppot the inlet manifold like stock

Made this mount

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Goes here

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and has a step for supporting the manifold

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Test fit

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Quite a bit still to do on the manifold but nearly there... The reason the TPS is facing up is due to the ICV height. Normally the ICV would be straight up but there is no space under the bonnet

hence the TB rotation.

Right next up was adding the PGT Heatshield to the Mk1 manifold

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That should help

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Next drilled and tapped the servo fititng to take an AN fitting

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And test fitted the fuel rail mounts i had designed, these pick up on the original inlet manifold

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Also designed a new rocker cover

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All that was left was to paint everything up and refit!

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All was going well!

Then...

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Seems when the previous owner changed the headgasket the front row of bolts were either left loose or backed off! The bolts were spinning when i removed them!

New Payne Gasket and Bolts