My Turbo Build

r&skxa

Gold Member
It's just been finished so this is just documenting what I've had done and a reference point.

Some of this is guess work on the dates, it's been a while so bear with it. It was supposed to take 3 weeks. It didn't. I don't want to name the 1st garage/mechanic although I'm sure most of you will know anyway.

The build started on March 12th 2016. The car was delivered to the 1st garage before that, but that's when the MOT was re-done so we will start it from there.
The MOT was about to expire so it was easier to get it done with the original engine as I then didn't have to worry about emissions for a year.

I managed to get a 1 owner from new, 100k mile Megane. My Clio only had 48k on it so it was always the intention that the engine was going to be rebuilt. 100k into less than 50k was never going to cut it for me.
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Megane went up to the 1st garage ahead of the Clio, so the engine could get pulled out and sent off.
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Couple days later the Clio then joined it and that was the last time it was driven in 15 months.

31st March and the Clio was stripped
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It stayed like for quite a while. By this time the Megane engine has been machined and it was back with the garage. It was totally stripped so it was decided to upgrade the internals slightly as it wasn't really going to cost much more. Megane 250 pistons and rods were ordered from SC Autos. As we were using 250 pistons and rods, we decided to upgrade the associated parts. 630CC injectors and a new Megane 250 Turbo was ordered from RPD.
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4th April vents and side skirts fitted (well holes made in the bonnet)
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Between 31st March and 3rd May, all parts from Renault got delivered so we had the gaskets and pumps etc but still no rods and pistons from SC Autos.

I asked for an update on the 11th May, no reply.
19th May, no reply.
2nd August.....got a reply! The garage has been given 2 weeks to leave the premises. A heads up prior to that would've been nice but I guess he had his own problems to deal with. He still wanted to complete the build just somewhere else. Fair enough, he had a good reputation so though I'd give him the benefit of the doubt.

I ended up doing the chasing to SC Autos to get the rods and pistons. I arranged the courier as he just couldn't be bothered.
This is what I got. 3 pistons and no rods. What good is that! I called him and he was shocked that I wanted rods too! I'm glad he shut down, the guy was a nightmare to deal with.
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Enough was enough, I got the hump. I spoke to Andy at Engine Dynamics and got some new PEC and Wossner parts delivered. It was never the plan to go even that way as far as the build was concerned, it was not a big budget project. I also still had faith in the Mechanic, although it was dwindling rapidly.

These were delivered to me on the 11th August
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Sent them to the mechanic and they were delivered to him on the 12th August. See how quickly things can be sent when you put your mind to it.

I thought it was finally getting done, so I ordered some other bits and pieces.

New style steering wheel from Tim Finch
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Boss, Sparco Revs seats, runners and bases from Demon Tweeks
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I went up to see the car 20th August. On the way I picked up a new gearbox from Josh Cooks R26 race car. Rebuilt complete with Gripper diff :smile:

I didn't get to see my car when I was delivering the other parts, but I did meet the mechanic and handed over the seats, runners and 'box.

Waited until 14th September for updates, messaged him and no reply.
3rd October, messaged for update and no reply.
5th October he messaged me saying he was going to start the engine build as soon as he was settled into his new job. By this time, I had actually found out the car had been sent to SJM. It took for them to contact me, I didn't know it had been sent there. It was in my interest to get the car recovered. My contract for work wasn't with SJM so whilst it was in their possession, it was't insured for damage or theft.

I told the 1st Mechanic that I was knocking it on the head. I'd had enough of him and had enough of nothing getting done.

10th October I had the car collected. I had already paid the mechanic to do the work, now I had to pay for a company to go and get the car to deliver it somewhere else. I also had to hire a car to get from Dover to Bournemouth so I could pick all the other stuff up from him. My other half had our daily so had no choice.

I called around asking for companies to take on the build. There was a lot of dead ends but came across Beaniesport in Milton Keynes. On the credit of Stubonez build in the PFC mag I called him and he agreed to take it on. Happy days. Car was delivered to him and I drove to him from Bournemouth with an Astra full to the brim of car parts.
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Home for the next few months.
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The engine had to be sent of again as Chris couldn't guarantee the work if it wasn't checked over.
By the 19th October it had been sent off and was skimmed slightly. The valves were pitted and needed replacing so as we had forged the pistons and rods, I decided that Supertech valves were the way forward. ED supplied the valves and forged parts.

27th October bottom end was built up.

31st October we had something that resembled an engine
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Spoke to Chris in between doing other things and decided that now we're forged with bigger turbos and injectors that I might as well improve the cooling side of things.
27th November, I had the Megane 70mm "low lagg" intercooler form Airtec delivered. Great piece of kit, heavy, but well made. The weight did involve Chris designing heavy duty brackets.
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12th December, clutches, flywheels and a decat were ordered and delivered.

21st December had another update. I know this isn't going particularly quick but I told Chis I was in no hurry and he had other work on. He took the car on as a project and he was always keeping me updated so I was Ok with that.
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Christmas came and went, Happy New Year and all that jazz.

3rd January, another update.
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There is another guy that works for Chris did some other bits on the engine build. He was an ex F1 and touring car chief mechanic. Having 2 perfectionists working on the car is always nice.
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Few parts were found to be missing. Few bolts , clips, nothing too major.

Chris then became a daddy so work stopped for bit. Again absolutely happy with that, I call that a legitimate excuse.

I went away on holiday for a couple of weeks and he sent me these, that was the 1st 2 weeks in March. It's in!!

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18th March gearbox mated to the engine, custom loom completed and fitted, suspension, Megane driveshafts all mounted. Still plenty to do but it's getting there.

23rd March another exhaust was sourced. I had already sold my Scorpion system as I was suppose to be getting something from 1st Mechanic but that never happened so Chris found me a Pure Motorsport one.

28th April the intercooler was put into it's final resting place
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For the next month it was finishing bits up and tidying it all up.
This was never going to cut it
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Another call to Paul at Renault Parts Direct and got this instead. Much better.
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Boost pipe powdercoated and Powerflex bushes ordered
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22nd June the car was put on the dyno at Engine Dynamics and pulled a very healthy 300bhp and 321 lbft torque
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Collecting the car from Chris on 29th June, as it needs another MOT now. It's done 0 miles since the last one so I'm not worried about that.
15 months from start to finish. Chris has been fantastic and anyone thinking of using him, you have nothing to worry about. He's helped me so much.

Below is the spec of the build and anything else that was added during the time it was away. What started off as a normal conversion, went a bit too far.

Engine and Transmission
Engine conversion to Megane 225 2.0 Turbo
Engine machined, re-skimmed and cleaned
Megane 250 Turbo (new)
PEC Forged pistons (new)
Wossner Forged Conrods (new)
Supertech Forged Inconel exhaust valves inlet and outlet (new)
Siemens Deka 630cc injectors (new)
Airtec Intercooler (new)
Heat wrapped Miltek link pipe (new)
Pure Motorsport Exhaust
Quick Shift (new)
RamAir Filter (new)
Forge Dump Valve (new)
Scanguage II (new)
Megane R26 Gearbox and Gripper Differental (sourced from Josh Cooks racing Megane)
Megane R26 Lightweight billet Steel flywheel and clutch kit (new)
Megane 225 ECU from Donor Megane 225 with Megane 250 software by RS Tuning. Coded to Clio
Remap and dyno by Engine Dynamics Colchester
Powder coated boost/intercooler pipe & miscellaneous parts
Air con deleted (would not fit with Airtec Intercooler)

Powerflex Upper engine mount inset bush kit Road Series (new)
Powerflex Upper engine mount torque arm bush kit Road Series (new)

Genuine Renault Sport side skirts (new)
Bonnet Vents (new)

Genuine Renault Sport Sabelt Steering wheel (new)
OMP Steering wheel hub boss kit (new)
Buttons for cruise control and stereo control (custom made)
Sparco REVS driver and passenger Seats (new)
OMP Seat mounts driver and passenger (new)
OMP Runners driver and passenger (new)
Genuine Renault Sport Gear Knob "R.S" Style (new)

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That's a fantastic build hate to think of the costs bud are you happy with everything now.looks amazing now it's all together you must bring it on the Jolly Boys outing next year
 
Dedication and perseverance should be in the title !

So....have you still not actually driven it yet ?
 
Cheers for the write up Rob. What an emotional rollercoaster that has been. You must be so relieved that chapter is almost over and you can actually start enjoying the car.
I did actually see Beanie Sport mentioned on Facebook a few times and looks like the best place to get the conversion done for peace of mind.
 
what a write up..!!looks like you are a very happy bunny atm..not long to go before collecting..
have you got a picture of your bonnet vents??
where did you get the Airtec Intercooler from pls??
 
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What a crap story, I read about similar things on many different forums. It's such a shame but I'm glad you kept going and got it sorted, bet you cannot wait to get into it and use it now!
That jump in power and torque is going to be phenomenal!
 
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That's a fantastic build hate to think of the costs bud are you happy with everything now.looks amazing now it's all together you must bring it on the Jolly Boys outing next year

I'm too afraid to add it up lol. Yes I'll be there with bells on

Dedication and perseverance should be in the title !

So....have you still not actually driven it yet ?

I had to think about it. I was either going to lose money selling it as a project or lose money completing it. Stuck between a rock a hard place! Not yet. Thursday will be the 1st time. Pretty much go and collect it and back to Dover to put it on a ferry.

what a write up..!!looks like you are a very happy bunny atm..not long to go before collecting..
have you got a picture of your bonnet vents??
where did you get the Airtec Intercooler from pls??

Yes I'll get one put up. The intercooler came from Auto specialists.

Cheers for the write up Rob. What an emotional rollercoaster that has been. You must be so relieved that chapter is almost over and you can actually start enjoying the car.
I did actually see Beanie Sport mentioned on Facebook a few times and looks like the best place to get the conversion done for peace of mind.

Tell me about it. I know it's only a car but it properly stressed me out.
Chris has been brilliant throughout. I did go and see the car a few weeks back just because I didn't have anything to do and fancied a road trip, the work he had done, the engine was in the car at the time, looks like it's from factory which is exactly what I wanted. Everything is so tidy. Really impressive stuff.

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I live in Dover, but going to Nurburgring early doors Friday morning.

Sent from my SM-G935F using Tapatalk

Oh my goodness !

No shakedown, no test-run.....just straight into the fire.

Have a cracking time there. The right place for this car for sure :smile:

Be safe and have immense fun.........
 
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Great write-up. I had a similar experience with my build, but it 'only' took 3 months instead of the 2 weeks originally quoted. Can't imagine your frustration but as I said in another thread you won't be disappointed with the resulting car.
 
Mate, this is amazing. A whole year of a build thread (ok it should have been less, granted) in one post!!! Epic work.

Firstly, if the shady arsehole who messed you about in the beginning is still in business, you should absolutely name and shame. But that's you call to make, fair enough. Be a shame for other people to be throwing money at him though.

Hats off to you for sticking it out. Hope it's all worth it when you do your first few laps. It seems like it's going to be!
 
Wow, what a thread.

Well done to you for your perseverance!!

That engine cover not going to give you heat problems?
 
Wow, what a thread.

Well done to you for your perseverance!!

That engine cover not going to give you heat problems?

nah it doesn't, only thing it did on mine was peel the Renault Sport stick off, but I think that's more down to me not using enough high-temp lacquer:oops: I used normal Albi Blue paint on it though and it's fine so I don't think it gets that hot.
 
which radiator have you got??

Just the Meg radiator. I'm sure I heard a few run Evo radiators though.

Mate, this is amazing. A whole year of a build thread (ok it should have been less, granted) in one post!!! Epic work.

Firstly, if the shady arsehole who messed you about in the beginning is still in business, you should absolutely name and shame. But that's you call to make, fair enough. Be a shame for other people to be throwing money at him though.

Hats off to you for sticking it out. Hope it's all worth it when you do your first few laps. It seems like it's going to be!

He's not. I think he knew he was going under so took as many people as he could, down with him. I wasn't the only one he stitched up. There were a few.

nah it doesn't, only thing it did on mine was peel the Renault Sport stick off, but I think that's more down to me not using enough high-temp lacquer:oops: I used normal Albi Blue paint on it though and it's fine so I don't think it gets that hot.

Hope not, that cover took ages lol
 
Saw your car in the flesh on Saturday morning at BeanieSports!!!! WOW what a beast, it looks ready to hammer on track.....