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Birdman's B204 MINI (Mid Engine RWD)

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  • #31
    The way I have set things up now, the car should run pretty low with floor and sump 4" from the ground. 4 to 6 inches suspension travel, depending upon the angle I incline the coilovers at. I will have a steel sump protection tray, try to work on air under the car and probably have a diffuser.
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    • #32
      Now to see if the corsa c saab conversion mount will work out good... 20200501_082829.jpg
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      • #33
        OK, so I started on the belts end of the engine on the weekend. Hit a few issues. There are various belt / idler setups , the Saab 900 setup being different from Saab 9000 that I have. Then there is the fact that some have power steering and aircon etc. .. What I hadn't realised is that the pullies have different offset between the two models as well. I believe this is due to a steel water pipe that wraps closely around the timing cover , with the 900s having a different piping system. So the extra pulley on my Corsa mount is offset wrong.

        This can be remedied with grinder and welder of course. I took off the top engine steady, bracket and power steering pump, all of which I should not need and can recycle. This has saved a few kilos. I hope to use a split driveshaft setup from a 900, on which the intermediate bearing carrier is also a bracket to relocate the alternator down low. Still have not worked out the belt run, due to many idlers on Saab 9000 setup, but will push on for now.

        Set about modifying corsa / saab top mount, so I can raise horizontal frame tubes upwards to mount to. 35451432470_0c70eb27c3.jpg20200502_105049.jpg20200502_105103.jpg
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        • #34
          Yep, just realised that the diagram really shows saab 900 belt run options. Need to look up 9000 options now. Parts remove in pics and redrilling the main mount bolt hole further up the bracket. 20200502_112049.jpg20200502_121445.jpg
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          • #35
            Then I tried to move the frame over an inch to give some more trailing arm clearance on the gearbox side. Lots of swearing and mucking about later and it looks practically that I can only get 1/2 inch there, because I would have a clash between frame tubes and pullies on the opposite side. So it would appear that like my XE build, I will again be fighting for every millimetre I can get in some places.

            Will need to keep funding this budget conscious build, so I set about refurbing the monster driveshaft setup I have from Chevrolet v8 pickup. I do not think I can use these shafts and hubs now, but once cleaned, degreased and painted, they look like they should fetch a few quid. Really enjoying being back in the workshop... 20200503_163438.jpg20200503_163449.jpg20200503_163455.jpg
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            • #36
              Some pics of fuel tank, short shifter and hydraulic handbrake... 20200504_132457.jpg20200504_132801.jpg20200504_132618.jpg20200504_132541.jpg
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              • #37
                OK, what has been going on this weekend...? Have been playing around with some old spare Vauxhall driveshafts to help visualise driveshaft angles. Unfortunately the inner CVs are splined for big block Vauxhalls like F20, F18 and F16 gearboxes so won't go fully into F23 Diff with different spline count, but they helped to give some approx lengths and angles.

                The output from this is that I have decided to follow the Vauxhall or Saab (GM) route and leave autograss Ford Sierra stuff mainly out of the equation. This is because the cost was too big sourcing the parts and I am dealing with GM gearbox. I am really trying to keep the overall width of the back end to something acceptable. Needs to be not too stupid looking and to be able to go through garage doors. Width at the back I think is between 14 - 16" extra width at present with the 205 tyres being 8" wide.

                I hope to get away with not having to shorten / lengthen the driveshaft on the drivers side and I believe that I am looking at either Astra G single piece shaft, Saab 93 old generation intermediate or 900 shaft incorporating alternator relocation bracket as part of the intermediate bearing carrier, Or some hybrid mix with Corsa C outer shaft. So, the split saab shaft setup is not so easy to source but I think the Saab 95 bearing carrier bracket might be the same and then I can get the other parts from a saab 93/ saab 900.

                On the other side I might get away with a Corsa C small shaft , or have to make up a custom shaft. Whatever is stronger will probably now be the preference...

                20200509_120237.jpg20200509_120228.jpg
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                • #38
                  Please excuse the rubbish welding you see in some pictures, none of it has been done by me. This build will take some time, but I am trying to move along with things so I can get the drivetrain in, mounted and without clashes. The other issue I have is that I have to keep an eye on the spirit levels, because the sheer weight of the unit is slowly crushing my trolley's wheels that it is sat upon.

                  It occurred to me that if I start with the std GT25 Turbo and manifold, I would need to now if my higher power setup would also fit without major changes down the line, so I set about swapping it out too see if the huge 3" downpipe will fit between the sump and gearbox. Couldn't have been happier with the result, as it fits spot on, so car can be run ultra low and downpipe enclosed by planned undertray. 20200509_104409.jpg20200509_104344.jpg20200509_104334.jpg
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                  • #39
                    Pictures of it fitted. Sorry about the crusty cam cover, must get that sorted 20200509_122737.jpg20200509_120057.jpg20200509_123021.jpg
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                    • #40
                      Some more... 20200509_120140.jpg20200509_120156.jpg20200509_123034.jpg20200509_123004.jpg
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                      • #41
                        In between doing that, I have been practicing some tube notching freehand, as I will have 4x compound notches to do to reinstate the frames horizontal bars higher up. I keep slowly fettling those and placing them back onto the frame to check for clashes. You can also see from second picture the width of rear end. I will be using some specialised Vaux hub converters inside the rear trailing arms that take a Vauxhall wheel bearing and allow the use of outer Vauxhall CV Joints. 20200509_155358.jpg20200509_122908.jpg
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                        • #42
                          So now it is time to order some Ebay parts and shafts and hope my measurements / plans work out. I am happy that the turbo and downpipe fit and will probably just go straight to this setup now, however buying a clutch to take that power straight off will be an expense as it will need to be a paddle clutch and uprated cover. Not sure how long the F23 Gearbox will cope with the power hike...
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                          • #43
                            Has just dawned on me that I will need a better intercooler for the setup than the one I have right now..
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                            • #44
                              Looking at my downpipe it seems to have been made by or using components from Profusion. Googled them..

                              Link to their site: https://www.profusionexhausts.com/


                              I'm liking their exhaust and manifold component prices
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                              • #45
                                Nice and reasonable. Bookmarked. Good find Birdman.

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