Dunc's Mk2 Uno 2.0 16v Turbo Thread

[Dunc]

Well, i thought i would start a new thread on my 1992 K Plate Mk2 Uno. I did have a huge thread with lots of pictures on the old turbo Collective site, but unfortunatly all was lost when the site went down

Anyway, this thread might not be as detailed, but it'll give you all something to look at and see where i am up to with the Uno.

So, November 2008 i bought this 2 owner, FSH, original bill of sale, 46k genuine mileage Mk2 Uno 1.0 i.e.




POWER!!!


Bit manky looking!


I used the car like this for a run about for a while, and during this time i slowly did a few small things to it like colour coded the wing mirrors, fitted clear indicators, did a few other bits to make it more Turbo replica, painted the arches and fitted a refurbished Jamex Suspension kit. Basicly i raided my spare parts as i still had the Green Mk2 Uno Turbo at the time.

So heres a few general pics for you all during this time which was over about a year whist in use as a run about.











Fitted a turbo interior


BEFORE


AFTER








I fitted UT clocks which i adjusted the mileage to the correct mileage of the car to keep everything genuine and legal!




Picked up a set of headlight protectors (first of 2 sets )


Picked up some cheap wheels off my mate Smed




Got round to fitting the front and rear UT arches along with the side skirts. I also tried on some 14" Fiat Tempra alloys i had....the tyres were knackered so they didnt stay on, just for the picture.




This is how i was driving it about, lowered on Jamex kit with a full UT bodykit fitted. I Still had my Green UT which was my priority, so getting the wheels fitted were down on the 'to do' list at this point.


I also had started collecting a few bits to turbo it. It was always gonna happen wasnt it?? lol This was around 2010 ish




Eventually got hold of a UT front bumper


Fitted


Painted the strips back up as they are all faded to orange rather than the red they should be


Next up, i decided to clean the front arches to match the clear rear ones......dunno why, as it was still a 1.0 at this time! Heres a few pics







And i eventually got a set of Yokohamma S Drive tyres fitted to the 15" Fox alloys




And thats how i used it for a bit. a full Uno turbo replica (with a 1.0 engine!) It was around this time, the green uno turbo was sold.

I decided to modify a 1.0 downpipe with the help of wayne. We fitted a Uno Turbo flange onto the end of the 1.0 downpipe so i could bolt up a UT Scorpion exhaust to complete the Replica look. hehe!








I then jacked it up and decided to clean the arches again and paint the whole underside......








Finished!


And this is how it was then


being as the my other uno turbo was now sold, i used some of the proper parts as i was now loving the white uno!

Coilovers on


Bought some standard mk2 UT alloys


and then slammed the coilovers and fitted the mk2 UT alloys! remember....it was still a 1.0 at this point! but i LOVED how it looked!


I decided that i wanted to go 2.0 8v turbo now instead of the 1.4 UT engine. So all that was sold. Shaun who used to be on here and built a 2.0 8v was the culprit for wanting me to go down this route! So i started buying bits ready to convert it in the future.

Fiat Croma 8v Turbo Engine bought


Lancia 1.6 HF Turbo FWD gearbox bought. very simlar to the mk2 UT box.


Then i did a UT rear disc conversion


fitted






My compomotives off the old uno then went on along with the brembo 4 pots off the fiat coupe




Genuine Fiat wind deflectors


And this is how it was..........STILL A 1.0 REMEMBER!!! looked mint though lol


picked up a Eibach anti roll bar. These are 18mm thick, compared to the standard UT anti roll bar which is 14mm




Built up the 2.0 8v turbo engine. i never rebuilt the bottom end.....which i should have which u will see later on


ignore the HUGE turbo lol


bye 1.0 engine!


newly powder coated subframe with new Powerflex bushes and Eibach ARB fitted!


wayne stich welded the engine bay for me, cheers mate


engine bay painted!


next few pics are of general building/fitting of the 2.08v turbo lump.....








turbo peddle box fitted


B&M


more build pics....




















Running!!!




modified driveshaft!




new Compomotive TH2's!




in my old garage!




mileage at this time on the car. This is around 2011/2012


MOT


new leads


lol




Mine and Smeds together and one of the only times we have had unos on the road together at the same time LOL




new seats




More to come! But this takes us up to about summer 2012 when it all went wrong and the piston rings went! Serves me right for not rebuilding the bottom end!

TO BE CONTINUED

Dunc

[gtirx2]

Oooh I have seen this one before   

I am liking the new seats,they suit it well   

[Dunc]

Oooh I have seen this one before   

I am liking the new seats,they suit it well   

indeed you have

Im well pleased with the seats......not so new now....that was 2 years ago lol!

Dunc

p.s. just uploading the next batch of pics to bring the thread upto date!

[Dunc]

So, to continue the thread.......end of summer 2012, i blew the piston rings. It was smoking like a chimney. im guessing 160k on the bottom end didnt help! lol!

Anyway, i was going to rebuild the the engine, but decided to just go for it and fit the 16v version of the twincam lump. Found in Fiat Coupe, Lancia Integrales as well as a few other 2.0 16v turbo'd lancias.

So i got myself a running Fiat coupe with a genuine 57k miles from new on the clock. Shame the car was a little ropey (had been bumped and rebuilt). But the engine was standard, it ran MINT and no smoke what so ever. Perfect for what i wanted!

Heres a few pics! NOTE: Garage base is now down, the old wooden garage is long gone! This Is Summer 2013 by the way (yeah i know i didnt touch the car for ages LOL!)



Started to strip the engine



Last pics of it with the 2.0 8v Turbo lump in place


Engine out




Coupe engine out!




8v on left, 16v on right


Now, as they are basicly the same bottom ends, gear boxes between all twincam engines, be it 8v or 16v are interchangeable depending on what you want! Now, on my 8v engine i ran a Lancia Delta 1.6 HF Turbo FWD gear box (looks very simlar to a Mk2 UT box). To keep things simple for now, i fitted the HF turbo box to the coupe 16vt engine so i can use my existing gearbox mounts. BUT, i can't use the custom mount on the cambelt side as the mount point is different. It's hard to explain over the internet. But trust me....its a ball ache as you will see going from 8v to 16v

Engine in place, gearbox mounts on, jack holding the cambelt side up (no mount fitted)




Can see the HF box here


close






The problem is that the 16v turbo engines run balancer shafts, and therefore the belts go as follows...

8v engines - CAMBELT > AUX BELT
16c engines - CAMBLET > BALANCER SHAFT BELT > AUX BELT

and hence, the aux belt actually would run where the chassis rail is on the uno.........

So, i decided to use the Fiat Coupe engine mount on this side of the engine.

Fist off, i cut the actual mounting point out of the shell of the coupe. You can see the mount attached to this (rusty!)


FROM NOW ON YOU WILL NOTICE I HAVE A NEW GARAGE!! WENT UP IN OCTOBER 2013

Heres the turbo i shall be using. Standard 16v Turbo Coupe one on the Right, my T34 Hybrid on the Left. Considerable bigger.



Mount fitted to the bracket off the engine. Then checked to see if the wheel would still go round LOL



Mount welded into position with supporting bar


inner arch notched ready for new chassis rail




Wayne Welding...cheers matey







As you can see, it has a nice slant on it to allow the suspension to be fitted lol!





Next up, boxing in the mount


Some purchases (ignore the stonechip.....this is shit, i didnt use this!)


Took all the underseal off


Tickled all the welds up to make them very neat. Wayne had truely made sure they were full penitrated (ooo errr). I then etch primed the inner arch and then seam sealed it.




Then i took some brave pills............Goodbye chassis rail! The new chassis rail now on the wheel side of the inner arch goes way past the end of the old chassis rail so there is an over lap. This has been fully welded up and well penitrated. Wayne welds for JCB, so know what hes doing


etch primed again after sealer


getting there


Decided to use the Fiat coupe 4th engine mount. The stabilising mount. Trimmed ready to weld!


Also got given this rear part of an Ex Uno Challenge Roll Cage.....may use it, not sure yet!


Decided to make a removable slam pannel for ease of getting the engine in and out and getting the turbo off (they sit at the front of the engine on a twincam lump)
I wanted to make sure it looked factory, so got wayne to weld plates in and weld nuts on the back to its eay to fit and remove.


Chassis rail finished off neatly at the front of the car


4th engine mount bracket welded on


Getting there with the removable slam pannel!


This shows how ive neatly ive removed the chassis rail. I am obsessed with making this car look factory!




U-POL GRAVITEX going on the inner arches. LOVE this stuff!


Seam sealed the joints around the engine bay as i left these before when it was previously stich welded by wayne whern the 2.0 8v lump went in. Looks neater sealed IMO.


getting there!




Fully coated in Fiat 210 White and laquer, including over the UPOL GRAVITEX.


First part going back on! The coupe engine mount!




New Avo Coilover boots!


Cleaned and painted coilovers


One thing ive always wanted to do was spray around the windscreen satin black. This is how all turbo were front the factory (mk1 and mk2). Even though mine isn't a genuine turbo shell, i want it to look exactly like one!




First batch of goodies back from the powder coaters! The quality is brilliant! really really pleased!



Wiper motor refurbished


Some more bits going on


New suspension topmout bushes and roller new roller bearings


And some pics of where its pretty much at now.......












Now, it is taking me a while, but over the last year ive got married, had a garage built, continued doing my house, had extension built and run my own business. I cant do everything LOL!

Plus, this time i want everything to be spot on. No short cuts, no rushing, just get it done in my own time and how i want. And now i have a PROPER garage instead of a wooden shack/working outside i can do this.

Also, this isn't exactly a common conversion....its a massive learning curve! and me being fussy and wanting it to look like fiat could have built it does take me longer lol!

Will now keep this thread updated

Enjoy!

Dunc

[jas_racing]

Incredible work, keep it up!

Next year a Coupè 20VT conversion?  

[Dunc]

Incredible work, keep it up!

Next year a Coupè 20VT conversion?  

cheers mate. Regards the 20vt conversion, personally i prefer the 16vt lump as its more retro old skool 4 pot turbo power! And, the fact that me and a friend have actually tried to physically fit a 20vt into an uno bay, it's never gonna happen lol!

Dunc

[richvans]

Nice job!

As well as my Trackday Uno, i have 16v Integrale, I'm doing a lot of welding / bodywork at the moment.

A lot of owners seem to remove the balancer shafts and belts, apparently it will run fine without them, some say rev easier! I don't know if that would have made your fit easier?
(i've left them in on mine as engine is running sweet, just renewed all tensioner bearings / belts)

Chassis works looks good though, you should CNC up a 'UNO TURBO 16 VALVE' cam cover!

[Dunc]

Nice job!

As well as my Trackday Uno, i have 16v Integrale, I'm doing a lot of welding / bodywork at the moment.

A lot of owners seem to remove the balancer shafts and belts, apparently it will run fine without them, some say rev easier! I don't know if that would have made your fit easier?
(i've left them in on mine as engine is running sweet, just renewed all tensioner bearings / belts)

Chassis works looks good though, you should CNC up a 'UNO TURBO 16 VALVE' cam cover!

Cheers rich!

Regards the removal of the balancer shafts, this is something i am going to do. However, this only removes the balancer shaft belt, it doesn't bring the Aux belt further in. This will still run in the exact same place. Hope that makes sence!

Dunc

[Mintys-turbo-mk1]

  Great work Dunc

Must come up and see you soon. Is the smaller turbo the T3?

[Dunc]

  Great work Dunc

Must come up and see you soon. Is the smaller turbo the T3?

yeah you must! lol!

Yeah the smaller turbo is the T3....and is yours as you paid for it ages ago! Its sat here with the manifold and the ignition leads!   

Dunc

[st1allstar]

epic build, hope it all goes well dunc

[Dunc]

epic build, hope it all goes well dunc

cheers mark! I'm busy cleaning and painting, getting things powder coated, engine being spruced up...it's all coming on well. So hopefully, the best is still yet to come! Things are a little slow at the moment, but soon be onto bolting things properly together!

Dunc

[le1gh]

looks ace dunc ,ist there any mounting point on the coupe for where the lancia engine was ? as oppose like pgt has the uno mount could be fitted

[Dunc]

looks ace dunc ,ist there any mounting point on the coupe for where the lancia engine was ? as oppose like pgt has the uno mount could be fitted

Cheers leigh,

Unfortunatly, its all down to the balancer shafts. The engine mount on the 8v comes off the water pump, but on the 16v lumps, the water pump is totally different (even though the bolt patterns the same), it actually bends round the casting in the block for the balancer shafts and there for the engine mount isn't on this, it's totally different and hangs off the oil filter housing. Hope this makes sence! Taken me 4 years to work out all the differences and changed between the 8v and 16v twincam lumps!

Its massivly difficult to explain on the net. I need to show people with the different water pumps in hand and both engines infront of me lol

Dunc

[doody]

i'm looking forward to this getting done and running, it's going to be a quick car.

[Dunc]

Well, i've done a bit more on the Uno. But as always, life seems to flash by and weeks just go! Holidaying to NYC and Orlando don't help lol!

Anyway, heres an update from the last couple of months! sorry its not much!

First off, my plastic top mounts were knackered! cracked, split and bits missing!


So, Paul (Unograle) sorted me out! Theyre like brand new!


I stripped the underseal off the passenger side back to metal and re applied it all so it matched the drivers side.






Heres a couple of pics i took randomly of bits going back on








Sprayed up the fuel rail


New oil filter (note genuine )


Got the rocker cover back from the powder coaters. Its finished in a wripple effect black!


This shows the wripple


I then sanded and polished the raised areas! pretty pleased with this!


More powder coated parts. These are just done in gloss black


And one grubby engine out of the coupe! Perfect runner, genuine 58k miles, 100% standard.




messy garage! not normally this bad!


More parts powder coated. As you can seen i had the rear strut brace finished in the wripple!




powder coated Wripple finished on the inlet manifold!


New gasket set. Not going to use 50% of these as im not splitting the engine, but its the cheapest way to get the gaskets!


Now onto cleaning and painting up the engine and fitting some freshly powder coated parts!



Really pleased with how its looking




As you can see, i polised up the raised lines on the inlet manifold too




Had my front strut brace powder coated in the wripple finish to match.






I then started to fit my refurbished Avo Coilovers, lower arms, hubs etc






Nice attention to detail shot. all powder coated parts and new bearings with new plastic top mounts


rare Eibach 18mm Anti Roll Bar fitted with Powerflex bushes. The whole car is fitted with these FYI lol




Bemebos cleaned (not painted, will get another set refurbished later) and discs all cleaned up and painted to keep them fresh


Brake servo refurbished and painted and wiring starting to go in




Oh, and resprayed the wing bolts lol



That pretty much brings me up to date. There are a few other bits i have done, but im now waiting for my cambelt kit and balancer shaft removal kit to come. Once these are fitted, i only have to refit the sump once i have welded on the AN-8 turbo oil return to it and painted it and then the Engine is ready to go in. Oh, and clean and repaint the gearbox!

I have put the Coupe 16v turbo engine wiring loom in as best as i can too, but now need the engine in to start wiring it up!   


Dunc

[st1allstar]

looking good dunc! what are your plans for the engine? are you leaving the lump standard?

[Dunc]

Hi mark, plans for now are to run the actual engine as standard as it has only done a steady 58k from new and never been modded. It's a great runner as i could test it when i bought a complete coupe. They are 195bhp as standard, so with my T34 Hybrid, exhaust, filter, FMIC, cossie grp A fuel pump, adjustable fuel reg, more boost and a remap i should see a steady 260bhp without straining anything.

My overall plan is once i have ran the car for a while, i will build another engine on the side and go for 350/400 with forged goodies, aftermarket ecu and bigger turbo etc. but this will be a way off yet.

I just want to get the car drivable and iron out any issues etc with it being an un common conversion. dont want to build a mega lump and then find for some reason it'll never work! lol! (not that thats going to happen as ive researched like mad!)

Dunc

[st1allstar]

sounds like a good idea just put the engine in as it is, even with 260bhp it will be a monster how long is it going to be till its on the road?

[Dunc]

time scales, im aiming to have it all running mint and setup buy the end of the year. Will MOT it asap around xmas time, then all i have to do is tax it once sping arrives in 2015. Then i can just tinker and develop and tweek during 2015

well.....thants the plan! i have pretty much everything i need to complete it now! oooo, except sending my ECU off for de-immobilising!

Dunc

[jas_racing]

Looking stunning Dunc, it'll be a beast when done but also a superbly engineered one! :-)

[Dunc]

Looking stunning Dunc, it'll be a beast when done but also a superbly engineered one! :-)

cheers mate! Hopefully it'll be pretty damn clean...maybe not your standard, but still very clean. It's going to get some hammer on the track too tho lol!

fingers crossed its engineered right...and doesnt pull itself apart lol!

Dunc

[richvans]

Looking good, great that the ECU on these is mappable

Also top job with the ripple cam box, i've got to do my Integrale one also, tried some of the crinkle in a can on my Uno's cam cover but the finish was crinkly but very matt.

Did you just block through the powder coat with sand paper?

[Dunc]

Cheers rich! Yeah i did exactly that. Sanding block with 80 grit, then 120, then polished with Autosol! Took a bit of work getting through the powdercoat, but really pleased with the results!

Dunc

[Dunc]

Well, a little update for you all.

Been doing a fair bit over the last couple of weeks. Lots of cleaning, painting, de-greasing, and working out! lol

Cleaned up my gearbox and clutch cover. The clutch has only done 500 miles, but a lick of paint cleans it up....not that u see it LOL!


ooooooo fiat!


Shiney shiney!


Un masked it and painted up the black bits.



Next up, my Balancer Shaft Removal Kit from Deltaparts. Great quality bit of kit, but damn fiddly to fit in a engine even with the engine out the car! Can't imagine doing it with the engine in the car!


Now, i must admit, i have been a little slack with the pictures. I do apoligise! Ive just been getting my head down and building!

So, with the Fiat coupe 16vt flywheel bolted back on, my fiat croma turbo uprated clutch bolted up and the Lancia Delta HF turbo gearbox cleaned, painted and bolted up to the Fiat coupe engine, it was fitting time!!!

.........It's IN!









Now this was a week ago. Since then, it doesn't look like ive done much, BUT, i've been starting to wire it up, work out which halfshaft holder and halfshaft to use (coupe, delta, uno?!?!) and fitted water pipes and bits that you can't even see! all time consuming!

But, he is a picture from this morning. Cambelt all fitted and timed up, water pump fitted, water pipes at the back of the engine fitted and wiring going in.

Cambelt cover on, for a factory OE look


Water pump pulley at the top of the pic, and the Alternator pulley at the bottom! TIGHTER THAN A NUNS CHUFF!!!!!!!!! not much room!


Water pump close up. You can see in this picture where the chassis rail now ends


And a couple of overall pics


Boost pipe and more wiring etc


Bottom pulley yet to be fitted, but this picture gives you an idea of how it all bolts in




So, thats all folks!

Next jobs are as follows....

Fit Halfshaft holder and half shaft
Clean up and fit throttle body and plug in wiring to this
fit bottom pulley
clean up and paint alternator and fit it

Cheers

Dunc

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