Peugeot 505 Pushrod 4 Cyl Race Car Build Thread

"KanataSZ, Peugeot-lover in distress" (kanatasz) 11/01/2015 at 21:26 • Filed to: None

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Hello everyone,

As you may have read my 1987 Peugeot 505 STI V6 was totaled in a rear end crash on Wednesday evening (October 28 2015 at 5:39 PM... yes I remember it all that perfectly). Ever since this happened I’ve been looking for a replacement or what to do at least with the car - I found a friend from Alberta who wants to take on the task of giving a new life to at least the parts off of the crashed shell (rust free, never winter driven... won’t be ever now) and scrap the bare (and I mean bare!) shell after he’s done with it.

The exchange will be for RJ [name of the car] and two thousand dollars worth of parts sitting inside of it, as well as a spare PRV 2.8 motor with very low mileage off of a similar model/trim level/year car.

In exchange for all of this I will be receiving a straight bodied but probably slightly rusty Peugeot 505 shell, equipped with a 2 liter pushrod inline-4 with K-Jetronic CIS and a distributor ignition (codenamed “XN6” by Peugeot), and a 5 speed manual (BA7/5, for lower output cars compared to the BA10/5 in the Turbo, V6, and diesel models).
It will be equipped with 1985/86 pre-ABS model 505 Turbo suspension (stiffer spring rates and lower ride height) all around as well as the respective wheels (as shown in the picture), the interior will be FULLY stripped out with only a driver’s seat remaining and the rear fuel tank as well as the spare tire and jack/tools and barely any dashboard (Series 1 dashboard will be used due to it being lighter), the rear end will be a 4.11 final drive with limited-slip capabilities (clutch-pack type), A/C delete, power steering will be kept but a quicker turbo rack will be used. That’s about it for the modifications that will be made by the shop in Alberta.
TL;DR version -
- used decent condition 505 shell
- xn6 engine (1971cc 4 cyl pushrod with k-jet and dizzy ignition)
- ba7/5 (5 mt)
- 505 turbo suspension and wheels
- stripped out series 1 interior with only a driver’s seat remaining
- 4.11 rear end with LSD
- A/C delete
- P/S will be kept but turbo rack will be used

My modifications however? That’s another story!
Here comes a shitload of info about the engine itself (which will be my primary focus). First of all I recommend reading up about the engine by following this !!!error: Indecipherable SUB-paragraph formatting!!!
The stock XN6 makes only 96 horsepower with all the emissions stuff (air pump, catalytic converter)... that’s not enough for me!
Bottom end wise I will be changing pistons to XN1A (Argentina special version) to raise the 8.35:1 compression ratio to a more modern 8.8:1 [raises HP from 96 to 118 hp, when emissions controls are taken out as well], the crankshaft, connecting rods, and pistons will all be balanced, the camshaft will be given a MUCH more aggressive profile (Wade profile no. 112, as shown in link).
TL;DR version -
- only 96 hp [8.35 CP]
- emissions delete
- XN1A pistons [8.8 CP]
- engine balancing
- aggressive cam profile
Top end wise shaving the head 0.5 mm (and changing all gaskets for new ones) to raise compression ratio by 0.4 [9.2:1 CP by now], the head will be refurbished with lighter valves, uprated valve springs, shaved pushrods, exhaust ports will be ported fully to a better flowing design [follow link for more info], intake ports might as well use a bit of porting as well, polishing the combustion chamber a bit as well.
TL;DR version -
- shaving head 0.5 mm [9.2:1 CP]
- lighter valves, better valve springs
- shaved pushrods
- ported exhaust and intake ports
- combustion chamber polish
The exhaust manifold will be fabricated in stainless steel (as well as the entire exhaust system, which will be free flowing) and in a 4-2-1 design.
Injection system will remain K-Jet, and if needed will be tuned for more fuel delivery.
Ignition timing will be played with for more aggressive curve.
Since emissions controls will be deleted for the exception of the oil catch can / charcoal canister (custom made), the engine bay will be much cleaner since most vacuum lines will be gone.

Aside from the engine, the suspension will be worked AKA springs will be cut (mathematically perfected so no BS here), shock oil will be replaced with Honda motorcycle fork oil for thicker oil and stiffer shocks, the bushings will be replaced with Poly-urethane. Lower ride height, stiffer ride, MORE GRIP.

There will be a rollcage installed, the fuel tank will be refurbished and most probably moved further up front for better weight distribution, the rear door glass will be replaced with some lightweight alternative and it will not be possible to roll the windows down.

The tires will be replaced with Yokohama S-Drives in lower sidewall and wider tread (205/55R15 instead of 195/65R15).

Eventually the hubs will be modified to 4x100 instead of the odd-ball 4x140. Brake pads will be upgraded to deal with fade, rotors will be upgraded to Turbo 505 rotors with more ventilation properties, calipers will be kept as-is (plenty good), brake fluid upgraded to DOT5.1, rubber brake lines to braided lines, fittings upgraded to AN Fittings.

Cosmetically the car will receive a Turbo model front fascia (complete with shitty sealed beams... with projectors), the front and rear bumper will sit much more flush with the body (a bit of modification needed), E36 sideskirts fit perfectly so the M3 version will be used. Eventually there will be a completely flat-floor installed (probably plywood or maybe steel), and aerodynamic modifications will be performed.

Interior wise, the comfy driver’s seat will be kept for as long as I have to until I can afford actual racing seats or sportier bolstered seats off of some other car. Preferably racing seats so I can install racing harnesses (not cheaping out here, buying brand name so I don’t DIE!).

This car will be as close to an actual race car as possible while still remaining possible to daily drive the car if needed (as much as I will hate my life daily-ing it).

RallyDarkstrike - Fan of 2-cyl FIATs, Eastern Bloc & Kei cars > KanataSZ, Peugeot-lover in distress 11/01/2015 at 22:11

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Looking forward to this :D

CB > KanataSZ, Peugeot-lover in distress 11/01/2015 at 22:16

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Going to install a second seat so you can rally it this winter?

KanataSZ, Peugeot-lover in distress > CB 11/01/2015 at 22:18

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Next winter for sure. Sadly need to wait till the spring for Hugh to even come pick up the car!

Zipppy, Mazdurp builder, Probeski owner and former ricerboy > CB 11/01/2015 at 22:49

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this winter is the rallybeater, which should be soon enough

Zipppy, Mazdurp builder, Probeski owner and former ricerboy > KanataSZ, Peugeot-lover in distress 11/01/2015 at 22:55

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when engine work is involved, its often a better idea to do it all at once, from what ive experienced, unless it involves minor things such as timing.

KanataSZ, Peugeot-lover in distress > Zipppy, Mazdurp builder, Probeski owner and former ricerboy 11/01/2015 at 23:21

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Good idea. I would be doing this over the winter, I would be parking the 505 where RJ is at right now, preferably. Engine-less of course.

sdwarf36 > KanataSZ, Peugeot-lover in distress 11/02/2015 at 00:13

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Where did you find that pic? I know everyone in it-and you can see the nose of van.

KanataSZ, Peugeot-lover in distress > sdwarf36 11/02/2015 at 01:32

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I believe it’s on 505Turbo. That’s Arlo and Nick Cota’s 505 Turbo race car. I’m friends with Nick on FB, and I’ve been following his 505 Turbo race car build thread actively.
I take it you’re from the north-east?

KanataSZ, Peugeot-lover in distress > sdwarf36 11/02/2015 at 01:34

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http://www.505turbo.com/forum/index.ph…

sdwarf36 > KanataSZ, Peugeot-lover in distress 11/02/2015 at 07:07

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Yes. I meant to say thats the nose of my van in the pic.

Old pic-pretty sure that car is gone-and as of 2 weeks ago so is that Subbie. (Arlo tossed it in the woods.)

KanataSZ, Peugeot-lover in distress > sdwarf36 11/02/2015 at 15:05

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Oh man... good old Arlo!
The Peugeot is probably dead by now... who knows. Lots of work goes into those cars!

sdwarf36 > KanataSZ, Peugeot-lover in distress 11/02/2015 at 18:11

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I dont remember that paint-so I’m not sure which shell it was. Last one running Nick was driving. His last crash wasn’t that bad, but it was like crushing a beer can + folding it back + forth. At some point its gonna fail. It had been folded too many times. The had to scrap the shell. Arlo had just been running the Subbie. Well-until a couple weeks back. Rut hooked on the right-went across the road to the left onto a bank-kept his foot into for 100 yards-bounced over large rocks + downed trees-rolled + ended down a 50 ft bank on the right.

I’ve know him for 15 years-our wives are BFF’s. He’s been at it much longer. Check this vid from 1988. Zoom to the last 10 min or so.

KanataSZ, Peugeot-lover in distress > sdwarf36 11/04/2015 at 13:19

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Considering Arlo ran a racing team back in the 80s thanks to his dealership, I wouldn’t doubt he’s been at it for longer.

505 - morphine not found > KanataSZ, Peugeot-lover in distress 07/07/2016 at 06:30

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Hey, I’ve just been directed to this post by a fellow oppo, are you still building this car...? I have an XN1 505 as my daily you know... although in Europe, so parts exchange maybe too expensive. So how’s your build coming along?

KanataSZ, Peugeot-lover in distress > 505 - morphine not found 07/10/2016 at 12:29

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Oh, I changed to a 1985 505 Turbo! No XN for me anymore :) If you need Peugeot parts, I am selling parts off of my 1987 Peugeot 505 V6 :)

505 - morphine not found > KanataSZ, Peugeot-lover in distress 07/11/2016 at 03:20

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Turbo might be even better, a very nice 1985 Turbo got me to love the 505. Although I have no idea if there still are performance parts for that, don’t know if the people behind the Politecnic page are still working or not. How is the build going?