Project Double-stock HDi - On hold pending removal of thumb from arse

[Fozzy]

Pikey midbox back box FTW

[Niall]

This is starting to look really good mate. If you ever need any help, you know where i am

[Poodle]

The R70 came with a regulator, yes. Don't assume all refurb'ed pumps will do though, phone to check beforehand as most companies don't include it as standard.

Cheers Niall, might just take you up on that if ever you're passing.

Had a bit of a shit afternoon on it tbh, beam was being a bastard, sort of. Several nuts and bolts have gone missing since it's been in my care, so had to dig out replacements, then there was my mate's... don't want to sound ungrateful for the help, we'll call it enthusiasm... cue two mounts with the thread stripped/damaged beyond repair and a smashed up brake pipe...

Never mind, will have to fit the low-mileage mounts i've got hanging about and rob the hard pipe off the old beam, then try again another day. Preferably with a different helper lol.

End of play for the day:



Not as far as i'd liked, but progress all the same. Still excited by shiny.

[Dum-Dum]

This is why i was avoiding helping with your beam.

Looking good though mate.

[Poodle]

Hahaha funnily enough i did think it was a lot like you minus the mechanical sympathy. No offence meant of course.

Tackling my fronts today, just to do something pleasantly easy for a change as much as anything.

[Poodle]

Had a read through the first post and realised i should probably update with new ideas/changes to plans. Obviously the springs/b4s idea has gone out the window now i have found good coilies at an acceptable price, and it's rapidly becoming clear the exterior is only ever going to be somewhere between sleeper and rat.

On more technical details...
Fuelling-side i've got some plans, keeping it quiet for now until i know it works though, will just say it involves shorter durations. The idea of a home-brew pump has been shelved for the time-being until i've got the time and money to look into it properly. The EGR system is also staying while i do some research on it's relation to economy. I will be fitting the tweaked turbo, fmic and 1800 bar sensor in the next six months, but first i want it mot'd and to be able to make sure it's running properly.

[Dum-Dum]

You know where i am if you want my discount on the FRPS

[Poodle]

Rad, cheers babes.

[Poodle]

Not had much time off work recently, but have been making up for it in the last couple of days.

Dan came round Wednesday to help me fix the mess at the back end (giggidy), so now there's the new mounts on the beam and it's back where it should be, managed to get it done with no further incidents. I've also hung the centre-section properly, fitted and plumbed in the '6 calipers with new pads and discs, fitted the coilies at the front and sorted out the handbrake.

Want to try and mot her before the end of next week really, as the other ones' due on the 15th and i'm not sure she'll pass.

[samass]

what are you plans for the underside? aero wise i mean. this is what im doing my disseretation on btw... told you we should knock heads

[Poodle]

In the immediate future? Simple front and rear undertrays and a splitter, nothing too complex yet. Many more ideas in the bag though, we do need to talk about this.

[samass]

Mmmmm liking ideas of aero tastiness! Need to get a model on the go

[Poodle]

Been held up by another 12-day working week. However, i've kept working on her in between work and the rain so she is nearly ready to go for her MOT, all that's left is to fit the front end and bleed up the brakes. Will update properly when i get a spare moment, watch this space!

[Dum-Dum]

good times babe, cant wait to see you able to drive this.

[Poodle]

She's rolling. Exhaust is bouncing off the subframe and the brakes are shocking, but otherwise she feels good. Going to be be fixing the remaining issues and doing a bit of fine tuning, want to have her MOT'd by next Thursday (so i can take her to the crimbo meet). I'm a bit behind schedule there, but I had to do some work on the other car to get it through it's own MOT too, not as much as i expected tbf to the shed.

Once she's MOT'd i'll be doing some work on the aero, then it'll probably get paused again while i sort out the other car for sale.

[Dum-Dum]

OMG its moved !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!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[Ben Jay]

She's rolling. Exhaust is bouncing off the subframe and the brakes are shocking, but otherwise she feels good. Going to be be fixing the remaining issues and doing a bit of fine tuning, want to have her MOT'd by Thursday. I'm a bit behind schedule there, but I had to do some work on the other car to get it through it's own MOT too, not as much as i expected tbf to the shed.

Once she's MOT'd i'll be doing some work on the aero, then it'll probably get paused again while i sort out the other car for sale.

in regards to aero what ideas do you have?

[Poodle]

Hahaha yeah first time it's moved under it's own power in over 12 months now, so i take my time, and what. :p

Um, says up there dude. ^^^

[Matt]

Nice tinted rears

[Fozzy]

Good news that its moved, i Thought you would break the other car for parts.

[Poodle]

Haha ta Matt, they suit it cos their rough as f*ck. :p

I did think about that Foz, but it's not worth it at 175k.

[Poodle]

To sort the binding rear brakes i picked up a pair of calipers from the scrappy and refurbed them myself with new sliders etc. However, plans for MOT'ing this in the near future have temporarily ground to a halt, mainly because i can't work out what's causing the appalling noise when i drive it forwards. Turns out the exhaust is nowhere near the subframe, so i don't think it's that, the noise seems to be coming from the osf hub area (at least it does when it's up on axle stands, hard to pinpoint the source when i'm driving it), maybe driveshaft or wheel bearing...? Can't feel any play and the cv boots look good, so nothing obvious to suggest a problem. And it doesn't add up to me either, why only in forward gears and not reverse...?

Now i'm just waiting for some good weather/daylight outside of working hours so i can fit the brakes and work out what the fook is going on with this noise.

[Poodle]

Slow progress as i'm still uber busy at work, all my recent days off have been taken up with either the christmas meet or helping my mum move house lol (for the fourth time in as many years, fickle doesn't begin to describe... ). Managed to get to it today though, so update time.

Turns out the grinding from the nsf hub was unrelated, just something caught near the caliper where it wasn't visible. Credit to Sean-306 for giving me the idea to solve the main noise, turns out the lower engine mount was rubbing on the strut brace under load. It's a good job it was resolved so quickly, i'd only done maybe 100 metres with it making the noise and there's already a substantial dent in one of the ridges on the mount bracket and another slight one in the lower strut brace.

I removed the strut brace earlier, at least until the solid lower engine mount turns up. Took it for a test drive and the noise is definitely gone. Also fitted the refurbed rear brakes and spent some time sorting out bulbs, wipers, door pull and other MOT-friendly items. So nearly there, just keeping my fingers crossed nothing else crops up. Hopefully my next pay cheque will mean she WILL be on the road as of the 1st January...

[Dum-Dum]

Good work mate. Your not the only one who needs to sort engine mounts and rubbing issues

[Poodle]

Ta man, beginning to get embarrassed at the continually delayed MOT tbh lol. Hahaha yeah, how's your steering column doing?

[Dum-Dum]

It still steers lol

[Mr Whippy]

Solid lower engine mount hehe...

No offence intended, but have you ever driven a 306 HDi with one on?

I can only assume it's what it'd feel like to drive a giant vibrator


I personally hated it, and for the net bonus of no apparent improvement in engine movement characteristics even with 155bhp/290lbft, I wasn't really sold on it to be honest

OEM always feel crap when they are 100k miles old and 10yrs of rubber degradation, but it's unfair to judge OEM till you've fitted an original.






Just to continue my mini rant. I bought fancy upgraded stiff mounts for my Z4 and in many ways it's just ruined it. Creaking noises, harsher ride in a bad way, and I swear it's made my drop links wear faster and start rattling as there is less give in the main suspension now.

As much as many of these things sound great, they just are not. They are shit to put it bluntly. The Z4 is known for riding like shit already, people think their cars are stiff and then after 10 miles in a Z4 on your average road they have a new appreciation for how nice their sports car is haha. I think it's quite ok so I think that puts it in perspective how tolerant I am of a firmer more in yer face ride/feeling of the road.

But honestly, those solid engine mounts are NOT something you will appreciate in any way shape or form unless you are planning on tracking it, probably for competitive reasons, as it's main use!

Otherwise the positives it brings to the show are totally offset by it's complete lack of consideration for NVH and road use.

Mini rant over.



Very interesting build so far.

My 2p, you can't double everything. There will be a compromise somewhere.

If you can double economy and double handling/grip easily, or even boost both for net positives by say 25%, then you should go work for an endurance racing team
Not trying to put you down or anything, but I think you'd have more fun forgetting the lateral g's and handling thing. Subjectively AND quantitatively the 306 isn't really bad out of the box for handling, and without going for slicks you won't get near 2g.
Even with R888's and totally optimised everything you'll probably only add 30% to lateral g's vs Eagle F1's or similar on a standard car.

And with R888's you are gonna have horrible tyre drag, wide tyres will also cause more aero drag...


Funnily I was thinking the exact same thing as you, but just go for eco.

Get some narrow eco tyres, lower it a bit to reduce aero drag, reduce weight to say 950kg or maybe even 900kg. Remap and intercool for a decent power figure but focus on the 2000-3000rpm range for economy.
Spend a lot of time reducing aero drag. That is the thing costing you about half your fuel at 60mph as standard.


All very fun and interesting any way, can't wait to see more!


Dave

[Poodle]

I've had an OEM replacement more than once and i don't particularly care about NVH, having a car that tries to shake off it's fixings at idle just adds to the fun of driving it for me lol. And half the plan for this is for it to be an effective track weapon. Regardless of all that, the bracket rubbing on the lower strut brace is more the issue that's prompting me to look at alternatives, i reckon there'd be enough movement in a new OEM bush for the thing to still rub under load. Fair comment though, i haven't driven one with a solid mount and couldn't find anyone who had, so appreciate the input. Looks like i'm going for vibratechnics kit all round when i've got the money then...

Yeah i know i'm going to struggle with doubling everything, certainly all at once, i'm fairly sure that's not possible on my budget. And as you say, the handling bit is definitely going to be the most challenging, i should have started with an old merc or something, would have been a lot easier to "double" handling ability lol. I know you've done a lot of data-logging and testing in the past, i don't suppose you've got any info saved on how a standard 306 handles on track, the kind of forces it can generate etc..?

The aero package is what i'm going to be focussing on over the next few months, spoiler, air dam and basic undertray to begin with. Also have some ideas for a blown diffuser that should considerably reduce drag. As luck would have it, PPC did an article on a similar project of their own last issue, so i've got some more ideas from that.

UPDATE:

I've got tired of chasing the various "last thing"s on this car now, every time i fix one another pops up in it's place. This time the osr abs sensor is causing problems, so i've decided to just give it to the garage and let them sort it and do the MOT at the same time. Booked for 10am Friday morning, fingers crossed!

[Dum-Dum]

What you planning on making an under tray out of cos im probably gonna do mine out of polycarbonate, the stuff they use on conservatory roofs not the window stuff. Im only gonna do a rear one.

Also considering hinging the top of the rear number plate and having some very large holes drilled behind it in case there is any build up of pressure causing drag behind the rear bumper

[Poodle]

Not sure yet, haven't done much research into it, probably what's cheapest out of the viable options tbh lol.