305 Dervmafia Winbus

[Sambarker]

http://youtu.be/eudMsjd3AtM

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Bit of progress this weekend

[zx_volcane]

Amazing, lot of effort has clearly gone into getting this both fitted physically and then actually running.

Must be dead chuffed for it pretty much to start first time on the button like that.

Thats got to be the biggest hump out the way on this project now that the engine is in and running - all else can go back together relatively easily, just takes time.

Really can't wait to see this on the road, its going to be properly properly epic.

[Poodle]

Awesome! Sounds a bit rough being revved, is that a sticky valve or something?

[Ruan]

We've figured it's a fuel supply problem, lots of air and a slight fail in the plumbing of the low pressure side... Pretty sure we've got it sorted now.

[Uberderv]

Mine was very similar, once you run it for a while it should clear right up. Awesome work though

[Sambarker]

Wheels are back from powder coat/paint

Tomorrow is going to be fitting driveshafts (206 2.0 hdi non abs) and also doing front brakes

Going for a 266mm vented set up. Calipers are from a 405 mi16 with brand new discs and pads and also just ordered a brand new 21mm non abs 306 master cylinder

Then end of week panels will be ready so can start to build the front end back up and get the radiator etc rigged back up and can start to tie everything else together.

4 weeks I reckon I'll be on the road

[Piggy]

Good effort sam and co

[zx_volcane]

Then end of week panels will be ready so can start to build the front end back up and get the radiator etc rigged back up and can start to cable tie everything else together.

 
EFA
haha, joking aside and just to reiterate, this is going to be a proper win build once it all comes together. The progress has been swift considering how custom everything has been.

[Danny Wideboy]

A lot of good projects being updated recently.

This is one of my favourites. Full of win.

[Piggy]

Shows this year will be full of wins!

[pioneer DJ paddy]

Good work sam fair play to ya :-)

[Poodle]

Fair enough, goodo.

LOVE those wheels, should look epic!

[Sambarker]

[darrenjlobb]

The bus dosnt know whats hit it!

Loving it, cant wait for euro trip now, time will soon come round!!!

[Sambarker]

Ok so this is due a bit of an update

I suppose last post I was starting to put it all back together bodywork wise and sort out the final hdi running issues.



Welding panels into place



Diagnostics



Fiat punto 1.4 gt aluminium race rad



Starting to take shape



Almost finished



Bodywork done.



I had quite a lot of issues with fuelling, and getting fuel from the tank to the engine through a lift pump and keeping it at a suitable pressure etc. it turns out the walbro in line pump I had did not like pulling fuel from the tank, even when positioned close to the tank.

So to rectify, I had to use a 206 hdi lift pump from a spare car and this solved all the issues



And with that I was back on boost



So headed down to Cornwall to do some tuning



And got it on the rollers for a base figure on the stock map

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First run on the dyno was about 89bhp.

By then end of the day we had squeezed out a reasonable 138bhp.





Good derv Mafia turnout



So moving on, the car got remapped a couple more times to fine tune, and then the annual euro trip took the car to Croatia and Italy on an epic adventure











Completed the journey with only a couple of very minor issues!

Once the trip was out of the way, progress could then be done in relation to further tuning the hdi motor.

So another trip to Cornwall resulted!



And a gearbox change while I was there

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After numerous runs on the dyno, tweaks to the map, turbo etc etc the highest figure achieved on the dyno was

176bhp and 288ftlb

Not a bad result considering this was still on stock R65 pump, rail sensor and injectors.

This was with turbo set to 1.8 bar



However as a result, the return journey had a slight issue or two





Split boost pipe and broken wishbone bush.

This we're both addressed shortly after with a 4 ply hose and a wishbone bush sourced from the spare car.



Spare 305 going to scrap, been useful for a lot of bits but not a lot left of any use.

A few weeks ago had issues with power loss and smoke from engine bay, which turned out to be a snapped stud on the exhaust manifold to turbo adaptor



An absolute PITA to change, but finally got it all back together yesterday and got round to fitting the 2.2 hdi r70 pump I've had for a while.

Once back together had issues with back pressure but this was quickly diagnosed as sticky turbo veins which was fixed by shoving the air line onto the actuator.

So an up to date spec list of the car is as follows:

1988 305 GLD estate (originally 1905cc nad)

110 2.0 8v hdi conversion from 2002 xsara
Forged connecting rods
Fully recommend head with victor reinz head gasket and xud style ARP head studs and custom spacers.
R70 2.2 hdi fuel pump
Volvo GTB2056VLK @ 1.8 bar
GTi6 flywheel
Xud style CG Motorsport 4 paddle solid clutch
Hdi gearbox from a 306
3 inch turbo back straight through exhaust
Charge cooler with custom inlet manifold and front mount rad
MBC

405 mi16 front brake setup
Citroen c15 rear axle with custom spring shims
Gti6 steels, 195/50/15 front 175/55/15 rear

Scan gauge II
Stack egt gauge
Tim boost gauge
Tim oil pressure gauge used for EMP

[Jimmy306uk]

So in love with this car

[Uberderv]

Awesome

[Sambarker]

Awesome

How's the 205?

[Uberderv]

Awesome

How's the 205?

Its OK, everything is sorted now ready for an mot, but........ Move house on the 1st of july so it will have to wait a bit longer.

 Do you think the fuel pressure reg is necessary? I've removed the original filter/housing for intercooler space so mine goes intank pump-freelander filter-HP pump. Not tested it yet though...

[darrenjlobb]

<3

[Sambarker]

Awesome

How's the 205?

Its OK, everything is sorted now ready for an mot, but........ Move house on the 1st of july so it will have to wait a bit longer.

 Do you think the fuel pressure reg is necessary? I've removed the original filter/housing for intercooler space so mine goes intank pump-freelander filter-HP pump. Not tested it yet though...

Apparently fuel pressure wants to be about 2 bar. There is a regulator in the fuel filter housing so if you have removed that then I don't know what the unregulated fuel pressure will be

[zx_volcane]

Ahh man that stud must have been a pig of a job to sort out, but at least you're boosting now without the engine bay coaling up.

Must be running rather keen after fixing that boost pipe too eh?

Bringing it to pugfest?

[Sambarker]

Yeah it should be at pugfest. If not I'll be in the 306 I've just bought

[MY95]

Epic project Sam!
Looking forward to seeing it at Pugfest

[Piggy]

So love to see this at pugfest <3

[James]

305 can't go to pugfest now! It's currently my daily!

[mr_fish]

305 can't go to pugfest now! It's currently my daily!

shutthefrontdoor

you wouldn't be driving a peugeot.

[darrenjlobb]

305 can't go to pugfest now!  It's currently my daily!

shutthefrontdoor

you wouldn't be driving a peugeot.

He's finally seen sence and come to the bright side!

Oh wait, im driving a Citreon!

[silverzx]

Loving the hall of shame Darren.

[Sambarker]

Ok so been having numerous issues with the 305 lately.

1. Splines worn on steering rack - has been now welded solid!

2. Turbo has had to come off twice in the last month or so (an absolute fucker of a job) as it keeps snapping studs on the manifold adaptor. Obviously the weight of the turbo down the back of the engine and the weight of the 3" exhaust isn't helping!

Spent a day taking it off and a day refitting, made a temp brace to try and help out



And also the boost can decided to shit itself last week so had a spend an unexpected £40 on a new one which arrived yesterday as needed one in time for pugfest



So it's all back together now after another full day on it.

Few jobs for pugfest

-refit alternator
-adjust exhaust
-track rod ends to rebolt after welding up rack
-torn cv boot to bodge as not got time to change shaft before pugfest.

As long as these few jobs get sorted it will be at pugfest. This time last week it was looking very likely it wasn't going to make it!