darrenjlobb's Project M-TDI Twin Turbo Supercharged Derv Bus

[kernow_joe]

just been catching up on where you're at top work as always fella have to come round have a catch up and check the beast out, in regards to insurance thats rediculous, so should I have had a certificate when I changed my engine myself? or in fact all the other maintenance I did myself?!

Are you back in the UK for a bit Joe??

yup for the summer at least, maybe more if work takes off and can afford regular trips away.

[Ruan]

I'll definitely pop down for a meet up again, Joe!

Definitely need a night out in Falmouth!

[kernow_joe]

too right, this time with money and no boring girlfriend!

[darrenjlobb]

too right, this time with money and no boring girlfriend!

Haha get the frig on,

Your still driving the vagcrap tho Joe?

[THE_Liam]

I've got an idea if you lads are up for a meet, I'm down in Perranporth 16th-23rd of June and will be spending the whole week getting drunk....

[Ruan]

Sounds good to me

[THE_Liam]

Excellent :mrgreen:

[kernow_joe]

Haha get the frig on,

Your still driving the vagcrap tho Joe?

yup its shit, nothing breaks on it, haven't had to fix anything!!

[darrenjlobb]

Sadly things have been going a bit bad just recently, which has removed the chance of being able to bring it along to FCS, although ive been thinking this could be the case for a while now

Have been waiting for a part for a while now and sadly the guy who was making it has got mechanical issues with his lathe, so is unable to complete it for me, which has left me with no time to sort anything out in time now, not helped by the stupid insurance problem which is still an ongoing saga as of the moment.

Due to not being able to get the car up and running / ive been working on silly little things, so got the cooling system piped up as far as I could without the front end on, mounted the accuators on the VNT, and big turbo, and also made my homemade boost bypass valve, doesn't look like much, but surprising what time it takes welding up little brackets / stripping actuators to reverse spring movement etc...

VNT Can: (ignore solid oil line as have now replaced with homebrew flexis) (this was a bit of a tight sqeeze!)





Wastegate on the big blower (clears clutch arm by 2mm, altho have since moved it due to pipe route issue):



And the bypass valve, its made from a petrol throttle body which i modified to close fully, welded up some brackets to hold a boost can, then welded wastegate lever to the butterfly shaft,and reversed the spring inside the boost can, hey presto:





And a bit of a mock up of how im going to sqeeze the sequential setup in the bay, hence having to re clock the blower:

[4WayDiablo]

Damn that really sucks about fcs :-(
But I suppose its vest not rushing it to get it there as its not the end of the world
That last picture though is epic, it coming together!

[Andy]

Damn what a shitter.

Hope things are resolved quicker rather than slower.

Last pic is looking awesome

[Niall]

Bit gay that things are taking longer but this will be fapping epic when done!

[Ed Doe]

Bloody hell that looks faptastic Darren!! Can't wait to see it up and running! Shame about FCS; will you still be coming up? Perchance you could borrow Ruan's gti6?

Gah I need to take a trip down to Lobbland again; I miss the good old days!

[londondan86]

Soz to hear about the bad news. That last pic is pure engine porn

[darrenjlobb]

Perchance you could borrow Ruan's gti6?

I wouldn't be seen dead in a moonstone gti6

[Jimmer021]

Shame about fcs, can't wait to see this finished though!!

[Alee83]

BIG shames.... But on the upside, car is looking really porn. Really simple but affective valve that, was wondering how you were gonna set it up! :-)

[strictly_perv]

A right pain that, atleast look on the bright side- you now don't have a spcific dead line so you wont be rushing yourself.

Can I see Rover written on the VNT that writing just being there will cause the headgasket to go you know...

[Dum-Dum]

Sucks that you wont be making FCS in the beast mate but itll feel all the more worth it when it does eventually hit the road.

Your gonna have to come to the Christmas meet though to make up for it.


The boost piping looks AWESOME though, amazing what you can fit in a 306 bay when you try.

[Jacko]

The boost piping looks AWESOME though, amazing what you can fit in a 306 bay when you try.

And if it doesn't fit, there's nothing an angle grinder can't fix

[darrenjlobb]

Ok so progress has been pretty slow, I'm having serious headaches with the ongoing crank pulley saga, but have possibly found a new person to do it (many thanks to Scott) so we will see how that one goes.

In the meantime have been sorting out some other issues, timed up the pump to get a base timing figure, which will make tuning much easier in the future, seems going by "knock" is very much impossible with DI as the window for engine to run is absulutly tiny in comparison to the idi which seems to run even if pumps 180deg out!!



As some people have no doubt noticed on my facebook, have had another fail in that the charger I bought (old one got broke on last engine) has turned out to be dud, basically on the eaton chargers one end of rotors is oil filled, so generally fine, but other end runs in sealed needle bearings, which often fail if not rebuild / greased, turns out some **** fooked me over on ebay and sold me a screwed one, sadly bought it months ago and only just got around to digging it out, so no way to get refund now, so will have to order up another!
But basically the bearings have been gone a while / rotors have been rubbing the casing / screwed it totally, either way, I repacked the buggered bearings with grease / re built the blower just so as I can still start the car in the workshop etc as without it the belt dosnt fit and decomp isnt happy!

Few photos of the rather pointless rebuild:







Other than these fails, not much to report sadly!

[Jacko]

That seriously sucks mate. Hopefully the end result makes you forget about all this present hassle and the outcome will be an animal of a car!

[kernow_joe]

progress is still progress, you still going fcs then? I'm pretty tempted, was gutt3ed I didn't make it last year!

[londondan86]

So thats what that bolt is for in the middle of the pump head lol.

Gutted about the charger, extra money that could always be spent better elsewhere. Is there no way of using bits from the old charger and this one to make something usable for now?

[darrenjlobb]

progress is still progress, you still going fcs then? I'm pretty tempted, was gutt3ed I didn't make it last year!

Am coming to fcs just not with the car, but coming up with Chris, alex is also coming from down here with this 306..

So thats what that bolt is for in the middle of the pump head lol.

Gutted about the charger, extra money that could always be spent better elsewhere. Is there no way of using bits from the old charger and this one to make something usable for now?

Casings are trash on both chargers, last one was ran with no filter for to long, and this one is just dicked, so only good for snout parts tbh...

[Dum-Dum]

That sucks mate. It will be worth it in the end though.

[con67]

I near fell off my seat when I saw that last engine pic! unbelievable work there bud!

[darrenjlobb]

I near fell off my seat when I saw that last engine pic! unbelievable work there bud!

Thanks con, where ya been?!

[Dicky]

Can't wait for the end product!

[darrenjlobb]

Little boring update, still waiting for stuff to be sorted out so cant really make any serious progress, so started work on a few side lines, one of which being getting the tacho to work, as the DW10 has no pickup point for the old XUD style pickup, as they use the ecu / 42-2 sensor, which would be very hard to get working with a ph1 dash.

So just mounted the original XUD tacho sensor in the bell housing cover, and hey presto we have a tacho!