Dum-Dums Stupid HDi Project 2009 - Now Scrapped!

[Dum-Dum]

27/08/2009

Shes Back! 3 Weeks, 6 Days and 14 hours after blowing the box.

I cant tell you how much Ive missed driving alough I am really paraniod about every little noise right now while i get used to it again. So when one of my boost hoses (that wasnt done up properly) popped off with a pop and a big increase in induction noise I nearly filled my pants.

The lightened flywheel is really good in the lower gears and the car actually feels smoother at idle and when revved. The clutch slips a little and is especially bad in the higher gears but its to be expected till the clutch has bedded in. The new linkages feel really good and I recon that the clutch is actually lighter than my mums Berlingo that has the same engine and box. I thought theyd forgot to attach the cable when I first put my foot on it as it was so light.

Good to have it back. Ill post pictures after the weekend and give a full run down of the bill.





4/10/2009

Right a bit of an update. Spoke to Piper the other day about the acm and the bloke said that it should give 8-10bhp without any other mods. Its not got alot more overlap so the peak power should be within 500 rpm of where it currently is however they list the powerband as 1500-6500rpm. 6500RPM!!! :o:o OMFG :o:o that would be crazy.


Ive to get a second engine to rebuild cos sods law says that if i put a new turbo and head on the old bottom end its gonna go pop within 2 weeks just to spite me sowent on ebay and got an engine and box all for just £138
[url="http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=120473979054&ssPageName=STRK:MEWAX:IT"]http://cgi.ebay.co.uk/ws/eBayISAPI.d...=STRK:MEWAX:IT[/url]


Ive got some more bits i need to photo and a big pile of stuff to do so hopefully ill do a full update within the month.



11/11/2009

Right, Where to start?

These are gonna be a little out of the order they happened in cos thats how theyer uploading.

A brief run down of the last 3 weeks.
- Exhaust de middle boxxed and back box re-welded.
- Upgrades for W/M system ordered.
- Inlet L-Bend EGR hole permanently welded over then gasket matched and smoothed internally.
- Interior Stripped.
- 302mm brakes bought (inc braided hoses and mintex and brembo kit).
- Rear lowered another 40mm (now 100mm lower than a std 306 and on the bump stops)
- New front speakers.
- Air bag system removed.
- Snap off wheel.
- Battery box made for boot.
- Lightened crank pulley.


And thats all i can remember for the min.


Right Brakes First then.
Got Calipers off a 307 HDi 135bhp for £90. Theyer a straight fit and take 302mm discs. The photos are of a test fit with the GTi6 discs still on. My GTi set up is already sold before you ask. I got brembo front discs comming with mintex rear discs and mintex pads all round £150. also got a full set of braided hoses for under £50 off Camskill. Just gotta get some DOT 5.1 fluid and fit it and Ill be well happy.









Next up is a lightened Crank pulley from Rich @ Lynx (the people who make the supercharger kits). I can honnestly say thats £90 well spent. the HDi revs like a petrol now its mad. Feels much smoother to drive too. The light one is 700g and the std one is 2300g so thats another 1.5kg off my drive line





Also fitted at the same time as the pulley was my new HDi box. I cant tell you how nice it is to drive with this back on.




And a quick snap of my spare engine and my Oil Pressure Gauge




Next up is the inlet L-bend.

Im getting rid of my Dump Valve so i needed a new one.

First i cut off the flange for the egr pipe and took it to the welders to be welded over.
Next I Put a gasket over it and lined it up and drew a line round the excess metal.
I then got a flap wheel sanding attachment and enlarged the hole to the edge of the line. the tight corners were alot harder to do so ive left some excess on them.
Then a 16mm hole and i screwed another mondeo take off in and now i just gotta drill and tap it for my new W/M nozzle














11/11/2009

Next how about some strippage. Finally i have decided i can do without rear seats in aid of going faster so theyve gone (they smelt funny anyway). Im gonna do a big write up on its own but ive already taken 60kg out of the rear and all the airbags.






Got a snap off sports wheel







and after all that weight the car had risen another 15mm so Kris dropped it another 40mm onto its bump stops to compensate lol





So with a stripped out rear i decided i had to fit the battery in the back (weight distrobution and everyhting lol) decided i could make one cheeper than everyone sells them for so £12 for a sheet of zintec and a couple of pop rivits later happy days. Also got some hardcore 50mm 345amp battery cable and a kill switch.






OOh boot tidy






Exhaust. really pretty self explanitary ber the orange PU mounts.