Dum-Dums Stupid HDi Project 2009 - Now Scrapped!

[Dum-Dum]

30/11/2009

Welly welly welly. A little more has been done now. really need to take more photos when im doing things.

Erm seats first then. You really wouldnt beleivew how low they are compared to standard seats. I now have real propper head room and leg room too.









Saxo PAS pump. Looks to me like the fittings on it are the same as the fittings on the 306s engine driven pump so im gonna have to find somewhere clever to mount it. Got the pump and all the wiring for £40. not the best price I know but its nice and clean and i took it off a 51 plate low mileage car that looked cared for and the fliud in it was clean too.






307 Brakes. Mmmmmm 302mm discs are huge and weigh a ton but theyer on and definately an improvement over the GTi6 stuff even when i had the redstuff pads.









This is most of the wiring that i stripped oput the car (minus some of the airbag wiring and the amp wiring kits). Swapped the pug boot light switch for a normal one and this alone saved about 3m of wiring.





Also getting there with fitting the battery in the boot and the big methanol tank. The new tank takes about 10.5l and the old one took 4 US Quarts or about 3.5l so this should give me a bit more range with it.




Oh and my oil catch tank. I could only get a cheep one in red so this is after i sprayed it matt black



Last but defo by no means least is the ongoing head work. Now the head is stripped all i need if for jonny be to give me a call about getting his mate to take a look at it and hopefully well be away.


Oh and did I add that I sent my cam off to piper on friday too so hopefully thatll be back to me with its new profile soon.

Anyway back to the head. I started stripping it out the other day. first to come off was the leak off pipes (held on with a clip on each injector) and the glow plugs and fuel rail that my socket set made light work of. Then undid the nuts to the side of the injectors and they just wiggled out. Stuck a screwdriver through the pulley onto the head and undud the nut and then the 3 nuts that hold the vaccume pump on. Next started on the cam holder thing. went round it in a spiral cracking each nut then a couple of rounds giving them 1 turn then took the bolts all the way out and off the cam came. Easy peasy. Last and probably most difficult job was taking the studs out the head. this involved screwing 2 nuts onto the end of the stud and tightening them againse each other then using a spanner on the inner nut to undo the stud. this worked on all of them except the last studd that i snapped and now need to drill out of the head.







Next to take the valves out. I went out and brought a valve spring compressor (thirty five ****ing quid :o:o:o ) and a box with a load of compartments to keep all the valves and bits in. First i lifted out the hydraulic tappets and rockers and left them in their own compartments. Valve spring compressor is so easy to use. The inlet valves are absolutely caked in shit as are the ports (and this engine is only on 60k) and finally i popped out the core pulgs and threw them away.














03/12/2009

Ghaz the meth system was rebuilt with a bigger tank different nozzles and new hoses.

Ben the ko3 was fitted cos its a straight swap and Ive still not got the gt17 machined.

Darren it cant be the catch tank cos its been popping its dip stick for a while now.

The new turbo is a definate improvement however we think the problem is its loosing too much boost pressure past the piston rings so i gotta hurry up with this rebuild. Gonna try and get it done over christmas and fitted in january




10/12/2009

Well got all my parts from pug now bar the pistons that should be here monday.

Block, crank, head and brand new rods are at the machinists.

Gotta pick up manifolds and fly wheel from kris tomorrow and take them to the machinists as well along with turbos that need machined.

brand new bosch glow plugs arrived today £25 off ebay.

just about to call piper about my cam and see how thats comming along.




devils_fuel
any ideas what bhp will this new beast produce at the wheels chris??

Dum-Dum
Well other cars with a fmic and big turbo hit 175bhp ish. plus 5bhp for methanol. so call it 180bhp but thats at the fly prob only 140 ATW

might be more with all the other mods though

I really aint got a clue if im honest could hit 150-210bhp ATF i honestly dont know


Ideally Id love to see a nice round 200bhp but realistially i dont expect to see over 180bhp.

The rebuild is all about knowing the engine is perfect for pushing to its limits when i get the fuel pump and injectors. Basically it makes the final stage a £500 job. £170 for injectors, £170 for a pump and £170 for a map.

The lightening and balancing and removing the PAS pump is all about making sure the engine spins as freely as possible and bringing the ATF and ATW figures closer (theres something like a 23% difference on most 306s)

The overbore, and porting work is to give the engine an easy life by not needing so much boost to flow the same ammount of air. You need less psi to flow 100cfm of air through a 2.5" pipe compared to 2" pipe.

The Rail pressure sensor and remap is to ensure im getting the absolute maximum fuel from the pump and at higher pressure to get the bset possible atomisation and burn.