Dum-Dums Stupid HDi Project 2009 - Now Scrapped!

[Dum-Dum]

14/12/2009

Hahar! Looked like the Exh housing of my GT15 was ****ed so not sutiable for machining out. However Turbo Dynamics say theyy think theyve got a spare and theyll do all the work for me for £200 or for £500 thell also put a bigger compressor wheel into my GT17 so id really be able to make some boost.

The engine shop has all my bits now, theyer moaning cos diesel kills the chemicals in their steam cleaner so they been waiting till the stuff nearly needed changed anyway then clean all my bits. They seem happy enough though and work is comming on at a pace.

Pistons turned up on saturday so fresh from pug HQ in france you can still smell the garlic on them.




24/12/2009

Ive got my turbo sorted now. KO3S inside a KO3 housing with water and oil cooling £700.

Cam has arrived. £152 Delivered and it looks good at least.

Got my 3" exhaust ordered. 1 silencer, 2 long straights and 3 45deg bends £170

As far as engine machining goes the block is bored and the fly wheel is down to 7kg but the machine shop shut early for christmas due to the bad weather so i aint got any of it back to start building up. now looking tight for being run in by santa pod




24/12/2009

Well it would be rude not to add pics as im at home now


Turbo








Cam, i wont show you inside the box, you all know what a cam looks like.







Right as somebody asked for it heres the full spec for my engine (as far as i can remember anyway)


Big bits that Ive brought
Piper Cam
40mm External wastegate Demon Motorsport
Pug +0.6mm oversize pistons (comes with rings) takes capacity to 2025cc)
Pug Standard HDi rods (theyer the same across all DW10 engines)
Turbo Dynamics Custom KO3/KO3S Hybrid turbo
Saxo Electric PAS pump
ARP rod bolts
Adaptors for oil temp and pressure gauge sendors
Brand new bosch glow plugs
3" straight through single box exhaust
Oil catch tank
Grp N engine Mounts
Nissens Alloy Rad
probably a new oil cooler to go in the wheel arch



Little bits from Pug
Rocker Cover Gasket
Inlet and Exh gaskets
Head Gasket (when i work out what thickness i need)
Crank Bearings
Con Rod Bearings
Fuel Pressure Sensor 1.6HDi
injector copper washers
Full set of manifold studs and nuts
Full set of core plugs (head and block)
Exhaust fitting kit
Oil pump chain
head bolts
bottom end bolts
cam shaft oil seal
crank shaft oil seal
valve stem oil seals
leak off pipes



Machining services
All parts steam/chemical cleaned
Block overbored, honed and faced
manifolds Ported, polished and faced
Head ported, polished and faced with multi angle valve seats.
Valves lightened
New valve guides pressed in
Fly Wheel, Lightened to 7kg and balanced
Crank, Rods and Pistons all balanced
A/C sump (as the drain is at the back rather than underneath) with a plate welded on the bottom to cope with speed humps.




04/01/2010

Engine Build Started

Right I got my block back today, its been skimmed, overbored and honed so finely youd hardly be able to notice.

So as its already been cleaned I got straight to masking it up and painting it. I put it on a skate board so I can wheel it in and out of the garage to keep her warm when Im not painting. Shes just had her first coat of blue hammerite and Im just about to go and do another.

Think I should of given her a coat of white primer as the blue isnt coming up as light as Id like on the dark coloured block.












Its been so cold outside today the paint wasnt drying so Ive sat in the garage with it for the last 2 hours with the big gas heater on it and Im now wishing that Id left the door open cos Ive got a headache from the fumes. Shame the paint was still tacky after that. Think its cos it wasnt drying between coats earlier so itll take ages to dry now.

Its gonna sleep in the kitchen tonight and hopefully Ill be able to feed her a crank and some pistons tomorrow afternoon.

Piccies of after the second coat (she got 3 in the end) and in the garage warming up.








05/01/2010

Oh and did I say I popped up to Serdi this morning, bribed them with 3 boxes of biscuits and they said Id have the bottom end by tonight and the rest by the end of the week. Happy days. The head porting looks really good. The inlet ports are now huge, I recon I could get 3 fingers in there. If it dosent make good power I think I might cry.





05/01/2010

Crank, Fly and Exh Mani Here Now


Right ive got back late form rally design (gatting buckets, oil cooler and other shiny bits) so ive not started building tonight but

The exhaust manifold is here ready for me to fit the wastegate flange and the lightened and balaned crank fly are here ready to fit.














Erm bugger, forgot to buy engine assembly lube so didnt get far tonight, just got crank shells in, core plugs swapped and cleaned paint off the bottom of the block.








06/01/2010

Bottom end nearly done

Bottom end is nearly done, just waiting for rod bearings to arrive and ill have it done in a hour or 2.

Right piston oil spray jet. Got really worried with these cos i tried cleaning them through with WD40 but it wouldnt go through. realised after 5 mins theres a valve inside them thats gotta be pushed in before itll soray through, suppose its to make the pressure so it actually hits the piston rather than dribbling out.
Got the bearings in the block to (thats easy, just clip in.)







Got myself a novelty coaster for the all important engine building tea.
Also Blue gaskey, engine lube and water wetter which i dont know if itll work but its gotta be worth a try.







Lubbed up the bearings and dropped the crank in, then swiftly took it out because i forgot the thrust washers. thrust washers in and crank back in i stopped worrying about the face my marker pen on the main caps had rubbed off when i realised pug had their numbers cast in. End float is pretty much zero, so small i cant measure it so well within tolerances.

Eventually found a torque wrench that went low enough to do the stage 1 tightening on the mains as its only 20 torques then found that when i went on to the angle tightening i was having to use so much force the engine was just spinning on the bench. Clever solution was put it on its side on the floor and push down on the breaker bar.







End plate on the block all blue gasketed up ready to go on once id put the oil pump chain on the sprocket and then put the pistons and rods together. for the balancing the pistons were within 6g of each other (they only weigh 190g ish (IIRC)though so 3% difference) but they are all no exactly the same to within 0.1g. Rods were only 5g apart but supposedly the big end to small end weight ratio thingy was the worst bit. However now also within 0.1g.