Dum-Dums Stupid HDi Project 2009 - Now Scrapped!

[Dum-Dum]

Update from KrisB
Old engine is propper ****ed


One of the valves is covered in oil
You can move the pistons side to side in theit bores
The bores are all really scored
One of the pistons if full of metal shards
Ive eaten that K03 in under 3000 miles

Scrap value only really.






15/01/2010
KrisB

Here ya go lads, you're daily dose of pictures.

I've got the manifold welded and the wastegate pipe onto it now £80 to get that done, rip off!

Everything else is self explanitory, head on, manifolds on, fuel pipes and filter on, flywheel on. Just waiting on some more money from chris so i can get the cambelt kit and waterpump ordered in. Once i've got them and a few other bits then i'll be dropping the engine back in.

Anyways, loads of random pics so people can have a nosey.

Head on and torqued down.







Wastegate welded shut



Clean!



Next updates will be monday, i'm busy with other things 2moro and i'm off on sunday.

Now, a question...

Turbo is obviously fed with oil, so two of the ports are for oil. The other two are for water. Chris asked me to remove the water/oil heat exchange sandwich plate. Can i use the hoses from that and run them to the turbo?




19/01/2010
KrisB
I didnt really acheive much today, got the cambelt and waterpump on, one or two other bits. I can't finish it yet as we need a custom oil feed pipe for the turbo and i need some kind of reducer to take the water pipes to the turbo down to 8mm.

Got a new pipe for the oil/vapours from the cam, new cambelt pulley for the crank. O ring for the water manifold on the block. I've got smaller aux belt for it to run with just alternator. Talking of the alternator... it's rather noisey, bearings are a bit shot.

Me thinks clutch isn't liking 165bhp either. 6.5mm total thickness on the paddles, seems low to me.







22/01/2010








In the last two pics, you can see the piping for the water to the turbo from the stat housing. Although, i'm unsure as to if this is correct.

You can also see what looks to be arather expensive cutom oil feed pipe with built in filter.

23.5 inch aux belt, using just the alternator, bottom pulley and the small tensioner.




28/01/2010








29/01/2010
Kris
Weve had a few holdups, for starters rad lower hose has rusted through.

BTW, dumdum is on the phone to fooby. He reckons that we're only going to have 23.5 hours in the day from 2moro, reckons his car will rotate the earth quicker

Anyway, waiting on a new bottom hose from pug tomorrow, all pipes are back on, engine ready to be filled with fluids in the morning. It's ready to run now apart from welding on the wastegate and making the exhaust - which isn't going to take too long. Then a few cosmetic things to go back onto the front end, wire in the washer bottle, put arch liners back in.

At the moment, we're waiting on an adaptor for the oil pressure t-off, the one chris got is the wrong size. The lower hose.

Power steering is up and running, but not at it's full potential as battery hasn't been charged for 2 weeks.

Some random pics chris took.













30/01/2010

- Filled the car with fluids and had a few leaky core plugs

- uploaded the new map

- tried to start it and it wouldnt go

- Tried testing the crank sensor by waving a spanner in front of it, seemed dead so we replaced it.




01/02/2010

- still dosent start on new sensor.
- eventually realised we hadint swapped 2 wires on the plug for the new FRS. Doh!




03/02/2010

- Car Starts first time



Back to 01/02/2010

Kris
Right, chopped off the flange from the old downpipe and started from there really. One bend, a bit of straight pipe (welded on at a funny angle on purpose), then 2 more bends. I'm gonna use a bit of scrap from the first bit of straight pipe to join the last bend to the backbox so i don;t have to 'break into' a meter of pipe.

Measured up the tip chris cut off some ebay backbox, measured up the the outlet of the backbox then headded over to kelvik welding where they made me a ring on the plasma cutter for a tenner. Saves me having to bodge the tip on.

I'll let the pics do the talking. Welds are actually tidier than they look. Just need wire brush treatment and them Chris's high temp paint. Like i said, the wonky exhaust is needed... if it's not wonky it'll either sit too low or hit the gear selector rod.





(Chris won't be happy, it took me all of 2 mins to remove all the silencing crap from the middle of that tip... bought a better drill)















02/02/2010

Well, i got the exhaust finished and on, sits propper nice without knocking too

Gave it a wash and started to weld in the seat bars for the passenger side, ran out of box section so i'll grab more 2moro. Finish welding thursday when i get the welder back.

Also, i left my camera cable at work, so no pics just yet, i'm gonna go through the alley to sainsburys to see if they have a card reader. If not i'll get a taxi to tesco and back.




02/02/2010
KrisB
Anyway, some pictures.





Is very shiney!!










Screamer pipe








I found some stickers under the dirt...










05/02/2010

Went to pick my car up and give her a run but ater letting her warm up (which she did very nicely) we noticed a puddl of oil underneath. Turned out the crank seal (that i fitted) on the fly wheel end was leaking.

So i had to get a train home. It was such a shame cos the car sounded so nice especially the exhaust.

[url="http://www.youtube.com/watch?v=M42gzVwiNN4"]http://www.youtube.com/watch?v=M42gzVwiNN4[/url]



Someone asked what my plans are for when i get her back.
The list is;

Cosmetically im gonna paint the interior satin black
re-tint the back windows
consider twin oil coolers
attack the bumper for air flow
fit my deep rear spoiler
fit second washer bottle
smooth fake filler cap
strut brace
colour coding and polishing on the engine

then as for power
merc injectors
bmw pump
maybe propane and nitrous injection instead

before power mods though im gonna buy myself a new bike, a decent digital camera and take the missus on holiday.

oh and i want a 206 HDi ECO box and a LSD




11/02/2010







14/02/2010

Big Hissy fit as car is all ready but stupid new CG motorsport clutch dosent work. It wont fully disengage. tried fitting a new clutch cable and spacing out the ends but to no avail.




20/2/10

Long story but the car is now at home outside my garage sadly missing its towing eye. Spoony towed me back from krisses. I kept telling him to keep left so i could keep right to keep the bar as straight as possible but hes an ignoramus and kept right to the point he was drgging me over the cats eyes in the middle of the road. That is scary as **** when all i can see, due to the sun strip and sitting so low, is a focus. Anyway we got about 40 miles done out of 50 and braking up to a roundabout with him still in the bloody wrong position ping scraaaaappppppppppppeeeeeeeeeee he ripped my towing eye clean off. I am going to kill him slowly and painfully when i think of a fitting method.

Anyway after calling all of my mates who have tow trucks or car trailers I called the AA who took nearly 2 hours to come out then realised there was no good way of getting my car onto the truck without a tow eye or being able to get to the loops underneath. The AA flat beds dont carry tools and arent allowed to carry tools, not even a jack so there was no way of getting under or getting the splitter or even whole bumper off.

In the end I had to sign not to sue for any damage and we wrapped a strap round the slam pannel and towed it up the "special ferrari ramps" and up the bed with that.

Drama over anyway.

Absolutely loving my new fixxed back bucket seats. So comfy