02-02-2015, 07:12 PM
Ok so I'll give a little more info about what's been going on this weekend
Big thanks to Ruan and James for coming up and lending a hand.
So saturday was spent stripping the old block and swapping the stock rods for the forged ones that Tom sourced.
They were fitted with new sputter bearings and the original 70k Pistons and rings.
We then assembled the top end using the original head which had been freshened up with new seals, and skimmed etc.
A victor Reinz headgasket was used along with a set of XUD style ARP head studs however these were unexpectedly (fault in my part!) too long. Not to worry, a 7pm visit to a farm to use a lathe to turn down the some stock xud spacers (from 28mm to 20mm)
So they were fitted and torqued down, and a gates cambelt kit and new water pump also went on for good measure.
James got busy and made up an adaptor for the gtb2056vlk so that it would bolt straight onto the stock hdi manifold.
I had some turbo adaptor plates made at a local machine shop.
And that was pretty much it for day one.
Day two was spent continuing to build up the rest of the engine with cooling system components, injectors, fuel rail etc etc.
And today was spent timing up the engine, fitting a gti6 flywheel, XUD style CG Motorsport 4 paddle rigid clutch kit, and a 306 Hdi gearbox (converted to pull type)
The gearbox got new seals, and we also fitted the alternator on a cut down bracket and the rest of the bits such as cambelt covers etc
![[Image: bba68e7fefea53587d1bd5ce65360556.jpg]](http://tapatalk.imageshack.com/v2/15/02/02/bba68e7fefea53587d1bd5ce65360556.jpg)
![[Image: c4437c00a3a5eaf60b2c5cf7d93d7bd5.jpg]](http://tapatalk.imageshack.com/v2/15/02/02/c4437c00a3a5eaf60b2c5cf7d93d7bd5.jpg)
![[Image: 703e2bf897445147be69d77b2c278976.jpg]](http://tapatalk.imageshack.com/v2/15/02/02/703e2bf897445147be69d77b2c278976.jpg)
So then it was time to trial fit the engine. We had little knowledge whether the turbo was going to foul the bulkhead, or the steering rack, or the heater matrix, or the master cylinder, or the brake servo!
![[Image: d5496c3753d335a7a2f5ad8a8d468f0b.jpg]](http://tapatalk.imageshack.com/v2/15/02/02/d5496c3753d335a7a2f5ad8a8d468f0b.jpg)
So anyway, first attempt the turbo was sat on the ARB.
![[Image: b10430508f80d43bf37d181070d06a8e.jpg]](http://tapatalk.imageshack.com/v2/15/02/02/b10430508f80d43bf37d181070d06a8e.jpg)
So that was fettled by trimming excess turbo away.
![[Image: 6156936fd1907f8180e7030a72247f2e.jpg]](http://tapatalk.imageshack.com/v2/15/02/02/6156936fd1907f8180e7030a72247f2e.jpg)
And she's in........sort of.
Slight issue with turbo being VERY close to the steering column. But I am going to re drill the holes on the rack to move back an inch.
![[Image: 4bae5f9b712d04462bcc883a6e91ed9f.jpg]](http://tapatalk.imageshack.com/v2/15/02/02/4bae5f9b712d04462bcc883a6e91ed9f.jpg)
But there is definately plenty of bulkhead clearance!
![[Image: 52e8deb97da9dbe028f9f3400f8847b7.jpg]](http://tapatalk.imageshack.com/v2/15/02/02/52e8deb97da9dbe028f9f3400f8847b7.jpg)
The only other slight issue!
So anyway progress being made, wiring to sort, rear axle to rebuild, fuel pipes to run, I've got a Walbro low pressure fuel pump, fuel regulator, and a 7 row oil cooler which im going to run the return fuel through.
Also need to sort oil and water lines for turbo, exhaust, rear axle, chargecooler, a lot of body work to do, and Ideally want the car back on the road in no more than 10 weeks!
Big thanks to Ruan and James for coming up and lending a hand.
So saturday was spent stripping the old block and swapping the stock rods for the forged ones that Tom sourced.
They were fitted with new sputter bearings and the original 70k Pistons and rings.
We then assembled the top end using the original head which had been freshened up with new seals, and skimmed etc.
A victor Reinz headgasket was used along with a set of XUD style ARP head studs however these were unexpectedly (fault in my part!) too long. Not to worry, a 7pm visit to a farm to use a lathe to turn down the some stock xud spacers (from 28mm to 20mm)
So they were fitted and torqued down, and a gates cambelt kit and new water pump also went on for good measure.
James got busy and made up an adaptor for the gtb2056vlk so that it would bolt straight onto the stock hdi manifold.
I had some turbo adaptor plates made at a local machine shop.
And that was pretty much it for day one.
Day two was spent continuing to build up the rest of the engine with cooling system components, injectors, fuel rail etc etc.
And today was spent timing up the engine, fitting a gti6 flywheel, XUD style CG Motorsport 4 paddle rigid clutch kit, and a 306 Hdi gearbox (converted to pull type)
The gearbox got new seals, and we also fitted the alternator on a cut down bracket and the rest of the bits such as cambelt covers etc
So then it was time to trial fit the engine. We had little knowledge whether the turbo was going to foul the bulkhead, or the steering rack, or the heater matrix, or the master cylinder, or the brake servo!
So anyway, first attempt the turbo was sat on the ARB.
So that was fettled by trimming excess turbo away.
And she's in........sort of.
Slight issue with turbo being VERY close to the steering column. But I am going to re drill the holes on the rack to move back an inch.
But there is definately plenty of bulkhead clearance!
The only other slight issue!
So anyway progress being made, wiring to sort, rear axle to rebuild, fuel pipes to run, I've got a Walbro low pressure fuel pump, fuel regulator, and a 7 row oil cooler which im going to run the return fuel through.
Also need to sort oil and water lines for turbo, exhaust, rear axle, chargecooler, a lot of body work to do, and Ideally want the car back on the road in no more than 10 weeks!