Hi, as title says, my daily 205 is getting some power up it soon. I started posting on here a couple of years ago but couldn't remember either my user name or which e.mail address I used so I'm starting again. My engine is built from a 98 306 XUD I bought from Sam Barker. It had been in his old 305 before he built an HDI for it. I've been guided in this build by James ( blue ZX ), Sam, Ruan and Darren too. I've gearbox mounted my Turbo and followed the usual Chinese rods, ARPs, hybrid Bosch pump route and my engine just needs a couple of turbo oil and coolant fittings and it'll be harassing the type R lads round here. The car's staying stock looking with 13" wheels and nothing to hint at its power. Even the exhaust tailpipe is a dummy pea shooter with its 3" system exiting through the bottom of the rear silencer.
Welcome! Plans sound good, I'd definitely be looking at a brake upgrade after all those mods mind! 266s are the next step up but need 14s to clear the callipers
Sounds good man. The idea of the three inch system exiting the standard exhaust at the back is a nice touch as well. Would have never of thought of that.
On a break from 306oc for personal reasons. If anyone needs or wants me most of you have my number and or facebook messenger
Thanks for the good times guys n gals. I might be back. Who knows.
31-01-2016, 07:59 PM (This post was last modified: 31-01-2016, 09:55 PM by 399road.)
[attachment=26498 Wrote:MY95 pid='575297' dateline='1454194549']Welcome! Plans sound good, I'd definitely be looking at a brake upgrade after all those mods mind! 266s are the next step up but need 14s to clear the callipers
Thanks, but Sam's sorted me a vented set up with brand new discs and these are already on.
(30-01-2016, 11:02 PM)darrenjlobb Wrote:
Thanks for your help so far matey. I'll bring chips when it's done.
(30-01-2016, 11:47 PM)Sambarker Wrote: Hi Luke.
Ay up Sam, thanks again for your generousity. We're not far off ready for fitting now....
Here's a picture of that sneaky back box too. Started with a brand new 205d rear box, slit it open, gutted it and then rammed a bloody great 3" pipe and swept bend through it. Some of the original perforated tube was fitted into the walls of the 3" pipe and all the wadding was refitted, so it has room for expanding into the box and quietening it down a little, but in reality - she's straight through.
31-01-2016, 10:02 PM (This post was last modified: 31-01-2016, 10:18 PM by 399road.)
Knocked a bit of a tubular manifold up too! Made from a bit of plate, two fiesta tdci centre pipes and a Land Rover 90 tailpipe. The reducer into the turbo was the trickiest bit
Piggy's old Turbo in its new home...
Knocked up a gearbox mount, Volvo XC90 D5 turbo to hdi box, Impreza actuator, BMX brake cable and a bit of A team.
Manifold finished and it bolts up dead flat and straight. Might be a different story though once it's had 1100 degrees celcius through it!
Just needs a couple of bosses in it now for manifold pressure gauge and egt sender... LSE initials on it are my initials plus an e for exhausts and are a piss take of my Red top Manta's beautifully fabricated Tony Law exhaust with its TLE tag on one of its primaries.
(31-01-2016, 10:26 PM)zx_volcane Wrote: Welcome back great to see updated on this. What's with the a-team spec vnt lashup?
Hi mate. Had to convert 11mm of Actuator expansion into 22mm of VNT lever movement. James suggested the VNT was fully over by 10 psi, so I've had some tube on the actuator pipe with a push bike inner tube presta valve glued into it and my bike track pump as a test rig. Cable should allow mounting of actuator in an easy place for any adjustments and the whole set up can be unbolted fairly easily. Looked all over for info about Arduino but couldn't find much and my turbo came without the electronic actuator.
(01-02-2016, 10:41 AM)Ruan Wrote: I've been hearing the updates from James as always - must pop up again soon and see the progress with this, it's going to be an absolute riot.
Yes mate. There will be 155mm wide black lines all up the bypasses round here. Be good to catch up with you again and you'll have to come round to the new bat cave Ruan.
16-02-2016, 08:25 PM (This post was last modified: 16-02-2016, 08:38 PM by 399road.)
Been collecting more bits this week for the little 205. A new aluminium radiator with two slim fans, two boost gauges, egt gauge, coolant temp gauge, oil pressure gauge, oil temp gauge and a custom oil feed pipe for the turbo. The turbo's oil drain or return pipe is looking a bit tricky to get a decent fall on, with the turbo being over the gearbox, so I'm thinking about running another return down the front of the engine and into the top of the front of the sump. It'll bolt through with some swept hydraulic fittings hopefully, as long as It's above the oil level. There's a bit more welding to sort along the back of the boot floor to deal with too. Another picture of that manifold showing how close it hugs the back of the engine.....
Well, the 1800 stock motor's clutch has finally died tonight. Been limping it along for a month or so now while I finished the XUD motor. This weekend it's out with the engine and box and then a trial fit of the new motor, box, turbo, intercooler and that manifold. Still waiting for some gauges to turn up that will be easier to pipe in with the motor out of the car. Poor old 205.
02-03-2016, 09:40 PM (This post was last modified: 02-03-2016, 09:57 PM by 399road.)
Old n/a engine is out, but new one never made it in as the engine crane bailed. There's a couple of brake pipes to do while access is ok and I wondered about a bit of engine bay seam welding to strengthen it before it gets 200 horses up it. The XUD just needs sender units fitting for my new dash gauges. It seems I need a clutch cable that pulls from the front of the bay and also the clutch fork lever for an HDI 306 box to get it running. That turbo oil return drain is fine now it's bolted through the front of the sump just below where the dipstick tube is. The stealth exhaust back box is hung in place and looks exactly how it should do ( almost invisible ).
I can see this be scary quick once all done, my 205 goes pretty well with a slightly tuned dt lump.
As for clutch cable when i did mine i bought a new 205 cable and took the bits off the gearbox lever end of a 306 cable and made work with the use of an exhaust manifold spacer. Does the job nicely.
08-03-2016, 06:41 PM (This post was last modified: 08-03-2016, 09:05 PM by 399road.)
Engine is now sat on its mounts and that turbo manifold fits a treat. Spent last Saturday seam welding engine bay's subframe and engine mounting brackets, bending lower bulkhead seam to give clearance for exhaust downpipe, replacing crusty brakepipes, removing power steering ram and pipework, flaking loose rust off front subframe and painting black and then wrestling engine and box in using a tyre lever to lift it into place as the engine lift is still nackered. I've got next week off to get it in properly and finished.
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