darrenjlobb's Adaptronic Managed Compound Blown Derv Bus Build

[bashbarnard]

nice to see one of these pumps finally being put to use have been looking into them with the help from other members recently as im not to good with the common rail stuff. some of the aftermarket american stuff for these is mad!! 30,000 psi of pressure. Really nice to see this coming along as this is the first time ive been able to activly follow one of your builds to a 306. keep up the good work i say will be great to see the finished project at some point in the futre

[Ben]

That's some good progress, its interesting stuff!

[Piggy]

great work as always

"great work" is when someone does a pucker job of brushing the workshop floor...

"great work" does not relate to this inspired move and just pure porno pulleys!

And that r110.... Ohhh hubba hubba 

[zx_volcane]

great work as always

"great work" is when someone does a pucker job of brushing the workshop floor...

"great work" does not relate to this inspired move and just pure porno pulleys!

And that r110.... Ohhh hubba hubba 

Fizz?

Glad you're finding time to keep on at this Darren, going to be epic when it comes together

[darrenjlobb]

Thanks for kind words,

Another small update, finally got the transmission back on the motor today, not before fitting the Quaife LSD though,

So got the BE4 I cleaned up / painted on the bench:




Stripped it down and removed the stock open diff:



Removed crown wheel and fitted to new LSD:



And fitted back into box, along with new release bearing and greased up the clutch fork etc:



Thought it would be rude not to bolt it up to the engine, even got excited and mounted the starter!:





And swapped the gear linkages over as forgot while the box was off!



Thanks for looking

[bashbarnard]

love the preemptive starter motor. shows youre getting excited.

[Dum-Dum]

That's some fantastic progress, it amazes me you don't need to spin that CP3 fast to make big power.

[Piggy]

Yeeeaassss!

[Ruan]

That's some fantastic progress, it amazes me you don't need to spin that CP3 fast to make big power.

It's spinning faster than it would be to be capable of 400-500hp at engine 2500rpm!

[darrenjlobb]

That's some fantastic progress, it amazes me you don't need to spin that CP3 fast to make big power.

It's spinning faster than it would be to be capable of 400-500hp at engine 2500rpm!

Its actually spinning faster than a stock pump would be...a stock HDI runs the pump at half crank speed, this one is not....if you do the math, you will see its capacity is fairly extreme, it may be to fast yet / run out of reg, but hoping it will be ok....

[darrenjlobb]

Time for another update,

Been working on getting the manifold / turbos fitted to the motor, largely this is the same as on the mtdi setup, however the GT2256V has been replaced with a GTB226VK, HX30 remains for the time being however, although will likely be replaced with a big BW at some point into the future.

Anyway, started by roughly bolting the manifold up to the head to see how things were looking, as things were likely to have moved welding on the new turbo flanges / pipe arrangement, and things were extremely tight before!



So first problem was fairly immediate, small clearance problem with the water flange, had two option here, either cut up the manifold yet again and tweak it, or modify the water flange for clearance, decided to do the latter, to avoid having to re tweak all the suport brackets etc for the manifold, as change one thing, and nothing else works!

So chopped the offending outlet off:



Put an angle into it, and welded it back up:




Then decided to weld in the boss for new EGT probe, and also two wideband boss's one in the ideal situation before primary turbo, and one after just incase of temp problems with the sensor. One will obviously just have a bung in it when not in use. Have got an Innovate wideband controller and gauge which will come into play further into the project.

Started by hogging out the holes:










Next up was to modify the down pipe, the engine before in MTDI form ran a small 2.25" temp downpipe at the time as just needed it to work for testing, I have now replaced this with a 3 inch item, however routing this down and around the back of the motor is likely going to be a fairly big nightmare, as was a big enough issue before. So decided to split the first part of the downpipe off the turbo from the rest, so it could be fitted as two parts, making fitting / removing much easier, and will allow me to fabricate the downpipe once the motor is in the car on the mounts. 
So welded a v band on the engine of the turbo dump:



All welding / tube is 316 stainless for anyone interested, bar the first pictures of wideband bosses where there was an epic fail with the wrong wire in welder despite correct gas bottle being on the welder,! Result was hacking it all back off and starting over, but no photos of that!!

Next up was to get the manifold bolted on properly. Decided to replace the bolts I was using before, with some studs to prevent wear / damage to the threads in the head during tightening, head owes some money now, so precautions taken in course!
So cut up some stainless bar and dressed up the ends:



And bolted her up fast:






Followed by attaching the blowers etc:






Also fitted new valeo alternator, and remaining oversize 8 rib pulleys:



Thanks for reading

[Piggy]

Oh damn. So damn. Much wow.

Just...oof.

Feeling good then Darren? Must be getting close to hanging it?

[Paul Baldwin]

Oh damn. So damn. Much wow.

Just...oof.

Feeling good then Darren? Must be getting close to hanging it?

For someone that doesn't smoke you seem to blow an awful lot of it, more than that 2.1 of yours infact!

Still not convinced on the use of 316 in these sort of situations Darren, it's food grade and shiny but any sort of extended heat and useage/vibration seems to give it problems. If yours isn't going to be used too much hopefully it'll be ok, otherwise..... :-)

[darrenjlobb]

Oh damn. So damn. Much wow.

Just...oof.

Feeling good then Darren? Must be getting close to hanging it?

For someone that doesn't smoke you seem to blow an awful lot of it, more than that 2.1 of yours infact!

Still not convinced on the use of 316 in these sort of situations Darren, it's food grade and shiny but any sort of extended heat and useage/vibration seems to give it problems. If yours isn't going to be used too much hopefully it'll be ok, otherwise..... :-)

Cracking / extended use tends to give problems with any form of stainless in general to be honest....I am yet to have any of my manifolds crack, and have all been 316..... However I have welded up plenty of 304 / mild steel bodge manifolds in the past : It comes down to the design / supports etc just as much as the material imo...  Time will tell, but either way I generally stick with what I find effective

[Dum-Dum]

Great progress mate, that manifold and turbo mounting is a work of art.

HX30 remains for the time being however, although will likely be replaced with a big BW at some point into the future.

I assume in this context BW is Borg Warner?

[welshpug]

not likely to be big wang.

[Chris306]

I might sound stupid but, what's the black valve looking thing I between the turbos, are you running sequential instead of compound?

[Midnightclub]

Looks like an external wastegate to me, could be wrong

[Piggy]

Looks like an external wastegate to me, could be wrong

Yup. Gotta control 250psi somehow

[Ruan]

External wastegate to bypass the HP turbo hotside.

[darrenjlobb]

External wastegate to bypass the HP turbo hotside.

LP hotside*

[Rippthrough]

Sensible with the lambdas - think you will see temp issues with the pre-turbo one in any extended running - might be worth turning up a copper heatsink on the lathe just to pop under it and take some heat away from the body - I used to run one under mine as it was too close to the head.

[darrenjlobb]

Dropped engine mounts in place today and finished up some other small bits that are awkward to get to once engine is in the car.

Top engine mount fitted to car (This area I think is going to need surgery for clearance...but leaving alone until I have test swung engine into bay to see what im dealing with!)




Trans mount fitted to cradle and box, have to do it this way round due to impossible clearance once in the car!:




And lower engine mount fitted, and yes, its another Powerflex, don't start Powerflex haters!!



Other mounts are all vibratechnics units.


Think am now at the point where crane needs attaching, and engine needs to take a flight up in the air into the engine bay to start finding all the clearance problems!



Thanks for reading

[Piggy]

Good effort...that top mount looks like a behemoth of a mount!

[Dum-Dum]

[darrenjlobb]

Well yesterday was a fairly big day for the D Turbo, we are mid harvest at the moment having some weather related issues (along with major mechanical failures!) so have been plugging at this engine in between jobs a bit, and finally this weekend, I realised I had actually ran out of things to really do other than swing the motor into the car and see what needs clearance etc...

So Sunday morning once things were caught up in the yard, we pushed the DT outside (sadly someone fitted a dyno in the workshop making inside engine crane use a real farce!) jacked it up, and for the first time in years, we were about to hoist an engine into the thing...until...It rained...and rained......and rained some more...so after waiting around most of the day (did manage to have a good tidy up in the workshop mind and find half the bits I had lost for my car) the weather finally somewhat cleared!

D Turbo outside again:






Dont ask how much time, and money is hanging off the end of that over used and very tired engine crane!!:




After some fettling around, the engine was roughly in its position, ended up just having to clearance the top engine mount support bracket a bit to let the pump pulley fit and retaining nut, and also a slight tweak to the other side on the suspension strut.



Once that was sorted, bolted up the trans mount, top engine mount and bottom mount, took the crane away, leaving the car with an engine in it, which I must admit did feel good, has been a very long time coming for the little D Turbo!

Anyway soon after this the weather started closing in again, so a quick push back inside, and it now resides back over the pit with its new block in situ:







Investigated down the back of the motor and also discovered we had zero interference with the Satch shift setup, so fitted and adjusted the linkages for that, which gave me a fully working gear shift:



Got the bonnet mounted up to check for clearance, only real issues is the HP pump pulley sits to close for comfort on the bonnet support , so going to have to clearance that, and also one turbo rubs, so again will have to clearance, both in areas of support strutting on the bonnet so easy to remedy. 

I know its a fairly short / boring update, however I have been waiting for this moment for years! So fairly pleased with yesterdays progress!

Thanks for reading as always

[Jonny81191]

Absolutely amazing update man, bet you're over the moon!

[Dum-Dum]

good progress mate, your workshop looks so clean after a days tidying.

[bashbarnard]

nice man. realy nice. also good to see there are minimal clearence issues as well.

[zx_volcane]

Hah it's in! Proper milestone that looks suitably badass too