305 Dervmafia Winbus

[darrenjlobb]

Nice work Sam, love this car

[bashbarnard]

Really liking this car. Nice to see something a little diffrent.

[Sambarker]

Again not a massive update!

Had a couple of hours free today so started stripping steering rack, hubs etc off. Even dropped the subframe to inspect/clean up

Before:

[attachment=20132]

After

[attachment=20133]

Also trimmed down the exhaust tunnel to give a bit more room

And cleaned the rusty scuttle panels up ready to cut the rust out and repair

Drivers side

[attachment=20134]

Passenger side

[attachment=20135]

Wednesday this week I should be trial fitting the 406 power steering rack, c5 hubs and 407 brake calipers

[Grant]

Awesome progress.

Cant wait to see all the new stuff fitted!

[procta]

getting there! how are you going to wire in the Hdi lump, would you just drop a 406 loom in?

[Sambarker]

Using a single plug 206 loom

[procta]

Using a single plug 206 loom

are you not going to wiring in a few extras from a one that was better specd?
I just kept it all basic for weight and for less of a f*ck on. No ICE for me!

[Sambarker]

The car will use its exiting wiring loom for everything bar the engine management which will run from a separate stand alone stock ecu and wiring

[bashbarnard]

The more you do to this car the more it makes me want one!!

The way your doing the wiring would be how I would. Saves a lot of trouble trying to splice things in its not necessary. One thing ive seen done in the past as well is to put an led on the dash somewhere for the "ecu" light.

[Sambarker]

The more you do to this car the more it makes me want one!!

The way your doing the wiring would be how I would. Saves a lot of trouble trying to splice things in its not necessary. One thing ive seen done in the past as well is to put an led on the dash somewhere for the "ecu" light.

I'll probably use a spare light on the dash for that.

[Sambarker]

[Piggy]

Cracking work me old mucha

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by the pics, does the GTB just bolt up?!

[pugtk]

if you ever want to sell that block

[Piggy]

Is it just the pic or does the belt look proper in the skew?!

[Sambarker]

Engine not timed up in pic there's no tension on the belt

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[Piggy]

Nicely done. Looks real tidy fitment

[205 Mardi gras]

Wow! Looks like you really cracked on this weekend. When I left you'd only just dropped the pistons out. Looks really tidy and thanks Sam for all those parts you gave me. The Turbo adaptor looks impressive too. Now I need to get a move on with 205. ......Luke.

[Uberderv]

Nice work, are the head studs off an XUD? Just wondering because of the spacers you've machined.

[Sambarker]

Nice work, are the head studs off an XUD? Just wondering because of the spacers you've machined.

Yes they are XUD style head studs

[mr_fish]

nice one sam!

[Sambarker]

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







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!

[zx_volcane]

That's some great progress there, engine in on the mounts and pretty much clearing everything, win win. Can't wait to see this on the road again

[Paul Baldwin]

Can't wait to see this running Such a rare car now that's having a new lease of life breathed into it!

I found an article on French cars yesterday and they reckon there's only 97 left registered in the UK. http://petrolblog.com/2014/02/the-rarest...n-britain/

[Piggy]

Awesome work!
Wish I'd known I would have come and lent a hand!!

[Frosty]

Coming along nicely Sam. How come you went for a XUD style clutch rather than a hdi 1 just out of interest?

[bashbarnard]

Love this. Would've gone for xud style as well due to better clamping force

[Sambarker]

XUD clutch is pull type and a much stronger design of clutch

[procta]

that's progress!

[Sambarker]

Simple alternator rig



Experimenting with mk1 focus 23mm m/c





Quick mock up of chargecooler

[Piggy]

Nice wok Sam