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VNT'd ZX Volcane 1.9TD | Fixed ...for now
#1
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Time to start a project thread now its turned into a project

Picked up a 3 door zx volcane in black a while back, been looking out for one for ages as already have a collection of 5 doors, but 3 doors are hard to come by.

So here it is on the way back

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and in the daylight

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First thing was to get some better wheels on as the zx alloys all had crap tyres, enter a set of 205 speedlines

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Ride height was a bit ridonkulous

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Told it had a 306 replacement back axle put on it, maybe an estate, not sure but it was high!

So set about dropping the rear, had a seized axle from another zx that I gave a good bashing to see if it was worth reconditioning and swapping over, it wasn't :

[Image: zx_beam-rear-knackered.jpg]

So set about trying to lower the one that was on it.

Gave it two attempts and failed and broke a sledge:

[Image: sledge_broke.jpg]

So busied myself shimming the gov and replacing the cradle with with a transit one:

[Image: IMG_0412.png][Image: IMG_0414.png]

3rd time lucky

Dropped the axle from the car and found a bigger sledge and spent a day knocking the crap out of it

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Success

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Put in the volcane anti roll bar as was thicker than the 306 one.

Lowered the front to match, but can't find any photos of the progress

Basically replaced the shocks with bilstein B4's, lowering springs, new drop links, and new top mounts and bearings.

All good for literally a day then this happened:

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catastrophic oil leak from headgasket

see here, a bit of gasket that fell out as I loosened the head studs :

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urggghhh, so then had the joyous task of doing the headgasket

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Did the the cambelt and waterpump at the same time.

Oh and changed the turbo because it was whistling slightly, only to find out the one I'd replaced it with sounds like a full on police car.

Also fitted an MBC whilst it was off

[Image: IMG_0458.jpg]

Replaced the bottoms arms and balljoints and TRE and got the car tracked, so all the front suspension has been replaced now.

the p bushed were both mashed

[Image: IMG_0459.jpg]

also chucked on some bilstein b6 shocks on the rear as the ones on it were knackered. Think you can just about see the braided brake lines I fitted whilst the axle was off, again the rubber ones were both completely shot, to the point I actually managed to tear one with my hands it was that badly cracked.

[Image: IMG_0470.jpg]


So I'm currently waiting for some gti-6 brake discs to turn up to go with the callipers I have had for ages now.

And it  seems down on power since the headgasket, turbo change and MBC fitting. Still boosts ok, and turning up the fuel just destroys my mpg, took it on a motorway run with it up half a turn and literally thought it had sprung a fuel leak.

apologies for length...
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#2
Keeping a close eye on this! Looks lovely Smile
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#3
Looks tidy mate. Still got the red strips, they haven't flaked off yet. TongueP

Any turbo plans?
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#4
silverzx Wrote:Looks tidy mate. Still got the red strips, they haven't flaked off yet. TongueP

Any turbo plans?

its supposed to be my daily driver whilst I strap a T25 to the silver one, but you know, its been difficult to focus ....
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#5
zx_volcane Wrote:its supposed to be my daily driver whilst I strap a T25 to the silver one, but you know, its been difficult to focus ....

Hehe, fair enough! Did you weld the T25 yourself?
Supercharged GTi6 Build
S14 Zenki Build
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#6
Wow you've got a fair bit of work done to that! good work, she'll be a beaut, love the old ZX's, something so retro about them, especially when they have near on 200hp from the derv under within Wink
[Image: 22f2b6b2-758b-4c1c-96fb-6fa9c6059b13_zpsf306b56b.jpg]
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#7
Rainbow 
silverzx Wrote:
zx_volcane Wrote:its supposed to be my daily driver whilst I strap a T25 to the silver one, but you know, its been difficult to focus ....

Hehe, fair enough! Did you weld the T25 yourself?

still sat on the bench next to a manifold waiting for something to happen

haven't got a stick welder, so just building up the energy to make a plate
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#8
Got the fmic on today (thanks James)

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air filter has had to go to make room for pipes

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These things pop out the bottom of the fan cowling and go back on the radiator so it sits properly

[Image: IMG_0523.jpg]

Slight modification needed to allow pipes through

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and shaving a bit off the radiator

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okay a bit more modification needed with a lump hammer

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sits nice

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zip ties ftw

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wired up a slimline fan to existing feed

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bags of room left behind bumper

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all piped up and back together

[Image: IMG_0531.jpg]

[Image: IMG_0535.jpg]

Beauty being I didn't have to think about pipes as they were already together, amazing


Also bypassed all the filter housing and leak off crap today to see if power might be down to air ingress, we'll see, got it plumbed in with a straight inline fuel filter atm and last leakoff going back to pump rather than through some mangle of pipes.
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#9
She looks awesome mate, what turbo is she gonna have on her? Wink
[Image: 22f2b6b2-758b-4c1c-96fb-6fa9c6059b13_zpsf306b56b.jpg]
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#10
That looks awesome, best wheels as well Smile
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#11
Bought a set of gti-6 brakes and been waiting for about 6 weeks for discs to turn up from seller, got fed up and ordered some new ones which arrived today.

So finally some big brakes Smile

Clearance on 205 speedlines is minimal, and had to relocate some wheel weights that were fouling the calliper :o

Also fitted front set of braided hoses to match rear

[Image: IMG_0565.jpg]

Think there is still a bit of air lurking, but ran out of fluid to top up so it'll have to stay in for now.

Can't wait for them to bed in.
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#12
Crappy standard 'see-thru' inline filter clogged up in about 200 miles.

Que road side repair on motorway, lucky I'd left all the original filter system hanging about and had enough pipe / jubilee clips to get it back on and a handy couple of tools in the car.

So back to air ingress :/

Now looking out for an inline filter that will do a proper job.
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#13
This turned up today

[Image: IMG_0603.jpg]

After the fairly ease of getting the T25 on, thought it rude not to get something on this one too - plus the current one sounds ridiculous so needs to be changed really.
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#14
be interesting to see what difference it is compared to the t25 and ul be able to test both with ease!
Perv 106 1.4 xs First Pug Love - Scrapped
Perv 306 1.6 5 Door Hore - Sold
110bhp 207 Hdi Sport - Used as a Brake
173bhp T25 Ph1 Diablo Dturbo - Scrapped
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51bhp Berlingo Nad DT Van - Sold
Slow as f*ck Dispatch Work Horse

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#15
I'd love a volcane and you have it in the best colour too, I really like your project.
Bye Bye D-Turbo
Phase 1 GTi-6 now has a new owner
Rolling in the: Phase 3 HDI Wagon

The current estate project: http://306oc.co.uk/forum/thread-22237.html
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#16
(03-07-2012, 08:34 PM)Jenkosowls Wrote: be interesting to see what difference it is compared to the t25 and ul be able to test both with ease!

I'm thinking straddling through the windows of both, a foot on each accelerator ...
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#17
EGT gauge has turned up

Looks like I'll have to relocate my headunit now - time to dremel the lower console

[Image: IMG_0604.jpg]
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#18
(04-07-2012, 09:55 AM)zx_volcane Wrote:
(03-07-2012, 08:34 PM)Jenkosowls Wrote: be interesting to see what difference it is compared to the t25 and ul be able to test both with ease!

I'm thinking straddling through the windows of both, a foot on each accelerator ...

You'd better hope one isn't faster than the other!
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#19
New turbo almost ready to go on

ninjaninjaninjaninjaninja

[Image: IMG_0965.jpg]
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#20
Good work mate.
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#21
changing out the interior so thought it'd be rude not to check the pick up filter in the tank

clean as a whistle

[Image: IMG_0973.jpg]
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#22
Nice car, I like the 3 door ZX's Smile
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#23
love the volcance deffo one of the best colours in them apart from white my brother used to have a 5 door 1 was a comfy thing to sit in and drive
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#24
(10-09-2012, 09:21 PM)Curt Wrote: Nice car, I like the 3 door ZX's Smile

Thanks, yes had to wait a while for one to come up for sale, have got a few 5 doors...

(11-09-2012, 11:27 AM)jonny1.6 Wrote: love the volcance deffo one of the best colours in them apart from white my brother used to have a 5 door 1 was a comfy thing to sit in and drive

would have to agree, the white ones look mint!

[Image: IMG_0979-1.jpg]

shiny shiny

For anyone thats wondering, the thread in the block is m16 x1.5

Just need to sort out an inline filter
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#25
Finally got new turbo on today, its got some serious kick Smile

[Image: IMG_0975.jpg]

Also sorted gauges / relocated headunit - cardboard ftw! Room for more gauges when they turn up, got oil temp/pressure and water temp coming and ipp to install.

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#26
WOW amazing project thread!! Never really paid much attention to these, but i have got to say... I want one now!! Looks mental mate!! I will deffinatly keep an eye on this project thread from now on!!! Good work!!
GUMBALL3000's MOODY 306D TURBO PHASE-1 WORK IN PROGRESS
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#27
Looking good, more pics of the car as a whole?
[Image: sigjpg.jpg]
Serious.
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#28
A/R .59... O.o How's the lag?
306 HDi Deathtrap - 130bhp / 220lbft
...UPGRADING...



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#29
(13-09-2012, 03:54 PM)Poodle Wrote: A/R .59... O.o How's the lag?

Pretty non existent...
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#30
What turbo is that?
Stage 2 XUD Sedan
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