Dr_Jekyll & Mr_Hyde Estate Project

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Dr_Jekyll & Mr_Hyde Estate Project
(02-10-2015, 09:46 AM)Paul_13 Wrote: Sweet Cheers
No problem [OK HAND SIGN]
Still Living For The 306  Rofl

306 Ph1 Dturbo Estate
205 1.9 GTI (Rust.In.Pieces)
306 HDI Stage 3 Estate (Rust.In.Pieces)
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Looked good a the expo. Good work! Big Grin Itll be in the video too.
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(02-10-2015, 11:00 AM)Eeyore Wrote: Looked good a the expo. Good work! Big Grin Itll be in the video too.
Thanks Smile what videos that?
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306 Ph1 Dturbo Estate
205 1.9 GTI (Rust.In.Pieces)
306 HDI Stage 3 Estate (Rust.In.Pieces)
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(02-10-2015, 11:01 AM)dr_jekyll Wrote:
(02-10-2015, 11:00 AM)Eeyore Wrote: Looked good a the expo. Good work! Big Grin Itll be in the video too.
Thanks Smile what videos that?

The one I was filming all day on the gopro with the massive carbon gimbal. You were in the car whilst i was wandering round and you then left so i could get the camera inside the car Tongue
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Didnt realise that was you! Gimmie a shout once its up Smile
Still Living For The 306  Rofl

306 Ph1 Dturbo Estate
205 1.9 GTI (Rust.In.Pieces)
306 HDI Stage 3 Estate (Rust.In.Pieces)
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(02-10-2015, 11:37 AM)dr_jekyll Wrote: Didnt realise that was you! Gimmie a shout once its up Smile

yeh i left you and your gf alone in the car haha. Ive downloaded the footage but having trouble choosing a song. Found one today and will start editing over the weekend as i have been away with work during the week.
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(02-10-2015, 12:44 PM)Eeyore Wrote:
(02-10-2015, 11:37 AM)dr_jekyll Wrote: Didnt realise that was you! Gimmie a shout once its up Smile

yeh i left you and your gf alone in the car haha. Ive downloaded the footage but having trouble choosing a song. Found one today and will start editing over the weekend as i have been away with work during the week.
Netsky - rio!
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306 Ph1 Dturbo Estate
205 1.9 GTI (Rust.In.Pieces)
306 HDI Stage 3 Estate (Rust.In.Pieces)
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Right so done a couple of bits now since expo, now got full working heaters thanks to aggy again!
Ended up being a small peugeot meet at his house
[Image: ed8e5877cbad96de49a1aa989066d8c6.jpg]
[Image: b7639de3889b778163a13d7a9074059f.jpg]
His xud 205 im still jealous off! Must make my own one day in a gti shell [GRINNING FACE WITH SMILING EYES]
[Image: 830ddde8e1d188c9b0b2128057bdcbe0.jpg]
After searching for seats for a while bit the bullet and bought piggys seats aswell. Turned out some bright spark had welded a bracket to the subframes for the seat belt pre-tensioners which has saved me heaps of work!
[Image: 0bd55ed45f0675aa6d7eabce1f00fd2e.jpg]
Also modded up some gti6 rear seats to fit, genuinley cannot believe how easy it is to do. Did start by pulling a meridian seat to pieces fully removing the cover from the sponge.
[Image: 3cec7cf9e20ef1e426ebd7467024a504.jpg]
Then when i came to remove the gti seat it dawned on me they do actually come away with the sponge so what i though was a 30min job ended up being 5mins.
As everyone knows the latches are different.
[Image: ceada9ff7b8415c1c873a0bcec40ca61.jpg]
But the hole still lines up without cutting and the plastic trim can be fitted and screwed through the material.
Once in the hole isnt visble either.
[Image: ac10eea10c0827042f38ff7d0ae01515.jpg]
The only gash thing is that theres a hole left from the button so i think its best to push and glue it in to plug the hole neatly.
All in all gti bench is a nice touch with the bucket seats and suede roof lining.
[Image: 76092c6e49ec58f3c6b0cc445bc2b86e.jpg]
Next is to suede the door cards and center console again
Still Living For The 306  Rofl

306 Ph1 Dturbo Estate
205 1.9 GTI (Rust.In.Pieces)
306 HDI Stage 3 Estate (Rust.In.Pieces)
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Made a start on one door card tonight, think its pretty self explanatory so heres a few pics of my first effort
[Image: 02d71d01144b32bae9a4ae25e60a4643.jpg][Image: cc276af57472e9e5cf912be89129a552.jpg][Image: 5e7491a27368b21276b6085016191a6b.jpg][Image: 5a52c944e4a65b4cef9f29a0c438911b.jpg][Image: d8dbdd1302418116e69216680646b265.jpg][Image: d6ff9fb5cc29e036ae2590da467335b0.jpg]
Still Living For The 306  Rofl

306 Ph1 Dturbo Estate
205 1.9 GTI (Rust.In.Pieces)
306 HDI Stage 3 Estate (Rust.In.Pieces)
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thats rather smart tbh.

nice finish.
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(21-10-2015, 09:18 AM)mr_fish Wrote: thats rather smart tbh.

nice finish.
Cheers Smile front are a nightmare -.- having to pull tge material so tight to get the bubbles out its untrue, but mehh heres 1 front done, 2/4 so far
[Image: b9edf842b4325c628e5df817c7a5566e.jpg]
Still Living For The 306  Rofl

306 Ph1 Dturbo Estate
205 1.9 GTI (Rust.In.Pieces)
306 HDI Stage 3 Estate (Rust.In.Pieces)
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[Image: d6f295b7f5e38a6c1972164e9e666e0d.jpg][Image: f635642a272c42db84be4aefa7fb26d9.jpg][Image: e9f3b696f86879b19835e48afab6efc7.jpg]
All done, not perfect but what can you expect i suppose.....
Still Living For The 306  Rofl

306 Ph1 Dturbo Estate
205 1.9 GTI (Rust.In.Pieces)
306 HDI Stage 3 Estate (Rust.In.Pieces)
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Well heres some boring stuff for now.
Little bit of winter prep, boot floor was starting to show so light spots of rust so got under there today and sealed her off.
[Image: ffbfb0ac39d6c4786577db645fe025d5.jpg]
[Image: a84c3e5bc6422f42910a33bc1ef95d27.jpg][Image: 696e0306ae35feaf529bfe1917e94190.jpg]
Also took some time and did the underside, had to peal some of the rubber shlitz stuff of where ive ground the car out a few times so payed attention to those areas to. Rear arches were done when i had the rear inner welded so just splatted the fronts up to.
[Image: f6bd9b084baeb9c7ac9d6b7d553188d3.jpg][Image: 2e414569eef808c112e53b4ee66cc2cc.jpg][Image: 6d1a6ff3dbfb0689f219c96abbc14d4a.jpg][Image: f4f69e70cb872dbb0b58a377884e3c98.jpg]
Just got the oil change tommorow to do now. Gotta replace the sump gasket to, originally used silicone when i put the sump through last but after thats started to leak im just opting out for an xud9 gasket. Just seems to make sense.

wheels wise ive no advance on owning the wheels i want. Gf cheekily offered to have mine banded out for xmas so that seems a viable option to run wider tyres. Wont phisically alter the fronts as will have the backs banded out instead. Simply for the reason with the 30mm bolt on spacers i'll be able to run a brembo setup at a later date
Still Living For The 306  Rofl

306 Ph1 Dturbo Estate
205 1.9 GTI (Rust.In.Pieces)
306 HDI Stage 3 Estate (Rust.In.Pieces)
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Lots of work there! Big Grin Great stuff!
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(12-11-2015, 02:36 PM)Eeyore Wrote: Lots of work there! Big Grin Great stuff!
Cheers, things have slowed alot atm
Still Living For The 306  Rofl

306 Ph1 Dturbo Estate
205 1.9 GTI (Rust.In.Pieces)
306 HDI Stage 3 Estate (Rust.In.Pieces)
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what you use to undersea on? paint on or spray on?
new wheels.... how bout my old cosworth wheels Tongue
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(13-11-2015, 03:46 PM)Leemus Wrote: what you use to undersea on? paint on or spray on?
new wheels.... how bout my old cosworth wheels Tongue

yeh how did you put it on? did you ahve to wire wheel all the old stuff off?
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(13-11-2015, 03:46 PM)Leemus Wrote: what you use to undersea on? paint on or spray on?
new wheels.... how bout my old cosworth wheels [emoji14]
Hmmmmmmm.. swap? Lol
Gf turned around and suggested having mine banded for xmas so gonna do that for now, major problem was that i had stretched for "scene points" and rolled my rear arches to the point they look stupid without!
Banding the landy wheels seems like abit of a win win, more grip, more road contact, can keep the stretch aswell and wont alter the look at all (banding the backs out not the face)

As for undersealing it was spray on comma stuff, 3 cans did the whole underside and worked out around £15.
All i did to prep it was wire brush it. Boot floor wasnt shlitzed (if thats how its spelt) from factory so was pitted and had very mild surface rust. Two main rails that run down the underside of the car have taken a good beaten and run most of the shlitz off so had to cut it back till it wouldnt flap up (and trap water) then spray it. Wheel arches were pretty fine, just cleaned them up and sprayed them because i could. Inner wing tho on the front had the start of some corrosion which is now treated but have seen alot of inner wings on 306's showing fatigue signs latley..
Still Living For The 306  Rofl

306 Ph1 Dturbo Estate
205 1.9 GTI (Rust.In.Pieces)
306 HDI Stage 3 Estate (Rust.In.Pieces)
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Well oil change is done so thats winter prep complete Smile just picked up some cylclones to sit ut on while the other wheels are sent away for banding.

Am i the only one who loves the exhaust note of a diesel? Just love how raspy this back box ishttps://vimeo.com/145724596
Still Living For The 306  Rofl

306 Ph1 Dturbo Estate
205 1.9 GTI (Rust.In.Pieces)
306 HDI Stage 3 Estate (Rust.In.Pieces)
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So decided its time to up my game. With the winter months im not planning on getting my hands dirty with the car, but dosnt mean i cant parts horde for stage 3.
From what ive been told all i need to achieve stage 3 on my build is the following:
Turbo
Downpipe
Oil feeds
Adapter plate
Stage 3 map
R70
16.hdi sensor
Gaskets

Been watching turbos for a while on ebay but after selling some parts decided to pounce on a gt2052s unit that come up for a very good price with warrenty. Turns out all the feeds from the gt15 unit will also fit.
[Image: 3c8fb526b9e8a3bd96fee35547756de7.jpg]
After speaking to adam fields (soon to be stage 3 green cabby) about fitting the turbo he shed some light onto needing a 406 manifold to help clear the block a little more. Picked one up from ebay for £17 so wasnt a hard task finding one. Adam also supplied me with an adapter that requires minor edits to the exhaust port.
[Image: c58e9f846fe62dff7cd74f4ca0cc8cd5.jpg] Good friend of mine has supplied me with a stage 3 map, this has come from the same ecu code and we both plan to run identical setups.

So the list now stands at this for the parts hunt:
Downpipe
R70
1.6 hdi sensor
Gaskets
Egt gauge

***gauge has been added to the list for the simple fact i think id be mad not to moniter it when this is first built***
Still Living For The 306  Rofl

306 Ph1 Dturbo Estate
205 1.9 GTI (Rust.In.Pieces)
306 HDI Stage 3 Estate (Rust.In.Pieces)
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Quick update,
Ordered the r70 fuel pump and 1.6fps today.
Turbo arrived the other day, was a little concerned by the amount of side to side play it appeared to have but been told not to worry about it.
406 manifold also arrived today so offered the manifold up to it with the adapter.
[Image: adcb7dc4a3ffdbb441b6e778c744b6d9.jpg]
So first glance i can see that im going to need to drill a hole in the manifold.
[Image: 86166be134a0a4071fc1b38c1bcb8364.jpg] Looking at it im thinking that the studs will need to be removed from the manifold in order to run nut and bolts because of clearance issues. This will also require some grinding....

Anyway as for the exhaust atm it seems like i will have to go from the turbo straight to a 45°. This is because the turbo exhaust exit points directly at the bulkhead. unlike the stock turbo the exhaust mount isnt conical and is just a flat plate so a flexi is gonna be needed aswell.
Still Living For The 306  Rofl

306 Ph1 Dturbo Estate
205 1.9 GTI (Rust.In.Pieces)
306 HDI Stage 3 Estate (Rust.In.Pieces)
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Saw you on Dereham road in Norwich today.. Was in my van flashing my lights at you lol
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Was miles away dude [FACE WITH TEARS OF JOY]
Still Living For The 306  Rofl

306 Ph1 Dturbo Estate
205 1.9 GTI (Rust.In.Pieces)
306 HDI Stage 3 Estate (Rust.In.Pieces)
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Right had some lovley play time the other day with the new turbo. Was given an adapter plate by adam fields as a template with an incorrect exhaust port (gaskets leaked) so decided to have a crack at making my own.
[Image: b6759a29b74cc06a29b467973166fba7.jpg]
[Image: 11cd50e521d829a43b7541d733d0e3cc.jpg]
Once the basic plate was made i was able to offer the turbo and manifold up to each other to see what issues i would have. First obv problem was that one of the studs on the turbo was going to conflict with the manifold, solution? Drill the bastard through
[Image: cc4749b9fb9daadf371f97f24be0c117.jpg]
After that it was apparent the stud would not be long enough so it was extracted to be replaced with a bolt.
[Image: 1061207f99272ae1c434ca8f15da8b51.jpg]
Next problem was that two of the studs on the turbo were far too long and conflicted with the manifold. Rather than cutting these i simply flipped the studs over making the thread standing out shorter.
[Image: 8151d8b73a7fbca6aa8a19bffd13ddde.jpg][Image: 65ab77cc4a608ea0ec6a071087ee8412.jpg]
Final issue was two of the studs on the manifold. They sit so tight to the turbo its impossible to get nuts on them, solution? Grind down the exhaust side on the turbo
[Image: 04abbe0444aed0d6c3185f25f3089e58.jpg]
[Image: b252b8febaf5b598fa2b0261d25962c5.jpg]
Final task was to now cut the hole for the exhaust port.
Now this is were i cocked up. Rather than matching the exhaust to the manifold, i matched it to the turbo itself -.-
[Image: 6c850477a3a9af9f8466f7b8b68846a8.jpg][Image: 106b0dda4ad508ba3ea26beda63c6fef.jpg]
[Image: ce20fd8a5c70a526d3f7b94ef4bea4b1.jpg]
[Image: 1a76f53e029e3ca2b0e84ae874179ac4.jpg]
Because the adapter was matched to the turbo its left it unsealable to the manifold and actually left a hole.
[Image: 717453b7da9bdc429fc86fb8d7ae7426.jpg][Image: fb4d212db6a7d3758e0bf50d070e91b7.jpg]

So after a few hours work ive still got an unuseable adapter [FACE WITH TEARS OF JOY] tommorow im popping over a mates whos going to fill the edges full of weld. Plan is to flow it correctly so that uts not "stepped" between the two exhaust sizes. I realise this may be a pointless excersise but i have awful ocd on stuff like this.

Anyway we shall see what tommorow brings
Still Living For The 306  Rofl

306 Ph1 Dturbo Estate
205 1.9 GTI (Rust.In.Pieces)
306 HDI Stage 3 Estate (Rust.In.Pieces)
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I would really start again with that adaptor, filling the edges full of weld is going to be a disaster and will warp that plate like a bannana. Its a shame as its beautifully matched to the turbo Big Grin
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Why not just weld it straight on to the manifold?

All you will need to change, if it pops, is the internals anyway. Hotside stays attached.
                                             [Image: 2ljm03k.jpg]


                                                                                      I Don't Have A 306.
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Will see tommorow but never liked that idea
Still Living For The 306  Rofl

306 Ph1 Dturbo Estate
205 1.9 GTI (Rust.In.Pieces)
306 HDI Stage 3 Estate (Rust.In.Pieces)
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You've gone to a fair effort so far with it, so may as well use it anyway really.

Iv'e not had a problem welding them. Made the same mistake as you did making mine up for a GT2052S then thought bo11ox and welded it.
Wasn't the first or last one that lasted a long time.

But looking good regardless.
Hope the new wheels turn out as expected.
                                             [Image: 2ljm03k.jpg]


                                                                                      I Don't Have A 306.
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The adapter I made for mine was similar but I simply ported the manifold then made the adapter as big as I could get away with..  
   
Welding and fabrication projects undertaken, contact me for more information.

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(07-12-2015, 07:19 PM)Jonny81191 Wrote: The adapter I made for mine was similar but I simply ported the manifold then made the adapter as big as I could get away with..  
Did yours ever leak? Mines ported slightly larger
Still Living For The 306  Rofl

306 Ph1 Dturbo Estate
205 1.9 GTI (Rust.In.Pieces)
306 HDI Stage 3 Estate (Rust.In.Pieces)
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