Paul's Hdi Estate

[Paul_13 212 1 Cars]

Thought I'd copy this over from 306oc it might interest some people

 

After the last one died a premature death I decided to get another!

 

Here's the dirty slag

 

 

When I got I pretty much mapped it straight away, although I think I buggered the hp pump as it's no where near as fast as my last one. (the fuel pipe blew off on the way back from picking it up as I was driving)

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Is pretty specced up suss pension wise with a rebuilt beam, grp n rear shocks and b8? Front shocks and eibach springs.

 

I took the vts wheels off straight away as I didn't like them and put the cyclones back on. Decat is fitted already

 

Jobs to do:

 

Raise rear

fit solid beam mounts

fabricate a back box

Fit slim line fans (as I've removed the fan cowling)

fit intercooler and swap inlet elbow etc

fit 6 flywheel & dturbo clutch

Fit d turbo clutch cable

R70 pump

stage 2 Remap

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Bit of progress with the intercooler, just a few pics to help other people if they're doing the same.

 

I'm hoping the pipes will squeeze through, I'm going to shove the rad over see if it will give me any more clearance. They're reduced elbows and reduce down to 2"

Clutch is now slipping like mad grrr....

 

Any way I cleaned it

 

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Excuse the steelie that pesky paving slab gave me a puncture

 

Relocated the tps Flipped the bracket and drilled a hole in the slam panel

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IC fits not a problem, hoses go around the rad easily

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Trimmed down the 180' pipe a bit and made a double sided clip

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This bracket is going to be a problem, what have people done with it before? If I take it off I lose the cold air feed

 

I want to retain the standard air box

Right big update today, well just lots of pictures!

 

Fitted the front mount and plumbed it all in. I'll make a guide on this when I get time

 

I fixed the intercooler through the bottom panel, used the existing hole (removed the clip)

 

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Drilled a hole in the slam panel and put a bit of 8mm rod through.

IC is solid and doesn't move now.

 

IC sits dead central and the hoses either side needed trimming 10mm

 

Just to note I have kept the radiator in the standard position

 

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The only bit that needed modifying was the slam panel. It needed pulling towards the front bumper a little to clear the 180 degree hose

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Pic of the pipes down the side

 

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Where it leads to

 

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I'm going to change this a bit as I'm not happy with it

the 90' in the middle will be alloy instead of silicon

 

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The cold air feed is retained

 

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I cut a bit off the 406 top pipe, this ends up being 2" when you do so

 

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The old inlet elbow and air doser removed

 

 

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Where it came from

 

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This was an absolute twat to remove, easiest way was a hacksaw after undoing the jubilees, one on the turbo (accessible from the wheel arch) and one on the inlet elbow/air doser (accessible from under the car through the exhaust tunnel)

 

Very restrictive design down to around 1" in places

 

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New all alloy inlet elbow

 

Here's the bottom turbo pipe, a thanks to Allenallen (sp?) on this one. The pipe is not a direct fit!

 

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Here's the bits you need to trim

 

 

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The part of the subframe that needs relieving (I was in a rush so this could be done neater

 

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Turbo pipe fitted. The PAS pipe gets right in the way

 

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Then a 90/90 to bring you back to the intercooler

 

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All back together! My air duct bolt had sheared off hence the cable tie

 

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Nice and subtle

 

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I'll list all the bits I've used when I get a chance

[calvinhorse 870]

Nice job, looks very factory from the top

[cheesegrater 43 1 Cars]

How come you didn't use a twin pass intercooler?

[Paul_13 212 1 Cars]

The ones I looked at were a bit expensive and they were on the large side.

A bloke on the 306oc forum said there wasn't a lot of room under the headlights.