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406oc.co.uk • View topic - Replacement daily hack!

Replacement daily hack!

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Re: Replacement daily hack!

Postby dgt » Sat Apr 06, 2013 1:08 am

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Re: Replacement daily hack!

Postby jonsowman » Sat Apr 06, 2013 8:22 am

Talk about making it look effortless! Well done, great stuff. I enjoy reading your threads 8)
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2002 V6 SE Coupé (210bhp) - (Aegean Blue)
2002 D9 2.2 HDi Exec Estate - Samarkand Blue
PM me for PP2000 diagnostics around Surrey
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Re: Replacement daily hack!

Postby dgt » Thu Jun 13, 2013 2:21 pm

Cheers! I enjoy doing this stuff, more than happy to share! :)

Been long overdue.... But an update!

Not much happened in between as I'm bogged down with college and other projects.... Alas, summer and plenty of time :)

So I'll start off where I left off: A shiny car :cheesy:
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Of course I wasn't happy with that so it got a full work over later that week :)
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Looked well at night!
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Service time...
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While I was doing that I decided to change my boot trim and whack a dent out!
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Much happier with the pocket :cheesy:
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Then some suspension altering occurred....
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Quote fed up of my cracked tail light so I replaced it with a new one :)
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The leveller broke one night..... :?:
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Eh.... Yeah! :?
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For the crack I tried the projector lights.... Thoughts?
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And had to change my front tyres with a quick wheel refurb!
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Before and after!
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A quick camber adjustment.... Before
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After
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So as it stands!
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As for the turbo.... How could I forget that! :wink:
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Beside a GT15 8)
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And on you go! :cheesy:
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Still plenty to do..... :shock: :wink:
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Re: Replacement daily hack!

Postby dgt » Sun Jun 30, 2013 3:37 am

With a few issues to address with the TB25, not much more I can do for the mo....

Plenty of driving about though. With 20psi of boost and a Transit spring in for a gov the power is there when I need it.... It'll do for now :cheesy:
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Quite rapid as is :wink:
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Re: Replacement daily hack!

Postby dgt » Sun Jul 07, 2013 1:29 am

I learned how to work picasa somewhat better! :cheesy:

Fuel filters don't last long here due to the washed diesel epidemic
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5k Miles :shock:
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Exhaust boo-boo
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It'll do for now....
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I got a D9 console as I as pestered with botles flopping about everywhere :evil:
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Quite.... Dusty
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3 completely different cig lighters....
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Yaaaay! 8)
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Only thing left was the big gaping hole to fill.... So I made up a filler :D
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Fluid change was a must
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Bulb change as I couldn't see the miles for a while!
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Wind deflectors are a must :cheesy:
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As for my turbo swap project, I couldn't justify spending more time on it so I gave up....... :cry:


















......And got a bigger turbo instead :shock:
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Beside a GT15
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Beside a similar sized turbo as the TB2509! :shock:
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I didn't hang around
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And again beside the GT15, on an XUD mani, correctly clocked :cheesy:
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Just the oil drain pipe, wastgate sampler and downpipe to worry about, apart from a bit of adapting the rest was almost bolt on :cheesy:

With the pace the turbo is going at the engine should be in soon :wink:
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Re: Replacement daily hack!

Postby dirtydirtydiesel » Sun Jul 07, 2013 9:36 pm

Have been following this thread with great interest, it's looking good 8)
Can't wait to see how it performs :twisted:
2002 110 HDi estate, Rapier in monaco blue!
With great power comes great responsablity!!!!!!
(I'm still looking for the f*****g power)!!!!!!!!!!!!!!

pp2000 owner / user, can offer Diagnostic's / fault code, reading / clearing for beer tokens in Leicestershire.
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Re: Replacement daily hack!

Postby dgt » Tue Jul 23, 2013 12:34 am

And the saga continues.... :wink:

First, Irish laundered diesel problem in a nutshell. Off with the sender
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Traditional ring too big for hole :evil:
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Oh dear
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Back to the turbo :cheesy: after a lot of experimenting with pipes I found that a shortened thermostat/ heater pipe from a Fiesta on a modified Merc oil return pipe works as a return :cheesy:
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Box off reveals this beatuy
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Newish glow plugs
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Original thermostat. For shame!!!
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Cleaning the fuel heater
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Polishing the LDA hat to a millimetre of its life :P
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And rocker cover
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Swapping all the little bits and bobs.... Xantia to 406, a lot of differences!
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The standard pipe fits with a bit of manipulation
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Sadly, not a hope!!! :(
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So out with the consaw and a slab of steel
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Drilling to fit
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And this was timing to perfection.... This happened as I almost had the engine ready!


Sigh....
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Onwards and upwards :D Pump fun.... Swapping dynamic advance shims to Transit ones :cheesy:
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Next, wastegate woes..... Finding a way around it was fun 8)
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A very crude EGR blank
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30k mile clutch..... It's 3rd flywheel :cheesy:
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Refurbd pump top
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Later that evening....
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Next day
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But..... Does it work?


Oh yes 8)

Still needs adjustment, downpipe now fouls the linkage but I'll get around that :)

Looking foreward to a test drive when I have it set up the way I want it! :cheesy:
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Re: Replacement daily hack!

Postby dirtydirtydiesel » Tue Jul 23, 2013 9:10 pm

Looking good dude, the effort you put in is mega, are you going to plumb in a intercooler cos you'll need it with th boost temp's that bad boy could run :twisted:
2002 110 HDi estate, Rapier in monaco blue!
With great power comes great responsablity!!!!!!
(I'm still looking for the f*****g power)!!!!!!!!!!!!!!

pp2000 owner / user, can offer Diagnostic's / fault code, reading / clearing for beer tokens in Leicestershire.
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Posts: 1154
Joined: Sun Apr 28, 2013 11:02 pm
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Re: Replacement daily hack!

Postby dgt » Fri Jul 26, 2013 1:39 am

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dgt
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Re: Replacement daily hack!

Postby dgt » Tue Aug 06, 2013 7:53 pm

It's just more developing for me.... Looking to try and fit a Sofim 2.8 air cleaner infront of the box! :shock:

For now, I've assembled a pipe from a Volvo and 2 Ivecos :P
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Brand new tyres
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Completed a long run happily enough too 8)
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And some vids of the turbo in action :cheesy:

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dgt
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Re: Replacement daily hack!

Postby dgt » Sat Dec 28, 2013 9:09 pm

Time I poked my head in here again :cheesy:

As of the 5th of Jan, I'll have this car a year :cheesy:

Since the K14-2 swap, this car is an EPIC daily driver. Very few can outpace it, as a young fella in a WRX found out one night at the lights :cheesy: :cheesy: :cheesy:

Not much has changed, although the car is in a sorry state at the moment :( more on that later...

Apart from that, what have I been up to? Enjoying my car 8) and enjoying the way it goes!!! :cheesy:

I needed a filter, hated running de filtered...
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One day on the motorway, I lost all power.... :?:

Back of the car looked like this after cleaning it that morning!
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The culprit for my loss of poke
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From a Xantia
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And back on my way I went :cheesy:

Didn't clean the back of the car for ages after that :lol:
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Small exhaust issue....
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Only a small issue....
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Mock up for correct length
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Back on the road again :D Time to enjoy the car 8)
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However, I wasn't happy with the way it handled.... And lost diesel :shock:

So I got a small box of parts :)
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After the linkage broke in an irritating manner, it was first on the change. Pikey bodged at the side of the road! :lol:
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Better :)
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Now.... The fuel leak....
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Am thinking of fitting these :supafrisk:
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Painted the drums when they were off
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Out!
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Culprit
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Cleaned the sender when it was out
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Considerable hours later, after much swearing.....
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Done! Arb bushes now, note it's feckin dark....
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Much needed!
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Needed to sort the downpipe
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And weld another hanger
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Job done! Next day was just configuring the exhaust.... Uh oh :oops:
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Can't have that, emergency pikey fix!!!

Take a lump of a Stilo....
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Cut it
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Shape it
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Bend it
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Drill it
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Now we hack the pipe off
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Jam this lump of a coat stand onto the pipe.....
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Weld it and a lump of a 106 box onto it....
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Rivet the piece from earlier on...
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And now we have a handy way of covering up a mess that would have needed a new bumper otherwise :cheesy:
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Next was to sort an awful banging from the front.... I was sure it was the stabilizer

So I rooted this one out
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Hmmmm....
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Out you go!
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Oh dear.....! :shock:
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Honestly not surprised it went with the power from it :cheesy:

Messy job though
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But that cured that :cheesy:

Strengthening the tail pipe hanger
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See, coat stand :lol:
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Then..... Disaster. Timing belt went :cry: Not overly upset as it was a development engine. But annoying to say the least!

To my inventory, out with a spare head..... No make that a full engine! Head for now :D
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Now let the porting madness begin...
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Can't wait to have that in the car.... Actually, I can't wait to have my car back full stop, I miss it so much! :cry:

How it currently looks...
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But how am I getting about? Well, this is the daily hack for now....
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RWD is addictive (I have gone through 4 sets of tyres :shock: ) but it can't hold a candle to the 406 :cheesy:

Also that E39 isn't the blue one from earlier in front of the 406, I have 2 of them. It's a :supafrisk:

What will my next update entail? 8)
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Re: Replacement daily hack!

Postby dgt » Fri May 16, 2014 8:50 pm

Time I poked my head in again.... :wink:

Lets wind the clock back to March.... I needed my car back and fast. Onwards and upwards!
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Getting there....
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Pump off
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On with the hybrid pump, static advanced
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Sump off
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I could eat me dinner from that :cheesy:
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Many minutes later....
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Pistons next
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Bin
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New!
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Need the pulley
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W/Pump, rollers etc
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Diesel pump work 8)
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On with the pump lines again
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Cleaned up my cam
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Pump on
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Injector plumbing
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Studs and manifolds
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In the car it went 8)

New brakes
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A week later, the accelerator cable snapped
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So as it stands :cheesy:
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Sounds as good as ever too 8)


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dgt
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Posts: 97
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Location: Rolling coal...

Re: Replacement daily hack!

Postby jonsowman » Sat May 17, 2014 9:44 am

I love reading your threads, fantastic work :cheesy:

You're going to have basically new 406 at this rate!
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2002 V6 SE Coupé (210bhp) - (Aegean Blue)
2002 D9 2.2 HDi Exec Estate - Samarkand Blue
PM me for PP2000 diagnostics around Surrey
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Re: Replacement daily hack!

Postby dgt » Mon Jul 21, 2014 2:07 pm

Cheers! But like all good things, they have to come to an end sometime :cry:

Time I closed the book on my fantastic daily driver

Since the engine was done I covered 4k miles in it in I think 6 weeks.... There was one week I had over 600 miles put up in 2 days, I was looking to blitz well into the 1000 mile week and beyond :shock:
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However, on day 3 of that week, I decided to stop driving the car to sort out a small oil leak. Was running it on 5w40, it went through it very fast :oops: the one and only 406 ever to enter my garage to add to the list of legends that have graced those doors over the years 8)
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When I had that sorted, I put up the final 200 odd miles with new oil. The juddering was only getting worse and worse The last time I drove it I was merging onto a motorway when I lost all drive, the clutch completely rang I found out after. Not surprised really :lol:

So it had to be brought home on a recovery truck where it stayed at the front of my house for 6 weeks.

The last bit of work I done was to change a tyre on it, then replace the spare with the new wheel and tyre
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The later that evening, I waved goodbye to my old friend. Literally heartbreaking to watch it being towed off
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I know it's gone to a good place, I know the lad who bought it well, mad into XUD's too. He has it running too! :cheesy:

As for my next car? I can't see myself with another 406, as that one was very special to me and any other one just couldn't cut the mustard compared to it. Although I said that before about Alfas.... :oops: So you never know :wink:

For now, I drive a Mercedes C200. It has a welded diff :cheesy: I serviced it, sorted out a propshaft issue, got some 17's for it and slammed it. It's great for drifting :cheesy:
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It's a really nice car but is a stopgap while I source parts for my next sleeper car: . Initially I had a strict deadline to get this car running by but with the waiting time for parts and the stress it was causing me, I decided to scrap the deadline, use the Merc instead and build the 156 in my own time :)

Then when up and running I have a turbo to put on it..... :supafrisk:
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Should prove to be interesting when up and running!

So that's me done with 406's for now. I'll never forget my 2, for different reasons. But I'll look back with fond memories of this one in years to come :cheesy:
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