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martin_r_smith
Tuesday 12th August 2014, 17:49
Well I think it about time I start a little project thread for the smokey one as I've had it a while, and as most know, I have already changed a few things.

The list so far:

Engine - Decat, egr removal, mbc, custom ecu with my own tune, modified turbo (wastegate porting mainly). Running well but I have had to turn the power down until I get a better clutch and beefier pressure plate!

Exterior - Only a set of comets so far and a good polish, but I have an R front bumper and a spoiler to go on. Will also put a tc splitter on it.

Brakes - 302 mm fronts (Ate power discs with mintex 1144 pads). New volvo rear discs and pads last week.

Suspension - Going on this Friday :) All new bilstein shocks, eibach pro springs, meyle HD droplinks, genuine front spring seats and rear top mounts, and a strut brace.

Interior - ummm nothing yet unless you include a boost gauge and sill trims?? Tailgate repair to do soon.

I can't wait to get the suspension done, I think it will make a good difference. Well it can't get any worse than the leaky nivomats and bouncy front struts I have now! Still on the list are a few paint jobs like the bonnet and mirror covers but I have a few engine parts to sort first, clutch and new injectors the most important. Then expect I'll go for more power but to be honest I really enjoy the nice balance of power and economy I have now so I'll be in no hurry for that.

martin_r_smith
Friday 15th August 2014, 16:59
So today all the suspension goodies were installed and I'm very impressed with the transformation. The ride quality hasn't been adversely effected but the covering stability is 10x better. And the drop, about 40mm (even though eibach say 30mm), makes it look much better.

We encountered a few issues on the rear, namely the upper spring seat (metal plate) was no longer! They just fell to bits! Quick call to volvo and....."sorry not available anymore sir". So out comes the plasma cutter and some steel, hey presto homemade equivalent.

The strut brace fitting required a small modification the the diesel filter bracket but wasn't difficult at all. I was told I would have to put additional crimps in the brace to get it to fit, but I didn't have to mod the brace in any way at all!

Pics will be up later.

martin_r_smith
Sunday 17th August 2014, 13:47
http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0235.jpg
Past its best I think.

stribo
Sunday 17th August 2014, 13:53
http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0235.jpg
Past its best I think.

Is that the rear top spring seat?

martin_r_smith
Sunday 17th August 2014, 13:53
http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0244.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0244.jpg.html)
DIY at its finest

martin_r_smith
Sunday 17th August 2014, 13:54
Is that the rear top spring seat?
It was yes

martin_r_smith
Sunday 17th August 2014, 13:57
http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0242.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0242.jpg.html)
Circle'o'matic in action

http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0245.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0245.jpg.html)
The finished product

http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0247.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0247.jpg.html)

martin_r_smith
Sunday 17th August 2014, 13:59
I love new shiny stuff.
http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0238.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0238.jpg.html)http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0239.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0239.jpg.html)

jamesy12345
Sunday 17th August 2014, 14:04
http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0235.jpg
Past its best I think.

I was just starting to thing about suspension (for the S70) & was wondering if the Bilsteins were any good

surprised how bad that part is! My bits & pieces are looking crusty but corrosion not so far advanced like that (iHope)

26306

26307

martin_r_smith
Sunday 17th August 2014, 14:04
http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0248.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0248.jpg.html)

And the strut brace because I'm sure you have never seen one if those before lol.http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0250.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0250.jpg.html)

jamesy12345
Sunday 17th August 2014, 14:09
Looks mint

martin_r_smith
Monday 25th August 2014, 22:12
Right quick update. I gave into temptation and larger injectors are on the way, now with all that extra fuel my poor little kkk k14 turbo is no longer man enough for the job. So end of last week I had a chat with the chaps at Owen Developments and I will soon be getting a garrett gt2056. All being well it should be done fairly soon, but Christmas is my goal. The mapping will be the interesting part but I think I have that sussed.

stribo
Monday 25th August 2014, 22:38
Good progress Martin, look forward to seeing what results you get on the rollers, and more importantly, the strip. ;)

klunk
Wednesday 27th August 2014, 16:00
Me aswell.

Jamest5r
Wednesday 27th August 2014, 20:01
Right quick update. I gave into temptation and larger injectors are on the way, now with all that extra fuel my poor little kkk k14 turbo is no longer man enough for the job. So end of last week I had a chat with the chaps at Owen Developments and I will soon be getting a garrett gt2056. All being well it should be done fairly soon, but Christmas is my goal. The mapping will be the interesting part but I think I have that sussed.

Ooh missed this,could be very interesting :)

martin_r_smith
Wednesday 27th August 2014, 23:01
I
Good progress Martin, look forward to seeing what results you get on the rollers, and more importantly, the strip. ;)

Well my reason for not going on the strip already, the clutch, has reared it's ugly head again. Perhaps I should stop pissing about and get it done, I struggled to get the old girl into first gear a few times today!

So anybody used cg motorsports for clutches before? I'm thinking their dual friction kit as I don't want a full on paddle clutch and this is half and half

t5 pete
Wednesday 27th August 2014, 23:25
Looking forward to seeing it go when done

Casual Alien
Monday 1st September 2014, 15:25
With regards to the top mount, does the poly bush make the cabin shake or is that just a myth?

The Flying Moose
Monday 1st September 2014, 16:54
Nice little project Martin, certainly coming along now. Rare too to see a diesel being worked so extensively... you may well start a trend??? Certainly expecting big torque figures.

Any pictures of it sat on the new suspension?

martin_r_smith
Monday 1st September 2014, 17:18
Nice little project Martin, certainly coming along now. Rare too to see a diesel being worked so extensively... you may well start a trend??? Certainly expecting big torque figures.

Any pictures of it sat on the new suspension?

There will be when I give it a wash!

I'm expecting a good amount of torque too but with it all being so low in the Rev range I have to be careful. Recent conversations with a crazy swede suggest a max of 500nm @ 3000rpm. We will have to see.

In the mean time some new goodies arrived today!

martin_r_smith
Monday 1st September 2014, 17:33
http://youtu.be/nn8xzhMelkQ

Thought I'd try an finish the clutch off lol.

martin_r_smith
Monday 1st September 2014, 17:43
The new goodies!

http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0268.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0268.jpg.html)

http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0269.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0269.jpg.html)

martin_r_smith
Monday 1st September 2014, 22:35
With regards to the top mount, does the poly bush make the cabin shake or is that just a myth?

A little maybe but when your moving it's no different, apart from sounding better (new vid shows the sound off a bit). It does make things rattle when you turn the engine off lol.

martin_r_smith
Thursday 4th September 2014, 21:21
Small update but an important one as it's been getting right on my tits for some time now, the tailgate repair kit has been fitted! Pure bliss, no more rattling from the back when you go over every bump.

Better still we're booked in Monday for flywheel & clutch, going to be hard work sticking to the 500mile break in period :(

martin_r_smith
Saturday 6th September 2014, 14:41
Finally gave her a wash so here's how it looks with the new suspension
http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0271.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0271.jpg.html)
http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0272.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0272.jpg.html)

stribo
Saturday 6th September 2014, 15:29
Finally gave her a wash so here's how it looks with the new suspension
http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0271.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0271.jpg.html)
http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0272.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0272.jpg.html)

Looks much better mate. :B_thumb:

Jamest5r
Saturday 6th September 2014, 17:52
Much better :)

klunk
Saturday 6th September 2014, 19:20
Nice, Makes mine look horrendous! BTW mate, When you decatted it did you just remove the downpipe and smash it out with a long bar or something similar or did you saw off the cat, Gut it and reweld it on? Cheers.

martin_r_smith
Saturday 6th September 2014, 21:53
I just cut it off and put a piece of 2.5" in its place :)

martin_r_smith
Monday 8th September 2014, 18:26
Clutch is in with new flywheel,bearing ect. Also did the crank oil seal, gearbox flush and oil change, engine oil and filter change, and a new air filter for good measure.

BUT... I am a little down in the dumps because the new clutch judders so bloody much. I got the impression from CG that the dual friction kit, although having half paddles, would not act like a full on paddle clutch and still a bit like a normal one. So right now I want to set fire to the thing but I'll try and live with it at least to the end of the break in period, just incase it improves.

We spoke to CG motorsports about the juddering and they said it might improve after 500-1000 miles, but the juddering is a side effect of having a performance clutch that can cope with above standard torque.

Utterly cheesed off!!!

martin_r_smith
Monday 8th September 2014, 18:41
If you read this can you see why I thought it would be ok?

http://www.clutch-specialists.co.uk/dual-friction-kit-for-volvo-850-inc-combi-25-tdi_p23371675.htm

t5 pete
Monday 8th September 2014, 18:46
What sort of judder are you getting are reslly once its bit it shouldnt be juddering any way while your having a break you get any piccys yet

martin_r_smith
Monday 8th September 2014, 18:55
Once its bit its absolutely fine, but unless you dump the clutch out it shakes the whole car!

I haven't no but to be honest mate they're worse than I thought, the corrosion is too deep into the alloy. I don't think they are worth a ££££e.

Jamest5r
Monday 8th September 2014, 20:00
I run a.6 paddle clutch and get no juddering

t5 pete
Monday 8th September 2014, 20:43
Still I like piccys its like buying a news paper whats the point in it not having piccys so get some for me pretty please and ill let you know what I think

klunk
Tuesday 9th September 2014, 11:05
Sorry to hear this mate, Clutch is hardly a 5min job, Hopefully it'll bed in and improve with a bit of heat through it.

martin_r_smith
Wednesday 10th September 2014, 22:50
100 miles down of the break in and it's getting better, or I'm getting better, Not sure which one really. But I'm a lot happier than I was 2 days ago! One good thing though, it really effing grips :D

martin_r_smith
Wednesday 10th September 2014, 22:51
Oh and new turbo arrives this week so I'll keep you posted, hopefully I'll get it fitted before the rolling road day.

Casual Alien
Thursday 11th September 2014, 12:48
Looking good Martin. (I Should have taken advise on the speed sensor, Frankie said the same)

Have you done any mods on the intake manifold or no point? I have a spare as you know, and thought I might give it a go, but don't see much room for improvement.

martin_r_smith
Thursday 11th September 2014, 16:25
There's no pointing doing anything with the inlet manifold, the turbo is far more of a restriction to be honest. You could always cut it in two and smooth everything out, you won't gain anything with a standard turbo but it you plan on changing it may be worth while.

t5 pete
Thursday 11th September 2014, 16:28
You could gain some pennys tho by sending piccys lol

martin_r_smith
Thursday 11th September 2014, 16:36
You could gain some pennys tho by sending piccys lol

I've not been back over to the lock up yet but hopefully this weekend, although they may go well on a new project in the pipe line.

Casual Alien
Thursday 11th September 2014, 17:38
There's no pointing doing anything with the inlet manifold, the turbo is far more of a restriction to be honest. You could always cut it in two and smooth everything out, you won't gain anything with a standard turbo but it you plan on changing it may be worth while.

Ok fettling session postponed.

What turbo do you recommend?

martin_r_smith
Thursday 11th September 2014, 18:27
Not sure yet, I'm working on it myself. Important thing is though to get the fueling sorted first, as it doesn't matter how much air you've got going in if you have no fuel to burn!

Casual Alien
Thursday 11th September 2014, 20:23
Not sure yet, I'm working on it myself. Important thing is though to get the fueling sorted first, as it doesn't matter how much air you've got going in if you have no fuel to burn!

Got ya....I'm just collecting recommendations for my pipe dream!

Henk
Thursday 11th September 2014, 22:47
would have thought the stock manifold would give a fairly imbalanced flow, it would be interesting to compare across there.
Might be a consideration if the target was seriously high hp
Modifying the inlet to be a dual plenum would be a solution

but for 200hp... wouldn't have thought so

martin_r_smith
Saturday 13th September 2014, 12:52
I've had enough of the juddering so having the clutch changed again next week, not bad 2 clutches in 10 days lol. This time a stage 2 kevlar clutch from CG motorsports. They kindly offered to swap it for the dual friction one i have now as I was quite disappointed with how it behaved at slow speeds.

Hopefully the kevlar one should be a lot more like a standard clutch for everyday use, anyone used one before?

t5 pete
Saturday 13th September 2014, 17:39
That's really decent of them to swap it now its your turn do do a good deed and get my pictures lol

martin_r_smith
Saturday 13th September 2014, 17:50
Well after I gave them an ear bending about how it wasn't still "daily driver feel" like the quote on the website, I think there doing it just to shut me up! In all seriousness I couldn't fault the clutches performance when driven hard but you can't drive like that all the time and for me the slow speed drivability was far to compromised to be acceptable.

About the wheels, I think I'm going to keep them for now for a little project, ford based :( lol. But... there is a 940 up the road with a set on for sale so I'll keep an eye it.

martin_r_smith
Monday 15th September 2014, 21:37
16t arrived today, hopefully I'll get it fitted before the dyno day. Just need to figure out where to root everything and plumb in some water lines.

martin_r_smith
Monday 22nd September 2014, 20:31
Hit a small hurdle, I thought my turbo shared the same inlet flange as a 16t, but no. So progress has been halted currently until I can get a 850/70 manifold and cut the flange off to weld on my manifold.

On a good note however the second new clutch is in and I'm very pleased to report it is judder free! Happy motoring again.

martin_r_smith
Sunday 14th December 2014, 23:24
Small update.

16t now mounted to a spare manifold, lots of cutting and welding was needed in the end and the use of various flanges. New map is on the way from Dirty Torque in Shrewsbury, I gave up myself simply because I just didn't have the knowledge to do a good job. DT have been very helpful and I should have the first map tomorrow ready for a dyno sesh on Tuesday.

I'm hoping with the new turbo, bigger injectors, 3" intercooler with 2.5" pipework, map to suit and a couple of fuel pump tweeks I should (fingers crossed) be making around 240bhp and somewhere in the region of 340-360 lb/ft. I'll put some pics up soon too.

Does anyone know of another high power 850/v70 tdi in the UK?

Henk
Monday 15th December 2014, 10:44
Hmm, I'm in Shrewsbury, may have to get into contact with them.
have you had to do anything to the ECU to have it remapped, Thought they were 'fixed' like the TDi VWs are.
Care to share what parts you're using? Still got the air-con condenser too?
Have been looking at DSS or HFLO-X injector nozzles, have a GT2256v turbo but will get an adapter instead of cutting and welding.

Respect for breaking new ground with these engines, only yourself and Shadowmaker that I know of that have done anything to them.

martin_r_smith
Monday 15th December 2014, 11:40
Hmm, I'm in Shrewsbury, may have to get into contact with them.
have you had to do anything to the ECU to have it remapped, Thought they were 'fixed' like the TDi VWs are.
Care to share what parts you're using? Still got the air-con condenser too?
Have been looking at DSS or HFLO-X injector nozzles, have a GT2256v turbo but will get an adapter instead of cutting and welding.

Respect for breaking new ground with these engines, only yourself and Shadowmaker that I know of that have done anything to them.

Yeah the ecu is socketed to accept reprogrammed eproms. I do still have air con yes but it might not stay yet as it doesn't currently work anyway! I use DSSR nozzles from United diesel, also in Shrewsbury. Keith there has been very helpful and I can't recommend them highly enough. The intercooler is a little unknown, I bought it off cherry on here but not sure on its history. Interesting you choosing a vnt turbo, I did think about it and I'm sure DT could utilise the egr map to control the actuator. A GT2256v should bolt straight on as the tdi has a T2 flange, but if not an adapter should be ok as long as it's not to long as it pushes the turbo right up against the master cylinder. My exhaust is a 3" downpipe to a decat 2.5" with only one small silencer.

I know of Shadowmakers crazy beast, but i wont be going to those levels, 240/350 will be fine for me.

martin_r_smith
Thursday 15th January 2015, 21:53
Thought I would put a few build pics up.

All the front end removed ready for the big intercooler. It seems I have even less space than a T5 to wedge a 3" one in but it is going to be possible.
http://i1164.photobucket.com/albums/q568/martin_r_smith/DSC_0490.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/DSC_0490.jpg.html)

Manifolds removed to make way for the 16t.http://i1164.photobucket.com/albums/q568/martin_r_smith/DSC_0495.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/DSC_0495.jpg.html)

After some swear words the 16t fits a treat. A custom bracket for the actuator had to be made due to the turbo being rotated.http://i1164.photobucket.com/albums/q568/martin_r_smith/DSC_0491.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/DSC_0491.jpg.html)

http://i1164.photobucket.com/albums/q568/martin_r_smith/DSC_0492.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/DSC_0492.jpg.html)

The oil feed and return lines needed modifying and I was quite surprised how much smaller the diameter of the c70 return line is compared to the tdi one. Going to see how I get on without water lines to start with, I have read up on it and asked several experts their opinion and they think it will be fine as a diesel runs a lot cooler.

martin_r_smith
Saturday 17th January 2015, 10:44
Found some more pics..

The modified manifold ready to take a td04 16t, next to old k14 housing.
http://i1164.photobucket.com/albums/q568/martin_r_smith/DSC_0438.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/DSC_0438.jpg.html)

It is surprising how restrictive the standard one is really. With the poorly designed wastegate setup of the standard k14 too its not surprising 200+bhp isn't really possible, believe me I tried!! Exhaust manifold pressure is huge due to the restrictions, so much so the exhaust valves cannot seat properly due to the back pressure.

Modified 16t flange to mate up to standard t3 flange.
http://i1164.photobucket.com/albums/q568/martin_r_smith/DSC_0433.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/DSC_0433.jpg.html)

This is the manifold with the 16t on.
http://i1164.photobucket.com/albums/q568/martin_r_smith/DSC_0437.jpg (http://s1164.photobucket.com/user/miartin_r_smith/media/DSC_0437.jpg.html)

I have used the old egr port to place a fitting for monitoring emp.

Jamest5r
Saturday 17th January 2015, 18:06
Looking good mate, reckon your ready for the strip now :)

Doingitsideways
Saturday 17th January 2015, 18:15
Excellent build. Following this with great interest.

I've just bought myself an 850TDi for work.
Will never be modded to the level of yours, but I'm sure some of your experiences will be transferable.

Just need to find someone around Manchester to map the bloody thing first!

martin_r_smith
Saturday 17th January 2015, 19:04
The big intercooler was a tight fit but managed to go in with minimal trimming to the front panel. I know people will wonder why I haven't relocated the horns or trimmed the centre piece out for 'increased' air flow, but i wanted a completely standard look so they are staying where they are.
http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0502.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0502.jpg.html)

Nice shot of the turbo all plumbed in. The copper coil is to disapate heat from the exhaust gas before it gets to the guage to monitor emp.http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0508.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0508.jpg.html)

General overview of the engine bay now it's all back together. I'm going to paint the shiny pipe black as it's not 'factory' enough for me.
http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0503.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0503.jpg.html)

http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0504.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0504.jpg.html)

http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0507.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0507.jpg.html)

The pipe work from the turbo to intercooler had to be changed due to the outlet on the intercooler coming out of the side not the front/back where the original one is. The hardest part was replacing the stupid twisty factory bottom pipe, what a crap design that is! Anyway all 2.5" now and nicely routed. Couldn't get great pics of it but you'll get the idea.

http://i1164.photobucket.com/albums/q568/martin_r_smith/DSC_0500.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/DSC_0500.jpg.html)

http://i1164.photobucket.com/albums/q568/martin_r_smith/DSC_0501.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/DSC_0501.jpg.html)

Can you spot what's missing here?? http://i1164.photobucket.com/albums/q568/martin_r_smith/DSC_0509.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/DSC_0509.jpg.html)

Give you a clue it weighs about 15kgs and is the size of a suit case lol.

martin_r_smith
Saturday 17th January 2015, 19:07
Excellent build. Following this with great interest.

I've just bought myself an 850TDi for work.
Will never be modded to the level of yours, but I'm sure some of your experiences will be transferable.

Just need to find someone around Manchester to map the bloody thing first!

There good engines really, very strong. I have a plug in box for one of these that gave me 170bhp and 270lb/lb on its own, 190bhp with an mbc and decat. Id sell it to you if your interested.

martin_r_smith
Saturday 17th January 2015, 19:09
Looking good mate, reckon your ready for the strip now :)

Maybe but going to run it for a while to see how the DMF handles 360+ ft/lb at 2500 rpm!

Jamest5r
Saturday 17th January 2015, 19:50
Maybe but going to run it for a while to see how the DMF handles 360+ ft/lb at 2500 rpm!

That's going to be interesting :)

stribo
Saturday 17th January 2015, 19:59
Looking forward to seeing it smoking it's way up the strip. ;)

martin_r_smith
Saturday 17th January 2015, 20:27
Looking forward to seeing it smoking it's way up the strip. ;)

If the mapping goes well it shouldn't really be smoking at all! I'm trying to keep it as clean as I can to be honest, I'm not into this 'rollin coal' malarkey.

Jamest5r
Saturday 17th January 2015, 20:40
If the mapping goes well it shouldn't really be smoking at all! I'm trying to keep it as clean as I can to be honest, I'm not into this 'rollin coal' malarkey.

You will be once you start chasing times trust me :)

Doingitsideways
Saturday 17th January 2015, 23:12
There good engines really, very strong. I have a plug in box for one of these that gave me 170bhp and 270lb/lb on its own, 190bhp with an mbc and decat. Id sell it to you if your interested.

Yeah, I have/selling a 960 that I dropped a D24 in, the D5252's 6cyl daddy.
That responded really well to a massive hike in boost (from 8 to 22psi) and some fiddling with the fuel pump.

I'd be very interested in the tuning box. What's involved with it?
Just it just turn it into a smoking machine and make it drink like a fish, 'cos I have the T5 for that! Lol
Have to collect it yet and assess it as it stands yet anyway. It's done a fair few trips to the moon and back.

Let me know how much you'd want for it though :)

klunk
Sunday 18th January 2015, 20:59
You still on your standard main bearing bolts martin?

martin_r_smith
Sunday 18th January 2015, 22:35
No I've got newer vag tdi 12.9 grade.

Doingitsideways
Sunday 18th January 2015, 22:46
I've heard about the crank bolts being weak.

Any idea what sort of power they become suspect?

martin_r_smith
Sunday 18th January 2015, 23:21
Not really, they can go on standard cars just as easy as tuned ones. Shadowmaker ran his 280+hp one with standard bolts with no issues. I don't know of many that have actually snapped but whilst I had the sump off to replace the gasket I thought why not!

Probably best to worry about it when it happens I reckon.

MaxTS
Friday 23rd January 2015, 11:26
Cool project. I had a Peugeot 205 with a 1.9 XUD CG paddle un-sprung clutch, KKK K04 turbo, FMIC and 11mm hybrid Bosch pump from a Transit van. I had it dynoed at 190BHP and in a 800kg stripped shell it was great fun!
I do still have a GT2052s sat in my garage ready to fit an XUD.
I was looking into VNT turbo's and a few guys from the French side use those with inverted boost cans (standard VNT's run off vac so the need the spring swapped over to go the other way as you probably know anyway) and they oven up the vanes with boost, it's crude but it works. The trouble with that is they can surge because of the mechanical pumps being hard to control so you have to control them with your right foot. But with ECU controlled DI they are very very good.

klunk
Saturday 24th January 2015, 21:53
D24 the D5252's 6cyl daddy.

Hardly mate, The D24's a dog in comparison!

martin_r_smith
Sunday 25th January 2015, 19:25
I've been having a few boost problems but pinpointed the issue, the mbc! As it had to be wound in so far to hold 24-26psi the tension in the spring was so great that after it had opened it would release pressure and snap shut agai, thus causing my pulsating boost.

I've turned it down a fair bit now but I'm on the look out for a better mbc, any ideas or recommendations? I would use an electronic controller but they are pretty pricey.

I should be getting my updated tune in the post next week ready for a bit of dyno testing!

Henk
Monday 26th January 2015, 11:43
I was looking into VNT turbo's and a few guys from the French side use those with inverted boost cans (standard VNT's run off vac so the need the spring swapped over to go the other way as you probably know anyway) and they oven up the vanes with boost, it's crude but it works. The trouble with that is they can surge because of the mechanical pumps being hard to control so you have to control them with your right foot. But with ECU controlled DI they are very very good.

I'm looking at putting a VNT on mine (GT2256v), but controlling it is a bugger. A simple standalone ECU would be best, to be able to modulate boost better, as driveability should be better. Have a solution using boost and throttle position, have seen engine vacuum used also but not sure what that means exactly (load, speed?)

For the hassle though a standard wastegate turbo is probably much easier!

martin_r_smith
Thursday 12th February 2015, 23:43
The joys of modifying cars...... Or not!!

On the rollers testing out the latest remap, 3-4 power runs in we noticed the coolant level rising and the pipes getting very hard. The conclusion is the head lifting under full boost, b0ll0cks!!

Need to source some stronger head bolts now and as usual there is nothing of the shelf for this. If anyone knows of a M12x1.75x115mm head bolt that's high tensile (12.9 grade) could you please enlighten me.

martin_r_smith
Friday 6th March 2015, 19:09
Right new head bolts in, try her out up the road, come back for a check and the expansion tank is full to the brim. Cooling fan on (first time I've seen it on) and monumental pressure in the coolant pipe, but the bottom hose is still stone cold?? So out comes the brand new thermostat in a pan of water, low and behold 100 degrees and still not opening. Just goes to show even new stuff can be defunct . Fitted another new one but tried it first! All is good again!

Had a cheeky blast on the dyno and got 237bhp 364ft/lb. Pretty happy but still needs some tweaking, not so much for power but to tone down the delivery a little!

Doingitsideways
Friday 6th March 2015, 19:26
Awesome!

Bet it comes on boost with a bang!!

t5 pete
Friday 6th March 2015, 19:28
Right new head bolts in, try her out up the road, come back for a check and the expansion tank is full to the brim. Calling fan on (first time I've seen it on) and monumental pressure in the coolant pipe, but the bottom hose is still stone cold?? So out comes the brand new thermostat in a pan of water, low and behold 100 degrees and still not opening. Just goes to show even new stuff can be defunct . Fitted another new one but tried it first! All is good again!

Had a cheeky blast on the dyno and got 237bhp 364ft/lb. Pretty happy but still needs some tweaking, not so much for power but to tone down the delivery a little!

Good news

martin_r_smith
Friday 6th March 2015, 19:37
Awesome!

Bet it comes on boost with a bang!!

It does! But the poor 16t isn't man enough for the job so I'm on the hunt for a suitable replacement, either garret gt3067 or if I'm very lucky to find one a holset he221w. The later is preferred really.

Bad news though, on fuelly I've dropped to 40.3 mpg :( sure I'll get over it though

Doingitsideways
Friday 6th March 2015, 19:43
Pmsl!!

Nice turbo choice there.
How much boost are you running?
Not surprised the 16t's shatting itself!

merc85
Friday 6th March 2015, 19:46
How about one of these? GT2359v good for around 280bhp @ 1.8 bar ;)

28296

martin_r_smith
Friday 6th March 2015, 19:50
Pmsl!!

Nice turbo choice there.
How much boost are you running?
Not surprised the 16t's shatting itself!

A modest 2 bar.....lol but that's not the same as doing it on a petrol as I'm only at 4500 rpm max. But still she's not happy.

Merc - that is an option but it's a lot of programming to get the vnt turbo to work. You selling one are you?

merc85
Friday 6th March 2015, 19:52
The Gt2359v is from the w210 3.2cdi upto 2002, and is not VNT buddy 2003 onwards s211 is vnt as has the Electronic actuator as i understand it. ;)

martin_r_smith
Friday 6th March 2015, 19:55
Any garrett with a v on the end is a variable vain turbo

merc85
Friday 6th March 2015, 19:57
Any garrett with a v on the end is a variable vain turbo

oh right, i thought if it had a non electric actuator it was not vnt ?? Learn summit every day :)

martin_r_smith
Friday 6th March 2015, 20:01
The new ones are electronic control but the older ones use a vacuum actuator to control the vains. The ecu controls the actuator but my ecu doesn't have that specific map. But the old egr map can be utilised to do the job. The only other down side is they are geared towards low end power and run out of puff up the Rev range. Unfortunately all modern diesels are like this, loads of power low down the just tail off! I've still got a healthy 300ft\lb at 4250 rpm

merc85
Friday 6th March 2015, 20:09
Cool thanks bud learnt summit there :) The Later Turbo on mine has electronic Actuator and around 418ft lbs as she's been mapped but at what rpm that is tbh i dont, std they have 370ft lbs between 1800-2600rpm

martin_r_smith
Friday 6th March 2015, 20:20
That's when it will be. Normally a big spike which looks good as a figure on paper but not on the road. The area under the torque line on my graphs is massive compared to newer 'high power' diesels, it's not all about peak power. I'm sure I could get mine to spike over 400 but my dmf wouldn't agree lol

martin_r_smith
Friday 6th March 2015, 20:22
Oh and im only getting fully spooled up at 2600 rpm! These old 5 pots like a bit of revving

martin_r_smith
Friday 6th March 2015, 20:35
Got a little tarty under the bonnet toohttp://i1164.photobucket.com/albums/q568/martin_r_smith/DSC_0589.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/DSC_0589.jpg.html)

merc85
Friday 6th March 2015, 20:41
Awesome looking bit of kit ;)

martin_r_smith
Friday 13th March 2015, 21:53
All is not well :(

It would seem my head lifting incident has damaged the head gasket too much and it is now buggered lol, So head off time! I'm going to take advantage of the crappy situation and do some more modification. I have a fully reconditioned head on the way, new valves, seats, guides, re-face, springs, pressure tested etc etc.

Once I get it I'm sending it to Gardias Engine Services in Witney to start opening it up a bit. Hopefully with a bit of work on the head and a thicker gasket (maybe 2) I will be able to push the boost up a bit more, add more fuel, and get some more power.

I'm getting a little frustrated by all the things going wrong at the moment but modifying cars is never easy (or cheap) as we all know. But it will all turn out well in the en, I hope!

martin_r_smith
Wednesday 25th March 2015, 13:25
The postman brought me some shiney stuff today!

http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0626.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0626.jpg.html)

http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0628.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0628.jpg.html)

http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0630.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0630.jpg.html)

Lightly ported and smoothed, with new everything really. Hopefully get it put on after easter.

The Flying Moose
Wednesday 25th March 2015, 20:56
Very nice Martin... watching with interest. It'll be good to see the finished product.

Joolz_850R
Wednesday 25th March 2015, 21:16
Looking good there Martin. Can't wait to see the end results if there is such a thing as an end to a project!!!!

Doingitsideways
Wednesday 25th March 2015, 21:21
That head looks luuurrrrvly!

Won't stay that clean for long though when you start making soot ;)

martin_r_smith
Wednesday 25th March 2015, 21:32
I've got a nice list for my brother for when it's booked in, including finally sorting the saggy rear bumper! as the heads coming off we're doing all belts (again), port matching the manifolds, new coolant temp sensor, glow plugs etc etc. Basically all new stuff for a new head.

I'm not really going to up the power much more this year as I can't decide on which turbo to replace the inadequate 16t with. I will keep it to ~240 as that's the 16t's limit.

Then need to think about a maf-less tune as the maf is a huge restriction, so plenty to still get on with!

martin_r_smith
Wednesday 25th March 2015, 21:34
That head looks luuurrrrvly!

Won't stay that clean for long though when you start making soot ;)

No soot from me! I'm not a fan of rolling coal lol.

Not sure whether to paint it or not to be honest, what do you think?

Doingitsideways
Wednesday 25th March 2015, 21:53
I think it looks lovely as it is.

Would be good if it could just be laquered??

Not sure on that one, would be good though and go well with the black rocker cover

martin_r_smith
Wednesday 25th March 2015, 22:03
Hmm heat proof lacquer, I'll start looking.

Doingitsideways
Wednesday 25th March 2015, 22:16
I guess it's either that or paint it silver!

MA'R'K
Thursday 26th March 2015, 12:46
This is amazing!!! When I first saw this thread, I thought you might have acquired my old car!!! I know a lot of people who mess with these engines in the VW crowd, and the idea was to turn it into a beast! I had it chipped with blanked EGR etc but that's about as far as I went before removing the Polaris wheels and selling as I had to get rid of some cars :(

I will be very interested to see where you take this mate :biggrin:

http://i669.photobucket.com/albums/vv56/Goshawk79/The%20Oil%20Burner%20Rises%202013/D5ROilBurner10-03-13Header01_zps871dc756.jpg~original (http://s669.photobucket.com/user/Goshawk79/media/The%20Oil%20Burner%20Rises%202013/D5ROilBurner10-03-13Header01_zps871dc756.jpg.html)


....and stick a set of V70R seats in it... so much better than those awful 850 tdi seats and hold you in so much better ;)


http://i669.photobucket.com/albums/vv56/Goshawk79/The%20Oil%20Burner%20Rises%202013/D5ROilBurner26-03-1309_zps67313424.jpg~original (http://s669.photobucket.com/user/Goshawk79/media/The%20Oil%20Burner%20Rises%202013/D5ROilBurner26-03-1309_zps67313424.jpg.html)

MA'R'K
Thursday 26th March 2015, 12:49
Go mad!!!!

http://i669.photobucket.com/albums/vv56/Goshawk79/TDI%20Power/TunedVW25TDI_zps989a7200.jpg~original (http://s669.photobucket.com/user/Goshawk79/media/TDI%20Power/TunedVW25TDI_zps989a7200.jpg.html)

http://i669.photobucket.com/albums/vv56/Goshawk79/TDI%20Power/091_zps1d216b3e.jpg~original (http://s669.photobucket.com/user/Goshawk79/media/TDI%20Power/091_zps1d216b3e.jpg.html)

http://i669.photobucket.com/albums/vv56/Goshawk79/TDI%20Power/090_zps6aa9a602.jpg~original (http://s669.photobucket.com/user/Goshawk79/media/TDI%20Power/090_zps6aa9a602.jpg.html)

http://i669.photobucket.com/albums/vv56/Goshawk79/TDI%20Power/089_zpsf32750b7.jpg~original (http://s669.photobucket.com/user/Goshawk79/media/TDI%20Power/089_zpsf32750b7.jpg.html)

MA'R'K
Thursday 26th March 2015, 12:52
No soot from me! I'm not a fan of rolling coal lol.

Not sure whether to paint it or not to be honest, what do you think?

Keep it Granddad red!!! Ultimate sleeper ;)

MA'R'K
Thursday 26th March 2015, 12:56
Got a little tarty under the bonnet toohttp://i1164.photobucket.com/albums/q568/martin_r_smith/DSC_0589.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/DSC_0589.jpg.html)

Could you take the aluminium intake off..... grind the 3 stupid plastic cover fixing lugs off and all the casting texture and polish it? It was the next thing on my list before I sold the car and really wanted to see it done because it would look the dogs!!

I couldn't help but do it with the R..... was a heck of a job, but the inlet on the TDI would be easy ;)

http://i669.photobucket.com/albums/vv56/Goshawk79/The%20Machine%20is%20clean%20in%202013/20130420_185546_zps835ee48d.jpg~original (http://s669.photobucket.com/user/Goshawk79/media/The%20Machine%20is%20clean%20in%202013/20130420_185546_zps835ee48d.jpg.html)

martin_r_smith
Thursday 26th March 2015, 13:54
Could you take the aluminium intake off..... grind the 3 stupid plastic cover fixing lugs off and all the casting texture and polish it? It was the next thing on my list before I sold the car and really wanted to see it done because it would look the dogs!!


I'ts on the list when the heads off! Not sure about polishing it, I'm not really into to much shiney under the bonnet. I will probably paint it. But yes the lugs are coming off and the casting marks.

Funnily enough it was your car that inspired this build. I loved the look of it in granddad red so searched until I found this one. I plan on changing the interior eventually but the engine build is taking up the funds first.

I'm not changing the colour of the car, we were on about the colour of the head! I'm just going to get a few bits resprayed on the exterior as it's in pretty good nick anyway.

Your old car sold fairly recently on ebay, unfortunately it looked in a sorry state and only went for about 500 quid.

MA'R'K
Thursday 26th March 2015, 15:31
Cool cool.... I think the engine looks pretty sick so definitely gives a good basis for a fab looking engine bay!!

The guy who I sold the car unfortunately sold it to some guy who wasn't interested in cars.... I was a bit upset after the attention I put into it! The interior was pretty mint and the comets I put on were mint.... I would have bought it back for 500 if I'd've known as I need two front seats for refurb! ...plus I wouldn't mind some comets again :( .....the exterior defo needed a full respray though, so I would imagine it would have been looking rough!

Good luck with the build though.... I hope you make a beast! I'd love a ride in it if you ever come midlands way as I did enjoy the power delivery (sooo much torque!!) and I imagine uprated would be :rice: :lol:

martin_r_smith
Tuesday 7th April 2015, 18:18
Busy day today, got the new head on, ported the inlet manifold, removed the lugs on the inlet manifold, new coolant temp sensor, glow plugs etc etc.

And finally the coolant system isn't pressurising so hopefully problem solved.

Few piccys

http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0648.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0648.jpg.html)

http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0650.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0650.jpg.html)

http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0651.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0651.jpg.html)

http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0653.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0653.jpg.html)

http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0658.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0658.jpg.html)

Hard to see in the pictures but i was pleasantly surprised to still see the honing marks in the bores. Not bad for over 200k miles. Also put new wishbones on today and will fit the new rear bumper brackets tomorrow

martin_r_smith
Wednesday 8th April 2015, 22:23
Bumper brackets done, after removing the wheel arch liners and the side bolts, the bumper literally fell off!

http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0659.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0659.jpg.html)

Looks a bit better now though
As
http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0660.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0660.jpg.html)

The bumper looks much better but as it's been hung badly for a while it's a little out of shape, so I'm hoping it will settle back to normal after a short time.

t

martin_r_smith
Monday 31st August 2015, 22:50
Ok quick update. After a few months of running with the current setup I'm very happy really. Power is very good (will confirm the exact amount in a week or so), and everything is holding up well.

A couple of issues have cropped up, one being the fact I have some fuel starvation past 3500 rpm and the other being the fuel getting to hot, over 70c on a blast.

So this week I'm going to fit an inline pump to assist the injection pump so it will always see some pressure rather than having to try really hard to suck the fuel from the tank. I will also fit a fuel cooler (from a bmw 535d) to help keep fuel temps below 35c.

Hopefully once these little additions are on a shall be able to maintain the bhp I've paid for rather than losing it due to hardware being able to keep up! I don't expect bhp gains per se, but i do hope to see the bhp not to drop off after 3500-4000 rpm.

I'll take some pics as and when, probably Thursday, and maybe dyno results by the end of next week.

Doingitsideways
Tuesday 1st September 2015, 00:12
Make sure you fit some sort of bypass before the injection pump, I managed to blow a shaft seal on my VE pump on my D24-tic.
That resulted in THE most spectacular fuel leak the world has ever seen and emptied half a tank in 20 miles!
No T5 is that thirsty!!

martin_r_smith
Tuesday 1st September 2015, 06:41
What pressure pump did you use?

Doingitsideways
Thursday 3rd September 2015, 00:05
Ah, I can't tell you that through fear of ridicule! :(












It was on my converted 960, so I used the standard in tank pump for from the petrol system.
So probably about 5bar! :lol:

martin_r_smith
Thursday 3rd September 2015, 23:52
Lol. The one i fitted today was 7-10psi!

martin_r_smith
Monday 7th September 2015, 18:40
I have been monitoring fuel temps with the new pump and cooler setup and after a 3 hour drive it was 37 degrees so all seems to be working well. The inline pump has greatly improved the fueling situation at higher rpm. My butt dyno suggests a good improvement in power over 3500rpm and holds all the way to 4500.

500tie
Monday 7th September 2015, 21:06
Not looking forward to chasing you into Lechlade now mate reckon I'll be left in a cloud of diesel smoke, sounds like she's coming along nicely though bud

martin_r_smith
Monday 7th September 2015, 21:42
Nah its still not that smokey, but unfortunately for you your normally behind me first thing in the morning when it's a little worse.

Incidentally on the mot today she scored her lowest ever on the emissions/ smoke test, thats with all emissions control removed!

500tie
Tuesday 8th September 2015, 19:45
That's made me chuckle a bit, by removing the emissions controls its scored lower love it

martin_r_smith
Sunday 4th October 2015, 13:38
So after my recent head gasket disaster I've put a few miles on it again now and have total confidence in it, Knowing that i have the best possible quality gasket now fitted. The 16 row setrab oil cooler with mocal thermostatic sandwich plate is doing its job and temps are all good. Interestingly now though, if i drive it hard i can get the temp gauge up to normal 3 o'clock position but if i then slow down and drive steady i can get the gauge to drop down to 4 o'clock position.Looking on vol fcr this is only a difference of 91 and 87 degrees but it shows that the cooling systems, oil and water, are working extremely effectively. The fuel cooler i added a while ago is also doing a great job keeping the temps below 35 degrees even if i've got less than quarter of a tank where it previously would reach 60+ degrees.

Overall the car is running better than ever, it even sounds quieter and smoother the wife actually noticed too! So this now means that I may be in a position to push things a little further power wise as i feel i have done everything i can to improve reliability. The hunt shall now start for a better suited turbo,the 16T has done great up to now but it has run out of steam over 240bhp. I am going to try and find a Holset he221w as they have been proven on this engine to 300bhp, They are however fairly difficult to come by in this country so it may take a little while.

Injectors nozzle size will also be increased as I have currently maxed my 0.240 nozzles. I'm not sure which size to go to yet but at least 0.260's. Mapping is again a problem but i may have solved this problem,time shall tell.

Speaking of mapping, my plan is to have the MAF mapped out and run purely on MAP based smoke limitation. The Bosch mechanical flapper style maf is a massive restriction and is seriously hampering top end performance. It will also be better in the long run as good working mafs are getting harder to come by.

Other plans are just to keep tidying it up, Emma keeps nagging me about getting the bonnet sprayed so that is first on the agenda really as it lest the whole car down. A wheel refurb is also on the cards as the comets are starting to look a little ropey.

I'll upload some pics of the work later..

martin_r_smith
Sunday 4th October 2015, 16:07
Fuel cooler, feed pump and oil cooler in.http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0860.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0860.jpg.html)

http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0905.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0905.jpg.html)

http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0861.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0861.jpg.html)

And back to looking good again, to me anyway..
http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0908.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0908.jpg.html)

500tie
Sunday 4th October 2015, 18:41
Looks bloody tidy that mate you've put a lot of effort into the old girl

martin_r_smith
Sunday 4th October 2015, 19:03
I certainly have bud. It did nearly break me though and just over a week ago i was ready to call it quits and part it out, if it wasn't for my brother telling me to man up and get on with it!

500tie
Sunday 4th October 2015, 21:41
Worth it in the end though mate

martin_r_smith
Friday 8th January 2016, 21:08
Update! Since the last engine drama mechanically the car has been brilliant. I have been working with a great tuner in Germany who has really helped improve the cars performance. We managed to squeeze out a little over 240bhp and loads of torque but alas the wee 16t cannot cope, Infact it is over its head at 210!!! So, for drivability and relatively smoke free performance we have cut the power down. She now sits at 200bhp-335ft/lb and im very happy with this for everyday use and until I find a suitable turbo to supply more air this is how it will stay.

In the mean time I'm concentrating on several other aspects. Firstly the grey valour has gone and been replaced with V70 black leather and alcantara, it looks so much better.

The sound system is part way through getting a full Alpine upgrade. I have installed an Alpine IDE-178bt head unit with an Alpine KTP-445a booster pack. Front speakers have been changed to Alpine SPG-13CS components and the rear doors to Alpine SPG-13C2 coaxials. The back is being treated to a custom made box to house an Alpine SWR-10D4 subwoofer powered by an Alpine MRD-M501 amp. Even without the sub the sound quality is amazing. For the rear doors I utilised the original speaker housing by bonding the Alpine speakers to it and sealing. Without this the midrange was severely lacking. The fronts were just a straight swap but the tweeters required dremel intervention but now fit perfectly giving a factory look.

Next job is finally going to be the paintwork! It is provisionally booked in for the last week of Feb for bonnet, front bumper and wing mirror covers. The rest isn't too bad for now and polishes up nicely. No doubt I'll get it all done eventually!

MoleT-5R
Saturday 9th January 2016, 15:09
been a busy boy then Martin, look forward to seeing the upgrades soon mate

500tie
Saturday 9th January 2016, 17:42
Been very busy since we last spoke then mate fitting all the audio equipment, we should meet for a beer one evening so I can ogle over your new install

martin_r_smith
Saturday 9th January 2016, 18:32
We will mate, always time for a beer! Not really much to look at because it's all hidden away, but i can whip the grills of so you can see them. The sub box should arrive next week so I'll fit that next weekend, you could come over and lend a hand if you want ;)

500tie
Saturday 9th January 2016, 19:37
If you were doing it this weekend or the weekend after next mate I'd be there but it's my youngest' 1st birthday next Sunday so I'll have my duties for that one. The hidden factory look is definately the way to go though mate looks far more upmarket that way, says he who is putting two big subs in the boot on show (when the cover is open).

martin_r_smith
Saturday 9th January 2016, 19:55
It might well be the following weekend I'll let you know.

500tie
Saturday 9th January 2016, 20:13
No worries mate Sunday's are much better for me though as my eldest has rugby training on Saturday"...busy life these days lol

martin_r_smith
Friday 20th May 2016, 16:23
The quest for more power is back on! I have just purchased a bigger better more suitable turbo so the fun and games can begin again.

Doingitsideways
Friday 20th May 2016, 21:18
The quest for more power is back on! I have just purchased a bigger better more suitable turbo so the fun and games can begin again.

Yay! :D

Now I have tyres that aren't as bald as a baby's arse and my brakes aren't made of milk bottle tops, I will be soon also :)

Looking forward finding out how poorly Euro Part's own 280s can haul down an 850 with 300kg in the boot.
Should be a laugh. :lol:

Did I say my brakes aren't made of bottle tops any more?
Hmm... I'll get back to you.

Doingitsideways
Friday 20th May 2016, 21:26
What turbos do these run standard, Martin?

I still have the T3 from my old D24 and always wandered how it would compare.

martin_r_smith
Friday 20th May 2016, 21:47
A kkk k14, which flows a little bit more than the d24 t3 unit.

martin_r_smith
Friday 20th May 2016, 22:03
The one I've just bought flows lots more
http://i14.photobucket.com/albums/a345/Alcaid/Jetta/HE221WCompressorMapfromCTTlbs-1.jpg

In fact flows a bit more than a 19t at much higher pressures than the 19t can operate happily at, upto 3 bar if I was crazy enough.

martin_r_smith
Tuesday 21st June 2016, 20:33
I have been busy gathering parts so thought you might like a few pics.

http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0086.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0086.jpg.html)

http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0083.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0083.jpg.html)

http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0084.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0084.jpg.html)

http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0077.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0077.jpg.html)

http://i1164.photobucket.com/albums/q568/martin_r_smith/Mobile%20Uploads/DSC_0080.jpg (http://s1164.photobucket.com/user/martin_r_smith/media/Mobile%20Uploads/DSC_0080.jpg.html)

All 3" pipework for inlet, with the anti-surge housing she'll sound like a jet on spool up! Also have a 3" GWE downpipe (thanks Soulboy) but that's at the garage being modified to fit. The turbo is a holset HE221W with a billet wheel, capable of 39lb/min flow (approx 390bhp on a petrol, 280-300bhp on a diesel) and very fast spool up. I won't be using the holset exhaust housing but the angled housing off my 16t, happily holset used a mitsubishi chra on these so it fits perfect! Quick remap for more fuel and timing then dyno to see where we are. I suspect I will run out of fuel at 250 ish so I'll have to fit larger nozzles. Then it's a case of upping fuel and boost until the smoke is too much then backing off a bit, which should result in ~280bhp with torque limited to 550-600nm so I don't James the gearbox ;)

Doingitsideways
Tuesday 21st June 2016, 20:55
so I don't James the gearbox

:lol: :lol: :lol: :lol:
Bahahahahahahahaha!!!!

Mmm... Holset goodness :)

Jamest5r
Tuesday 21st June 2016, 21:55
Haha very funny :) means your not trying hard enough

martin_r_smith
Tuesday 21st June 2016, 22:36
Well once this lot is all fitted and mapped it will be diff time so we'll see what happens when I try hard then!

MoleT-5R
Wednesday 22nd June 2016, 00:14
Broken shafts....lol ....well they're the next weak link

martin_r_smith
Saturday 15th October 2016, 10:34
Update- Didn't realise i hadn't updated since installing the new turbo and accompanying goodies. Happy to report all is going well really, the holset turbo is much better suited to the derv engine than a td04. I get quicker spool up and much more flow and the turbo isn't being pushed past its limits like the 16t was. I run about 2 bar boost at the moment with nearly maxed at fueling for the size of injectors i currently have. I am trying to keep it as clean as possible too so no coal train style diesel smog for me.

I have been spending a lot of time learning and perfecting the tuning side myself now instead of trying to find someone to do it. And to be honest when you get into it it's not as scary as you might think. I have mainly been using winols but now i have created an XDF file to use with tunerpro which makes it all a bit more user friendly. I have got a wiring diagram that shows how to wire up the ecu for using ostrich for emulation. The only downside is i need 2 ostriches :( so this is going to have to wait a while. At the moment i'm still happy to write the files to chips and keep checking and changing as necessary.

I'll put pics up later.

MoleT-5R
Saturday 15th October 2016, 14:56
Nice update Martin. Mods are working nicely then..:)

martin_r_smith
Saturday 15th October 2016, 15:28
yep all is doing well, I'm really happy with the performance for everyday use. And i'm enjoying being able to tune it myself, its very satisfying!

MoleT-5R
Saturday 15th October 2016, 15:30
Running the 1/4 next season to see what it can do

martin_r_smith
Saturday 15th October 2016, 15:47
I think so yeah. All play is on hold at the moment though (except mapping as its free) as we are in the process of buying a house and it is taking all my dosh!

MoleT-5R
Saturday 15th October 2016, 17:56
Tends to do that and as you say mapping is free and time well spent, the rest will come in time.

martin_r_smith
Wednesday 21st December 2016, 21:35
It's a sad day for me, the car is dead

Unfortunately she suffered oil pump failure resulting in unrepairable engine damage. It breaks my heart to do it after all the work I've put in too it but I will be breaking it for parts rather than repairing. There are going to be a lot of custom parts up for sale soon including:

Custom manifold adapted for T3 flange.
3" stainless downpipe for td04 exhaust housing.
Custom bracket for actuator (needed when using td04 or holset.
Custom oil lines for td04/holset
Smoothed inlet manifold (see pics in thread)
0.240 dssr injectors.
Holset HE221W turbo (once I've had it checked)
Fuel cooler setup.
Oil cooler with thermostatic sandwich plate and custom lines.
Custom top intercooler/inlet pipe with boss welded for 3 bar map sensor (including wiring harness).
Big intercooler and all custom pipework from turbo to inlet.

And probably other bits too. I would be willing to do a deal for everything and also help with mapping too.

Let me know if you want anything

MoleT-5R
Wednesday 21st December 2016, 21:52
It's a sad day for me, the car is dead

Unfortunately she suffered oil pump failure resulting in unrepairable engine damage. It breaks my heart to do it after all the work I've put in too it but I will be breaking it for parts rather than repairing. There are going to be a lot of custom parts up for sale soon including:

Custom manifold adapted for T3 flange.
3" stainless downpipe for td04 exhaust housing.
Custom bracket for actuator (needed when using td04 or holset.
Custom oil lines for td04/holset
Smoothed inlet manifold (see pics in thread)
0.240 dssr injectors.
Holset HE221W turbo (once I've had it checked)
Fuel cooler setup.
Oil cooler with thermostatic sandwich plate and custom lines.
Custom top intercooler/inlet pipe with boss welded for 3 bar map sensor (including wiring harness).
Big intercooler and all custom pipework from turbo to inlet.

And probably other bits too. I would be willing to do a deal for everything and also help with mapping too.

Let me know if you want anything


come on Mr Sideways get this little lot on your tdi and smoke us on the strip....we you know you love that tdi on the strip

Blackdog
Thursday 22nd December 2016, 00:17
Could be interesting as we have a R plate V70 TDI with only 135K on the clock....

Doingitsideways
Thursday 22nd December 2016, 01:41
come on Mr Sideways get this little lot on your tdi and smoke us on the strip....we you know you love that tdi on the strip

Will likely be knocking on for 320k by the time the season rolls around.

She canna take it, Captain!

Think I need to have a chat with Martin...

martin_r_smith
Thursday 22nd December 2016, 07:54
Will likely be knocking on for 320k by the time the season rolls around.

She canna take it, Captain!

Think I need to have a chat with Martin...

Think you better break her in gently with a map first then see what happens!

martin_r_smith
Thursday 22nd December 2016, 07:55
Could be interesting as we have a R plate V70 TDI with only 135K on the clock....

Is that msa 15.7 or 15.8 on an R plate?

Blackdog
Thursday 22nd December 2016, 09:38
Is that msa 15.7 or 15.8 on an R plate?

If only I knew what you were asking? and then how to find out?

martin_r_smith
Thursday 22nd December 2016, 10:40
Haha. Look at the maf, if it looks like a square box it's msa 15.7, if it looks like a normal round style maf it's msa 15.8. The difference is the engine management, 15.7 I can remap now but 15.8 I'm working on!

Blackdog
Thursday 22nd December 2016, 11:13
Haha. Look at the maf, if it looks like a square box it's msa 15.7, if it looks like a normal round style maf it's msa 15.8. The difference is the engine management, 15.7 I can remap now but 15.8 I'm working on!

Lifts the bonnet and finds a square MAF. 15.7 it is then.

martin_r_smith
Thursday 22nd December 2016, 12:06
Well if you wanted just a remap for it I can sort that for you. You would have to send the ECU to me as it needs socketing, then I will remap it with you're files and send it back.