RossW's 90 Restoration / Upgrade Project

Hello Chaps.
Ive started this thread to record the progress on our D90 upgrade and restoration.
The base car is a 1998 D90 CSW with a snip over 100k miles, FSH, 2 owners from new, and pretty much standard.
Id always been a fan of the 300TDI and mechanically injected motors so chose this over the TD5 onwards powerplant - howevever I do you think that it is lacking power slightly ha ha! I'll come to the solution to this later



1. Needs a new rear X member - rest of the chassis looks good. But do I replace the x member and treat the rest of the chassis or bite the bullet and replace the whole chassis? If anyone can give some advice on this it would be much appreciated.
Will be refreshing arms and axles at the same time.

2. Bushes through out. - Not a big fan of non OE bushes like powerflex etc. Can anyone advise on these?

3. The lack of power I will be addressing with this 2.8 engine picked up last week
- Plenty to be getting on with there



4. Transmission refresh will be done at same time - what uprated bits are recommended? We'll be tuning the engine to ~400lb/ft.
Was thinking of using Ashcroft L suffix box.

5. Usual minor corrosion on bodywork to deal with, that will be last thing.

If the rest of the chassis is good leave as is, mine is 25 years old and still going strong, it's about to get fully shot blasted and painted which should help let it last another 25 I'm very jealous of the TGV !!

Good much mate there easier to get all apart than they first appear

Thanks for that.
What's best route to preserve the original chassis.
Rub down and wax oil?
What about inside the the chassis?

Looks like a good start

RossW said:

Thanks for that.
What's best route to preserve the original chassis.
Rub down and wax oil?
What about inside the the chassis?

Click to expand...

Yeah wax oil is some of the best stuff spray it everywhere onto a clean chassis and it should protect it for several years for each application spray gun is the best way as you can spray it into the holes in the chassis to cover as much if the inside as possible.

verrrry nice enjin

Going to enjoy following this thread. Plenty of pictures please!

Presumably you are the mysterious lotto winner..........

Keep the thread updated with loads of pictures.