Started my 200tdi conversion today

looking good......managed to keep my battery in place by making up a new tray the same size as the battery, the old one was bigger than necessary for some reason, not sure if it was original as had a perkins conversion when I bought it. Did have to trim about an inch off the viscous fan which I've dispensed with now anyway

I had two batteries, one in the passenger foot well, one in the engine before, so, made sense to put them both under the seat + put all the relays, etc. under there together. Might then put a locable front on the cut out i've made and put a kill switch inside, so, someone has to work out how to break into the series, know where the batteries are and that there is a kill switch, break into the battery compartment and enable the batteries.

Seems a logical bit of additional security to me

got a hidden iso switch on my earth.....then fitted a winch which stated an iso switch has to be fitted on the positive or the gaurantee is invalidated.....so now the battery earths through the winch :doh: time for a bit of rewireing......

Finally got time to play with the Landy again.

Firstly: conditions:


(Ok this was in the early hours of sat and i actually worked on the landy on Sun, but, i like the pic )

So, fuel, as i had a petrol before there was no return valve, dug around in the shed as i have a couple of spare petrol tanks (as you do) and found another thing to go on top of the tank for the pipe, so fitted this to my now empty petrol tank.


This went in quite easily, although i had stolen the pipes off the donner disco and found that one was a lot narrower bore than the other and wouldn't connect to the petrol tank, so, popped down to the local car shop, to find fuel pipe prices have sky rocketed. So £10 later i had about 2m of fuel pipe and plumbed it in. Job done. Just need to move the fuel filter and attach it to the body at some point, but, at least the tank is in now. (Is that green thing on the fuel line one of those magentic fuel saver things?!?!?!)

Task 2 for the day was the exhaust. I had bought a bit of flexi, so, cut the old exhaust exit pipe and welded it on:



I realised it was easier to exit the exhaust through the wing and under the passenger seat. So cleared space for it:



I then tried to weld the other end of the flex to the exhaust. This failed. The flexi exhaust is incredibly thin and even on the lowest heat setting my welder put holes in it.

I concluded my welding skills are not good enough to work with flexi pipe, so, £30 thrown down the drain i now have a new plan

(Bit photo short now, it got dark to take photos)

I'm now going to come out of the turbo, onto a curve of solid pipe, through the wing, onto a bit of clamp on anti vibration flex (not like the flex i previously had) then onto the exhaust. This will be the next few evenings tasks.

I'm a bit concerned i may have cut a bit too much old exhaust up trying to use the flex, and don't have any spare exhaust or money, i will see when i grind off the flex tonight and piece it together again.

So bit of a fail on the exhaust front, but at least i got the fuel tank in, bit of progress.

Hopefully weather will be a bit kinder this week and i'll get more done, though, still that laminate floor to lay in the living room and dining room before Saturday

keep Going!

nearly there

Just been REALLY bad at updating thread. I shall do one now although missing a lot of pictures of the most recent work - why is it always dark when i'm working on it?

Right, well as stated when i started out on this journey it was aside the house project. I now have fully decorated and floored the living room, flooded the kitchen, broken the boiler, fixed both again, looked after the rather ill g/f and wimped out of working outside at anything below -10*c

So - i have finally built the exhaust system - photos to follow. Only thing i haven't done is made a mount to connect the rubber thing to - not a very big job though - but it is currently held together with good old bungy chord!
Photos will show it all - but i used a 200tdi exhaust, cut and welded in a few places and a short bit of flexi to get round the chassis. Exhaust sits under passenger and exits by the rear passenger side tyre.

Radiator:
Ok, i may regret this approach if i ever need lots of access to the front of the engine - but i'm confident there is enough space to do jobs such as the timing belt.
What i did was weld two lengths of angle across the chassis, with two small cross pieces, then after cutting the disco radiator and intercooler frame down to just the radiator section, i bolted this to the angled frame work and mounted the radiator in it.

Plan is to mount the inter-cooler in front of it and to one side of the radiator, although not 100% sure on how to mount it yet, got a few ideas i need to try out.







Found a great supplier of rubber hoses on good old eBay so have all the pipe now - and am building a snorkel which will then go through the disco air filter. Can't see any of that being a big issue and is the main part left to do.

Otherwise, a bit of wiring up to do and then to test it all

So, maybe i will be ready for the laning trip on the 2nd or 3rd of Jan... i keep saying i'll be ready for the next laning trip then not being, but i will be now! As long as the house behaves itself!

YAAAAAAAAAYYY!!! :5bparty:

lol party is tomorrow night, tonight is collapse and start to persuade the g/f she doesn't really hate me for dedicating the last few days to the landy

I'll do some more photos, etc. at some point

Well done :5bcheers2: :5bparty: :5bparty: :5bparty: :5bhurray: :5bhurray: :5bhurray: :beer2:

Hi when I did mine I used the series centre plate
and the disco pressure plate and had no trouble
with the slave cylinder rodand it all works as it
shouldCheers Stuart

Well i took it to Wales today and spent all day Green Laning - 13 hours of continous driving!

Conclusion:

Turbo is f**ked
Need to wire up heating - it is freezing without any
need to tidy up and re-do some of the wiring
Need to lift exhaust a bit hire

Engine however is brilliant, Even with the turbo consuming oil and ejecting it through a hole in one of the pipes (on the to-fix list) it performed well and i kept trying to top up the diesel when it didn't need any... not used to fuel effiency in a series!

Good stuff

Careful the engine doesn't run on oil it sucks through the turbo.

It could rev itself to death if you're not careful.

Mark