Meet the new non 300 Daily. Updates 17/08/13 LOTS OF PICS!!

[340GLT]

Day 2 of the week off started nice and early with lifting the engine out. I then cleaned and painted the new front subframe and started getting the new alloy intercooler to fit. I am relocating it to the front to increase airflow.

Adam

[340GLT]

Day 3 got the engine pretty much stripped, the rocker cover drilled for extra AN10 breathers. I also dropped that and the intercooler to my welder to get tigged.

I got the welding back same day and got the cover painted so it would dry in time. I have crinkle blacked.

Adam

[340GLT]

Next day saw engine torn right down and rods fitted. I have also used an S60R MLS head gasket machined at the rear cylinder to alloy coolant flow to the earlier head. My girlfriend also decided to cook me a BBQ whilst working on the engine. Cant fault her.

Adam

[340GLT]

Next was cylinder head back on and manifolds starting to go back on to work out pipework for the K24.

Engine starting to look like an engine again.

Adam

[340GLT]

Ok so rocker back on, plugs etc in, breather fitment checked, flywheel on engine (Thanks Greg) larger bulkhead poly mount.

I made a bracket to fit the oil cooler just behind the bonnet grill, its mounted on four rivnuts i fitted into the bumper reinforcer.

Adam

[340GLT]

One of the things i knew was going to be the biggest headache was the downpipe which i have made. I bought a few bends and cut up a 3inch stainless system from an impreza i had in work to make a downpipe. I used 7 parts in the end to get teh fitment really good. It clears everything with ample clearance, but just to make sure i heatwrapped the dowmpipe aswell.

Adam

[340GLT]

I am currently waiting on the fuel rail to get the car running so am just doing bits and pieces. This is how the car stands at the moment. I will be making a complete 3inch exhaust for it this week. A random picture of the ported K24.

Adam

[340GLT]

Right all links fixed and now have unlimited bandwidth.

So on to the exhaust, i have no pics of the centre section so will grab some at some point. So i fitted my new 3 inch cat.... :lolbang:

Anyway finally finished the system up, 3inch from front to back a 100 cell race cat and one small silencer.

The system asit goes over the rear suspension is wrapped same as the downpipe. The left over wrap i had i used to do the back box. I may wrap the centre section but im undecided at the moment.

I also finished up the new top radiator hose as the oil cooler lines were in the way for the standard item.

Still waiting on fuel rail until this thing can make some (lots of) noise.

All for now.

Adam

[340GLT]

Right some more fittings turned up for the breather system and the last fuel system parts.
I had to make a new pipe from the fan shroud to the ECU box so used vent pipe with heatshrink joiners.
I dropped the centre exhaust section off so i can drop the tank to run fuel lines too and fitted the FPR on a small bracket ready to start the fueling.
Adam

[340GLT]

*copied* Right she is running. Very happy so far.
Recap, custom made fuel rail finally turned up. Used hardline adapters to convert original feed and return lines from the fuel tank to run AN lines to the fuel swirl pot.
The original pump is now serving as a lift pump to the swirl pot, and the old return is now an overflow from the swirlpot back to tank. Now running AN line from the swirl pot to a volvo 240 fuel filter ( so i could get screw on ends) then to an 044 pump to the rail. Returns from the rail via an FSE regulator back to swirl pot.
I still need to make a cold air division in the engine bay with a proper cold feed. But for now at least the car is on the road.
I am running it in for now at actuator pressure but first signs are all good. Oil pressure is pot on and oil temps seem nice and low too. W
Will keep you updated when the boost gets turned up!!!
Adam

[340GLT]

I forgot to mention engine is now run in. Only teathing problem is the engine breathers, getting oil splash off the cams so i have rerouted them and fitted a restrictor to help stop the oil running through them, but still allowing vapour through. Catch tank has significantly slowed down filling up with oil.
I now have boost set at 1.25bar, fitting a wideband tonight to check things are all safe then up we go to 1.4 bar. It feels really strong now.
Makes some lovely 5Cylinder noises. Very UR quattro Esque!!!
All for now Adam

P.S i will try and get some videos up soon.

[MCHUDD]

Hi Adam.
That one hell of a mean piece of kit you have built. Well done.
Cheers Mark.

[V6 Man]

I'm surprised you didn't go the whole hog and fit and S/V70 front end to it while you had the front off - that would have really confused people....!

[340GLT]

I prefer the look of the 850 front end to be honest although the though has crossed my mind.
Adam

[SteveP]

Like! Hopefully will catch you at RR tomorrow - are you going to be tempted to run it?