BennehBoy's D2 adventure

Bit of drilling (by my mate Sam)



Bit of tapping



Bit of welding



Bit of painting



Another coat then it's onto the front axle, getting there, slowly but surely.

Cleaned up the front brake shields and gave them a coat of red (brown??) oxide...

Been chasing a minor coolant level drop, finally found the cause, it's the hose to the heater matrix...



Took the clip off, reshaped it from the oval that it was before and refitted. If it continues to leak I'll get a different kind of clamp on it.

Bought an airbox of another forum member, mine has the main clamp mount for the top cover bust off.

Did some mods for airflow...

Air spinner removed and main section of the cowl cut out (dremel)




Gorilla taped up the 3 small holes left where the air spinner clips sit


RTV'd up the small drain hole

Did the same to my airbox, fun to hear the turbo spooling

Air spinner? Is that like a factory kinda hiclone or something?

Saltlick said:

Air spinner? Is that like a factory kinda hiclone or something?

Click to expand...

Sort of, it lives in the inlet tract to the airbox, it's purpose is to spin dirt and water particles out of the inlet flow.

This is the bit...

hmm.. interesting
Is that a TD5 specific airbox, or the same part as the 300tdi? I've not really looked into mine much, but keep thinking about making a few little improvements like this to mine - airflow smoothing, port matching etc. just a few basic things really..

Not sure what the airbox is like on a 300tdi buddy.

TD5 Specific I think, though open up your airbox and have a look!

Any pros on RTV'ing the small drain hole on the air filter box?

Water doesnt get in.....

Just finished reading from P1 - now. Impressive to say the least!!

Out of interest are you using stock head bolts?

bankz5152 said:

Water doesnt get in.....

Just finished reading from P1 - now. Impressive to say the least!!

Out of interest are you using stock head bolts?

Click to expand...

Ha, surprised you were still awake by the end of it!

The head bolts I'm using are AMC ones. Avoid Britpart like the plague, I've seen the head break off them with very little effort.

fellipe said:

Any pros on RTV'ing the small drain hole on the air filter box?

Click to expand...

What bankz5152 said. I'd avoid doing this if you have a raised air intake fitted though, rain water can get forced down so it's best to have somewhere for it to drain other than the duck billed drain valve which will only remove water from the air spinner portion of the box.

haha was actually a really interesting read, especially since work has been so dull today! Good read showing all the bad points as well, helpful because mine doesnt have any of the bad bits you seem to have had! So im very happy.

Provent install was interesting, may consider that on my next Td5.

They holding up alright under the power?

Provent is doing a great job. I need to fab up a better mount and get the drain off t'd into the turbo oil return line (with a 1 way check valve), but that's a job for another day - will probably tackle that when I'm fitting the ARB air compressor in a few weeks as it's going to sit in the same general area.

BTW just had a bit of a slap forehead moment... I've been having problems with oil leaking from the half moon of the rocker cover gasket ever since I fitted the AMC 10p head.

Turns out that all AMC heads use the later 15p type gasket and numbnuts here has been fitting the 10p one! Ooops!

Silly!! Mines got a minor leak from there aswell, been meaning to sort it....

OK, Axle update....

Front and rear now fully painted





Started on refurbing the radius arms... tried the cold chisel down the side of the band option and that didn't work on the chassis ends, the bands are just too deep. Tried on the axle end to find that the bands are plastic/nylon, so drilled out the rubber and tried again and they all just popped out.

I'll drill the rubber out of the chassis ends then hacksaw the bands out with relief cuts, then they'll go for shot blasting before being painted up.

Before:


After:

Picked some bits up from the blasters...





Got a coat of primer on