I do beleive that the only things i’ve NOT done to this car are the easy bits that Mark can do himself with a basic toolkit, Like fitting his shiney interior bits. Oh, the Smoothing, Adjustable topmounts and Interior re-trim were out-sourced.

Of course, all work carried out has been done to the highest standard possible. This is usually pretty hard to acheive when custom bits and peices need to be made to get the Jigsaw from it’s 300 peices into one whole unit. Thankfully mark is a Guy who knows what he wants done and he’s got the faith in me to just let me get on with the work. I’m VERY proud of what me and Mark have acheived and I look forward to spending much more time working on this car and whatever car mark moves onto (Rumour has it may be a Porsche :s).

The list of work carried out is as follows…

Engine and Performance Modifications:

• Replacement engine including reconditioned cylinder head, Multi layer steel headgasket and all seals/gaskets replaced. New cambelt, tensioners, waterpump and so-on
• Bosch VE Mechanical Fuel pump conversion, Running a 10mm head (credit to  Darrenjlobb for the pump). Extesnsively tuned, Governor Mod, Reconditioned Bosch Injectors.
• Custom Garret T25 Turbo conversion, including 300zx T25 turbo, Custom adaptor plates to allow the turbo to Fit and be removed easily. Aftermarket wastegate actuator, Manual boost controller Fitted near fuel pump and EGT Sensor. Currently boosting an easy 20psi with more to give.
• 306 HDi Gearbox conversion including all new seals, GTi6 Flywheel, Dturbo clutch and clutch arm, New release fork bushes and Cable
• Full Front Mount Intercooler (FMIC) Setup including 2.25″ pipework, matching Silicone pipes, Alloy pipes and Mikalor style clamps. Also a 406/xantia inlet manifold.
• Derv doctor Dump valve and T-peice, with a quality Electro-Solenoid and Microswitch for activation.
• Brand new full set of Engine Mounts.
• Full stainless steel exhaust system, De-cat and Powerflex mountings. (De-cat legal on Diesels older than 2001)
• 13 Row oil cooler with braided piping, Mocal sandwich plate with ports for Oil pressure and Oil temp sensors (fitted)
• Nissens alloy Radiator, filled with 40% coolant, 55% water and the remaining 5% consists of ‘Wetter water’ additive to keep the temps low. Slimline fan.
• Powder coated blue Rocker cover, Blue cable conduit wrap and a few peices of Blue edging strip.
• Aftermarket air filter and piping.
• Earth upgrade (The Big Three).
• Serviced every 5000 miles, running 5w40w Fully Synthethic oil

Suspension and Brakes

• GAZ height adjustable Coilovers up front with Adjustable shocks at the rear to match.
• Adjustable metal rose jointed Droplinks and GTi6 Front anti roll bar.
• Rear disc beam conversion, with Added 22mm Torsion bars and Hybrid anti roll bar.
• Solid rear beam Mounts.
• MEYLE HD (Heavy duty, 4 year Guarantee) Wishbones. These are a great compromise between Standard mounts and Polybushing, also have Stronger balljoints.
• Replacement wheel hubs and wheel bearings all round.
• Compbrake Adjustable solid front Topmount conversion. (Not fitted by me), 1 Degree Camber
• Pirelli P-Zero tyres all round.
• Hi-Spec 4 pot Brake calliper conversion upfront with 285mm vented discs. 23.8mm Master cylinder.
• Braided brake lines all-round with all new underfloor copper piping for the rear with Load compensator fitted.
• Ride height currently -50mm

Exterior
• Phase 2/3 rear lights including Loom Splice
• After market rear bumper.
• Powder coated white Ariannes.
• 20mm hubcentric spacers on the rear.
• Side skirts.
• Smoothed phase 3 tail gate and de wipered.
• Gti rear spoiler.
• Smoothed rear door handles.
• Tinted rear windows.
• De locked front doors.
• Smoothed Ariel.
• Complete phase 3 front end conversion.
• Crystal head lights.
• Smoothed carbon wrapped bonnet.
• Smoothed grill
• Smoothed front bumper
• Megane front Splitter
• Rallye Blanks.
• Pirelli P Zero Nero’s all around.
• Xsara washer jets.
• Full respray in Ultra Marine Blue.

Interior
• Phase 3 stealth parcel shelf.
• Phase three lower centre console.
• Corbeau front seats retrimmed, door cards and rear seat to match.
• Colour coded centre console, vents and dial surround.
• Metal Monkey dials.
• Alpine head unit and component front speakers.
• After market Dturbo mats.
• Stainless steel handbrake leaver.
• Stainless steel door pins.
• Rear door poppers.
• Boot pooper.
• Leather steering wheel.
• Alloy top standard 5 speed gear knob.
• New pedal rubbers.
• Boost, oil pressure, and oil temp gauges.

Repairs
• New Alternator.
• New wheel bearings.
• New Cam belt set.
• New aux belt set.
• New Heater Matrix

Hopefully these pictures will arrive in the right order… Starting at the Beginning and finishing at the present time/state.

If you would like to share a link then please email it to me.

I Recently had a return customer bring his 406 Estate to me for the task of fitting a Bosch VE mechanical fuel pump. The reason for this was to do away with the sluggy Lucas EPIC ECU controlled pump and fit a Mechanical non-ecu controlled Bosch VE pump in order to free up bucket loads more power and to open his doors to the world of running Vegetable oil.

Well, I did the conversion and quite frankly found it a reasonably easy job to do. There were small issues such as injector pipes fouling and not fitting, finding an ignition live for the Bosch, modifying the loom holder and moving the bulk of the upper part of the loom. I also had to remove the boost sender from the upper boost pipe in order to have a boost take-off for the compensator on the pump.

The result was astonishing, despite the vehicle having a boost leak or two from the 4 rubber seals half way down the Inlet manifold, for this reason i was unable to finish tuning but despite this small issue the results were instantly noticable with a lot more Torque lower down the RPM, the engine ran so much smoother and power delivery was excellent. From memory on what the ‘heavy tuners’ report 180bhp is easily achievable, even more can be reached with the addition of a 10 or 11mm head fitted to the bosch.

I would recommend a conversion for any XUD11 owners for various reasons! For more proof and comments on the conversions you’re best checking out www.406oc.co.uk

I’m able to offer this conversion for £340 including all parts, cambelt and tuning. Waterpump, cambelt tensioner and idler are extra.

Stip down both heads, cambelt off, cams out and then drill and tap the existing holes out to an M8 thread. Peice the jigsaw back together and Bob’s you’re uncle!

One 3.0 V6 Back on the road!

After lots of consideration I have come to the decision that for ALL future bookings a £20 booking fee will be required. This is due to the large amount of people who think it’s OK to not turn up or cancel at the last minute.

The Booking Fee can be paid by Paypal or Bank Transfer and is deducted from the final bill. This deposit is ONLY refundable with at least 7 days notice of cancellation.

I’m sorry it’s come to this but i can’t keep throwing money away travelling to work or loosing a days work that could of been booked for somebody else.

KrisB

Lowering

• Adjust Torsion bar to any height & Fit front springs ~ £90 ( Shock fitting is Free)
• Just Torsion Bar ~ £60
• Fit springs ~ £20 per corner
• Group bookings ~2 cars @ £80 each. OR 3 cars @ £70 each. ~ This is for torsion bar and springs – Please organise amongst yourselves

All torsion bars are lowered the correct way as to not cause damage to the Trailing arm bearings. Lowering increases the risk of the bearing failure BUT Lowering the correct way minimises this greatly. All torsion bars are fully removed, splines cleaned, rust removed and re-assembled. As mentioned above, lowering may casue premature failure of the trailing arm bearings, it is your responsibility to periodically check for any play in the trailing arms (both rear wheels off the floor) and to check for camber on the rear wheels by standing at the rear of the car with the wheels on the floor and on level ground.

Lowering a car all round usually takes about 3 Hours.

Please be aware that on certain models of 106’s and saxo’s, lowering may cause the offside steering arm to rub on a power steering pipe. I will always check to see if it’s rubbing and adjust the pipe so that it clears,  However,  it is your responsibility to check periodically the clearance between the pipe and steering arm.

Cambelts

• TU Engine Series (1.0, 1.1, 1.4, 1.6) excluding 16v ~ £170
• XU Engine Series (1.9td, 1.9d, 2.0 8v, hdi etc ~ £220
• Gti6 &  TU 16v (eg 106 gti, Saxo VTS) ~ £270
• Camshaft and crankshaft oil seals – Extra £45 (excluding gearbox end)
• Aux/Fan belts from £8 if fited with cambelt, otherwise a further £20 labour.

*Cambelt prices include Waterpump, Idlers/Tensioners and Coolant, Also warranty

Clutches

• 1.0, 1.1, 1.4 & 1.6 ~ £190 fitted including valeo clutch. Cable £40 extra
• 1.8, 1.9td, 1.9d, 2.0,  Hdi, Gti6 ~ £230 fitted including valeo clutch. Cable £40 exra
• Driveshaft oil seals – £20 extra .
• Crankshaft oil seal – £30 extra.
• Gearbox input shaft seal £5 extra. << Recommended

Servicing

• Basic Service, All models ~ £80
• Full Service, All models ~ £130

*Basic service includes: Oil, Oil Filter, Air Filter, Fuel Filter.

*Full Service includes: Oil, Oil Filter, Air Filter, Fuel Filter, Brake fluid change, Gearbox oil change, Coolant change, Spark plugs and a thorough checking over.

Full Diagnostics

I now offer full Fault code Diagnostics to most Makes and Models of vehicles, including Live Data. £20 Per Scan.

• EML – Engine management lights / Service lights
• ABS – Anti lock braking lights
• SRS – Airbag lights
• ‘Health Checks’ on modern Vehicles

Tuning

• Stage 1 Tune, Turbo Diesels only ~ £60
• Fit cams on 8v vehicles… Please see Headgaskets, cam fitting is no extra.
• Fit cams on 16v models, £180 including new cambelt (not tensioners, idlers or waterpump).
• Loading HDi maps – £30 first time, £20 thereafter. I do not supply maps although i have a small collection.
• Fitting aftermarket manifold (TU engines) – £60 including gasket
• Supply and Fit 306 Turbo Diesel De-cat pipe c/w gasket and new clamps – £55

Mapping is your responsibility and i will require data sheets for whatever cam you’ve chosen.

Braking

• Replace front (or rear) Pads & Discs, All Models ~ £30 plus parts
• Replace Master Cylinder, All Models ~ £40 plus parts
• Replace Servo, 1.0 1.1 1.4, 1.6 etc ~ £170 all inclusive
• Replace Servo, 1.8, 1.9, 2.0 Petrol & Diesel ~ £200 All inclusive
• Replace Rear Shoes, All models ~ £80 all inclusive (new drums not included)
• Replace Handbrake Cables, All Models ~ £70 all inclusive

Driveline

• Driveshafts fully fitted from £80
• Front Wheelbearings – unfortunately I don’t have a press and cannot replace wheel bearings
• Rear wheel bearings from £65
• Topmounts from £40 each fitted.
• Droplinks – most models £55 supplied and fitted (optional Heavy duty parts available)*
• Lower arms / Wishbones from £70 fitted (optional Heavy duty parts available)*
• Balljoints (exc. saxo and 106) from £25 fitted.
• Driveshaft oil seals – Pair, fully fitted including fresh gear oil £70
• Engine mounts from £30 fitted.

* Heavy duty parts with a 4yr Guarantee – A good compromise between Good quality standard and polybush bushings and the Balljoints are also heavy duty.

Headgaskets

• 1.0, 1.1, 1.4 and 1.6 8v Engines – £340
• 1.6, 1.8, 2.0 16v Engines – £480

Headgasket includes – Full head rebuild, including new camshaft oil seals, valve stem seals, inlet and exhaust manifold gaskets, headgasket, head skim, new cambelt and tensioner/idlers, oil change, coolant change and new Thermostat.. Waterpump extra.

Conversions

• Bosch Conversion, Turbo Diesels only ~ £280 including pump, tune and everything needed.
• Bosch Conversion, Turbo Diesels only ~ £190, fuel pump not included but cambelt, fire seals and a tune are included.
• Hdi gearbox Conversion, Turbo Diesels Only ~ £120 including gear oil. Gearbox NOT included, you’ll need to source your own.
• 106 Rallye Inlet. £80 Plus parts.
• Disc rear beam conversion, All Models ~ £120 including cables, £80 without cables. £40 extra to adjust ride height. You supply beam.
• Diesel turbo swaps £110 plus parts.
• Saxo/106 gearbox swaps £100
• Engine conversions – £150 a day plus parts, you supply conversion parts.

Niggley Jobs

• I’m happy for people to leave me with a list of little niggles with their car, this can be anything from electrical to a rattle somewhere… I’ll be more than happy to spend some time giving your car some TLC. £25 per hour plus parts.

I will also consider other mechanical work on any other vehicle!

At a recent Rolling road meet, paddy’s Dturbo made a nice 129.9 bhp and 230ft/lb. There’s plenty of room for improvement when the time comes for fuel pump governor mods.

Styling

Sideskirts, Grille and light trims painted black, Black badge,  Colour coded spoiler, Golf v6 4-motion splitter,  and a few random stickers.

Tuning

Bosch fuel pump – heavy tune. Gt15 to GT2 turbo conversion (since rolling road), Hdi gearbox, Decat, Backbox replaced with straight pipe. Fuelled on premium Diesel.

Chassis

15″ Alloys, Gti6 brake upgrade, braided hoses, Lowered 60mm all round.

Future plans include FMIC, Governor Mods, Discs rear beam. After the GovMods and FMIC the graph will be nice and smooth!

Paddy’s rolling road video

TUNING:
2.0 litre 16v gti6 , Rotrex C30/94 superchager , Longmans ported and polished with 3 angle valve seats cylinder head, PT80 Kent cams ,Bosch 440cc injectors , Front mount intercooler , Aluminium radiator, Mocal engine oil cooler ,  Oil cooler for supercharger , oil catch tank , Aluminium Inlet , K&N breather filter, air filter , Maped ECU , Bosch super 4 spark plugs. Gates cambelt kit , Uprated Head Gasket. Lighter Flywheel , Lighter Crank Pully

Chassis:
Road wheels: 15″ compomotive wheels in white with 195/50/15 toyo proxes TR1 , Gmax 60mm lowering springs with shocks , OMP top strut brace , torsion bar lowered to match , uprated engine mounts.

Interoir:
Bucket seats, Sabelt 3 point harnesses, fire extinguisher, Nearly fully striped ,

Thanks:
Just big thanks to Dad , Krisb , Carl at mechanical repairs …And pug306.net

Future plans , roll cage and maybe high boost could be on the cards that would see near 400bhp.

Video on the Rolling Road!

Video of Noise!

0-70 run