Custom Exhaust Downpipe Part 2

Completed fabricating the exhaust downpipe. The modified 300TDI pipe was next joined to a downpipe from a 2.5TD 90. With a bit of chopping, and welding, this is the finished downpipe:

And as fitted to the turbo, and the front pipe attached.

Custom Exhaust Downpipe

At the Peterborough Show, managed to buy a 300 TDI disco exhaust downpipe for a fiver. As this has the same flange that fits to the turbo, it can be used to fabricate a custom downpipe.

Downpipe as brought:

First job was to cut off the end of the downpipe, at the turbo end. Then cut out the 90 degree bend in the pipe, and weld this onto the end of the flange.

The end of the curve is then trimmed to allow for a tighter bend from the turbo. This is necessary due to the the lack of space between the turbo and the bulkhead.

This is what it will look like once welded together:

The flange is then fitted to the turbo, and the downpipe held in position, whilst I put a couple of tack welds to hold the two pieces in place.

The downpipe is then placed in a vice, and welded all round:

Once welding is completed, the downpipe is ready to fit back on the turbo.

Once I've brought a defender exhaust, I'll convert the defender front pipe to fit onto this pipe, and weld the two pieces together.

Bulkhead Dent Repairs

Repaired the dents in the bulkhead door pillars. Dents were filled, sanded back and given a coat of primer. Bulkhead has also been rust treated prior to priming.

Bulkhead Stripdown

Timing belt, cover + water pump have now been refitted. Also the transfer box output seals have been replaced, just in case.

All dashboard components, electrics, washer motor, etc. have been removed from the bulkhead, ready for cleaning up and painting the bulkhead.

All the dash pieces removed from bulkhead:

Wiring Loom:

And the Washer Motor

Bulkhead Refitted

Bulkhead has been replaced onto the chassis, to allow full stripdown and working out how all engine bay parts need connecting together.

Timing Belt Removed

Timing belt has now been removed, with the engine locked at TDC. Tensioner has also been removed, ready for replacement.

Timing Cover Removal

Removed the water pump, crank pulley and timing cover, to allow the timing belt to be changed. Undoing the crank bolt was the hardest job. This required locking the flywheel (piece of 4mm angle iron through the starter motor hole), and the long pole from the trolley jack for leverage.

Various pulleys, belts, etc. Removed from front of engine:

Photo of the alternator wiring prior to removal:

The water pump. This is in reasonable condition, so should just require a clean up and remove old gasket.

The alternator, PAS Pump and bracket as removed from the block

Timing Cover Removed:

Finally the Timing gears and belt.

And the thermostat + housing has been removed