Crazyass

Well, i think it's time for me to start a build thread of the estate,
so here it goes...

Bought myself a diesel (1.8TD 75cv) estate to be my daily work horse, but like in every cheap car, it was feeling a bit sorry for itself..

Some pics:





The interior was all messed up..



The first thing to do was finding a full interior to sort that out... and so it was...

A due wash to the engine bay..



As the time gonne by, i gathered some parts..

- Ford Focus MK1 steering wheel



- Japan Racing '18 wheels all around



But these wheels only came with a 5 lug pattern, so had to sort that out..

- Full Rear axle from a Scorpio 2.9, as were the front hubs, discs and calipers..



to lower the damm thing

- Custom coilovers..



Assembling



And a little photoshop that i made just to look how she should look like..

Crazyass

a few more parts

bmw m pack seats



orange blinkers



anti roll-bar



Fibreglass sapphire bumper



New rear coilovers (hated the other ones)



Steering wheel fitted



As she sitted



Cossie front grill



Painted Black





At this stage, i moved to another country (France) for work, and someone took advantage of that fact to steal the wheels and vandalize the estate...

Needless to say, i lost interest in the project until recently...

found some new wheels for the estate..



engine wise....

was thinking of a om606 from a '99 Merc 300TD with a holset hx40, but i've put that idea to a side since the engine is massive, and most certanly required to cut the firewall to fit...

a replacement was found, it's under 2ltr and will upset some people...

more updates, soon..

dms04

visa_broke

following for more progress

gcfcos

Shame it got vandalised it looked awesome on them black wheels

Tev

iTrader: (2)

would love a estate

Marcyg

Hope you get her back to her former glory, she looked good

Cos500

Was looking good, what damage did they cause?

Mondi-DZK

iTrader: (1)

Shame about some asshole(s) wrecking your car mate. Was looking very nice how it was sitting with those wheels.

I know it must feel a bit fooked up, but i would buy the same wheels back mate.

Looking forward updating this.

Crazyass

For example,,they bent the drivers door in half..

Buying the same wheels was on the cards, but then i fancied a change. Also, to fit them on the front, i had to modify a couple of things, since clearence wasn't the best.
And looking at all the pics that i have of the sierra with them mounted on, they looked a little overzised. 17' look the best on this chassis.

Cheers

Jack and the Beanstalk

Hi There

Was reading your thread and came across where you fitted the Ford focus steering wheel. How did you fit the wheel if you don't mind me asking. I'm thinking of doing something similar?

cheers 🍻

dms04

Hello people!

As i know a few bits about this project, now i'll tell you the secret of this project: This will be a Super Turbo Diesel TDI powered! Yes, this Estate will have a 1.9tdi VAG engine...

I know, it might sound a bit disapointing but even me as a petrolhead must to recognise that this engine has lots of potential for its compact shape and lightwheight.

For those who dont know, well explored this engine can reach something around 360bhp (yes, it sounds funny) but with some respectable +/- 700mn torque, what makes this a very good weapon, having in mind that using in regular driving it can keep a very low fuel consumiption (will be nice to go from Portugal to UK for Ford Fair ).

For those dont know either, Europe fastest diesel has this engine and is a Portuguese car, AMmotorsport, the same guy who will build the engine after all conversion work.

A vid to have some idea:

And now, this is the Donnor:


Removing the engine:


1.9 TDI, AKA PD130


Half wiring loom


And this one, is one of the best choices, 5 speed ZF box from a 530Diesel E39 BMW, cheap and bullet proof . Ofcours a 6 speed would be better but we had not shure if they could handle the torque



And from the same car, rear diff (does anyone here has a LSD for this? )


By now its all.

Have a nice week guys

gcfcos

I bet that will be great fun when done

mancs

Hey man, I'm planning to do something similar, but with an older pump diesel (110hp tdi). So I'm curious how you will manage to deal with the problems!

Here in Hungary you can buy adapters from the offroad guys between the bmw transmission and the 1.9 TDI engine, the bigger problem I saw was the sump/oil pump.

Anyways, can't wait to see your progress!

rooos

love the idea, subscribed!
keep us posted...

Glenn_

iTrader: (1)

Cool car matey. Shame some coooont pinched your wheels.

Thats a differnt engine transplant.

dms04

By now, until que gearbox is been built ( Pics soon) a very hard-borring-painfull-mindfuck and so on work is up to do:









Now the work is to reduce wiring loom into the minimun, only what is necessary to make the engine run and control it. systems like AC, heating, ABS, airbags, and other stuff from audi must be removed, but is not that simple as the ecu gets signals from almost everywhere...

Nothing impossible to do

gcfcos

Good progress mate. That wiring looks like a headache

dms04

You may bet on it!! a Big one, three days working on this loom :-s But now its done, will be worse when i try to make it run whetever...

Yesterday:

Cleaning the heart







I hate to work on dirty parts, full of grease, oil and other stuff...

And started to study the BMW rear diff fittement (used a Scorpio Granada Cosworth rear axle as test bench, the one i had closer to me )





BMW one is a bit bigger, only a bit...

And started a moulding..











Some mesurements already taken, now is time to chop the cross member, this diff doesnt fit







Well.. is really big...







And by now its all, more news soon

gcfcos

I bet that big diff will take some abuse

dms04

Well... Let me see.. Probably 😁
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gcfcos

Have u changed your user name since the original post? I'm getting confused as 2 user names ??

dms04

I'm not the car owner, just the builder and cameraman 😁
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gcfcos

Fair play mate I was just getting confused lol

dms04

No problem mate 😁
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dms04

Hi!!
Some spare time and is moment to share some info about the work i've been on it.

As you can imagine, the gearbox is the main part needed by now.. Is not forgoten, only is building by a precision tecnician, in order to be more than perfect! but the same way i chose him to do it, so many other people does the same, and the time doenst stretches...

This is the progress until now:
At first, he made a nylon center to perfectly align the main shaft (is that the right therm? ) of the BMW box and the box pathern:


Made a Pattern base aswell, after chop it from gearbox will be the way to center in BMW box










Then, must built a base to fix the gearbox to chop it perfectly aligned











Until we wait for gearbox, there's so much work to do, then the BMW rear axle is on the way:

Been the diff in position, rear cross membre must grow into it, that way some moulding process is required







And chop.. and weld...





The same to the other side, but because the diff is by nature not aligned, the second part was so much more difficult





the same way, done the center fitment, this time in some stronger metal





And moulding again...



Rater than that, some reinforcements..


And welding.. almost all evening...





and reinforcements again.. and Welding...



And moulding again for some new reinforcements.. At this moment you may think this crossmember will wheight a Ton, but dont worry, is not that heavy and will stand nicely this massive diff.



By now this is the aspect it has by now, but still have so many weak points due to diferent diff..





By now it is all, new pics soon
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dms04

Just only some more reinforcements (the last ones)








(some welding may not look that good, the access is not so good, but it is very strong )

Ansd this is the final aspect, before to fit will go to sand blast in order to remove all the rust and paint properly





And now, almost all setup in study:




And the precision work continues:







More news soon

gcfcos

Awesome work there

Crazyass

Very nice!
Can't wait to see this thing on the road

dms04

ME too!!

Glenn_

iTrader: (1)

Some quality fab work here. You dont see this very ofter.

rooos

agree!
as for me, i'm pen&paper taking down notes...
that custom drive-train idea is awesome.
keep us posted mate!

dms04

Thank you guys! In Portugal we have a saying: A house takes 1 year to be done, but a bad construction makes it fall in one day.

News soon

dms04

Well, is not that a nightmare, this precision worker is a boss, he does it with a leg in his back lol

And is time to chop!!
Audi box having a sad end (due to a happy new life )






And its time to the BMW one, soon will be welded together





Until This work is making me wait, some new stuff must be studyed.

Now i need to get a way to fit audi's speedometer sensor into a wheel, i think this is the best way:





The idea is to fit magnetic ring inside the front hub and the speed sensor close to ASB sensor, more work to the guy how is building the box

News soon

dms04

hi guys!!
At first, my apologise for been missing this days, this project takes so much time, is not easy to keep updated in real time.

So, as my camera died as my new smartphone i picked up the crappy old one to take this pics, that is why its so bad.. but now is all ok, next post will be better

And the estate arrived to my garage, and the first thing to do was to remove her 'underwear':


Than found a huge problem: my first crossmember was tooooooo big, couldt fit diff mount or sway bar..

Chopped all diff back:


then fitted it into the car: (removed and fitted again this axle more than 30 times this week!!)



And this is how it looks now with a Corsa A gearbox mount to fit the diff to rear:



In this pics is not visible but i made so many reinforcements in order to make it as much stronger as possible

And the other parts are being built, this is the actual condition of the gearbox:


Now had some time to disamsemble all car in order to check if is all ok and clean the interior..






And removed the engine, suspension, power steering and some other bits


Found some cracks in the body, in the rear wheel arch, maybe the suspension made it



Remove the drivers door (bended) and send the car in this condition to the be repaired and painted:



By now its all, news every day, hope to have some time to keep you updated

It's Czech Mate

Subscribed

Crazyass

where's the updates?

dms04

Hi!!

More news about the TDI estate

After so many small things now i'll keep you updated about the clutch pedal and the accelerator:



The point is to fix que BMW 530D master cylinder into the sierra pedal house.




And the accelerator had some simmilar process, put the audi electric accelerator in the sierra one, to keep it original





Than, this is how it looks



If you look closer to the first picture, you'll see a brake sensor over the clutch pedal to, now it will be necessary to the VAG Ecu to map it properly.

Other stuff to do was the steering wheel, the first one was not that good, so i made a new one:





The process was very simple: just chop the original fixing and drill holes to fit a wheel hub to universal streering wheel, spot on

Still having in mind the heart will be VAG, the brain and the eyes will be too, that way, the cluster, fuel sensor, low pressure diesel pump will be the audi´s ones:

Luckly, some parts was almost plug n play on the first view only...


Only the cluster is not from the A4, it was to big and have to much information, so i found in the scrap yard this one:

Unfortunantely, it only shows 260kms/h

This is the way it looks in its place, a fez more hours moulding poliester and is done



For today its all, saved for the last this pic of my test bench showing how it is geting shape

dms04

Hi guys!!

Sorry been away of this thread but unfortunantely we stoped for a while in order to refresh some ideas and give me some time to finish my S(ierra)- Type (What didnt happened anyway ).

well, folloing what i've been doing to the cluster, it was time to keep going:
Used a womens shirt to give dash form


This way

Unfortunantely some problem ocurred and the polyester didnt worked on this silk, that way i'll need to do it again using some other fabric ...

But it was not all bad news, the precision worker gave me a gift



The gearbox is properly welded as the driveshafts to the axle, hope to get it tested soon.

Other stuff i started was the fuel tank. Inside it was full of s..t and in the outside too, but some other kind of it And had to weld some cracks





Now the interior is clean, only wears some rust, not a big deal.



The fuel Pump from the audi is ready too, had to chop it all around and fit new rails to be able to fit it inside the estate's tank.



Only the paint job was left, but now it is painted properly and completly ensembled , ready to go to its place



By now its all, hope you like it

Freeked

No news? Come on...there's got be "cooking" going on