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*In association with...* "Greener, cheaper fuel"	Peugeot 306 Cosworth 17th August 09 Work is still progressing well with the 306. The propshaft has been finished, shortened and balanced and the center bearing housing restored. The seats that we are installing are the Cobra Imola S range, which should provide good support which will be useful on trackdays. We have applied the finishing touches to the front suspension, now all that remains is for us to get the car to its wet weight and corner weight it. 12th August 09 Our HKS filter with 4inch neck has arrived and the sleeve to cover the fuel inlet pipe is here. The dump valve and main inlet pipe to the turbo have now been completely welded up ready to accept the filter. 3rd August 09 The Perspex windows and carbon roof are now being fitted, whilst some final modifications to the subframe at the front are made. Also parts are now here to allow the installation of the fuel tank inlet pipe from the C pillar, this will be enclosed with a fireproof sleeve as per Time Attack rules. 31st July 09 We have now test fitted the front end bodywork and the splitter is secured to the bumper, now only awaiting a pair of stay bars. The roof is cut out and soon the carbon item will be installed. The BD10 and BD14 cams are now installed and the final touches will be made to the fuel system over the weekend. 29th July 09 Our modified Turbo Intake trumpet has been completed and is back from the machinists, and we are very happy with it, work is now in progress to get the 102mm piping to a HKS Mushroom filter in the wing. We have made a small bracket for the waste-gate mounting and the Quaife ATB Diff and Big wing sump are both installed. Our Exhaust cam has finally arrived from Piper Cams, it is a BD10 item which should complement the BD14 inlet by producing less lag and more torque, whilst still giving good top end horsepower. On the suspension side the springs have been fitted and seem perfect, and our suspension expert has completed setting up the rear end such that it now doesn't bump steer at all, and the front end should be ready for corner weighting after this evening. 24th July 09 The progress of the car seems to be really gathering pace now as things usually do when the reassembly phase begins. Intercooler and Oil cooler are installed behind the turbo cooler, the dump valve piping has been assembled, the intercooler hoses are sorted and turbo feeds installed. The fuel system is now nearly complete, with ends to fit the swirl pot the only missing part at the minute. A fitting has been inserted into the header tank to take the top feed from the swirl pot, the Group A restrictor has been chopped, is being welded and will soon be filleted to a smooth curve, and routing to the air filter has begun. All parts for the steering assembly have now arrived, we are using a manual rack which required a different pinch spline joint. The rear anti roll bar is now installed with the polybushes mentioned in the last update. On the body and interior side the main dash panels are cut and just need to be secured in their final places, a roof panel to secure the headlining has been installed and carbon caps for the mirrors are made. At the rear sections of the body have been cut to enable further flow from the radiator. On inspection of our diff we discovered that there was some damage so we have decided to play it safe and have sourced a brand new Quaife ATB Item which should be more than man enough for the job. We have also bought a baffled big wing sump to ensure that oil starvation will not be a problem. 20th July 09 We gave the driveshafts a light coat of hammerite as they were also coated with rust, this along with the other clean up jobs will drastically improve the look of the underside of the car. Also at the back end we are using some 5 inch flexible hose to feed air from the roof scoops to our radiator, which will also feed from below the car. We obtained some custom polybushes which fitted our S14A Anti-roll bar inside Supra Mk4 U clamps that we had from our donor Supra. Considering the car had no ARB at the back before this should improve things considerably. For the interior we solved the problem with demisting the screen by sourcing a small electric unit which you can place where you like and only costs us 400grams, we can supply these if you want one. We are using a Bailey DV30 recirculating dump valve for this car and our Silvia, and in this case have made a custom take off pipe for it due to the very tight constrictions around the throttle body area. For the fuel side of things the setup is progressing well, we are using a main pump fed from the custom aluminium swirl pot which in turn is fed by the Facet lift pump. These are being installed at the minute. The intercooler is a thicker 60mm item, and again has been modified on the intake and exit pipes to fit the tight confines of this car. The bumper has been repainted and looks excellent, and the turbo cooler installed in front of the intercooler. 15th July 09 We have now completed de-rusting the rear end of the car, there was a lot more surface rust than expected buried under the underseal but nothing that went through the metal thankfully. As has been said before, we caught this car just in time. The rear beam was also teeming with surface rust, so this, the track control arms, diff carrier and hubs have all been painted. Also the fuel and Oil systems are taking shape, our custom tank has arrived and we are more than happy with it and the swirl pot. We have begun routing the hosing for the fuel, and in car are using 811 spec hose to prevent any smell reaching the cockpit. We have also got some replacement springs which will allow us to experiment a little with the spring rates. 22nd June 09 Over the weekend our BD14 Inlet Cam Arrived, we found an anti-roll bar for the rear end- the S14A front end start is of a good stiffness for this application, and the Turbocharger has been installed. 18th June 09 Noel has now removed a portion of the rear end to make way for the rear mounted rad and has installed a box section of metal to re-strengthen the area. The radiator has been mounted on its rubber mounts. In the engine bay the exhaust has been heat-wrapped and is being put together for the final assembly. We have now sourced a idle control valve suitable for our new 50% larger throttle body, and the engine is awaiting the inlet cam from Piper to complete it. In the interior the final pieces of unpainted area have been prepared and touched up in Matt black, as mentioned before all this will be covered with lightweight carpet and carbon. We have added a dash bar for essential side impact protection, opting for Square section instead of CDS tube due to this allowing us to use it as the primary mount for the dashboard, for which some flat sheet carbon is being produced. The rear beam has been sent off for machining work to begin to allow us to adjust camber and toe. The Power steering rack is being modified by a specialist in order to delete the power assisted side to give more feel. 9th June 09 In the last week we have done mostly tidying work on the 306, the interior is now rust free, had a coat of red oxide and is now painted matt black. This finish will be under a layer of lightweight carpet and our carbon dash but it is nice to know that all is in order and tidy underneath. The front bulkhead has been plated with carbon panels to block off any holes that were left from the stripping of the dash. This should prevent as much wind and engine noise as possible from coming into the car. Again these will be under the carbon dash but are part of thoroughly rebuilding the car. On the brakes side we have now installed a dual master cylinder setup, these both being compact items, this will allow us to run a adjustable restrictor on the rear cylinder to adjust the bias. The exhaust has been heat wrapped and awaits its coat of paint, and the wiring is being sorted out and the unnecessary disposed of by our electrician. We have extended the front wheelarch where it emerges in the bonnet to allow some extra room as the tyres were rubbing previously.The carbon tailgate skin has been produced and awaits fitting, the roof will be entering production soon. 4th June 09 Since the last update we have ripped out the ABS system in preparation for install of a simple race master cylinder, this alone has saved us a further 9.87Kg. Also we have installed the head with the ARP studs and WRC head gasket and we have test mounted the inlet manifold. The Turbo spacer has been deepened to give us further clearance and our Race Guru Colin Davids has leant his services to begin setting up the suspension and introduce features to the car to ease this process in the future. 1st June 09 Work on the car has been progressing well over the last few weeks. On the engine side new manifolds have been used on inlet and exhaust, using a custom HCS Inlet and a Cossie 2WD high flow exhaust to hopefully make full use of a new turbo, which is a Custom built Group A GT30. A spacer had to be machined to enable the turbo to clear the head, this sits between the two parts of the exhaust. On our new gas flowed head a BD14 Cam is now being fitted to the inlet, and larger "Grey" injectors, custom fuel rail, aeromotive Fuel pressure regulator and large short throw throttle body will also help intake more air. We are getting rid of the abs system to save weight and to this end a different ecu will be used, this will also utilise a wasted spark ignition system from a more modern ford engine, which removes the weight of the distributor. A genuine WRC multi layer metal head gasket and ARP studs are being used which will hopefully prevent any problems in that area. A new deeper radiator is being used to keep temperatures under control and a turbo cooler is going to be installed between the turbo and header tank on the water loop to cool the water at this critical point. On the carbon side a mould has been made for the roof and a Tailgate has been produced, all that remains is it to be polished before being put on. We have machined a pair of brackets to enable the mounting of the Skyline GT-R calipers and Ksport 356mm discs to the Cosworth hubs. 20th May 09 Since the last update we took a trip to the Nurburgring so most of our efforts were focused on the Porsche in the run up to this. Over the last day we have completely removed the dashboard, blower assembly and heater matrix in order to shed weight and improve the look of the interior. Also gone is the thick sound deadening around the gearbox, 3 layers thick in places. In total this process alone has yielded a 24.7kg weight saving. This figure is without the wiring we will be loosing when we strip the loom of the huge current excess. As you can see the car is in desperate need of this. This weight saving will add up with the 101kg lost on the conversion to 2WD, carbon panels, stripping interior, alloy rad and fuel tank to give we hope a curb weight of 1000kg down from the 1210 it came in at. 11th May 09 We have now received the 306 Cosworth back from the bodyshop for final assembly and geometry setup of the suspension. The Interior will be installed, front geometry adjusted and new Toyo R888s used all round, on the red and black Rota Torque Wheels. 9th May 09 All that remains in the bodyshop now is to flat and polish the 306 and we will have it back to us. The bonnet and doors have now been painted and our trademark carbon etching put in the paintwork. 25th April 09 The 306 has now been painted fully, the panels have been polished and trim painting of the bonnet and door skins are all that remain until it is shipped back to us. 27th March 09 The conversion to 2WD is now in progress and should be finished by tomorrow morning, while we did this we decided to replace the mounting points in the front cross member to bring the arms up into alignment as already discussed, this should greatly aid the handling of the finished car, remove bump steer and possibly erratic camber compensation. The rear end is complete and the front is waiting on engine mounts from Collins Performance. 25th March 09 The car has just been transferred to our workshop to undertake the work to convert the car to 2WD. Also the Tailgate has been received prepped and ready to mould from our bodyshop so work will begin on that soon. 19th March 09 The car has finished being painted by our bodyshop, and we have now decided to change direction slightly with it. Due to the problems associated with using the front driveshafts of the Cosworth on the 306 (ie they make a steep angle which will reduce life), we have decided to convert to the Cosworth 2WD setup, which also has the advantage of reducing weight with the lack of the extra diff. The parts have all been sourced and the car will be going in the workshop when the Silvia Vacates it next week. Parts to be changed include: -Gearbox -AP Racing Paddle Clutch -Baffled 2WD sump -Steering Rack -Steel Cross member -Propshaft -Rear 7.5 Diff -Polybushed rear beam and arms Please click here for the previous entries into the project log.