My First Build

[Tosh21]

Need a twin scroll turbo. Plus it's a bit more compliCated and I'd need either a normal collector or 2 collectors with secondary pipes on it to be able to split it

[RS Tom-Hundred]

Good luck with it That's definitely the case with CAD, very often harder to draw it than make it and I don't even use 3D CAD (all our stuff is either in 2D or isometric)

Cant wait to see the results and hope it all works out how you hope

[Tosh21]

Got all my exhaust bits today, I hope the cad model works after all this planning.

Stainless flange, those little holes were points I put in for referencing while I drew the flange and I forgot to delete them. Oops! They are pretty shallow though and the weld should penetrate into them fully. Hopefully




15mm thick! Ordered 12 but they said they will give me 15 for the same price as the 12 was bowed. Not complaining really, gives me plenty of meat to machine off after it's been welded so it's dead flat.



The 90 elbows. They are mega tight, ideally they should be long rad to flow nicer but being a turbo manifold it's not quite as important. Very high quality for the price!



All my exhaust materials minus the silencer which is gonna be a custom job again. The whole system after the manifold is 3" inconel starting from .9 at the downpipe and fading out to .7 towards the back.



Car runs like a absolute cr*p sometimes and I still haven't managed to figure out why, out of ideas now to be honest. Try and get some time to do a bit of diagnosing next week hopefully.

[Tosh21]

So turns out making manifolds from pipe is a whole new ballgame compared to tube! Had to scrap the collector, can't be done without a pipe expander so plan b! Made a jig off my current manifold to position the collector exit and wastegate, also took some measurements so I can avoid the water pipe and make the manifold on the bench instead of on the car. Will see when it's done weather it works or not.



Make collector and stubbs, mount in jig and just join the dots!



Started making the larger exhaust system. downpipe welded up and fits way better than before, managed to tuck it right up to the chassis so it won't scrape.



Check out the bowing in that baby!



Got a new fuel pump, 340LPH apparently. much quieter than the bosch, can still hear it but nowhere near as bad as before. Car stopped missing and juddering too, runs nicely and pulls alright like it used to



Went testing with a manufacturer and saw this beauty in the car park, it was owned by the test driver!





Got a lovely package from owen developments.



It's exactly the same size as my tr30 so works perfectly. Pretty light too



Wastegate was rebuilt too. New diaphragm, new body, new seal, new valve and a spring for £130. Pretty awesome price!



Turbo mounted for mocking stuff up. Hopefully I can get everything in and plumbed up so I can test run it in the next couple of weeks.

[url=http://s1295.photobucket.com/user/toshamov/media/IMAG0595_zpsonebl0de.jpg.html]

[Escy]

Interesting read. Impressive fabrication skills. I have to say, if you only plan on running 0.5bar how come you didn't just stick a Greddy kit on it? It'd have been done in a weekend and the end result would be the same

[Tosh21]

Only because I had lots of stuff for free. The tr30, intercooler, all the material and ecu was free. I should have got the turbo checked before I started really but I've learnt loads through all these screw ups. To be honest this whole build has been just cos I got bored lol it future proofs the car too, I know I'll want more Power down the line too so all I'll have to do is forge it and up the boost

[Tosh21]

Finally had some time to sit down and do an update, been insanely busy working till 11 every night and doing weekends.

Fitted an AEM wideband, for monitoring mainly. Just as a piece of mind for the ol boost.

Wired into cigarette lighter



Wee hole in the floor to run the wire, tucked away nicely behind the glovebox. Gonna fill it with some black silicone at some point



Can never have too many lambda sensors



Put back together and mounted up. Gonna make a 2 pod gauge holder and boost controller holder in one out of the top of the center console piece with some fiberglass and wrap it along with all the other plastic on the dash at some point



So I made this badboy, pretty hard to weld this thick stuff actually! Thought it would be easy but it's harder than the super thin wall stuff I'm used to



Ended up with one super long primary and the first 2 primaries are kinda in the way of everything but I'll make things fit even if i have to go through wheelarches or whatever



Made a water feed off the oil cooler (apparently it's an oil cooler anyway)



Fitted the manifold, was an absolute bitch and took 2 of us to fit it. Not looking forward to taking off and refitting it after I weld the wastegate port on!



Had to do a bit of milling on the oil drain



Mounted the turbo and hooked up the water and oil feeds



Made some of the oil return in ali tube cos it was quite close to the manifold and rubber might melt. Put a firesleve over all the rubber bits



The only picture I have of the rest of the exhaust for some reason. Made it a 2 piece system with a v band in the middle.




Fired her up and drove her home. Wow what a noise!! Turbo wasn't hooked up to anything so it was way loud, making turbo noises all the way home! you can hear it spool at 2k rpm if i open the throttle enough and at 3k it whistles whatever throttle I have so shouldnt have much lag. There is a bit of a delay between opening the throttle and turbo whistle but that's probably from having a long ish tubular manifold.
Drove to work and there was oil in the engine bay coming out the end of the compressor housing. Called up owens and they said it's because I don't have it hooked into the engine and not to run it like that or it can overspeed. Kinda obvious really, DOH! Haven't ran the car since and took the turbo off, will make a blank for it like I did before so i can keep it driving while I do charge piping, wastegate, screamer pipe (possibly) charge piping and an ecu extension harness.

Still loads to do!

[Tosh21]

Cut the wastegate pipe, collector was too small so I made the tube oval so I wouldn't compromise by using too small a tube. Was a bitch to cut in, shape was so weird and getting angles etc was not fun.










Driving to the airport, running late, sitting at 5k. Suddenly a loud pop, sounds like open headers and afr goes full lean. Thought I blew something up! I used an Ali bung in a turbo before and its been fine, not this time. Sitting at 5k must have just been too much for it and it melted and blew up, would love to have seen it happen! It won't have gotten the stainless anywhere near hot enough to fuse so it will all come off luckily and it should have all gone out the housing rather than into the manifold (I hope so anyway or I might need a new engine!) Gonna get a stainless one cut and fit it when I get back. Closed the bonnet and carried on, it's not actually that bad. Twat lol

[RS Tom-Hundred]

F*ck!!! Hope it hasnt done any damage mate! Keep up the good work!

[Tosh21]

This is all thats left of the bung after i got it out



Inside the snail itself it seems to be ok but the back end of the housing has a spiral pattern of ali which gets thicker as it goes round, pretty cool! Hopefully we get a lathe pretty soon at work so I can machine it out cos it's pretty hard to pick off. Apart from that I don't think there is any damage, there are some specs in the manifold though but I think they will disappear with time as it gets hot and melts the ali. There is a mess in the downpipe too, plan to drive the car hard for a bit to try melt the ali so it dislodges itself and heads down the rest of the exhaust with the wideband taken out so it doesn't do damage to it.

Made an earth kit too, hasn't helped idle much and still lose voltage when turning lights on etc. Haven't tried the power fc yet, hopefully the kit solves the problem. If not the car has to go to an auto electrician I think, Electrics are too much for me

See if you can find the earths! tried to hide them and used black cable so that it's subtle and blends in with the rest of the messy hoses

[RS Tom-Hundred]

Blimey! That bung has had it big style! LOL

[RS Tom-Hundred]

Good work on the subtle earth kit. Good luck with the Power FC

[Tosh21]

Finally got round to doing some ecu wiring.

The main power wire was frayed pretty badly



Cut, crimp and heatshrink any damaged wire



Think this is why the power fc isn't working. It would only read 3v across the pins. Gonna try and re solder it see if it makes a difference, got nothing to lose



So I went and got myself an F con Pro. Map sensor and all which makes things a bit better



Also found out I had a damper leak on the front. It's been rattling for ages but I thought it was just some plastic. Tein estimated £300 PER DAMPER and 2 weeks minimum for repair. Almost bought the street advance set but decided to bite the bullet and just get some nice coils so got myself some nice Meister R's



Drove about 14 miles home on them and WOW! They are incredible. Absolutely no roll, no understeer and incredibly responsive. Much better feel of the road too I can feel when the car is starting to want to oversteer a little. Quite impressed they perform that way without even a proper set up, I didn't do any allignment as it took way longer to fit than I planned. Will set them up properly at the weekend and she should be handling lovely.

Height adjustment on them is good, I have the rear as low as they can go but it's way too low for me so gonna lift it back up. I set the fronts to the same height as the teins but i'm about 10mm lower which is not good. I was wanting to go higher not lower! Had to leave the car a couple of streets down cos I couldn't get over the speed bump in my street. Got half way and the exhaust was scraping so badly I had to back up.

She's getting raised tomorrow, new plugs (hopefully sort out the terrible running) and a full stringing at the weekend. Think I will have to machine the camber bolts down so bring the camber in a bit. I have zero tread on 1/4 of the tyre from waaaaay too much camber

[hermit]

It's coming along well lad. Who will you get to map the f-con?

[Tosh21]

Think ill head down Abbey motorsport there only an hour away. Call em up in Monday see if I can get a slot for the end of August