Image Please bare with us while we are carrying out some much needed maintenance to the forum. New look coming soon!

My First Build

Once you've introduced yourself why not throw up a few pictures of your car or a project thread?
User avatar
Tosh21
Altezza Guru
Posts: 521
Joined: Mon Jan 20, 2014 10:12 pm
Location: Oxfordshire

Re: My First Build

Postby Tosh21 » Sun Jan 25, 2015 11:36 am

Took the manifold off to do the wastegate pipe and found this. Kept getting errors at high revs saying fuel trim too lean, Haven't tested if the issue is gone yet but I think it was the majorly blowing manifold. It was blowing at every join up to the lambda too so sorted all that. used the wrong size v-band! turns out there are a few tiny differences with them.

Image

Spent the rest of the night beating what I could flat and then grinding it on the big wheel which isn't actually that flat but got me close. Then it was onto the surface table with a ton of engineering blue and some sandpaper taped to the table. Took about 5 hours of hand sanding and some careful localized griding when the blue showed up massive high spots and eventually it got to this.

Image

Sorted out the wastegate, machining down the flange

Image

Image

Wastegate port cut into shape for the manifold

Image

Image

Image

Image

Manifold is now fully finished and should never have to come off again hopefully!

Next it was onto the wastegate pipe. I debated with running a screamer but i thought it's just going to be anooyingly loud and get on my nerves so dumped it back into downpipe. Made a pattern to cut round as ali is much easier to fettle than stainless.

Image

Cut it all in and mounted it up.

Image

Works pretty good. I took the top of the wastegate off and it was opening quite well as I revved and that's without the backpressure of the turbo forcing gas down the wastegate so pretty pleased.

The walbro pump I had died very very quickly so I threw in the bin with anger and found me a nice bosch 044. Apparently brand new, don't want to test it out of the tank as they don't like to pump air apparently so will just have to hope it's all good after it's in and wired up.

Made a new fuel pump assembly to hold it all. Just needs a feed and return hose fitting and then it can go into the tank and wired up using the oem pump positive as a trigger wire for the relay so I can draw straight from the battery.

Image

I start my new job in a week so I (probably) won't get the chance to make stuff anymore. Definitely no where near as much as I do now anyway so I have a week to fit the pump and get it running sweet, Make a new fusebox as the wastegate will melt it in t he standard position, do all the intercooler piping and the inlet piping into the turbo but I think I'll leave that until later when I decide what air filter to run.

Hoping with the new job and the paid overtime (finally!) to have the car fully turbod and mapped by mid spring/summer ready for the show season so I can make some meets and be able to keep up with my friends

User avatar
Tosh21
Altezza Guru
Posts: 521
Joined: Mon Jan 20, 2014 10:12 pm
Location: Oxfordshire

Re: My First Build

Postby Tosh21 » Mon Feb 23, 2015 7:31 pm

Finally got round to finishing off some bits.

Made a fitting to go on the back of the rail with a hose coming off it so I can screw the guage on whenever I need to check fuel pressure if it needs adjusting

Image

Fuel pump in and fully wired up

Image

Fused the battery and pump all wired in. Ghetto flying fuse all up in there

Image

pump all wired up and tidied away so it's nice and neat

Image

Fitted a filter on the line too, didn't have a sock for the pump.

Power delivery is messed up though. Usually pulls ok and sometimes starts to feel like it's missing until I change gear and power drops right off at about 6k. Sometimes although very rarely it will get it just right and pull like it's trying to escape from the scrap man it's crazy powerful. Only started since I fitted a new pedal position sensor which is odd as the throttle is now a standard set up and I set the tps voltages right, clean maf, everything. Gonna check the plugs and coils see if maybe they are playing up which would suck so bad at that price.

User avatar
RS Tom-Hundred
Tezza Fanatic!
Posts: 449
Joined: Fri Nov 28, 2014 3:31 pm
Location: Cambridgeshire

Re: My First Build

Postby RS Tom-Hundred » Tue Feb 24, 2015 10:15 am

Looking good, Tosh :) Good luck finding the power cutting out issue and getting it fully sorted :)

User avatar
mlcoolj
Altezza Guru
Posts: 1740
Joined: Tue Oct 20, 2009 8:14 pm

Re: My First Build

Postby mlcoolj » Wed Feb 25, 2015 10:46 am

those welds are a work of art! Good job! Keep us posted!
Image

User avatar
Tosh21
Altezza Guru
Posts: 521
Joined: Mon Jan 20, 2014 10:12 pm
Location: Oxfordshire

Re: My First Build

Postby Tosh21 » Tue Mar 10, 2015 9:09 pm

So I think I may quit :x :x :x :x

Took the manifold off to try push 2 of the primaries apart as they were touching. Bit of strategic placing of welds and a big ass wedge I managed to get it to settle at this distance. Still pretty dam close!

Image

Stripped all the insulation off the turbo as it was starting to break and the powder was coming out.

Image

Re did the insulation, this is the stuff that actually keeps the heat in. Need to cut and weld the stainless on top to seal it in.

Image

Need the dummy turbo fully built to fit a brace, even though the turbo is empty it still needs a brace as the manifold will droop drastically without one. Bung I machined to go in the end of the compressor.

Image

Fitted!

Image

Now the worst thing about this...

Image

Yup, that's one big ass crack! No wonder it was reading lean. Welded it up, refitted it using firegum and was fine.

Week later (today) I go to mount the brace and notice some white paste on primary 1. After close inspection it has a hairline crack in the same place and there is white stuff under it, looks like it cracked on the bottom too somehow. Just aswel I used firegum! I would not have found the leaks otherwise. So it's coming off AGAIN tomorrow and I am going to reinforce the crap out of it. Had a chat with an exhaust engineer at work and he said it's quite common for that to happen. I'll see what he says about strengthening it so that I can finally put it on and leave it on. If not I will just give up and make a heavy duty indestructible one. Very much a love hate thing with this project :(

User avatar
Tosh21
Altezza Guru
Posts: 521
Joined: Mon Jan 20, 2014 10:12 pm
Location: Oxfordshire

Re: My First Build

Postby Tosh21 » Sun Apr 05, 2015 9:39 am

Wrapped some 1.6mm round primary 1 and 2 to try strengthen it to stop it cracking.

Image

Seems to be holding up! been a few weeks now with no problem. Plan to pull it off again next week to flatten it right out and give it a proper look over to see if it's cracking and refit with a new gasket and no paste.

Finished lagging the turbo housing too. Came out of the oven with no leaks which is always good! might start to crack once it's on the car and vibrates but it should do a few months atleast. Pressings were too small so had to force it on which made it look a bit rubbish but we'll see how it goes

Image

Been thinking about getting another cheap as chips rwd car as a little drift missile I can rag about in while I turn the tezza into more of a full blown project after she's been turbo'd

User avatar
RS Tom-Hundred
Tezza Fanatic!
Posts: 449
Joined: Fri Nov 28, 2014 3:31 pm
Location: Cambridgeshire

Re: My First Build

Postby RS Tom-Hundred » Tue Apr 07, 2015 12:05 pm

Good work Tosh :) Keep with it and you will have it sorted and running sweet! :)

User avatar
RS Tom-Hundred
Tezza Fanatic!
Posts: 449
Joined: Fri Nov 28, 2014 3:31 pm
Location: Cambridgeshire

Re: My First Build

Postby RS Tom-Hundred » Tue Apr 07, 2015 12:06 pm

Good work Tosh :) Keep with it and you will have it sorted and running sweet! :) Did you sort the cutting out||? Was it due to it running lean with the exhaust manifold crack?

User avatar
Tosh21
Altezza Guru
Posts: 521
Joined: Mon Jan 20, 2014 10:12 pm
Location: Oxfordshire

Re: My First Build

Postby Tosh21 » Tue Apr 07, 2015 6:12 pm

Nah I did a few tests and narrowed it down to a fuel restriction somewhere. The pump is very loud and the pressure drops a little on acceleration. Got a nice proper 30 micron filter on the way so will try that and hope it solves it. If not then will have to keep digging. Its definitely a lean misfire though which I'm quite concerned about, dont want to be melting pistons

User avatar
Tosh21
Altezza Guru
Posts: 521
Joined: Mon Jan 20, 2014 10:12 pm
Location: Oxfordshire

Re: My First Build

Postby Tosh21 » Sun Apr 19, 2015 9:53 pm

fitted a new sytec billet filter. £55 compared to the £5 of the normal universal cheap filter but atleast I know it will cope and being serviceable I can keep it for years

Image

Didn't solve the horrible fpr noise so pulled out the jet pump and returned straight into the tank. Noise instantly went away but the fuel pump still sometimes gets really loud but it is rarer than before. I think the fuel tank breather might be blocked and it,s building loads of pressure. I noticed fuel seeping out of the fitting when I key off after a drive. Fuel is pretty warm too, was thinking about fitting a fuel cooler to keep the pump cool.

Still misfires on idle though and under heavy load so checked fuel pressure while driving with some ghetto gauge fitment

Image

Pressure didn't move at all through the whole rev range and didn't flicker when it misses under hard acceleration. This rules out fuel delivery being the issue as I know the rail pressure is always constant. Next step is to check injector resistances to see if any randomly change causing the idle misfire.

Start the car and suddenly there is a major misfire, engine is unbalanced and shakes like crazy, e-throttle dies too. Luckily I wasn't far from home so managed to drive her home. Cleared the codes on the code reader and the throttle came back then went onto disconnecting each pack to find the faulty one. Pulled out the faulty coil and it looks like it's been on the car from day one.

Image

Cracked rubber FTW! Arced across into the engine so wasn't getting spark. Covered in electrical tape and it worked really well! bought me some time so I can avoid going to toyota for a new coil.

Image

Don't have a pic but my manifold has finally given way. 3 and 4 have both cracked pretty bad, 2 looks ok but primary 1 which is always the worst has pretty much exploded. When inconel fails it fails in a pretty spectacular fashion so I got pretty lucky that it's only a small pop. The metal has split and peeled back on itself, this stuff is pretty dam strong so must have some major manifold pressure. Not sure why the pressure is so high, maybe because the wastegate pipe is blocked off and there is no turbine in the turbo housing but it would take ALOT of pressure to make it pop.
Gonna repair it on monday and have given up, time to make a steam pipe manifold!

Trying to make one CAD so I can get an idea of how many bends I need and try to make them equal length

Image

User avatar
RS Tom-Hundred
Tezza Fanatic!
Posts: 449
Joined: Fri Nov 28, 2014 3:31 pm
Location: Cambridgeshire

Re: My First Build

Postby RS Tom-Hundred » Mon Apr 20, 2015 10:45 am

Good work Tosh and looks like you are getting somewhere with solving the issues now :)

User avatar
peter0991
Altezza Guru
Posts: 580
Joined: Wed Jun 22, 2011 10:29 am
Location: Aberdeen, Scotland

Re: My First Build

Postby peter0991 » Wed Apr 22, 2015 8:30 am

Pretty sick read man!
Image

jaredschlechte
Noob!
Posts: 19
Joined: Tue Apr 14, 2015 10:14 pm

Re: My First Build

Postby jaredschlechte » Wed Apr 22, 2015 6:40 pm

Good read man! Looking forward to seeing more!

User avatar
Tosh21
Altezza Guru
Posts: 521
Joined: Mon Jan 20, 2014 10:12 pm
Location: Oxfordshire

Re: My First Build

Postby Tosh21 » Mon Apr 27, 2015 11:01 pm

Owens finally got back to me. The TR30 is definitely a no go, Garrett don't make the parts anymore so it would cost a fortune to repair. They did offer me £400 towards a new turbo though. Not sure when they will get one in but I am soon going to be picking up a brand new GTX28 with a TIAL .86 exhaust housing so I can keep the v-band fitment and externally wasted. Plus it looks much nicer and much lighter. I was tempted to just go for a normal GT28 but with the £400 trade in value I think it actually ends up being cheaper than if I bought a brand new GT28 journal bearing turbo.

Unfortunately, the TR30 has a 2.5inch outlet but the GTX has a 3 inch so my whole exhaust system is useless. Plan to hit it really hard one weekend and make the manifold and exhaust together. In preparation I made some purge bungs and press tools

Image

Also finished the manifold design. It's almost harder to mock up on CAD than in real life!

Image

Decided to not bother with a normal collector and just merge the pipes together. Makes it quite difficult to make but much easier to do the rest of the manifold. I think it's a better compromise too as the angles are really shallow even if they are all slightly different it will stop the gasses going into the other pipes so it should flow nicely and all the energy will go into the turbo. All lengths are exactly the same too, it won't be perfectly equal by the time I've made it and it's all shrunk and moved about but it will be close enough.

Will be getting on that in the next few weeks once work calms down a little and I get all the material together. Learnt a lot about making exhausts so the next one will hopefully last and perform really well

User avatar
hermit
Trc Off
Posts: 112
Joined: Sat Aug 24, 2013 2:56 pm

Re: My First Build

Postby hermit » Tue Apr 28, 2015 1:00 am

What about making the manifold twin scroll instead of a vband?


Return to “Member's Cars / Projects”

Who is online

Users browsing this forum: No registered users and 2 guests

cron